Semiconductor production expanded while factory continues to operate

The client is a global manufacturer of semiconductors for markets including household appliances, IT equipment and cars. To meet growing demand for microchips and help address a worldwide shortage in supply, the client wanted to increase production of chips for the motor industry. It selected the site for investment based on internal bids submitted from its factories across Asia. The successful bid from the factory in Vietnam was prepared with assistance from Royal HaskoningDHV and was more competitive with a shorter timescale than proposals from other factories.

Forward planning and close communication help meet challenging schedule

The project involved upgrading and extending cleanrooms, process utilities, power supply and fire-fighting capacity. New production equipment was installed, and existing equipment relocated and reconnected. Royal HaskoningDHV was contracted to carry out engineering, procurement and construction management (EPCM). The project was scheduled for completion within just eight months while ongoing production continued.

One of the challenges was a lack of as-built documentation at the site which had been in operation for more than 20 years. This was compounded by the fact that the project was started when Covid restrictions were in place, so access to the factory was limited. To ensure no time was lost, plans were made in advance using as much information as was available. Then, during the site survey, operational teams were able to provide the missing information while discussing and approving the plans. This was the start of close teamwork to limit impact on operations during the execution of the project. Similar close communication was maintained through twice-weekly client meetings when solutions were discussed and agreed in advance, saving time at the review stage.

Additional power requirements met through optimisation

When planning the project, it was clear that efficiencies in power consumption could be achieved by rearranging operations. The savings were such that new requirements could be met through the existing connection without the need for new facilities.
Cleanroom specifications were more stringent for the new production process, requiring expansion and upgrading. The specialists in the Netherlands who have carried out such projects successfully all over the world guided the team in Vietnam. This ensured production was maintained throughout the process.

Assets and utilities reused to minimise environmental footprint and waste

“To minimise the environmental impact of this project, we reused assets, utilities and pipework as much as possible - and reduced capex by US$1 million in the process,” said Truong an Nhien, Project Manager at Royal HaskoningDHV. “Following the site reorganisation, energy use is more efficient and we are working with our client to improve this further by introducing a monitoring and control system.”

Safety was really important during construction, particularly as operations continued on the site. To ensure the highest global standards were maintained, HSE managers from Royal HaskoningDHV provided training to align local specialist contractors with the requirements of the project and raise overall safety awareness.
The challenging eight-month schedule was met, and the new production area has been approved as meeting the exacting standards of a major global electric vehicle manufacturer.

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