Desapex, a leading digital engineering and a BSI Associate Consulting Partner specializing in high-tech industrial facilities, was tasked to setup & run a digital framework for project coordination for state-of-the-art semiconductor manufacturing plant in India. The project, valued at over $1 billion, required meticulous design coordination and quality assurance to meet the stringent standards of the semiconductor industry. To ensure the success of this complex project, Desapex adopted Solibri, a cutting-edge Building Information Modeling (BIM) validation and quality assurance software, to streamline design review processes and enhance collaboration among stakeholders.

Challenges:

1. Complexity of Design: The semiconductor plant involved intricate systems, including cleanrooms, HVAC, electrical, and process piping, requiring seamless integration of multiple disciplines with reference to structure.

2. Stringent Quality Standards: The project demanded zero tolerance for errors, as even minor design flaws could lead to costly delays or operational failures.

3. Coordination Among Stakeholders: With over 20 design teams and contractors working simultaneously, ensuring consistency and clash-free designs was a significant challenge.

4. Tight Deadlines: The project timeline was aggressive, necessitating efficient workflows to avoid delays.

5. Local Regulations and Standards: The plant, located in India, had to comply with both international semiconductor industry standards and local building codes and regulations.

Solution: Implementing Solibri for Design Review & Quality Assurance

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Desapex integrated Solibri into its BIM workflow to address these challenges. Solibri’s advanced capabilities enabled the team to perform comprehensive design reviews, detect clashes, and ensure compliance with industry standards and project requirements.

Key Features of Solibri Utilized:

1. Clash Detection: Solibri’s automated clash detection identified conflicts between architectural, structural, and MEP systems early in the design phase, reducing rework during construction.

2. Rule-Based Validation: Custom rulesets were created to validate designs against semiconductor industry standards and local Indian regulations, ensuring compliance with cleanroom classifications, equipment spacing, and safety regulations.

3. Issue Tracking: Issue tracking was setup to log, assign, and resolve issues efficiently, improving accountability and communication among stakeholders.

4. Model Comparison: The software enabled Desapex to compare different versions of the BIM model, ensuring that design changes were accurately implemented and tracked.

5. Visualization and Reporting: Custom intuitive visualization tools and detailed reports facilitated clear communication with clients and stakeholders, enabling informed decision-making.

Implementation Process:

1. Model Integration: Desapex consolidated BIM models from all disciplines into Solibri, creating a federated model for comprehensive review.

2. Rule-Based Checks: Custom rulesets were applied to validate designs against project-specific, industry, and local Indian standards.

3. Clash Detection and Resolution: Solibri identified clashes, which were then reviewed and resolved collaboratively by the design teams.

4. Quality Assurance Reports: Detailed reports were generated and shared with stakeholders, highlighting issues and providing actionable insights.

5. Continuous Improvement: Solibri’s analytics helped Desapex identify recurring issues, enabling process improvements and reducing errors in subsequent design phases.

Results:

1. Improved Design Accuracy: Solibri’s clash detection and validation tools reduced design errors by 40%, ensuring a higher-quality final design.

2. Enhanced Collaboration: The centralized platform improved communication among stakeholders, reducing misunderstandings and delays.

3. Time and Cost Savings: Early detection of issues minimized rework during construction, saving an estimated $5 million and reducing the project timeline by 10%.

4. Compliance Assurance: The project met all semiconductor industry standards and local Indian regulations, ensuring operational efficiency and safety.

5. Client Satisfaction: The use of Solibri demonstrated Desapex’s commitment to quality and innovation, resulting in high client satisfaction and repeat business.

Conclusion:

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By leveraging Solibri for design review and quality assurance, Desapex successfully delivered a state-of-the-art semiconductor plant in India on time and within budget. The software’s advanced capabilities enabled the team to overcome the challenges of complex design coordination, stringent quality standards, and tight deadlines. This case study highlights how Solibri can be a game-changer for large-scale industrial projects, ensuring accuracy, efficiency, and client satisfaction.