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Integrated design of complex liquid and gas delivery systems broken into manageable pieces for repeatable off-site manufacturing and expedited design and construction.

Getting liquid and gas materials to and from semiconductor manufacturing tools is essential, and it involves a large amount of piping. SSOE is a go-to designer of subfab laterals for a leading semiconductor
manufacturer, and for good reason. When we were asked to provide lateral piping designs for twin semiconductor fabs, one in the Southwest U.S. and the other overseas on a tight timeline, we knew we had to change how we did things. On a typical project, SSOE would provide design documents which are transferred to a fabricator to develop the spool drawings for manufacturing. For these facilities, we modeled the piping to a fabrication-level of detail, and provided the fabrication drawings.

By embedding these details into the design, we put constructability at the forefront of the project and eliminated a series of RFI back-and-forth, thus providing the client with great savings to budget and schedule. We also delivered innovative time and cost savings by designing the pipe support racks and piping to be built off-site, transported to the site, and installed in large modular sections. And, in order to facilitate inventory tracking and installation of these units between off-site manufacturing and on-site installation, we developed an asset tracking system that is integrated within our design models. Using barcodes on each spool, we were able to track whether a particular module was in fabrication, storage, or already installed with up-to-the-minute accuracy.

We further multiplied the savings created by applying our industry and client-specific knowledge to identify “building block” modules which can be assembled in various configurations. By using these building blocks, our lateral designs could be adapted for new site locations with minimal adjustments, allowing us to effectively perform detailed design work for two facilities in parallel. And for projects where off-site manufacturing was feasible, like this one, we improved construction efficiency and safety by limiting on-site materials and minimizing the manpower and logistics needed to install the lateral racks and piping.

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Nissan North America commissioned SSOE to provide the design of its new automotive assembly facility in Aguascalientes, Mexico. This 1.9 million SF facility is the first of three project phases planned for the greenfield site. SSOE delivered this fast-track project in partnership with Yates Construction, who served as the prime general contractor and provided at risk construction services for the manufacturing plant. The plant was designed, constructed, and placed in production within 22 months.

SSOE was responsible for the entire assembly plant layout and subsequent design of the automotive manufacturing campus. The project involved multiple buildings to be completed simultaneously, including more than 300 acres of developed land, a stamping facility, body assembly shop, paint shop, and final assembly area. Additional facilities were designed to support the manufacturing system, such as an electrical switchyard; water pretreatment, wastewater treatment, and stormwater systems; and a fire protection system, including storage tanks.

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SSOE’s approach expedited decision making and helped Goodyear streamline a design process that would typically extend throughout the entire construction phase.

In collaboration with Goodyear engineers and our construction partner, SSOE completed a highly integrated utilities and process installation design for a 1 million SF tire manufacturing facility in San Luis Potosí, Mexico. This is Goodyear’s first new manufacturing facility in the America’s in 25 years and will produce approximately 6 million premium tires will be produced at the facility annually.

Goodyear selected SSOE for its breadth of engineering services and advanced design delivery methodologies. For example, SSOE maximized use of advanced software tools (Bluebeam, Navisworks) for highly efficient, issue-focused design reviews. SSOE’s approach expedited decision making and helped Goodyear streamline a design process that would typically extend throughout the entire construction phase.

SSOE worked with Goodyear’s design engineers to introduce an alternative design approach, establishing a dynamic three-way SSOE-Goodyear-contractor partnership and adding value to this highly successful project.

As a result of our advanced engineering design services, SSOE was also asked to provide piping fabrication spool drawings for a major equipment set to assist the contractor with overall timing and installation.

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American Axle & Manufacturing (AAM) selected SSOE to assist with conceptual design and construction document development for their new 300,000 SF manufacturing plant in Silao, Mexico.

This project commanded strict design document reviews by all disciplines in order to comply with the requirements of Mexico’s local and state laws, as well as AAM’s international standards. In addition, effective communication between SSOE, the General Contractor, and AAM helped to log sufficient information in order to solve any problem or conflict that was presented.

SSOE also served as Owner’s Representative for the design / build phase of the project with a Construction Manager. We worked full-time on-site reviewing the quality of the construction, making sure that the contractor delivered according to the design and engineering, managing schedules, monitoring progress, and inspecting shop drawings, among many other activities.

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In Mexico, Walmart is ramping up its distribution capabilities with a number of new distribution centers to expedite and improve product delivery to its stores. The new distribution centers will allow Walmart to strengthen and expand its logistics operations, with the goal of reducing time and costs in the supply process.

With an ambitious multi-year schedule for program completion, Walmart’s plan involves the construction of new distribution centers and the upgrading of existing centers. The retailer has engaged SSOE as one of their strategic partners to help design and build new centers in Chihuahua, Tabasco, and Chalco, with potential for additional projects. The facilities in Chihuahua (35,000 m2) and Chalco (60,000 m2) are dry warehouses, while the facility in Tabasco (38,000 m2) is a refrigerated distribution center—a project requiring unique refrigeration experience that other A/E firms in Mexico were unable to provide.

SSOE’s phased design approach prioritizes close communication and coordination between multiple Walmart divisions (including logistics, human resources, safety, and operations) and the SSOE project team. This includes continuously updating coordination and communication tools used for project delivery, and leading workshops and design review meetings that incorporate 3D Virtual Reality walk-throughs. This approach ensures that the integrated design team is able to focus on project goals and provide an operationally efficient and flexible design.

The benefits of SSOE’s ongoing partnership with Walmart include in-depth understanding shared by all team members of Walmart’s goals, needs, and business objectives, as well as the ability to ensure consistent implementation of Walmart’s global design and construction standards from project to project.

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Kemin sought a research and development facility design that represents their entrepreneurial spirit and embraces the company’s energy and excitement for discovery. The laboratory and office spaces provide the basis for an orderly and innovative professional working environment.

The new R&D facility’s two-story lobby contains a large glass curtain wall and floor to ceiling external windows to allow natural lighting to flow into the facility. The entry and lobby are situated to establish a dominant façade, giving the building a formal presence on the project site. The front lobby contains a coffee bar with seating area, adding an extra collaboration environment for employees and customers. Reflecting the facility’s modern and concise style, a spiral, steel structured, glass stairway is the main vertical transport between the lab’s first and second floors.

The building’s floor plan was organized to facilitate efficient scientific analysis and interaction between labs and staff. This facility houses multiple lab types, including a general lab, specialized lab, pilot lab, laboratory support rooms, offices, and administrative areas. The pilot labs, mechanical rooms, and consumable items testing storage areas are located near the lab area, promoting internal experimental interaction and allowing for the central location of lab supplies. The general labs are open and modular, containing abundant natural light. Customers touring the facility will appreciate the flexibility of the general lab’s layout, allowing them to easily be reconfigured per the client’s needs.

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Input from programming phase was used to eliminate duplicate space requirements and reduce the building footprint by 15%. Additionally, developed method to capture and reuse energy generated during dynamometer testing process throughout the facility.

To meet the market demand for new products in China, GM built its first Chinese R&D facility in Shanghai. This facility, which is the most comprehensive and advanced automotive development center in China, included areas for advanced vehicle development, powertrain design, electrical and fuel cell design, chassis, HVAC, body, exterior and interior development, and telematics. SSOE applied its vast experience in designing automotive R&D facilities, and familiarity with the Chinese design and construction process to deliver this high caliber, sustainable project.

SSOE designed an interior hydrogen fuel cell garage space, along with an exterior hydrogen fueling station and garage space. Special considerations, including distance from nearby high rises, were made during design due to safety considerations. Fuel farms were also integrated to provide for blending and testing operations for hydrogen-based vehicles and hybrids.

A significant design feature was a central garage space that separated the building into two halves. The central garage space functions as a central spine and serves as a common use area for multiple groups. It potentially allows groups to share tooling.

Another feature was a visually secure, exterior patio for GM to view vehicles in natural sunlight. This requirement created an interesting challenge since the site was located within city limits and near a multiple story building. SSOE designed a visual screen to obstruct the view from the building while still allowing the natural sunlight to enter the space.

SSOE provided an innovative design which minimized environmental impact, while maximizing occupant safety, health, and comfort. Design criteria also emphasized the use of sustainable materials and other energy reduction features.

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Saved the client $26,000 through cost effective practices such as using aluminum conductors instead of copper conductors and reducing the quantity of clean agent tanks.

Boeing was contracted to deliver an end-to-end satellite communications system that included two new ground monitoring stations. Each station consisted of a highly technical control room and server rooms. Boeing called upon SSOE to provide mechanical, electrical, and fire protection engineering services for the rooms.

SSOE’s responsibilities included design of the facilities’ Uninterruptible Power Supply (UPS) systems, back-up generators, HVAC systems, and fire protection systems. SSOE used a clean agent suppression system as part of the fire protection that would not harm the sensitive equipment. Additionally, because both facilities are located in extremely hot and dry environments, special considerations were made for the HVAC systems. Seismic considerations were also incorporated into the design for the Mexico City facility.

SSOE designed the stations in accordance with International Building Code and worked closely with the end- user’s construction manager and architect in Mexico.

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Fast-track conversion of abandoned brownfield factory into full-fledged food manufacturing facility. Modified original site layout saving $500,000.

When Hershey embarked on the conversion of an abandoned brownfield factory into a new candy manufacturing facility in Mexico, SSOE was asked to join the design / build team that turned it into a viable production facility for its chocolate products. With a history of success on fast-track food projects, the team was able to immediately respond to the challenging project demands, which allowed for parallel design and construction.

SSOE’s scope entailed design for the addition of 300,000 SF of process and packaging space, which included nine production lines, an 85,000 SF warehouse, a new 15,000 SF cafeteria, and a new substation. SSOE also designed in-plant laboratory space and consulted with Hershey on the purchasing of utility equipment.

The original facility was not in compliance with U.S. food processing standards. SSOE provided expertise in this area throughout the facility design.

SSOE was able to provide an optimal design solution by enlisting the best labor force and working with local government and community agencies. Early bid packages for site, sewer, and foundation were issued within two-three months of project award. In the end, SSOE helped Hershey meet its ultimate goal, under budget and on schedule. What resulted was a state-of-the-art facility four times larger than its initial size meeting strict FDA standards.

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Executed 16,000 offshore engineering hours over the course of six months, exceeding the client’s goal.

When a household care manufacturer wanted to integrate an offshore engineering partner from India at its highest revenue generating site in North America, SSOE proved to be key to the successful integration. With more than 20 years of experience on the site, SSOE had personnel capable of managing, controlling, and delivering the entire site’s engineering capital as well as managing integration of an offshore partner over the course of a year.

Because the offshore supplier did not have familiarity with the site, SSOE first worked to integrate them into the existing processes, identify potential challenges and outline plans for troubleshooting them. This included a recommendation to provide a cultural training course for the offshore principles as well as the SSOE team. SSOE was also charged with a goal to manage 15,000 offshore hours over the course of a year and a $3 million site engineering budget for related yearly projects. Projects included capacity and efficiency increases, product additions, as well as site clearance to make the facility more usable. What resulted was the planning and support needed to improve the onboarding of future engineering suppliers, timing of projects, and breakdown of projects depending on complexity.

Additionally, SSOE’s experience and expertise allowed projects to be conducted as planned and exceeded the 15,000 man hour goal in just six months.

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Coordinating standards set by General Motors’ Global Facilities Group with the local design and construction standards of the actual plant in Silao, Mexico was a challenge that could have proved costly for General Motors. Without careful communication and teamwork, extensive redesign efforts could have been required to comply to all codes. SSOE’s understanding of General Motors’ Global Facilities Standards, as well as the local design and construction methods, provided a smooth incorporation of design into construction.

As a result of this close collaboration and understanding, this plant expansion project for a new, eight-speed transmission production line progressed on time and within budget through all three phases, while also meeting all client objectives. Serving as a liaison, communicating with both the Global Facilities Group and local plant officials, SSOE closely monitored the budget and schedule and quickly addressed concerns or nonconforming design elements. A 3D model was utilized throughout the program for integrated project delivery and interactive communication between teams. Representatives from SSOE’s León office attended construction meetings, facilitating the resolution of issues between design and construction.

In addition to project coordination and management, SSOE also provided the program’s Phase I bridging documents and bidding support. For Phase II of the project, SSOE partnered with a construction firm for a design / build delivery, further expediting the schedule. Phase II drawings were provided by SSOE for the transmission plant addition, office and cafeteria expansion, GSC warehouse building, and central utility complex building.

Due to the success of the first facility expansion, SSOE was requested by General Motors to design the project’s Phase III – a design / bid / build, five-bay addition incorporating as-built conditions into the 3D model. SSOE also provided construction administration services.

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Energy saving features with less than five year ROI.

To meet the market demand for new products in China, this automotive OEM built its first Chinese R&D facility in Guangzhou. SSOE’s relationship with this client extends more than 30 years and includes experience at no less than 10 of their facilities throughout the world. With robust expertise in R&D facilities and knowledge of China’s governmental standards for design and construction, SSOE was a clear choice for this project.

SSOE was selected to design an R&D facility that consolidated multiple facilities throughout Guangzhou, bringing the team together in a new location to foster more efficient internal collaboration. R&D areas included trial manufacturing, materials testing, body testing, aesthetic design, crash testing, and EMC chambers. Individual buildings were connected with access roadways separate from normal vehicle flow. The main site access was limited to one entry point in order to control entrance to the campus. The most notable design feature was an onsite high-speed test track for new product development. For the client, it was important to also build an onsite recreational facility reflective of its corporate culture. As part of the design process, SSOE interviewed individual client user groups to find out specific functions, demands, and cultural aspects.

The facility was constructed with an emphasis on use of recycled, renewable, and non-polluting materials. Though the campus had large power requirements, SSOE integrated features that provided the highest possible energy efficiency such as water conserving plumbing fixtures and strategies to reuse the power generated from processes, such as the engine dynamometers. A grey water system was incorporated to minimize overall water consumption and was used to provide the most cost effective method of supplying water for the testing processes on the test track. Such systems were designed to provide less than a five year return on the client’s investment.

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SSOE suggested incorporating high efficiency lighting saving the client approximately $300,000 annually in operation costs. SSOE also suggested using PVC roofing membrane and sandwich panel siding to minimize the installation time.

In order to provide R&D capabilities in India and to better supplement their existing fabrication plant, an automotive client set about to build a new technical center and office complex. Having completed several successful projects for the client’s U.S. facilities, as well as projects for other U.S.-based companies in Asia, SSOE was selected to provide full architecture and engineering for the project.

The center includes performance, structural, environmental, oil flow and lubrication, and metallurgical testing, as well as noise, vibration, and harshness (NVH) testing capabilities. SSOE worked closely with an Indian design firm to ensure the center met Indian regulations, while still providing the client with the international appeal that they were trying to achieve.

Comprised of two filled-in quarries with irregular soil makeup, the site posed a unique challenge. Special considerations had to be made in the facility’s structural design, specifically in the areas that house dynamometers and other large equipment. The site also lacked connections to public utilities, so city water storage tanks had to be designed.

The facility is state-of-the-art and places a high priority on features that maximize occupant safety, health, and comfort. As a result, air conditioning and fire protection systems were included in the center’s design, going above and beyond government requirements for R&D facilities.

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No reportable injuries despite maximum of 500 workers on-site at times.

Based on its long-term relationship with SSOE in the U.S., Ford China hired SSOE to coordinate development and construction of a Research and Engineering Center in China to improve product development. The facility included offices and testing laboratories on Ford’s Nanjing campus. Ford performed master planning and retained a local design firm for engineering services. SSOE coordinated the team so that all were working together toward cost control, quality, and safety. SSOE met the client’s expectations on every level, including challenges posed by an aggressive schedule.

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