Plant Expansion Readiness Checklist (Free)

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10 critical items still open - these are the highest-risk gaps.

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Demand and business case

Demand forecast is supported by customer commitments, not only sales estimatesCRITICALCurrent constraint is identified and the expansion actually relieves itCRITICALCheaper options were compared: OEE gain, extra shift, outsourcingBusiness case includes working capital, ramp-up losses and training costCRITICALSensitivity cases for 70 percent and 130 percent of forecast volume were runApproval path and capex limits are confirmed with finance

Site, utilities and layout

Floor loading, ceiling height and column spacing suit the new equipmentCRITICALPower capacity, compressed air, cooling water and gas supply are confirmed in writingCRITICALMaterial flow and forklift routes are drawn for current and future volumesRoom is kept for future expansion and for maintenance accessFoundation, vibration and temperature needs of precision equipment are checkedShipping and receiving dock capacity was reviewed

Permits, safety and environment

Zoning, building and occupancy permits are identified with lead timesCRITICALAir, water and waste permit changes were assessed with the regulator or consultantCRITICALMachine safeguarding and risk assessment are planned before installationFire protection and insurer notification are addressedHazardous material storage changes are covered

People and skills

Hiring plan covers operators, maintenance and quality with lead timesCRITICALLocal labor market can supply the skills in the volumes neededTraining plan exists, using the vendor and experienced staffSupervisor span of control and shift pattern are definedSpare parts and maintenance strategy are decided before start-up

Systems, quality and launch

Items, BOMs, routings and work centers for the new line are set up in the ERPCRITICALSupplier capacity and lead times for new raw materials were confirmedCustomer qualification or first article approval timeline is built into the planCRITICALMeasurement and inspection equipment is ordered and validatedCommissioning and acceptance criteria are agreed with the equipment vendorRamp-up plan has weekly output targets and an agreed review point

Do not pass the gate while any critical item is open. Treat unchecked non-critical items as risks with an owner and a date.

Check ERP setup for the new line

Optional: a review of routing, BOM and work center setup before launch.

Optional. The tool and every export work without this. No spam.

How to use it

Use it at two gates: before approving capex and again before installation. Assign each unchecked item to a person and date. Critical items are those that, if missed, can stop the project or cause a safety or compliance issue. Export the completed list to PDF for the approval package or a steering committee.

Why these checks

The checklist follows project stage gate practice. The demand and business case group tests whether the expansion is the right answer at all. Site, permits and people items represent long lead items that set the schedule. Systems and quality items are often forgotten until a late stage, when a customer qualification or an ERP setup delays first shipment.

Reading the results

A few unchecked items are normal at the first gate, but critical gaps should be closed or have a dated plan. Look at which group has the most gaps: many unchecked items in site and utilities suggests engineering review, while gaps in people and systems suggest the schedule needs more time before start-up.

Common mistakes

Teams often underestimate ramp-up, forget working capital, assume utilities can be upgraded quickly and plan training after installation. Another is declaring success at mechanical completion rather than at stable output at target quality and rate.

Frequently Asked Questions

Does this replace a project management plan?

No. It is a gate review tool. Detailed scheduling, budgeting and risk management still belong in your project plan.

When should I run it?

Before capex approval, before purchase orders for long lead equipment, and before start-up. The same list shows progress across gates.

Is it suitable for adding one line rather than a new plant?

Yes. Mark items that do not apply and note why. Utilities, people and system setup apply even to a single line.

What counts as a critical item?

Anything that can stop construction or production, or create legal or safety exposure. Edit the list to reflect your own risks.

If your expansion involves new ERP routings, BOMs and data setup, Netray can help check them before launch. The checklist is useful on its own.

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