New build, utilities first, production last
Commissioning software for a new factory where utilities have to be proven before anything can be tested.
A greenfield plant is built by a general contractor, filled by a dozen equipment suppliers and accepted by an operations team that arrives late. Deskely holds the building services, utilities and production equipment in one register with a certification order that reflects how the plant actually starts.
- Scope
- Building, utilities, production
- Parties
- GC plus 10–30 suppliers
- Order
- Utilities before equipment
- Gate
- Line acceptance and ramp
Choose your project type
The problem
Every supplier brings its own paperwork, and none of it adds up to a plant.
The general contractor tracks the building. Each equipment supplier tracks its own machine in its own format. The owner's project team keeps a master spreadsheet that is out of date the day it is issued.
Nobody can answer the only question that matters during ramp-up to rate and OEE targets: which utilities, halls and lines have actually completed SAT, and which single unproven asset is stopping SOP.
Deskely puts every asset in one register with one status model, so plant readiness is derived from signed records instead of assembled from supplier reports.
Setting up the register
Utilities, building services and production lines are separate subsystems with separate gates.
Compressed air, chilled water, steam, electrical distribution, HVAC, fire protection and process exhaust each reach completion on their own path — and every production machine depends on several of them.
Equipment lists, layouts, I/O schedules and utility single lines are parsed into a reviewed register, so every machine and every utility branch carries its drawing reference.
That structure is what makes it possible to energise a hall and commission a line while the rest of the plant is still being built.
FAT and SAT
The supplier's factory test is evidence, not a formality to be filed later.
Machines are proven twice: once at the supplier's Factory Acceptance Test (FAT) and once on your floor at Site Acceptance Test (SAT). Both belong to the same asset, and the SAT plan usually depends on punch raised during FAT and on utilities readiness for machine safety CE marking checks.
Deskely holds FAT results and open FAT punch against the equipment tag, so a machine cannot pass site acceptance while a factory finding is still open and unowned.
Suppliers execute their own records under scoped access rather than emailing scanned packs at the end.
Handover to operations
The plant is handed to a team that will run it for twenty years.
Operations and maintenance inherit the asset base along with its manuals, spare parts references, settings and test history. Compiled only once the line is running, that pack never arrives whole.
Because the dossier builds continuously, handover per line or per hall is an export rather than a project of its own.
Every signature keeps a name, role and timestamp, which is what makes the pack useful during the first plant audit.
The energisation sequence
A greenfield plant is proven hall by hall, and the sequence itself is the schedule risk.
The order in which halls are energised is not a formality — it is set by which utilities are live, which building services have completed their own FAT/SAT, and which production halls the general contractor is releasing for equipment installation. Get the sequence wrong and a supplier's team stands idle in a hall with no compressed air or chilled water while another hall sits fully utilities-ready with no equipment installed yet.
Deskely models utilities availability as an explicit prerequisite against every hall and every machine, so the project team can see, weeks in advance, exactly which hall will be ready to receive equipment and which one will hold the schedule. That is the difference between a GC handover plan built on assumption and one built on signed utility completion records.
By the time the plant reaches SOP ramp, the sequence that got it there — utility by utility, hall by hall, line by line — is a readable history rather than something the project team has to reconstruct from memory for the post-project review.
What the ready-for-production review reads
The records that carry a greenfield plant from empty building to a facility production is willing to accept.
A greenfield plant hands over utilities, building services and process equipment installed by different contractors on overlapping schedules. The dossier ties each system's commissioning record to the same tag register the operating organisation inherits, so ready-for-production is argued from evidence rather than a walk-through.
Utilities and building services commissioning record
Compressed air, HVAC, process water and power distribution meet design capacity before equipment install starts
Before mechanical equipment installation begins in each area
FAT protocol and deviation log
Equipment met the purchase specification at the vendor's works before shipment
At the factory, before equipment is released for shipping
SAT protocol and punch closure record
Equipment performs on site to the same criteria proven at FAT, after installation and interconnection
On site, after installation, before process trials
Safety circuit and interlock validation record
Emergency stops, guarding interlocks and safety-rated logic function as designed before power is applied to moving equipment
Before first energisation of any powered equipment
Utility tie-in and isolation verification
New process equipment is correctly isolated from and connected to existing site utilities
At each tie-in point, before the connected system is commissioned
Ready-for-production sign-off record
All systems in a production line or area have cleared commissioning and outstanding punch is categorised and owned
At handover from the project to the operating organisation
How it runs
From an empty slab to a line running at rate.
Greenfield projects reward structure set up before the first machine lands, because the ramp is where every documentation gap becomes visible at once.
- 01
Break the plant into subsystems
Utilities, building services, halls and production lines, each with its own completion path.
- 02
Parse the equipment set
Equipment lists, layouts, I/O schedules and utility single lines drafted into a reviewed tag register.
- 03
Template the record set
Installation, mechanical, electrical and functional records defined once per equipment type.
- 04
Give suppliers scoped access
Each supplier completes its own records against its own tags, without seeing or editing anyone else's.
- 05
Gate SAT on utilities
A machine cannot pass site acceptance until the utilities it depends on are signed and available.
- 06
Accept line by line
Line acceptance issued from signed records with punch categorised, and dossiers exported to operations.
FAQ
Questions about Greenfield plants scopes.
Keep reading
Manufacturing commissioning
The full sector view: asset registers, FAT and SAT evidence, punch lists and line acceptance.
Read moreCertificates
Mechanical completion, SAT and line acceptance certificates issued from signed records.
Read moreAI drawing parser
Layouts, equipment lists and I/O schedules turned into a reviewed asset register.
Read moreOther manufacturing project types: Production line installation and SAT, Automotive body, paint and assembly, Food, beverage and hygienic process, Pharmaceutical and life sciences facilities, Battery gigafactories and cell plants, Semiconductor fabs and cleanroom fit-out, Warehouse automation and intralogistics, Pulp, paper, steel and heavy process, Brownfield upgrades and line relocations.
