Expandable from day one
Phase 2 is not a hope — it is drawn, serviced and left clear. The second hall lands on prepared ground without disturbing production in the first.
Facility
One plant template, 100 by 50 metres.
Each GEMCO site is laid out to the same plan: a 5,000 m² plot carrying two production halls, an engineering and prototyping centre, storage, offices and welfare space — with land deliberately held back for expansion.
Concept design
The plant, as designed
A single-storey pre-engineered steel facility on a 5,000 m² plot: two column-free production halls fed from one service yard, with engineering, offices, storage and welfare grouped opposite them.
1Production hall — Phase 1: three lines (SMT, through-hole, module and cabinet assembly)
2Production hall — Phase 2: three further lines, built on land reserved from the start
3Engineering, R&D and prototyping centre
4Offices and meeting rooms
5Climate-controlled component store and finished-goods staging
6Canteen, welfare and visitor reception
7Service yard — goods-in at one end, dispatch at the other, one-way through the plant
8Landscaped green area held for future expansion
Concept design, drawn to the plot dimensions. Teal bands on the production roofs are the skylight and rooftop-solar zones; the green plane is land held back for Phase 2. Final architecture adapts to each country's plot, codes and utility connections.
Flow sets the layout
Material enters at one end of the service yard and leaves at the other. Nothing crosses back over itself, which is what keeps handling damage, mix-ups and rework down.
One drawing, three countries
The same envelope, spans and service runs are used at each site, so equipment layouts, training material and spare-parts lists transfer unchanged.
Site plan
How the plot is used
Production hallsEngineering, R&D and prototypingSupport, storage and welfare
Schematic site plan, drawn to scale. Zone positions are indicative and adapt to the plot and regulations of each country.
Schedule of areas
Every square metre accounted for
| Zone | Area | Purpose |
|---|---|---|
| Production hall — Phase 1 | ≈ 700 m² | Three production lines: SMT assembly, through-hole, module build |
| Production hall — Phase 2 | ≈ 700 m² | Three further lines added as volume and product range grow |
| Storage | 200 m² | Climate-controlled component storage and finished-goods staging |
| Engineering, R&D and prototyping | 100 m² | Board design, prototype assembly, bring-up and test-jig development |
| Offices and meeting rooms | 100 m² | Administration, planning, customer and supplier meetings |
| Canteen, recreation and guest area | 100 m² | Staff welfare and visitor reception |
| Green area and circulation | Balance of plot | Landscaping, parking, yard and reserved land for future expansion |
| Total plot | 100.00 × 50.00 m | 5,000 m² per site |
Construction and services
Built for electronics, not adapted for it
Dust, static, humidity and temperature swings decide the yield of an LED line. The building is specified around them.
Building
Shell and envelope
- Pre-engineered steel structure — fast to erect, column-free production spans
- Insulated sandwich panel walls and roof for thermal efficiency in Gulf summers
- Polished concrete floor with ESD coating throughout the production area
- Clear internal height of 3.6–4.5 m for ventilation and machine access
- Skylights and clerestory glazing to cut daytime lighting load
- Mezzanine-ready design so office space can grow without taking floor area
Systems
Services and controls
- HEPA-filtered HVAC holding stable temperature and humidity for calibration work
- ESD-controlled zones with conductive flooring and ESD-safe benches
- Local extraction at soldering stations plus general ventilation
- Centralised power distribution with UPS and standby generator
- Fibre-optic backbone linking machines, inspection systems and inventory control
- Automatic fire suppression suited to electronics, with signed escape routes
- Rooftop solar and rainwater harvesting where the site and budget allow
Why the same plan three times. A common layout means a process proven in one plant transfers to the next without redrawing it: the same line sequence, the same test stations, the same training material, and the same spare-parts list. It also lets the three plants cover for one another on capacity and specialist equipment.