When the Atlas Copco project team undertook the task of building a new production plant in Chakan, an industrial area near Pune, India, they also took on the challenge of building a facility that would set the benchmark for sustainable design and state-of-the-art production processes within Atlas Copco.
The Chakan Plant is the new production facility for industrial compressors from 5 to 90 kW and portable compressors from 85 to 1350 cfm. Spread out over 23 acres, the complex is 19 000 m2 and includes an administrative building, assembly workshop, finished goods storage and areas for R&D activities. The overall project development time was 18 months. It was completed without any work-related accidents and achieved more than 1 million hours of accident-free operations.
The plant’s layout was developed according to flow manufacturing principles. From goods reception to finished goods loading is one single, connected process flow, which focuses on the continuous flow of materials, products and information through the value-creation process. The manufacturing layout and logistics setup were designed to operate according to lean manufacturing principles. Consequently, the number of production lines and the overall assembly length were reduced considerably.
The factory was built in accordance with Atlas Copco’s globally accepted Sustainable Building Standard and in line with LEED (Leadership in Energy & Environmental Design) best practices has lately been certified by IGBC (Indian Green Building Council) as a Gold rated green factory building. Extra attention was given to energy-efficient design and technology to limit environmental impact and to reduce the use of energy and natural resources during the construction phase, as well as future plant operation.