Efficient Design and Layout

The Yazaki Chengalpattu facility was engineered to optimise production efficiency while ensuring safe segregation of people, materials, and utilities.

• Total built-up area of ~348,800 sq ft, comprising space for manufacturing and storage, a G+1 office block (~51,700 sq ft), and dedicated utility structures.
• 12 m clear-height PEB structure with skylights covering approximately 5% of the roof area to maximise daylight utilisation.
• Bay spacing of 8.0 m on the eaves side and 8.49 m on the gable side ensures structural efficiency and layout flexibility.
• Three external docking platforms with a total of 11 dock pits/dock levellers, along with two side-loading platforms for logistics operations.
• One drive-in shutter (4.0 m × 5.0 m) enables direct material movement for select processes.
• 16.5 m wide heavy-duty concrete apron designed to withstand high-frequency truck and bus movement.
• Two-track sliding windows with MS grills and mesh protection provided on all non-docking elevations.
• Roof monitor and louvre systems designed to deliver 4–6 air changes per hour (ACPH) across the shopfloor.
• Roof safety harness lifelines installed along the roof periphery and ridge ventilator for safe maintenance access.
• Separate man-entry and truck-entry gates, each controlled by dedicated security cabins, ensure safe traffic segregation.
• Separate worker entry with MS railing, platform, steps, and canopy, segregated from office and material movement.
• Additional washroom blocks designed to serve a daily population of approximately 2,000 employees.
• Dedicated 150 KLD STP, RO water systems, and enhanced domestic, flush, and filtered water storage.
• G+1 office block adjoins the manufacturing area, enabling direct administrative access and operational oversight.

Strategic and Well-Connected Location

Located at Horizon Industrial Park, Chengalpattu, the Yazaki facility benefits from strong regional connectivity and proximity to Tamil Nadu’s major automotive and electronics manufacturing clusters located in the Oragadam and Sriperumbudur industrial corridors. The park, located along Chennai-Trichy Highway enables efficient movement to Chennai and surrounding industrial corridors. The site is located about 66 km from Chennai Port and 50 km from Chennai International Airport, supporting both domestic distribution and export logistics. With improved road infrastructure and the development of nearby SIDCO industrial estates, Chengalpattu continues to emerge as a key manufacturing hub.

Solution-First Methodology: Built-to-Suit, Process-Led Onboarding

Horizon adopted a process-led, built-to-suit approach, aligning the facility’s design with Yazaki’s wiring harness manufacturing workflows. Early coordination ensured efficient zoning of manufacturing, utilities, office spaces, and logistics interfaces. Custom provisions such as dedicated dock infrastructure, drive-in access, segregated entries, and utility enhancements were integrated from the design stage to support smooth operational ramp-up. The resulting facility balances efficiency, safety, and long-term adaptability.

Partnership and Compliance Excellence

Project delivery followed a structured compliance framework aligned with Yazaki’s operational standards. Horizon ensured that all required statutory approvals – including planning approvals, fire NOC, environmental clearances, and pollution control consents – were obtained ahead of handover. Safety, quality, and regulatory compliance were maintained throughout execution, enabling Yazaki to commence operations within a fully compliant manufacturing environment. Mr. P. V. Raju, CEO of Yazaki India, affirmed the partnership’s value: “After evaluating several industrial developers, we chose to partner with Horizon, and they supported us in meeting our timely-delivery commitment to our customers … Horizon emphasizes quality infrastructure and gives us a dust-free environment which is crucial for manufacturing high quality products.”

ESG-Compliant & People-Centric Facility

Sustainability and workforce wellbeing are embedded into the Yazaki’s factory design.

• Roof structure designed for future rooftop solar power integration.
• Energy-efficient LED lighting and 3-star-and-above rated motors and pumps.
• Dual plumbing system with separate lines for domestic and flushing water.
• 150 KLD STP with 100% treated water reuse for flushing and landscaping.
• Rainwater harvesting pits and a recharge pond integrated into site planning.
• Skylights and continuous louvres reduce dependence on mechanical lighting and cooling.
• On-site canteen, creche, medical room, shaded walkways, and organised parking enhance employee comfort and safety.