Modular Cleanroom Project

Project Circle For Modular Cleanroom 

Plan: Design: Install: Operate: Performance Monitor and Control

Design Advantage

Design advantage approach is a project delivery method where both the design and construction of the clean room is contracted and managed by a single source.

As the single point of contact responsible for the successful implementation of the entire clean-room project and by using the Design advantage approach one can build process, Clean Rooms and receive a complete project scope and total cost before the project begins.

Why Design advantage approach?

Saves Time: Less time and fewer meetings required throughout the project

Saves Money: Clients know the true construction costs upfront allowing them to efficiently manage their budgets

Provides Piece of Mind: Clients select the clean-room solution that best suits their unique needs

“Fast Track” Process for project mobilization and commissioning:

ü  Site inspection for suitability

ü  Develop Drawings by understanding process requirements and Clean-room Specifications

ü  Manage all Material Procurements and resource study.

ü  Perform Site Staging target plan for execution.

ü  Ongoing Onsite Supervision for scheduled targeted completion.

ü  Coordinate Building Inspections with utility supply line planning.

ü  Manage all Subcontractors for timely completion and scheduled targets.

ü  Project Management regular checks on schedule follow-ups.

ü  Perform Final Balance, Test and Certification activities for final hand over.

ü  Manage all Final Inspections and operational efficient functionality of systems integrated.

ü  Complete all Final Documentation for hand over and sign of project completion.

“Fast Track” Process Clean-room

ü  Review Site and Processes

ü  Client Consultation

ü  Identify Contamination Issues

ü  Analyze Existing System Performance

ü  Prepare a Recommendation Report

Clean-room Engineering

ü  Review Client Requirements

ü  Analyze Potential Locations

ü  Estimate Preliminary Heat loads and Process exhaust

ü  Understand Client Space Utilization Requirements

ü  Create an Air Flow Schematic

ü  Design Architectural, Mechanical, Structural, Electrical and Plumbing drawings

ü  Develop Equipment Specifications

ü  Review/approve shop drawings and equipment submittals

ü  Obtain Final inspection and Engineering sign-off

Stages of Clean-room Project Installation

“Small First Step” Process ease with detailing done right from utility planning to man material movement, process organized in such a way that each process lot is not crossed by another to best suit process requirement giving facility a user and process friendly movement.

Installation of a clean-room can be simplified. The key components to a successful installation is understanding of what comes first and keeping not only movement but re-movement and space utilization in mind.

Typical Clean Project flowchart:

ü  Detailed Work Plan

ü  Design Drawings

ü  Project Submittals

ü  Project Management

ü  On-site Supervision

ü  Project Documentation

ü  Daily Work Log

ü  Daily Cleaning Report

ü  Material Inspection

ü  Release Log

ü  Testing

ü  Operational Verification Report

ü  Certification

ü  As Built Drawings

ü  Operations & Maintenance Manuals

Project Management for Understanding project Needs.

“Think to Act” Clean-room implementation depends upon how well the overall project is managed. Project management is the essential tool to organizing the tasks, resources and people needed for timely completion with plan, monitor and implement objectives of Project Management. The Think to act coordination in project management is the in-process planning and coordination solution to day to day roadmap and connecting the dot activities for reaching the objective set for project completion.

Process control of Project Management

Project Scheduling and timelines

Efficient operation and implementation of work force.

Economical approach for proper utilization of process material and man power concentrate and focused approach and quality work.

Project Management Process

Stage allocation: Scope of Work, Contract Documents, Preliminary Schedule

Planning with approvals, detailed plan in front: Final Drawings, Project Component, Working Schedule, Client Approval, Submit plans to local building authority, Procure long lead time components

In-process management: Material Staging, Room Layout, Subcontractors, Trade Installation, Building Department Inspections and sign-off

Controls and Validation: Personnel Safety Training, Personnel Clean/Build Training, Materials Inspection and Designated Release Location, On-site Documentation (Daily Work Log, Daily Cleaning Report, Materials Shipment Inspection Log, Building Department Inspections)

Closeout and Evaluation: As built drawings, Operation and Maintenance Manuals, Final Inspections and local authority sign-off, Certificate of Occupancy

Validation and re-validation Master Plan

Each installation specially for clean room has to meet the regulatory guidelines for certification which defines systems and procedures for measuring each process and its validation for compliance meeting the set designed standards.

The purpose of a clean-room is to control the following environmental factors: temperature, humidity differential pressure, sound, vibration and other process related specifications. After the clean-room is installed and before operation begins, the clean-room must be validated and certified to ensure:

ü  Consistent design for its intended purpose

ü  URS (User Requirement Specifications) guidelines for facility development and classified area requirements met and in line with set list of specifications with reference to defined process requirements.  

ü  Area defined in accordance with process requirement and conditions and all systems are giving correct measurable and efficient control solutions within the set guidelines of requirements.

ü  Regulatory requirements of safety and process flow in line with reference to guidelines and nomenclatures of quality control meeting and giving consistent results.

ü  Final Master Plan set for any change in process and up gradation system adaptive for future growth and user friendly as well as process friendly system in place.

Piyush Tripathi on Project Management

Project Management

Project management in any industry is the key feature that defines the system in place, if the system is not thought of or structured to give efficient functioning or operation, the entire exercise of planning and the system collapses giving results exactly opposite to what was expected. Most common error of project management or design error is prediction of growth or future due to its uncertain turn of events and non predictable market flow. But if project management is well thought of and the planning is done in the right direction all these errors can be eliminated. Basic tool for the system to function to its optimised level is to identify what is the requirement and where we intend to reach. Unless there is a drastic change in the trend the prediction can be averaged based on any industry growth flow path.

Any industry work flow is decided based on 3 basic steps.  

1. Process Flow what comes first and what comes next.
2. Work force movement from where individual work force with enter what should be the restriction and there flow according to their requirement.
3. Storage planning, may it be raw material or finish goods and of what will be the minimum inventory lead time to production and delivery planning.

It is irrelevant to produce in high quantity when we know that the material can be produced in much lesser time to avoid storage and supply error focussing on quality.  India is considered to be best in producing samples but when it comes to mass production or actual supply often manufacturing units are not able to deliver consistency in quality of product. Reasons are simple, when we make sample all the care and systems are followed but when the same comes in practice we tend to skip to check and bypass the system followed. Result is assumption of result which always falls apart. Any mechanical system or manufactured component made to follow the same steps and repeated. But to repeat steps the previous sample steps are not recorded, so how will we be able to replicate the results? Yes, we fail to walk the very step we took to produce the sample.  

Importance of project management is felt when product re-supplied fails the quality test. This is the basic factor constituting to development of project management system. Study cross link and implementation are basic factors of project management which has groomed skilled personnel through experience.

Like a great teacher always said

“Well, I have considered myself to be very fortunate in that I have been able to do mostly only that which my inner self told me to do… I am also aware that I do receive much criticism from the outside world for what I do and some people actually get angry at me. But this does not really touch me because I feel that these people do not live in the same world as do I.” ~ Albert Einstein

Project Management

Sir Albert Einstein quotes I follow, like

“Try not to become a man of success, but rather try to become a man of value.”

“A person who never made a mistake never tried anything new.”

“The only source of knowledge is experience.”

Experience and Variance

Variable Industrial experience and working with variable verticals of industry. Learning from leaders of industry as well each indifferent industrial experience, gives one a platform, a thinking process of known and un-known improvement. Each industry is what? How it operates? And how it has grown? My industrial experience have explored and installed projects of variable industries. Thinking process of each industry is different, each individual is different and each vertical and exposure is different.

Mechanical Machinery Manufacturing, packaging industries machinery, Process machinery for variable industry, projects of Chemical, bulk drug, hospital, pharmaceutical, API (Understanding of Man Material Movements), Flow path of material flow linear flow of material and installations, Safety requirements, BMS, IBMS, HVAC systems and Contamination control systems, security systems, utility systems mechanical pipeline requirements for basic and required utility systems. Last but not the lease paper industry, paper converting and binding stationary industry, most organized to un-organized sector.

Project management is required in each sector giving each industry its desired shape and groomed look to function to its most efficient form and perform by giving desired output which is the basic necessity of each industry.