Production Innovation 2023

Title: Turnkey Fitout, New Semiconductor Facility.

Client: Confidential.

Description: Primarily specialising in structural steel erection, our organization recognized the shifting demands of the industry and embarked on a strategic journey of diversification. Leveraging our expertise in project management and precision engineering, we undertook a new role for our semiconductor client. Through careful analysis, research and planning, we seamlessly transitioned into providing comprehensive fit-out services for semiconductor facilities. By adapting our skill set and expanding our capabilities, we have successfully positioned ourselves as a trusted partner in this dynamic field, enabling us to contribute to the growth and innovation of the semiconductor industry.

The installation of 2,286 state-of-the-art, first of a kind, manufacturing equipment(tools) used in the fabrication of silicon chips, in a new facility consisting of 150,000sqm. This was a complex and demanding undertaking that required a high level of expertise and precision. Our scope of work was extensive and covered every aspect of the installation process, from the initial surveying and setting out, to the final commissioning support of the tools.

The surveying and setting out involved a detailed assessment of the installation site to ensure that it was suitable for the equipment and that there was sufficient space for them to be installed and operated. We used specialized rigging equipment and techniques to ensure that the tools were installed at the correct location and orientation to meet the required layout specifications.

The de-crating process involved carefully unpacking the equipment from their crates and preparing them for move-in. This required a high level of care and attention to prevent any damage to the delicate components of the tools during the unpacking process.

Specialty rigging was used to move the equipment into position, many of these items were notable for their substantial dimensions and significant weight (10,000kg+), and required careful handling to ensure that they were not damaged during the installation process. Our team used specialized lifting equipment and techniques to ensure that the equipment were moved safely and accurately into position.

Once the tools were in place, we proceeded with the installation process, under the guidance of the vendors, which involved the careful assembly and connection of various components. This required a high level of technical expertise and precision to ensure that the components were installed to the required specifications.

As the scope developed, we were later awarded a retrofit scope that for the de-installation and removal of 182 tools and replacing with 165 new technology tools in a live facility, spanning 110,000 square meters.

The de-installation of existing tools was a critical part of the project, as it involved safely and efficiently dismantling and removing the existing equipment to make way for the new tools without interfering with a facility in full production.

Our team used specialized lifting and rigging equipment, such as gantries & air skates, to ensure that components were not damaged during the removal process. We also took great care to ensure that the removal process did not cause any damage or impacts to production to the surrounding facility or disrupt ongoing operations.