Solutions Tailored to Your Individual

PV Operations Requirements

Manufacturing Integration, Productivity and Technology Services

PV Manufacturing Integration

Solutions

As part of our ongoing commitment to environmental sustainability, this page has been left blank to accommodate two-sided printing.

Company OverviewCH2M HILL has long been recognized as a leading employer and admired company. FORTUNE magazine consistently ranks CH2M HILL among its “100 Best Companies to Work for in America,” and a “most admired company.”

CH2M HILL at a GlanceFounded in 1946 and headquartered near Denver, Colorado, employee-owned CH2M HILL is a global firm providing consulting, engineering, construction, operations, and related technical services to public and private clients.

• Approximately 30,000 employees in offices worldwide

• 100 percent employee owned• Broadly diversified across 10 business sectors:

– Energy & Chemicals – Environmental – Government Facilities & Infrastructure – Industrial & Advanced Technology – Industrial Systems – Nuclear – Operations & Maintenance – Power – Transportation – Water

• $6.3 billion in revenue (2010)

Recognized for Industry ExcellenceCH2M HILL earned Number One rankings and numerous Top 10 rankings from Engineering News-Record in 2011. These rankings include:

• #1 Top 200 Environmental Firms• #4 Top 500 Design Firms• #3 of Top 500 Manufacturing Design Firms• #2 of Top 100 Construction Management Firms

Performance Excellence - Recognized Across Industries

As a result of our processes and systems, we have won many industry awards from our customers for project quality, health and safety, and customer satisfaction. With an EMR of 0.74, our safety record is among the best in the industry.

At CH2M HILL, we strive to exceed your expectations and our industry’s standards.

It’s not the exception here. It’s the rule.

Each of our clients demands and deserves a completely satisfying solution on every project, regardless of complexity.

CH2M HILL Manufacturing Solutions - OverviewThe CH2M HILL Manufacturing Integration (MI) group provides full-service solutions, from initial planning through design, optimization, and integration. We serve a wide range of manufacturing clients, including photovoltaic (PV), microelectronics, flat panel display, energy storage, consumer products, and other high volume manufacturers.

CH2M HILL at a GlanceGlobal solar/PV manufacturing is hypercompetitive, with companies aggressively seeking to establish market share through technological and operational advantages. In this dynamic environment CH2M HILL provides leadership in achieving these goals through:

• Capacity planning, layout, analysis and risk mitigation to reduce capital factory costs for equipment and plant facilities

• Application of simulation and modeling techniques to optimize manufacturing lines and increase factory yield

• Focused programs in Manufacturing Operations Excellence to reduce operations costs

• Business process re-engineering utilizing techniques such as value stream mapping and gap analysis to improve efficiency of business processes

Manufacturing Integration, Technology & Productivity Services

Manufacturing/Facilities Planning

• Strategic planning• Support area requirements• Flow analysis• Warehousing/logistics• Utility requirements definition• Micro level manufacturing layout planning• Macro level manufacturing layout planning• Tool list development• Capacity modeling/planning• Manufacturing process definition• Manufacturing production plan definition• Operating procedures• Staffing plans• Manufacturing/process simulation• Workplace design• Microcontamination design

Strategic Planning/Risk Assessment

• Business risk analysis • Profitability analysis• Asset management • Operational goaling• Financial modeling• Cost of ownership model• Facility cost model

Factory/Line Optimization/Modeling

• Line/equipment layout• Static and dynamic modeling• Production flow modeling• Failure mode and effects analysis (FMEA)• Production equipment layouts • Layout optimization • Productivity studies• Manufacturing excellence/lean constraint analysis

Manufacturing Operational Systems

• Systems assessment, refinement, selection and integration

• Manufacturing execution system (MES)• Controls systems (PLCs, AB, GE, Siemens,

Mitsubishi, etc.)• Motion controllers• Vision systems• SCADA systems (GE Proficy, RS View,

Wonderware, etc.)• SQL, Oracle and other database systems• Ethernet networks• Industrial PCs

Automated Material Handling Systems (AMHS)

• Turnkey solutions• Automation simulation and modeling• Conveyors (belts, links, rollers)• Robots (SCARA, r- -z, Cartesian)• Warehouse layout planning• General material handling design • Sustaining engineering• Facility planning support• Layout services• Construction modifications• Equipment installation and integration

Equipment Install Planning

• Production tools integration and production readiness

• Line audit for factory acceptance • Equipment source inspection

CH2M HILL Manufacturing Integration engineers enter the project early in the pre-planning phase, to define and integrate the facility, systems, process equipment, and operational activities.

Photovoltaic ManufacturingGlobal solar/PV manufacturing is hypOur portfolio includes customers ranging from start-ups to companies in the top 20 list of manufacturers. We have provided design-build, design only, and consulting work in Asia, Europe, and North America.

Our experience base encompasses the full spectrum of PV manufacturing processes, from the initial production of polysilicon, including monocrystalline, to polycrystalline casting, amorphous, cadmium telluride (CdTe), CIGS and multijunction technology.

CH2M HILL provides a single point of responsibility for the complete life cycle of your project.

Engineers, designers, and technical specialists make up the core of our firm — professionals with unparalleled experience in all phases of the planning, design, and installation operations that support the development of wafer and thin film manufacturing systems.

CH2M HILL has worked with developers of solar/PV products in all cell technologies and has more than 10 years of experience in both crystalline and thin film technology.

Mitsubishi REC Spectrawatt Trina Solar

CRYSTALLINE SILICON

THIN FILM

polysilicon wafer cell module

silicon CdTe CIGS

various turnkey vendorsand their customers First Solar Solyndra

rendering: Studios Architectsphoto: First Solar

photo: REC

In-house Experience and ToolsPV Automation Expertise

• Automated storage and retrieval systems• Automatic guided

vehicle (AGV)• Rail guided vehicle (RGV)• Stack and single wafer handling• Wafer buffering• Raw wafer handling• Manufacturing execution systems• Cassette and stack

loading and unloading• Process tool loading and unloading

Process Technology Experience

• Mono- and polycrystalline silicon• Cadmium telluride (CdTe)• Amorphous silicon• Copper indium gallium (di)selenide (CIGS)

Production Line Layout and Material Handling Applications

• Single, stack and cassette wafer handling• Inline and batch wafer processing• Wafer buffering • Large glass thin film single sheet and batch

processing configurations• Alternate media applications (glass tubes, flexible

media, wafer)• Raw materials and finished goods logistics

Solution Evaluation and Optimization

• Lean planning for concept development• Business process mapping supporting optimized

methods• Dynamic capacity models for production line

evaluation (standardized models)• Material handling simulation models to validate

material handling solutions (standardized models)

Manufacturing Operations Systems

• Requirements definition – controls/manufacturing execution systems (MES)/material control systems (MCS)/enterprise

• Business process mapping• Programmable logic controller (PLC), human

machine interface (HMI) and instrumentation development for process and material handling equipment

• System design/implementation/start-up/ramp• Manufacturing execution systems (MES) –

genealogy/process data/recipe management/flow control/advanced process control/yield management

• Material control systems (MCS)• Enterprise/enterprise resource management

(ERP)/product lifecycle management (PLM)• Supplier management• Ongoing support – software maintenance/

equipment maintenance

ApproachCH2M HILL combines our process, material handling, and engineering experience when evaluating and optimizing potential solutions. The figure on the next page demonstrates the execution of the basic evaluation process.

Our approach includes the following activities, with the flexibility to tailor a solution to fit your needs and budget:

• Develop processing requirements as defined by the client team, creating a manufacturing requirements document. This process utilizes Lean methods to quickly converge on the appropriate definition.

• Execute a baseline process where existing concepts are evaluated both statically and dynamically, creating a validated baseline where alternative solutions and changes can be ranked.

• Develop alternate and potential solutions.

• Evaluate potential solutions statically to eliminate options that will not support efficiency improvements.

• Perform dynamic evaluation of best case options as defined by the static process; rank solutions per criteria.

Material Handling Modeling

Award ContractClient

Requirements

Validation and Modeling

Concepts

Layout

DYNAMICSimulation

STATICSimulation

Bids

ManagementApproval

Construction & Integration

Construct Software Systems

Install Equipment

Vendor Submittal, Review & Recommendation

Equipment SolutionsConcepts &

Validation

Bid PackageDevelopment

CH2M HILL

OPTIMIZEDmaterial handling

system design

STARTUPramp factory

Requ

irem

ents

Deploy & IntegrateSoftware Systems

From developing system requirements through the request for qualification, bid, selection and construction/integration, CH2M HILL vendor management for both material handling and manufacturing system solutions minimizes capital expenses while optimizing PV facility operations. We deliver cost effective, turnkey automation systems to meet your needs, not a supplier specification sheet.

The hybrid approach of static and dynamic analysis offers a comprehensive evaluation of all possible options yielding optimal solutions while minimizing time and effort.

Representative Client ProjectsThe MI team has supported the Solar/PV thin film market in various planning, evaluation and optimization activities. This support included layout, simulation, and material handling system recommendations within the crystalline silicon, amorphous silicon (a-Si), cadmium telluride (CdTe), and copper indium gallium (di)selenide (CIGS) manufacturing technologies. A representative example list is provided below. Intellectual property (IP) is extremely sensitive in PV manufacturing; to guard our clients’ IP, we keep client names and project specifics confidential. The following projects were implemented in factories in North America, Asia and Europe.

Manufacturing Layout Design

Amorphous SiliconCH2M HILL developed the manufacturing facility design and included the following MI services to validate the manufacturing space and production requirements.

Dynamic capacity modeling was used to evaluate delivery and work in progress (WIP)requirements affected by planned and unplanned production tool schedules.

Simulation modeling was used to support evaluation of potential material handling solutions and their impact on production capacity.

Simulation included the use of six-axis robotics, glass conveyance, tool loading robots and bulk sheet buffering.

Material Handling Design

Amorphous SiliconCH2M HILL developed manufacturing facility design options. MI services were used to create and test layouts adapted to support the site and facility constraints.

Simulation modeling was used to evaluate potential material handling system approaches.

We developed alternate layout configurations that supported the selected material handling approach that supported facility constraints.

Simulation and layout activities included overlapping RGV operation, ASRS stacking, batch transportation of WIP and single sheet conveyor transport of WIP.

Line Layout Optimization

Cadmium Telluride (CdTe) CH2M HILL conducted detailed manufacturing efficiency studies to support the client’s analysis of potential manufacturing line configurations. CH2M HILL further recommended potential material handling solutions to support the recommended line configurations.

Provided dynamic capacity modeling of production lines to determine the most efficient line combinations.

Identified detailed production line layout testing to desired production line configurations.

Provided simulation modeling of finalized material handling configurations and production layouts.

Simulation and layout activities included pick and place glass robotics, conveyors and conveyor logic, ASRS, and sheet buffers.

Manufacturing Layout Design & Implementation

Polycrystalline Silicon Materials CH2M HILL developed the complete manufacturing facility design for a multiphase polysilicon ingot and wafering facility, including the following services:

Evaluation of multiple sites in support of the client’s production process and manufacturing plans; the resulting facility fit the client’s plan and accelerated the project schedule.

Complete design-build activities for multiple production lines, including vendor coordination, utility planning and modeling, equipment layout, and material handling planning.

Significant coordination into facility and systems planning with the client’s Lean manufacturing team for the new manufacturing approaches.

Coordination of vendor design activities across different vendors and process steps, including automation transporting product between major process operations, process loading and unloading, and space management within the facility.

Vendor coordination and source inspections to validate production equipment performance to design.

Material Handling Flow Analysis

Amorphous SiliconCH2M HILL conducted detailed analysis of materials and production material handling requirements to resolve both traffic and space limitations associated with a retrofit facility.

Conducted logistics studies supporting general material handling between production lines.

Simulated potential solutions and recommended changes to warehousing layout, production layout, and associated space requirements.

Simulation and layout activities included forklift transport of glass A frames, conveors, ASRS, and logic supporting conveyor operation.

Wafer Manufacturing

Module Manufacturing

Empty Container Return

Module Manufacturing

Cell Manufacturing Cell Manufacturing

Material to Cell

Ingot In

Material Handling Strategy

Copper Indium Gallium (Di)Selenide (CIGS)CH2M HILL supported the analysis and identification of the corporate material handling strategy of the new production line as follows:

Studied and recommended material handling strategy for the new production lines.

Developed detailed layout options supporting the new strategy and testing facility, including layout constraints.

Simulated final solution, validating final hardware system requirements.

Simulation and layout activities included ASRS, AGV, six-axis robotics, and various conveyor configurations.

Manufacturing Equipment & Operation Systems/MES Integration

Amorphous SiliconCH2M HILL had total responsibility for manufacturing operations systems, including equipment control, production tracking, maintenance management and quality control.

Developed equipment specifications to drive standard operations and interface of vendor equipment.

Worked with equipment vendors to ensure specifications were met.

Developed equipment software to manage automated material transfer between production equipment.

Developed tool control software to upgrade or replace vendor supplied software.

Developed production tracking software for genealogy and production reporting.

Developed production dashboards and reports for operations management.

Gap Analysis on Manufacturing Operations Systems

Amorphous & Polycrystalline SiliconThis client had a polysilicon factory and an amorphous silicon (a-Si) factory; CH2M HILL performed a gap analysis on manufacturing operations systems.

Studied each factory and documented existing production tracking methods.

Met with stakeholders to determine priorities for improvements and additional functionality.

Developed gap analysis including development plan, priorities, and investment requirements.

Manufacturing Layout Design

Monocrystalline SiliconCH2M HILL developed the complete manufacturing facility design for a multiphase facility, including the following MI services:

Utility modeling, tracking and analysis to determine the effects of different vendor selections on the overall design of the facility and the start-up/commissioning ramp.

Coordination of vendor design activities across different vendors and process steps, including automation transporting product between major process operations, process loading and unloading, and space management within the facility.

Equipment layout and planning to ensure proper material, personnel, and maintenance activities.

Warehouse design, layout and flow planning.

Manufacturing Basis of Design

CdTe, CIGSCH2M HILL supported these clients in the process of scaling from a prototype line to the first high volume manufacturing operation.

Performed industrial engineering analysis of the manufacturing line configuration and defined optimal layout.

Performed engineering analysis of factory warehousing requirements; proposed solutions including warehousing sizing requirements, identification of storage and handling concepts and selection criteria.

Established process equipment utility matrix and identified utility loading for the new building.

Reviewed the logistical flows of raw materials and finished goods to, from, and within the site/building, including comparison of process manufacturing equipment with process flow methodology, identification of bottlenecks.

ERP

Application Server

Equipment Interface

ProductionManagement

MaintenanceManagement

QualityManagement

InventoryManagement

Human/MachineInterface

Historian

Process Equipment

Equipment Interface

processcontrol

cons

ume produce

Process Equipment

Equipment Interface

processcontrol

cons

ume produce

Process Equipment

Equipment Interface

processcontrol

cons

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Material Handling

Equipment Interface

materialstorage

cons

ume produce

SummaryCH2M HILL’s Manufacturing Integration group provides focused services to support the PV manufacturing industry.

These services include:

• Manufacturing planning• Risk assessment• Factory/line optimization• Material handling turnkey solutions• Manufacturing execution systems/solutions• Equipment installation and integration

By combining traditional industrial engineering and design with business process planning, simulation, and Lean strategies, Manufacturing Integration develops integrated solutions and systems to optimize the production line.

CH2M HILL’s extensive experience across the PV industry includes:

• Facility design of monocrystalline and polycrystalline wafer, amorphous silicon (a-Si), cadmium telluride (CdTe), and copper indium gallium (di)selenide (CIGS) based systems.

• Manufacturing and optimization studies of various systems including mono- and polycrystalline wafers.

• Simulation modeling of various production lines and material handling systems; material handling systems studied include ASRS, AGV, robotics, conveyor, sheet buggers, lifters, fork truck, and loading dock areas.

The unique experience of the CH2M HILL Manufacturing Integration team, with both facility and manufacturing systems, provides a strong foundation for the development and evaluation of systems optimized for PV manufacturing.

As part of our ongoing commitment to environmental sustainability, this page has been left blank to accommodate two-sided printing.

About CH2M HILLHeadquartered near Denver, Colorado, USA, employee-owned CH2M HILL is a global leader in full-service consulting, design, design-build, operations, and program management for public and private clients. With US$6.3 billion in revenue and more than 30,000 employees worldwide, CH2M HILL delivers innovative, practical, sustainable solutions—helping clients develop and manage infrastructure and facilities that improve efficiency, safety, and quality of life. The firm has long been recognized as a most-admired company and leading employer. CH2M HILL is an industry-leading program management, construction management, and design firm as ranked by Engineering News-Record (2011).

web: www.ch2m.com/solarpv email: solarpv@ch2m.com

©2012 CH2M HILLIAT102709092747PDX

www.ch2mhill.comwww.ch2mhill.com

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