Building Information Modeling
Building Information Modeling

How is Off-Site Manufacturing (OSM) mitigating the Semiconductor Supply Crisis?

It’s no secret that the semiconductor global supply chain is going through a crisis.
It has become clear that many industries and economies are dependent on the
supply of semiconductors. Construction productivity of new fabs (semiconductor
fabrication plants)
is lagging behind the growing demand as discussed in this article.
The industry’s goal is to double the global capacity of semiconductors within the
next few years. It is now the time to look for creative solutions. One of which
could be
Off-Site Manufacturing.

It’s no secret that the semiconductor global supply chain is going through a crisis.
It has become clear that many industries and economies are dependent on the
supply of semiconductors. Construction productivity of new fabs (semiconductor
fabrication plants)
is lagging behind the growing demand as discussed in this article.
The industry’s goal is to double the global capacity of semiconductors within the
next few years. It is now the time to look for creative solutions. One of which
could be
Off-Site Manufacturing.

The semiconductor industry has already reacted by launching the construction of
several Global Megaprojects to increase the capacity of semiconductor projects
(Intel, AT&S, TSMC, Bosch).
When building a new fab, there are many
considerations to be taken, including speed to market, material, installation
standardization, and of course, cost.

The semiconductor industry has already reacted by launching the construction of
several Global Megaprojects to increase the capacity of semiconductor projects
(Intel, AT&S, TSMC, Bosch).
When building a new fab, there are many
considerations to be taken, including speed to market, material and installation
standardization, and of course cost.

Does the fab construction process consider utilizing
recent technological innovation?

Many processes and systems have become available to improve construction productivity.
The issue, therefore, should be focused on the ownership, adoption, and standardization
of these processes into the construction processes. Unfortunately, while other industries
are improving their productivity curves via the introduction of technology, improved
processes, and continuous improvement methodologies, the construction industry is slow
when it comes to improving productivity.

Stagnation is pulling the industry to maintain traditional construction methods.
Failing to proceed into the next century of construction affects installation time, damages
the quality of the various systems involved, results in higher costs, and fundamentally
hurts the supply chain

Many processes and systems have become available to improve construction productivity.
The issue, therefore, should be focused on the ownership, adoption, and standardization
of these processes into the construction processes. Unfortunately, while other industries
are improving their productivity curves via the introduction of technology, improved
processes, and continuous improvement methodologies, the construction industry is slow
when it comes to improving productivity.

Stagnation is pulling the industry to maintain traditional construction methods.
Failing to proceed into the next century of construction affects installation time, damages
the quality of the various systems involved, results in higher costs, and fundamentally
hurts the supply chain

Utilizing off-site techniques – preFabrication and Modular Construction to support projects
is a major game-changer. Let us explain the merit behind it.

Utilizing off-site techniques – preFabrication and Modular Construction to support projects
is a major game-changer. Let us explain the merit behind it.

Faster, more reliable installation 

Designing and constructing the complex fluid systems required to construct a fab can be a
time-consuming process, involving a significant amount of labor and expertise. It includes
properly bending the appropriate tubing,
installing special components, and ensuring total
system integrity. This process can be especially difficult if contractors and installers are on-site
do not have the proper knowledge or training to assemble highly reliable, leak-tight systems.

Custom engineered and prefabricated fluid system assemblies can help eliminate installation
issues during construction and remove a significant amount of labor involved in assembling
these complex subsystems. OSM creates a complete, easy-to-install assembly made with
high-quality components. The time saved can help fabs become fully operational that much
faster, enabling full-scale semiconductor production to begin.

Reducing unnecessary connection points can also help save the fab builder money on extra
parts, and eliminate potential leak points. Any downtime resulting from a fluid system failure
can mean significant financial loss for every hour production must be shut down.

Designing and constructing the complex fluid systems required to construct a fab can be a
time-consuming process, involving a significant amount of labor and expertise. It includes
properly bending the appropriate tubing,
installing special components, and ensuring total
system integrity. This process can be especially difficult if contractors and installers on-site
do not have the proper knowledge or training to assemble highly reliable, leak-tight systems.

Custom engineered and prefabricated fluid system assemblies can help eliminate installation
issues during construction and remove a significant amount of labor involved in assembling
these complex subsystems. OSM creates a complete, easy-to-install assembly made with
high-quality components. The time saved can help fabs become fully operational that much
faster, enabling full-scale semiconductor production to begin.

Reducing unnecessary connection points can also help save the fab builder money on extra
parts, and eliminate potential leak points. Any downtime resulting from a fluid system failure
can mean significant financial loss for every hour production must be shut down.

Fig. The six stages of building life cycle. The image of six stages is based on the article
by
Ngwepe & Aigbavboa. Traditional on-site installation deals with installation late in
the construction process. On the contrary, OSM moves the installation stage earlier
in the construction process.

Fig. The six stages of building life cycle. The image of six stages is based on the article by Ngwepe & Aigbavboa.
Traditional on-site installation deals with installation late in the construction process. On the
contrary, OSM moves the installation stage earlier in the construction process.

Interface connectors – a time saving solution

Additionally, OSM involves the use of interface connectors, a modular solution that helps fabs cut
their installation time. The connectors are installed independently, prior to the arrival of the
machinery. The equipment thus becomes operational much faster,
which is especially important when projects experience delays in overseas shipments –
a phenomenon that has become quite common since the COVID-19 outbreak. This feature
can significantly help in meeting the time-to-market constraints of fab construction demands.

Additionally, OSM involves the use of interface connectors, a modular solution that helps fabs cut
their installation time. The connectors are installed independently, prior to the arrival of the
machinery. The equipment thus becomes operational much faster,
which is especially important when projects experience delays in overseas shipments –
a phenomenon that has become quite common since the COVID-19 outbreak. This feature
can significantly help in meeting the time-to-market constraints of fab construction demands.

Advanced and Customized Planning and Design

The digitalization of construction is at the heart of designing and installing pre-manufactured products.
Building information modeling (BIM) is a process supported by various tools, technologies and
contracts involving the generation and management of digital representations of physical and
functional characteristics. The virtual construction of a facility prior to its actual physical construction
helps reduce uncertainty, improve safety, work out problems, and simulate and analyze potential impacts.

The computer model visually highlights where parts of the building (e.g. pipes or ducts) may wrongly intersect.
Experienced BIM engineering teams are capable of delivering solutions that eliminate errors and discrepancies
during planning. They can identify clashes long before the project begins, resulting in a
significant reduction in project cost.

The digitalization of construction is at the heart of designing and installing pre-manufactured products.
Building information modeling (BIM) is a process supported by various tools, technologies and
contracts involving the generation and management of digital representations of physical and
functional characteristics. The virtual construction of a facility prior to its actual physical construction
helps reduce uncertainty, improve safety, work out problems, and simulate and analyze potential impacts.

The computer model visually highlights where parts of the building (e.g. pipes or ducts) may wrongly intersect.
Experienced BIM engineering teams are capable of delivering solutions that eliminate errors and discrepancies
during planning. They can identify clashes long before the project begins, resulting in a
significant reduction in project cost.

Fab fluid systems involve a variety of elements, including tube fittings, valves, regulators, hoses,
and tubing. High-end customized system planning, efficient design, effective tube routing, and other
installation practices can provide a system that is up and running faster, and will also be able to
function reliably for the facility’s expected lifetime.

Fab fluid systems involve a variety of elements, including tube fittings, valves, regulators, hoses,
and tubing. High-end customized system planning, efficient design, effective tube routing, and other
installation practices can provide a system that is up and running faster, and will also be able to
function reliably for the facility’s expected lifetime.

Improved Facility’s Life Cycle

Use of BIM goes beyond the planning and design phase of the project. The digital presentation
of the various systems can be extracted, exchanged or networked to support decision-making
during all stages of a fab’s life cycle. That may include cost management, construction management,
project management, and facility operation.

High-quality components and well-designed systems will enable easier and less time-consuming
MRO (Maintenance, Repair, and Operations) activities. Fewer necessary component and application
replacements will be required over time. The savings and reduced downtime obtained may help the
facility remain more productive and more profitable.

Quality and Standardization 

One of the main benefits of OSM is that a lot of quality and material placement issues are
automatically dealt with. Keeping safety and quality is done much more easily, especially
when delivering highly-complex and specialized projects.

Products can undergo leak tests, moisture tests and oxygen tests to ensure system integrity,
prior to their installation on site. This also brings coordination and higher
precision to the project​. 

Off-site manufacturing plants can meet the requirements of the latest and strictest standards
of constructions. This aligns with the overall advantages of reframing the supply chain process
of construction to allow for suppliers with better expertise and experience to execute
specialized stages of the process. 

The ability to deliver upcoming large projects will be constrained by the availability of
skilled construction labor. The global construction industry is moving towards offsite
manufacturing as one solution to this constraint. Clients have a key role in embracing
this transition and designing the solution. Clients can proactively engage in the improvement
process by demanding the modern solutions described in this article from their suppliers.

While any change can be initially perceived as disruptive to the traditional tiers of the
supply chain, the long-term benefits of these future technologies clearly support the
need for their quick adaptation.