Coordinating complexity at the gigafactory scale

THE ASPIRATION
Powering the UK’s electric future
The UK’s first electric vehicle battery Gigafactory set out to establish a critical piece of national infrastructure. Located in the Northeast, the £1 billion AESC Giga 1 strengthens the domestic EV supply chain, supporting Nissan’s battery production while accelerating the country’s transition to low-carbon transport. With a footprint equivalent to 23 football pitches and a complex, M&E led scope, multiple contractor design portions and an ambitious programme, the project demanded seamless coordination, strong digital processes and clear, hands on leadership to manage risk and maintain momentum.

OUR RESPONSE
Embedded leadership for complex delivery
We were appointed by Wates SES to provide full-time Design Management support, embedding two consultants within the SES Design Team for two years. We carried out an independent review of design maturity, identified process improvements and developed a comprehensive Design Management strategy aligned to project priorities.

Working hands-on, we oversaw daily design management activities across more than 30 work packages, coordinating multiple CDPs and chaired weekly design reviews with package managers and subcontractors. We built bespoke design management tools integrated with the project’s existing Common Data Environment, improving information flow and transparency. Digital dashboards and real-time reporting enabled early identification of risks, while Flow was used to support M&E commissioning strategy development and complex system modelling.

THE RESULT
A coordinated, delivery-ready design
Our approach improved collaboration, reduced delays and strengthened design coordination across disciplines. Clear interfaces, structured reporting and proactive risk management helped avoid costly late-stage design changes, supporting efficient project execution through to completion. The completed facility delivers 12 GWh of battery capacity, enabling production for around 100,000 electric vehicles each year.

THE LASTING IMPACT
Setting the standard for gigascale projects
AESC Giga 1 is now a cornerstone of the UK’s EV manufacturing capability. Our contribution helped create a robust, digitally enabled delivery model for complex industrial projects – supporting economic growth, strengthening the UK supply chain and helping drive the transition to a more sustainable transport future.

Find out more about our Project and Programme expertise.