In today’s fast-paced industrial environment, successful project management is not a luxury—it’s a necessity. Whether you’re setting up a new garment or leather factory, expanding your manufacturing capacity, or executing a turnkey industrial project, ineffective project governance can break the entire operation. Delays, cost overruns, and scope creep are not mere inconveniences—they are threats to business success.
I’m Kiriti Roy, a Factory Setup Consultant and Project Management Professional with over 29 years of experience managing large-scale industrial projects across India. Through my company, Lord Industrials Pvt. Ltd., I have led hundreds of projects from concept to commissioning—efficiently, on time, and within budget.
This blog will guide you through the complete project lifecycle, highlight why most projects fail, and introduce best practices to manage and govern your projects effectively, especially in the factory setup and industrial infrastructure domain.
📉 Why Most Projects Fail – The Real Picture
According to a survey by Standish Group International:
- 70% of projects suffer from budget and schedule overruns
- 52% of projects finish at 189% of their initial budget
- Only 16% of projects are deemed truly successful
- The rest are either underperforming (53%) or cancelled mid-way (31%)
These statistics reflect a serious issue in project management practices, especially in sectors like infrastructure, factory setup, and manufacturing where margins are thin and execution windows are tight.
🧱 Common Reasons for Project Failure
Let’s break down some of the core issues seen in failed or struggling projects:
1. Inadequate Project Governance
- No clear authority, accountability, or oversight mechanisms
- Lack of standardized review or approval points
2. Poorly Defined Objectives
- Ambiguous project goals lead to confusion in execution
- Stakeholder expectations are often not aligned
3. Weak Planning and Scheduling
- Improper estimation of time, resources, and cost
- Lack of contingency plans for risk mitigation
4. Shortage of Skilled Resources
- Inadequate team planning leads to over-reliance on key individuals
- Risk increases when team members leave or shift roles
5. Supplier and Vendor Problems
- Delayed deliveries, quality issues, or unclear scope of work from suppliers
6. Technical Challenges
- Incorrect machine specs, design flaws, or layout mismatches
As a result, many promising factory or infrastructure projects never converge, even after months of investment and crores in expenditure.
🛠️ The Solution: Standardized Project Management
The key to avoiding failure lies in adopting a standardized, structured project management approach. As I always say:
“A project is only as successful as the governance behind it.”
Whether you’re handling a 5000 sq. ft. garment facility or a multi-floor jute bag factory, managing a project from Inception to Closure requires a repeatable, accountable process.
📊 Five Phases of Project Management (PMI Standard Approach)
Here’s how you should structure every industrial or factory setup project:
1️⃣ Initiation – Setting the Foundation
This is where the project charter is developed and signed off. Key tasks include:
- Define project objectives
- Identify key stakeholders
- Establish initial budget & scope boundaries
- Identify constraints and assumptions
- Finalize high-level deliverables and timelines
Deliverable: Project Charter, Stakeholder Register
2️⃣ Planning – The Heart of Execution Success
The most important phase, where everything is mapped and visualized in detail.
Key Activities:
- Collect and define technical & functional requirements
- Define exact project scope (avoid scope creep)
- Create detailed Project Management Plan (PMP)
- Develop Project Schedule in professional PM software
- Plan for:
- Budget estimation (BAC)
- Quality benchmarks
- Communication & reporting
- Risk management & contingency
- Resource planning & manpower allocation
- Procurement & vendor coordination
A good plan ensures that nothing is left to assumption.
Deliverables: Work Breakdown Structure (WBS), Gantt chart, Risk Register, Quality Plan
3️⃣ Execution – Bringing the Project to Life
This is where construction, installations, purchases, and mobilization begin.
Execution Must Include:
- Following the approved PM plan
- Regular status meetings with team & client
- Creation of real-time progress reports
- Material and resource tracking
- Updating the project plan with actuals vs baseline
- Logging lessons learned (for final evaluation)
At Lord Industrials, we use PM tools to track deviations, ensuring alignment with planned cost and time budgets.
4️⃣ Monitor & Control – Guarding the Project
While execution is ongoing, monitoring and control run in parallel.
Activities:
- Performance reviews on quality, time, and budget
- Issue logs and risk registers updated weekly
- Approval of key deliverables by stakeholders
- Managing change requests and approvals
- Adjustment of project baselines when required
- Escalation of unresolved blockers
We constantly ask:
“Are we on track?”
“What’s at risk this week?”
“What corrective or preventive action is required?”
5️⃣ Closure – Finishing Strong
Proper closure avoids disputes and ensures knowledge retention.
Key Closure Activities:
- Final deliverable handover and sign-off
- Compilation of “lessons learned”
- Archival of documentation
- Post-project review meeting
- Recognition of team and stakeholders
- Knowledge handover to operations team
Deliverables: Final Status Report, Project Archive, Closure Certificate
🧠 Project Governance – The Secret Weapon
Project Governance ensures that:
- The project is aligned with organizational goals
- Communication is structured and timely
- Performance is monitored and audited
- Lessons are applied and continuously improved
Through structured Project Governance, I help clients:
- Minimize delays and disputes
- Gain real-time clarity on project status
- Ensure compliance with safety and quality standards
- Create repeatable systems for future projects
💻 Project Management Software – A Must-Have Tool
At Lord Industrials, we use professional PM tools to:
- Create Gantt Charts with dependencies
- Track real-time progress
- Allocate resources and adjust workloads
- Identify early warnings on cost or time deviations
- Generate weekly reports for stakeholders
This gives our clients full transparency and data-backed decision-making.
🎯 How I Can Add Value to Your Project
As a certified project management professional and factory setup expert, here’s how I bring value:
- Create practical and detailed project plans
- Track planned vs actual performance regularly
- Manage risk proactively, not reactively
- Conduct performance reviews and audits
- Ensure stakeholder alignment and satisfaction
- Capture insights to optimize your next project
🏗️ Real-World Applications – Factory Projects Done Right
Whether it’s a 100-machine garment unit, a jute bag production line, or an export-oriented leather workshop, I have managed:
- Turnkey projects from layout to execution
- Multivendor coordination
- Utility and compliance installations
- On-time completion of mission-critical factory setups
Through Lord Industrials Pvt. Ltd., my team also delivers:
- Industrial furniture
- Storage racks and trolleys
- Electrical and mechanical contracting
- Project-based turnkey execution
🔚 Conclusion – Don’t Just Execute, Excel
A successful project doesn’t happen by accident. It is planned, governed, executed, and closed with discipline.
By following a standardized project management approach, you:
- Minimize cost overruns
- Meet timelines with confidence
- Build a trustworthy industrial brand
And most importantly, you deliver value—not just to clients, but to your team and stakeholders.
📞 Ready to Manage Your Project Professionally?
Let’s connect and ensure your next project is a success story. I offer:
✔️ Personalized Project Planning
✔️ Factory Setup Execution Support
✔️ PM Tool Implementation
✔️ Technical Advisory and Governance
📌 Contact Kiriti Roy – Factory Setup Expert
🌐 Website: www.lordindustrials.com
🌐 Company: Lord Industrials Private Limited
📧 Email: info@lordindustrials.com 📲 Call or WhatsApp: +91 7603059695
- Turnkey Factory Setup Services : We offer complete turnkey factory setup services to help clients manage projects end-to-end.
- MSME India – Project Subsidy Schemes : Explore government schemes and support for project execution via the MSME Ministry.
- Standish Group CHAOS Report (on project success/failure rates) : According to the Standish Group CHAOS Report, most projects fail due to lack of governance.
- LinkedIn Profile – Kiriti Roy : Follow me on LinkedIn for insights into factory planning and industrial consulting.