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.