"Modular Construction Addressing the
Needs of the Bio-Pharmaceutical
Industry"
January 15, 2008
Paul Hochi, Jacobs
Agenda
• Industry Challenges
• Owner/Contractor Benefits
• Modular Definitions
• Project Example
• Modular Best Practices
• Question & Answer
Industry Capital Challenges
• Match capital assets to revenue stream
and outcomes of clinical trials
• Attain rapid speed to market for
commercialized products
• Minimize spending on products that don’t
pass clinicals
Owner/Contractor Drivers
• Schedule acceleration
• Local labor availability
• Safety
• Site constraints
• Environmental/regulatory
constraints
• Quality
• Risk Mitigation
• Replication opportunities
Lean Tool to Add Value,
Standardize, & Eliminate Waste
Modular
Definitions
Vendor Equipment Skids
• Vendor equipment skids include:
• WFI stills, clean steam generators, CIP skids,
chromatography, UF/DF skids, microfiltration,
scrubbers, vacuum pumps, etc.
• Use is standard in the industry
• Equipment units can be installed in stick-built
construction or integrated into superskids or
structural modules
• For off-the-shelf uses, not custom applications
Superskids
Structural Modules
Structural Modules
Modular Layout Example
Case Study:
Oral Solid
Dosage,
Puerto Rico
Case Study:
Oral Solid Dosage Facility
Confidential Client – Puerto Rico
• Key Owner Driver: Schedule acceleration
• Two duplicate solids processing facilities,
each with 84 structural modules & 42,000
square feet of modular operating area
• Integrated with stick-built dispensing area
Modular Building Shipping Blocks
Modules in Assembly
High Purity Pipe Systems
Purified Water Storage Tank
Barge Transport
Module Erection
East Wall (Modular & Stick-Built)
Processing Area
Clean Corridor
Purified Water Storage Tank at Site
Custom Built WIP after Site Installation
Processing Area
Oral Solid Dosage Facility, Puerto Rico
OWNER BENEFITS
• 6+ months schedule acceleration on Unit #1
• Module approach moved ⅔ of construction hours
off-site with better productivity, no weather impact
during fabrication
• Mitigated impact from site space limitations
• Achieved Repeatability Benefit – Unit #2 under
assembly while Unit #1 nearing site completion
Schedule Comparison
Summary
Modular Best Practices
• Modular is a LEAN technology to reduce
schedule and field resource requirements
• An early module decision is necessary no later than early conceptual
• Include life-cycle impacts in your evaluation
• Delivery of equipment is usually the critical path
- delivery earlier than conventional
• Leverage shop IQ
Questions &
Answers
Thank You!