PV Solar IE Solutions 2010
Transcript of PV Solar IE Solutions 2010
Tailored Solutions to Your Individual
PV Operations Requuirements
Manufacturing Integration, Productivity and Technology Services
As part of our ongoing commitment to environmental stewardship, this page has intentionally been left blank to accommodate two-sided printing
CH2M HILL at a GlanceFounded in 1946 and headquartered near Denver, Colorado, employee-owned CH2M HILL is a global firm providing consulting, engineering, construction, operations, and related technical services to public and private clients.
• More than 23,500 employees in offices worldwide
• 100 percent employee owned
• Broadly diversified across 10 business sectors:
» Energy & Chemicals
» Environmental
» Government Facilities & Infrastructure
» Industrial & Advanced Technology
» Industrial Systems
» Nuclear
» Operations & Maintenance
» Power
» Transportation
» Water
• $6.3 billion in revenue (2009)
Recognized for Industry ExcellenceCH2M HILL earned 13 Number One rankings and multiple Top 10 rankings from Engineering News-Record in 2009. These rankings include:
• #1 of Top 20 Manufacturing Design Firms
• #2 of Top 100 Construction Management Firms
• #1 of Top Five Design Firms in Semiconductor Industry
Performance Excellence - Recognized Across IndustriesAs a result of our processes and systems, we have won many industry awards from our customers for project quality, health and safety, and customer satisfaction. With an EMR of 0.74, our safety record is among
the best in the industry.
At CH2M HILL, we strive to “outperform,” exceeding your expectations and our industry’s standards.
It’s not the exception here.
It’s the rule.Each of our clients demands and deserves a completely satisfying solution on every project, regardless of complexity.
Company OverviewCH2M HILL has long been recognized as a leading employer and admired company. FORTUNE
magazine consistently ranks CH2M HILL among its “100 Best Companies to Work for in America,”
and a “most admired company.”
Fortune Magazine ranked
100 BEST Companies to Work For
CH2M HILL
20092009
www.ethisphere.com ranked
World’s Most
ETHICALCompanies
CH2M HILL
Improving Performance and ProfitGlobal solar/PV manufacturing is hypercompetitive, with companies aggressively seeking to establish market share through technological and operational advantages. In this dynamic environment CH2M HILL provides leadership in achieving these goals through:
• Capacity planning, layout, analysis and risk mitigation to reduce capital factory costs for equipment and plant facilities
• Application of simulation and modeling techniques to optimize manufacturing lines and increase factory yield
• Focused programs in Manufacturing Operations Excellence to reduce operations costs
• Business process re-engineering utilizing techniques such as value stream mapping and gap analysis to improve efficiency of business processes
CH2M HILL Manufacturing Solutions - OverviewThe CH2M HILL Manufacturing Integration (MI) group provides full-service solutions, from initial
planning through design, optimization, and integration. We serve a wide range of manufacturing
clients, including photovoltaic (PV), microelectronics, flat panel display, energy storage, consumer
products, and other high volume manufacturers.
• Productivity studies
• Manufacturing excellence/lean constraint analysis
Manufacturing Operational Systems
• Systems assessment, refinement, selection and integration
• Manufacturing execution system (MES)
• Controls systems (PLCs, AB, GE, Siemens, Mitsubishi, etc.)
• Motion controllers
• Vision systems
• SCADA systems (GE Proficy, RS View, Wonderware, etc.)
• SQL, Oracle and other database systems
• Ethernet networks
• Industrial PCs
Automated Material Handling Systems (AMHS)
• Turnkey solutions
• Automation simulation and modeling
• Conveyors (belts, links, rollers)
• Robots (SCARA, r- -z, Cartesian)
• Warehouse layout planning
• General material handling design
• Sustaining engineering
• Facility planning support
• Layout services
• Construction modifications
• Equipment installation and integration
Equipment Install Planning
• Production tools integration and production readiness
• Line audit for factory acceptance
• Equipment source inspection
Manufacturing/Facilities Planning
• Strategic planning
• Support area requirements
• Flow analysis
• Warehousing/logistics
• Utility requirements definition
• Micro level manufacturing layout planning
• Macro level manufacturing layout planning
• Tool list development
• Capacity modeling/planning
• Manufacturing process definition
• Manufacturing production plan definition
• Operating procedures
• Staffing plans
• Manufacturing/process simulation
• Workplace design
• Microcontamination design
Strategic Planning/Risk Assessment
• Business risk analysis
• Profitability analysis
• Asset management
• Operational goaling
• Financial modeling
• Cost of ownership model
• Facility cost model
Factory/Line Optimization/Modeling
• Line/equipment layout
• Static and dynamic modeling
• Production flow modeling
• Failure mode and effects analysis (FMEA)
• Production equipment layouts
• Layout optimization
CH2M HILL Manufacturing Integration engineers enter the project early in the pre-planning phase, to define and integrate the facility, systems, process equipment, and operational activities.
Manufacturing Integration, Technology & Productivity Services
Mitsubishi REC Spectrawatt Trina Solar
CRYSTALLINE SILICON
THIN FILM
polysilicon wafer cell module
silicon CdTe CIGS
various turnkey vendorsand their customers First Solar Solyndra
CH2M HILL provides a single point of responsibility for the complete life cycle of your project.
Engineers, designers, and technical specialists make up the core of our firm — professionals with unparalleled experience in all phases of the planning, design, and installation operations that support the development of wafer and thin film manufacturing systems.
Our portfolio includes customers ranging from start-ups to companies in the top 20 list of manufacturers. We have provided design-build, design only, and consulting work in Asia, Europe, and North America.
Our experience base encompasses the full spectrum of PV manufacturing processes, from the initial production of polysilicon, including monocrystalline, to polycrystalline casting, amorphous, cadmium telluride (CdTe), CIGS and multijunction technology.
CH2M HILL has worked with developers of solar/PV products in all cell technologies and has more than 10 years of experience in both crystalline and thin film technology.
Photovoltaic Manufacturing
In-house Experience and Tools
Solution Evaluation and Optimization
• Lean planning for concept development
• Business process mapping supporting optimized methods
• Dynamic capacity models for production line evaluation (standardized models)
• Material handling simulation models to validate material handling solutions (standardized models)
Manufacturing Operations Systems
• Requirements definition – controls/manufacturing execution systems (MES)/material control systems (MCS)/enterprise
• Business process mapping
• Programmable logic controller (PLC), human machine interface (HMI) and instrumentation development for process and material handling equipment
• System design/implementation/start-up/ramp
• Manufacturing execution systems (MES) – genealogy/process data/recipe management/flow control/advanced process control/yield management
• Material control systems (MCS)
• Enterprise/enterprise resource management (ERP)/product lifecycle management (PLM)
• Supplier management
• Ongoing support – software maintenance/equipment maintenance
Process Technology Experience
• Mono- and polycrystalline silicon
• Cadmium telluride (CdTe)
• Amorphous silicon
• Copper indium gallium (di)selenide (CIGS)
Production Line Layout and Material Handling Applications
• Single, stack and cassette wafer handling
• Inline and batch wafer processing
• Wafer buffering
• Large glass thin film single sheet and batch processing configurations
• Alternate media applications (glass tubes, flexible media, wafer)
• Raw materials and finished goods logistics
PV Automation Expertise
• Automated storage and retrieval systems
• Automatic guided vehicle (AGV)
• Rail guided vehicle (RGV)
• Stack and single wafer handling
• Wafer buffering
• Raw wafer handling
• Manufacturing execution systems
• Cassette and stack loading and unloading
• Process tool loading and unloading
ApproachCH2M HILL combines our process, material handling, and engineering experience when evaluating and optimizing potential solutions. The figure on the next page demonstrates the execution of the basic evaluation process.
Our approach includes the following activities, with the flexibility to tailor a solution to fit your needs and budget:
• Develop processing requirements as defined by the client team, creating a manufacturing requirements document. This process utilizes Lean methods to quickly converge on the appropriate definition.
• Execute a baseline process where existing concepts are evaluated both statically and dynamically, creating a validated baseline where alternative solutions and changes can be ranked.
• Develop alternate and potential solutions.
• Evaluate potential solutions statically to eliminate options that will not support efficiency improvements.
• Perform dynamic evaluation of best case options as defined by the static process; rank solutions per criteria.
Pho
to: A
leo
So
lar
Award ContractClient
Requirements
Validation and Modeling
Concepts
Layout
DYNAMICSimulation
STATICSimulation
Bids
ManagementApproval
Construction & Integration
Construct Software Systems
Install Equipment
Vendor Submittal, Review & Recommendation
Equipment SolutionsConcepts &
Validation
Bid PackageDevelopment
CH2M HILL
OPTIMIZEDmaterial handling
system design
STARTUPramp factory
Deploy & IntegrateSoftware Systems
Req
uire
men
ts
From developing system requirements through the request for qualification, bid, selection and construction/integration, CH2M HILL vendor management for both material handling and manufacturing system solutions minimizes capital expenses while optimizing PV facility operations. We deliver cost effective, turnkey automation systems to meet your needs, not a supplier specification sheet.
The hybrid approach of static and dynamic analysis offers a comprehensive evaluation of all possible options yielding optimal solutions while minimizing time and effort.
Material Handling Modeling
Representative Client ProjectsThe MI team has supported the Solar/PV thin film market in various planning, evaluation
and optimization activities. This support included layout, simulation, and material handling
system recommendations within the crystalline silicon, amorphous silicon (a-Si), cadmium
telluride (CdTe), and copper indium gallium (di)selenide (CIGS) manufacturing technologies. A
representative example list is provided below. Intellectual property (IP) is extremely sensitive in
PV manufacturing; to guard our clients’ IP, we keep client names and project specifics confidential.
The following projects were implemented in factories in North America, Asia and Europe.
Material Handling Design
Amorphous SiliconCH2M HILL developed manufacturing facility design options. MI services were used to create and test layouts adapted to support the site and facility constraints:
• Simulation modeling was used to evaluate potential material handling system approaches.
• We developed alternate layout configurations that supported the selected material handling approach that supported facility constraints.
• Simulation and layout activities included overlapping RGV operation, ASRS stacking, batch transportation of WIP and single sheet conveyor transport of WIP.
Manufacturing Layout Design
Amorphous SiliconCH2M HILL developed the manufacturing facility design and included the following MI services to validate the manufacturing space and production requirements:
• Dynamic capacity modeling was used to evaluate delivery and work in progress (WIP)requirements affected by planned and unplanned production tool schedules.
• Simulation modeling was used to support evaluation of potential material handling solutions and their impact on production capacity.
• Simulation included the use of six-axis robotics, glass conveyance, tool loading robots and bulk sheet buffering.
Wafer Manufacturing
Module Manufacturing
Empty Container Return
Module Manufacturing
Cell Manufacturing Cell Manufacturing
Material to Cell
Ingot In
Material Handling Flow Analysis
Amorphous SiliconCH2M HILL conducted detailed analysis of materials and production material handling requirements to resolve both traffic and space limitations associated with a retrofit facility.
• Conducted logistics studies supporting general material handling between production lines.
• Simulated potential solutions and recommended changes to warehousing layout, production layout, and associated space requirements.
• Simulation and layout activities included forklift transport of glass A frames, conveors, ASRS, and logic supporting conveyor operation.
Manufacturing Layout Design & Implementation
Polycrystalline Silicon Materials CH2M HILL developed the complete manufacturing facility design for a multiphase polysilicon ingot and wafering facility, including the following services:
• Evaluation of multiple sites in support of the client’s production process and manufacturing plans; the resulting facility fit the client’s plan and accelerated the project schedule.
• Complete design-build activities for multiple production lines, including vendor coordination, utility planning and modeling, equipment layout, and material handling planning.
• Significant coordination into facility and systems planning with the client’s Lean manufacturing team for the new manufacturing approaches.
• Coordination of vendor design activities across different vendors and process steps, including automation transporting product between major process operations, process loading and unloading, and space management within the facility.
• Vendor coordination and source inspections to validate production equipment performance to design.
Line Layout Optimization
Cadmium Telluride (CdTe) CH2M HILL conducted detailed manufacturing efficiency studies to support the client’s analysis of potential manufacturing line configurations. CH2M HILL further recommended potential material handling solutions to support the recommended line configurations:
• Provided dynamic capacity modeling of production lines to determine the most efficient line combinations.
• Identified detailed production line layout testing to desired production line configurations.
• Provided simulation modeling of finalized material handling configurations and production layouts.
• Simulation and layout activities included pick and place glass robotics, conveyors and conveyor logic, ASRS, and sheet buffers.
Manufacturing Equipment & Operation Systems/MES Integration
Amorphous SiliconCH2M HILL had total responsibility for manufacturing operations systems, including equipment control, production tracking, maintenance management and quality control.
• Developed equipment specifications to drive standard operations and interface of vendor equipment.
• Worked with equipment vendors to ensure specifications were met.
• Developed equipment software to manage automated material transfer between production equipment.
• Developed tool control software to upgrade or replace vendor supplied software.
• Developed production tracking software for genealogy and production reporting.
• Developed production dashboards and reports for operations management.
Material Handling Strategy
Copper Indium Gallium (Di)Selenide (CIGS)CH2M HILL supported the analysis and identification of the corporate material handling strategy of the new production line as follows:
• Studied and recommended material handling strategy for the new production lines.
• Developed detailed layout options supporting the new strategy and testing facility, including layout constraints.
• Simulated final solution, validating final hardware system requirements.
• Simulation and layout activities included ASRS, AGV, six-axis robotics, and various conveyor configurations.
Pho
to: S
ola
rwo
rld
ERP
Application Server
Equipment Interface
ProductionManagement
MaintenanceManagement
QualityManagement
InventoryManagement
Human/MachineInterface
Historian
Process Equipment
Equipment Interface
processcontrol
cons
ume p
roduce
Process Equipment
Equipment Interface
processcontrol
cons
ume p
roduce
Process Equipment
Equipment Interface
processcontrol
cons
ume p
roduce
Material Handling
Equipment Interface
materialstorage
cons
ume p
roduce
Manufacturing Basis of Design
CdTe, CIGSCH2M HILL supported this clients in the process of scaling from a prototype line to the first high volume manufacturing line.
• Performed industrial engineering analysis of the manufacturing line configuration and defined optimal layout.
• Performed engineering analysis of factory warehousing requirements; proposed solutions including warehousing sizing requirements, identification of storage and handling concepts and selection criteria.
• Established process equipment utility matrix and identified utility loading for the new building.
• Reviewed the logistical flows of raw materials and finished goods to, from, and within the site/building, including comparison of process manufacturing equipment with process flow methodology, identification of bottlenecks.
Manufacturing Layout Design
Monocrystalline SiliconCH2M HILL developed the complete manufacturing facility design for a multiphase facility, including the following MI services:
• Utility modeling, tracking and analysis to determine the effects of different vendor selections on the overall design of the facility and the start-up/commissioning ramp.
• Coordination of vendor design activities across different vendors and process steps, including automation transporting product between major process operations, process loading and unloading, and space management within the facility.
• Equipment layout and planning to ensure proper material, personnel, and maintenance activities.
• Warehouse design, layout and flow planning.
Gap Analysis on Manufacturing Operations Systems
Amorphous & Polycrystalline SiliconThis client had a polysilicon factory and an amorphous silicon (a-Si) factory; CH2M HILL performed a gap analysis on manufacturing operations systems:
• Studied each factory and documented existing production tracking methods.
• Met with stakeholders to determine priorities for improvements and additional functionality.
• Developed gap analysis including development plan, priorities, and investment requirements.
The unique experience of the CH2M HILL Manufacturing Integration team, with both facility and manufacturing systems, provides a strong foundation for the development and evaluation of systems optimized for PV manufacturing.
CH2M HILL’s extensive experience across the PV industry includes:
• Facility design of monocrystalline and polycrystalline wafer, amorphous silicon (a-Si), cadmium telluride (CdTe), and copper indium gallium (di)selenide (CIGS) based systems.
• Manufacturing and optimization studies of various systems including mono- and polycrystalline wafers.
• Simulation modeling of various production lines and material handling systems; material handling systems studied include ASRS, AGV, robotics, conveyor, sheet buggers, lifters, fork truck, and loading dock areas.
CH2M HILL’s Manufacturing Integration group provides focused services to support the PV manufacturing industry.
These services include:
• Manufacturing planning
• Risk assessment
• Factory/line optimization
• Material handling turnkey solutions
• Manufacturing execution systems/solutions
• Equipment installation and integration
By combining traditional industrial engineering and design with business process planning, simulation, and Lean strategies, Manufacturing Integration develops integrated solutions and systems to optimize the production line.
Summary
As part of our ongoing commitment to environmental stewardship, this page has intentionally been left blank to accommodate two-sided printing
About CH2M HILLHeadquartered near Denver, Colorado, employee-owned CH2M HILL is a global leader in full-service engineering, procurement, construction, and operations for public and private clients. With $6.3 billion in revenue and more than 23,500 employees worldwide, CH2M HILL delivers innovative, practical, sustainable solutions—helping clients develop and manage infrastructure and facilities that improve efficiency, safety, and quality of life. The firm has long been recognized as a most-admired company and leading employer, including being named by FORTUNE magazine as one of the 100 Best Companies to Work For (2009).
CH2M HILL operates out of more than 200 offices worldwide. For a complete list of office locations in your area, please visit us at ch2mhill.com.
GlobalHeadquarters9191 South Jamaica StreetEnglewood, CO 80112USAToll-free: 888.CH2M.HILLTel: +1 303.771.0900Fax: +1 720.286.9250
EuropeOptima Building, Level 1 North58 Robertson StreetGlasgow, G2 8DUScotland, U.K.Tel: +44 (0) 141.204.2333Fax: +44 (0) 141.204.2033
MiddleEast/NorthAfricaStar Holding BuildingGround Floor #2Dubai Internet CityPO Box 500554Dubai, United Arab EmiratesTel: +971 4.427.7600Fax: +971 4.427.7601
NorthAmerica2020 SW 4th AvenueThird FloorPortland, OR 97201USATel: +1 503.235.5000Fax: +1 503.736.2000
MexicoAV. Xola 535Piso 23 Col. del ValleDel. Benito JuarezMexico City, 03100MexicoTel: +52 55 5999 0400Fax: +52 55 5999 0410
BrazilVila OlimpiaRua do Rocio, 351 - conj.Suite 11, 12, 21, 22, 52, 61 e 62Sao Paulo, 04552-000BrazilTel: +55-11 3040 0800Fax +55-11 3040 0802
ArgentinaAzara 841, 1 FloorCiudad Autonoma deBuenos Aires, 1267ArgentinaTel: +54 114 309 0201Fax +54 114 303 3954
NorthAsia8F, Tower 1, Grand Gateway1 Hong Qiao RoadShanghai, 200030People’s Republic of ChinaTel: +86 21.6113.2000Fax: +86 21.6113.2199
SouthAsia150 Beach Road, 34th FloorGateway WestSingapore, 189720Republic of SingaporeTel: +65 6391.0350Fax: +65 6299.4379
Web Address: www.ch2m.com/solarpvEmail: [email protected]