Executive Launch Scorecard

A leadership-level view for owners, CEOs, COOs, Plant Managers, investors, and project teams.

Greenfield Readiness Assessment

Score each category from 1 to 5. This provides a directional readiness score and launch risk classification.

Facility Planning & Space Calculators

Material Flow & Layout Calculators

CapEx, Equipment & Investment Calculators

Startup Cost & Cash Burn Calculators

Workforce, Staffing & Labor Planning Calculators

Ramp-Up, Production & Revenue Calculators

Supply Chain Launch Calculators

ERP, MRP, Data & Systems Readiness

QMS, ISO, PPAP & EHS Readiness

Relocation & Go-Live Readiness

Best Practice Playbooks

1. Greenfield Startup Governance

• Set a weekly executive launch review with owners for facility, CapEx, people, supply chain, systems, quality, EHS, and ramp.
• Maintain one master launch schedule with dependencies and decision gates.
• Assign single-threaded owners for each launch workstream.
• Track critical path items separately from general task lists.
• Use red/yellow/green escalation with deadlines and decision rights.

2. Site Selection Playbook

• Evaluate labor availability, wages, utilities, logistics, incentives, permitting, zoning, taxes, suppliers, customers, and expansion capacity.
• Model freight impact and labor availability before committing to a site.
• Validate power, compressed air, water, wastewater, dock configuration, floor loading, ceiling height, and fire protection.
• Confirm hidden costs: tenant improvements, racking, permits, security, insurance, IT, utilities, and compliance.

3. Facility Design & Layout Playbook

• Design for flow from receiving to storage, production, inspection, packing, and shipping.
• Separate people flow, material flow, forklift flow, visitor flow, and emergency routes.
• Leave space for staging, quality holds, rework, maintenance, tooling, quarantine, and future growth.
• Avoid designing only for today’s volume; design for controlled scalability.

4. Equipment Procurement Playbook

• Define capability requirements before selecting equipment.
• Include installation, rigging, freight, utilities, tooling, training, spare parts, PM plans, and validation in the budget.
• Require FAT/SAT expectations for critical equipment.
• Link equipment purchases to capacity, margin, quality, and labor assumptions.

5. Workforce Launch Playbook

• Hire leadership and technical roles before mass hourly hiring.
• Create a staffing ramp tied to production ramp, not wishful revenue targets.
• Build training matrices for safety, quality, equipment, ERP transactions, standard work, and leadership routines.
• Define supervisor span of control and escalation routines early.

6. ERP / MRP Launch Playbook

• Clean item masters, BOMs, routings, units of measure, lead times, supplier data, inventory locations, and costing assumptions before go-live.
• Run conference room pilots using real scenarios.
• Train users by role, not generic system screens.
• Freeze data before launch and validate inventory accuracy.
• Measure transaction discipline during the first 30 days.

7. Supply Chain Launch Playbook

• Qualify suppliers before ramp, not during crisis.
• Build supplier scorecards for quality, delivery, responsiveness, capacity, and cost.
• Set initial safety stock based on startup instability and supplier reliability.
• Confirm packaging, labeling, receiving standards, freight lanes, MOQs, lead times, and escalation contacts.

8. Quality Launch Playbook

• Launch document control, inspection standards, nonconformance process, CAPA, audit schedule, training records, and quality holds before production scale-up.
• Use control plans and PFMEAs for critical processes.
• Validate measurement systems before relying on inspection data.
• Track first pass yield, scrap, rework, customer complaints, supplier defects, and corrective action closure.

9. EHS & Compliance Playbook

• Complete hazard assessments before equipment release.
• Establish PPE requirements, emergency response, OSHA logs, forklift programs, lockout/tagout, SDS, chemical storage, and incident response.
• Do not allow startup urgency to bypass safety discipline.
• Hold daily safety reviews during launch and first production ramp.

10. Production Ramp Playbook

• Ramp in controlled phases: pilot, low-rate initial production, controlled ramp, stabilized production.
• Define phase gates for quality, throughput, staffing, inventory, system transactions, and delivery performance.
• Do not scale broken processes.
• Review daily output, constraints, quality misses, downtime, labor variance, and material shortages.

11. Financial Control Playbook

• Separate startup costs, CapEx, operating expenses, inventory investment, and working capital needs.
• Track cash burn weekly during launch.
• Create budget vs actual reporting by workstream.
• Maintain CapEx approval controls and change order discipline.
• Translate startup delays into cash, margin, and customer impact.

12. Facility Relocation Playbook

• Build a move plan by department, equipment, inventory, customer commitments, suppliers, utilities, IT, and permits.
• Pre-stage materials and define what moves first, last, and never.
• Separate move readiness from production readiness.
• Communicate with customers and vendors before disruption occurs.
• Create Day 1, Week 1, and Month 1 stabilization checklists.

Launch Phase Gates

Downloadable Resource Library

Greenfield KPI Reference Table