{"id":1653,"date":"2026-02-21T21:45:57","date_gmt":"2026-02-21T16:15:57","guid":{"rendered":"https:\/\/singhamarpreet.com\/?p=1653"},"modified":"2026-02-21T21:45:58","modified_gmt":"2026-02-21T16:15:58","slug":"building-a-world-class-smt-factory-our-journey-with-pvr-controls","status":"publish","type":"post","link":"https:\/\/singhamarpreet.com\/index.php\/2026\/02\/21\/building-a-world-class-smt-factory-our-journey-with-pvr-controls\/","title":{"rendered":"Building a World-Class SMT Factory: Our Journey with PVR Controls"},"content":{"rendered":"\n<p>Some of the most rewarding consulting engagements start with a simple phone call.<\/p>\n\n\n\n<p>That\u2019s exactly how our journey with&nbsp;<strong>PVR Controls<\/strong>&nbsp;began.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"the-first-conversation\">The First Conversation<\/h2>\n\n\n\n<p>One afternoon, I received a call from&nbsp;<strong>Mr. Shresth Kanodia<\/strong>, Director at PVR Controls.<br>He had a clear vision:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Build a\u00a0<strong>world-class SMT manufacturing facility<\/strong><\/li>\n\n\n\n<li>Scale output significantly<\/li>\n\n\n\n<li>Improve lead times and service levels to customers<\/li>\n<\/ul>\n\n\n\n<p>He wanted to understand how&nbsp;<strong>Zenaca Consulting<\/strong>&nbsp;could support this journey \u2013 from concept to a fully running, high-performance factory.<\/p>\n\n\n\n<p>We discussed my work in SMT and EMS consulting, and he immediately saw alignment with what PVR Controls wanted to achieve.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"first-visit-to-navi-mumbai\">First Visit to Navi Mumbai<\/h2>\n\n\n\n<p>Soon after, I visited the&nbsp;<strong>PVR Controls office in Navi Mumbai<\/strong>.<\/p>\n\n\n\n<p>That visit was important for three reasons:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>I understood their\u00a0<strong>current operations, constraints, and ambitions<\/strong><\/li>\n\n\n\n<li>We aligned on\u00a0<strong>scope<\/strong>\u00a0\u2013 not just equipment, but people, processes, and layout<\/li>\n\n\n\n<li>We built\u00a0<strong>trust<\/strong>\u00a0\u2013 the foundation of any long-term engagement<\/li>\n<\/ul>\n\n\n\n<p>By the end of this phase, PVR Controls issued a&nbsp;<strong>purchase order<\/strong>&nbsp;to Zenaca Consulting to drive their SMT factory transformation.<\/p>\n\n\n\n<p>The engagement had officially begun.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"from-idea-to-smt-line-selection-and-planning\">From Idea to SMT Line: Selection and Planning<\/h2>\n\n\n\n<p>The first major milestone was&nbsp;<strong>SMT line selection<\/strong>.<br>This is where many companies either overspend or under-design. Our focus was on:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Matching\u00a0<strong>equipment capability<\/strong>\u00a0with current and future product mix<\/li>\n\n\n\n<li>Ensuring\u00a0<strong>throughput<\/strong>\u00a0aligns with business growth plans<\/li>\n\n\n\n<li>Balancing\u00a0<strong>capex, flexibility, and maintainability<\/strong><\/li>\n<\/ul>\n\n\n\n<p>We worked through:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Printer, pick-and-place, and reflow oven selection<\/li>\n\n\n\n<li>Inline inspection strategy \u2013  AOI<\/li>\n\n\n\n<li>Peripheral needs: loaders, unloaders, conveyors, baking ovens, printers, compressors, ESD infrastructure, etc.<\/li>\n<\/ul>\n\n\n\n<p>Each selection was backed by data, not just brand names.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"layout-and-peripheral-planning\">Layout and Peripheral Planning<\/h2>\n\n\n\n<p>Once the equipment strategy was clear, we moved to&nbsp;<strong>layout planning<\/strong>.<\/p>\n\n\n\n<p>Key objectives were:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Smooth\u00a0<strong>material flow<\/strong>\u00a0\u2013 from incoming stores to SMT, through to box build<\/li>\n\n\n\n<li>Minimal\u00a0<strong>WIP accumulation<\/strong>\u00a0and handling<\/li>\n\n\n\n<li>Clear separation of\u00a0<strong>ESD-safe zones<\/strong>\u00a0and controlled areas<\/li>\n\n\n\n<li>Future-ready design for\u00a0<strong>additional lines<\/strong>\u00a0and expansion<\/li>\n<\/ul>\n\n\n\n<p>We created a layout that integrated:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>SMT line<\/li>\n\n\n\n<li>Material staging and kitting<\/li>\n\n\n\n<li>Rework and inspection areas<\/li>\n\n\n\n<li>Finished goods and dispatch flows<\/li>\n<\/ul>\n\n\n\n<p>Peripheral equipment planning was done in parallel so that utilities, safety, and ergonomics were addressed from day one.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"building-the-right-team\">Building the Right Team<\/h2>\n\n\n\n<p>A world-class factory is not just machines and layout. It\u2019s&nbsp;<strong>people<\/strong>.<\/p>\n\n\n\n<p>PVR Controls understood this early, and together we invested time and effort into&nbsp;<strong>key hiring<\/strong>:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>GM \u2013 Operations<\/strong>\n<ul class=\"wp-block-list\">\n<li>To lead day-to-day execution, drive KPIs, and anchor culture on the shopfloor<\/li>\n<\/ul>\n<\/li>\n\n\n\n<li><strong>Warehouse Manager<\/strong>\n<ul class=\"wp-block-list\">\n<li>To bring discipline into inventory control, material movement, and traceability<\/li>\n<\/ul>\n<\/li>\n\n\n\n<li><strong>Supervisors and Executives<\/strong>\n<ul class=\"wp-block-list\">\n<li>Across production, planning, quality, and stores to support ramp-up<\/li>\n<\/ul>\n<\/li>\n<\/ul>\n\n\n\n<p>My role was to:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Define\u00a0<strong>roles and responsibilities<\/strong><\/li>\n\n\n\n<li>Support\u00a0<strong>shortlisting and interviewing<\/strong><\/li>\n\n\n\n<li>Ensure selected candidates fit both the\u00a0<strong>technical needs<\/strong>\u00a0and the\u00a0<strong>culture<\/strong>\u00a0PVR Controls wanted to build<\/li>\n<\/ul>\n\n\n\n<p>This combination of structured hiring and clear expectations gave the new factory a strong leadership backbone from the start.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"ramping-up-from-plan-to-performance\">Ramping Up: From Plan to Performance<\/h2>\n\n\n\n<p>With equipment installed, layouts frozen, and teams in place, we moved into&nbsp;<strong>ramp-up<\/strong>.<\/p>\n\n\n\n<p>Focus areas included:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Stabilizing\u00a0<strong>process parameters<\/strong>\u00a0\u2013 especially printing and reflow profiles<\/li>\n\n\n\n<li>Training on\u00a0<strong>IPC standards<\/strong>, ESD, and basic problem-solving<\/li>\n\n\n\n<li>Implementing\u00a0<strong>daily management routines<\/strong>\u00a0\u2013 production meetings, line performance reviews, and issue escalation<\/li>\n<\/ul>\n\n\n\n<p>The result?<br>The new factory started not just producing \u2013 it started&nbsp;<strong>performing<\/strong>.<\/p>\n\n\n\n<p>Over time,&nbsp;<strong>production numbers ramped up to nearly 3X<\/strong>&nbsp;of previous outputs.<\/p>\n\n\n\n<p>This wasn\u2019t just a capacity story. It translated directly into:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Faster\u00a0<strong>turnaround times<\/strong><\/li>\n\n\n\n<li>Improved\u00a0<strong>on-time delivery<\/strong><\/li>\n\n\n\n<li>Better\u00a0<strong>customer responsiveness and confidence<\/strong><\/li>\n<\/ul>\n\n\n\n<p>Customers began to feel the difference:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Shorter lead times<\/li>\n\n\n\n<li>More stable quality<\/li>\n\n\n\n<li>Higher confidence in scaling business with PVR Controls<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"a-world-class-smt-facility-built-with-intention\">A World-Class SMT Facility, Built with Intention<\/h2>\n\n\n\n<p>Looking back, the engagement with PVR Controls stands out because it covered the full spectrum:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Strategy and scoping<\/li>\n\n\n\n<li>SMT line and peripheral selection<\/li>\n\n\n\n<li>Layout and material flow design<\/li>\n\n\n\n<li>Hiring and building the right leadership and operating team<\/li>\n\n\n\n<li>Ramp-up support and performance stabilization<\/li>\n<\/ul>\n\n\n\n<p>What started as&nbsp;<strong>one phone call<\/strong>&nbsp;from Mr. Shresth Kanodia turned into a&nbsp;<strong>world-class SMT factory<\/strong>&nbsp;and a strong partnership.<\/p>\n\n\n\n<p>For me, as a consultant, the most satisfying part was seeing:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>A clear vision<\/li>\n\n\n\n<li>Thoughtful investments in people and process<\/li>\n\n\n\n<li>And finally, a\u00a0<strong>high-performing factory<\/strong>\u00a0that is now serving customers\u00a0<strong>faster and better than ever<\/strong>.<\/li>\n<\/ul>\n\n\n\n<p>If your organization is planning to set up or transform an SMT facility, this journey is proof of what\u2019s possible when&nbsp;<strong>vision, execution, and collaboration<\/strong>&nbsp;come together.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Some of the most rewarding consulting engagements start with a simple phone call. That\u2019s exactly how our journey with&nbsp;PVR Controls&nbsp;began. The First Conversation One afternoon, I received a call from&nbsp;Mr. Shresth Kanodia, Director at PVR Controls.He had a clear vision: He wanted to understand how&nbsp;Zenaca Consulting&nbsp;could support this journey \u2013 from concept to a fully [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1],"tags":[],"class_list":["post-1653","post","type-post","status-publish","format-standard","hentry","category-uncategorized"],"_links":{"self":[{"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/posts\/1653","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/comments?post=1653"}],"version-history":[{"count":1,"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/posts\/1653\/revisions"}],"predecessor-version":[{"id":1654,"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/posts\/1653\/revisions\/1654"}],"wp:attachment":[{"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/media?parent=1653"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/categories?post=1653"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/tags?post=1653"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}