Strategic Facility Planning
Strategic master plan and conceptual design for the expansion of a semiconductor facility in southeast Asia.
The traditional view of facilities as simply an expense is being eclipsed as businesses and institutions recognize that facilities either support positive change or impede it. No longer neutral, facilities can be used as tools that enable change and success. Facilities can impact human performance and morale, they project brand, they can improve operations and productivity, and they can reduce costs.
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Facilities are Tools that Enable Change and Success Our teams combine expertise in planning, architecture, design, engineering, and technology using a comprehensive but efficient approach to improve the value of your facilities. Our multi-disciplined approach covers a series of value-added services including facility condition assessment, space utilization assessment, master planning, space planning, architecture, interior design, lean process consulting, engineering, and landscape design.
Allegheny County Airport Authority
King Abdulaziz City for Science & Technology (KACST)
ALZA Corporation
Komatsu Electronic Metals
Applied Materials
Kunming Digital Forest
Axcelis Corporation
Kunshan Renewable Energy Resources Park
Battelle Bayer Corporation CB Richard Ellis/Pittsburgh, Tech 21 Carrier Corporation
Lavipharm Laboratories Lawrence Livermore National Laboratory Macronix Corporation Medeva Pharmaceuticals
Understanding Your Business Goals and Constraints
Celgene Corporation
We begin by understanding your short-term and long-term business goals and constraints, which are then translated and applied to your physical assets to inform more effective and specific facility planning strategies.
Central New York Regional Planning & Development Board
MODON Saudi Industrial Property Authority
Chi Mei Optoelectronics Corporation
Micron Technology, Inc. Motorola
Digital Optics
Oregon Health & Sciences University
Facility planning strategies frame a more focused assessment of existing conditions: • Technical condition assessments of existing structures, systems and equipment • Space utilization assessments that include an evaluation of space efficiency and flow (of products/people) • Site utilization assessments that include zoning code, density, traffic, and parking evaluations • Environmental and energy usage assessments
Gap Analysis Provides Short-Term and Long-Term Facility Improvement Strategies This strategy is evaluated relative to current conditions, and a gap analysis uncovers the areas of improvement needed to better position your facility infrastructure to support your goals. The gap analysis is just a beginning; using 3D modeling along with traditional planning and design tools, we engage your stakeholders through interactive workshops. Through the comparison of many potential scenarios and options developed in 3D (digital rapid prototyping) optimal solutions begin to emerge. Our team offers expertise across a wide range of facility types and industries—from architects and interior designers who specialize in human centered design; technologists and engineers skilled in specialized research and production environments, as well as critical environments like data centers; and planning, code and zoning experts who can help you maximize the use of your real estate portfolio.
Dubai Airport Free Zone Authority
Philips
Empire State Development Corporation
Qingpu Bio-Pharm CMP
Fujitsu Microelectronics
Samsung
Genesee Gateway Local Development Corporation GlaxoSmithKline Grubb & Ellis Hewlett-Packard Hitachi, Ltd. Huawei Technologies Company Ltd. IBM Corporation IFFCO Imperial Land Corporation Infineon (formerly White Oak Semiconductor) Janssen Pharmaceuticals, Inc. Jiading Industrial Park
Rockwell Semiconductor Sanofi Pasteur Shanghai Zhangjiang Group Solarex STMicroelectronics Suzhou Industrial Park Syntex Taiwan Semiconductor Manufacturing Corporation (TSMC) Tianma Union Carbide Vestas West Virginia University
Range of Examples and Success Stories
University of Pittsburgh 12-Year Capital Improvement Plan The university initially hired us to do a small study of 15 outdated science facilities at their main campus in Pittsburgh’s Oakland district. Pitt is a leading NIH-funded research institution, and they had concluded that their facilities were limiting their ability to grow their research program and attract and retain worldclass talent. However, their urban campus is quite congested, and other design firms told them the only thing they could do was tear down existing facilities and rebuild new. The costs and the logistical disruptions of this approach were unacceptable, and Pitt selected us because we proposed an alternative approach. Instead of tearing down, we promoted the value of rejuvenating existing facilities and bringing them up to 21st-century standards. Using in-house computer programming expertise, we developed a simple but powerful database tool to document existing conditions and build a series of ‘what-if’ scenarios. While Pitt originally sought a conditions assessment of existing systems and infrastructure, we promoted the need to evaluate existing space utilization as well as systems conditions. Through this effort we learned that space was indeed used very inefficiently, and we were able to demonstrate through 3D space planning tools that every one of the facilities could increase lab space from 10% to 25% without adding new space, and that through strategic additions usable lab/office/teaching space could be increased by 40% without disrupting on-going operations. Through the conditions assessment, we initiated a strategic systems and infrastructure plan that was sequenced over time and reduced long-term operational costs through energy efficiency strategies. Pitt used the database and the ‘what-if’ scenarios to generate a $1B 12-year capital improvements plan that was approved because of its pragmatic re-use of existing facilities. The plan has proven very successful, and Pitt has been able to transform facilities that were originally liabilities into assets, and has steadily improved its standing as a world-leading research institution.
Zhangjiang Hi-Tech Campus The Shanghai Zhangjiang Group engaged CH2M HILL to help develop a vision for the Zhangjiang Hi-Tech Campus. As a comprehensive, high-tech community, the campus will be home to emerging technology R&D facilities, business incubators, commercial, retail, housing and leisure components. The aim was to provide a planning approach and building prototypes to assist in the creation of an innovative campus supporting research, development and prototype-to-market space for bio-pharmaceutical, nanotechnology, microelectronics and other emerging technologies. Proposed development guidelines and building prototypes had to inform and promote a holistic, 24/7 community. Each building prototype study has two components. The first component is the measurement of the prototype against case studies and precedents. The second component of each study is the visual definition of the building prototype itself. In addition to the performance criteria, the prototype is defined in a three-dimensional “rapid prototyping” model, demonstrating key elements of the building’s program. These programmatic models show the architectural massing and material character of each prototype. In all, 15 prototypes were developed, including research, teaching, office and public buildings (such as libraries, expo halls and hospitals). Based on these possible iterations and specific planning precedents, two planning implementation examples were developed: Research & Development Mixed Use, and Residential & Retail Mixed-Use. These two planning examples were driven by the Shanghai Zhangjiang Group’s goal to address, in equal parts, the creation of a “knowledge-based” R&D Campus and the complementary “living” components of a healthy, attractive, sustainable and financially successful high-tech community.
IBM Fishkill Campus The IBM East Fishkill site began development in the “Big Blue” heyday of the 1960s. Today, IBM Corporation shares the site with tenant companies and is interested in maximizing development potential in the challenging, densely built industrial site. Besides designing some of the most sophisticated cleanroom facilities in the world at this site, CH2M HILL has assisted IBM management with the consideration of future development opportunities through the preparation of a range of master plan options over several years. These options have considered a variety of environmental issues, including air quality, wetlands, archeological, endangered species, and groundwater factors. Working closely with the local authorities having jurisdiction in this wealthy and highly environmentally conscious suburb of New York City, CH2M HILL has been able to get IBM’s space utilization in regards to allowable building area and FAR re-designated, which allowed the campus to increase its development density and its future value. The Building 323 project, a major retrofit of an existing building, is one example of the value of multidiscipline services and integrated project delivery approaches. CH2M HILL successfully met complex design challenges, including extensive building modifications within a constrained shell to accommodate larger 300mm production tools. Other tasks included removing four million pounds of concrete from the retrofit to recycle as campus roadbed, accommodating a special duct system enclosure at the top of the structure, and drilling 5,000 18-inch diameter holes in the waffle slab to provide access routes for power supplies that feed air handlers, deionized water subsystems, gas handlers, chillers, compressors, boilers and waste treatment systems. Other projects that CH2M HILL has designed for the site include landscape upgrades, a photovoltaic production facility within the shell of an outdated semiconductor plant, a major addition to Building 323 (the 323 Annex) which more than doubled the production capacity of the original building, studies for information technology research facilities, and on-going retrofits to testing and research laboratories.
Bayer MaterialScience Sustainability and Consolidation Initiative When Bayer acquired MEDRAD, a progressive medical device company, they became aware of IDC Architects, a CH2M HILL company who had designed Medrad’s global headquarters facility. Bayer approached us about doing some studies to help upgrade their campus and consolidate staff currently occupying expensive offsite leases. We used a recently completed occupancy study by Toffler Associates as a starting point, and worked closely with Bayer’s Pittsburgh campus leadership to develop a facilities strategy that would allow them to bring their staff on site without any additional space. Additionally Bayer recognized the need for facilities that could attract and retain talent (especially next generation talent) given the high-tech boom occurring in Pittsburgh (one of Google’s largest offices is located there). The plan focused initially on two of their largest existing buildings. Through the use of collaborative design sessions with staff and Bayer’s own internal cultural change program, we were able to get consensus from stakeholders for radically changing the space standards on campus (these changes have consequently been implemented at Bayer’s other North American campuses in New Jersey and North Carolina). We went from over ten different space sizes to two; one for open work stations, and one for closed offices. All offices were moved internally to allow direct access for daylight and views for 100% of the occupants. Conference and team space was increased from a ratio of one space per 47 occupants to one per 17. The increase in occupancy of these two major buildings allowed Bayer to consolidate their offsite employees to one location. Exterior upgrades increased parking and added exterior social spaces that had wireless access. Our work for Bayer’s Pittsburgh campus has expanded over the years. We recently completed an extremely challenging relocation of R&D and pilot production facilities from a remote campus to an existing building on campus. Much equipment was relocated but was a tight fit, so our teams documented and measured the process equipment to devise minimal renovations that could accommodate the process within a very tight budget and schedule. We have also worked with Bayer in joint research on the development of high performance building envelopes using Bayer Materials. Several innovations were deployed to reclad the first three buildings on their Pittsburgh campus, which were outdated and uninsulated midcentury buildings. This included new insulated fiber-reinforced curtainwall systems that could replace aluminum framing and several applications of insulation systems to rain screen envelopes.
Boehringer Ingelheim Site Expansion The Boehringer Ingelheim group is one of the world’s 20 leading pharmaceutical companies. Its site in Shanghai, China required expansion of a pharmaceutical manufacturing campus including an existing oral solid dosage facility, a new multi-product packaging facility for tablets and ampoules, a new highbay warehouse with an automated storage and retrieval system, a center of competence (research) lab, quality control labs and a new canteen. The client’s objective was to achieve world-class production using a modular, Lean manufacturing approach supported by optimization of material flow. CH2M HILL’s scope of work on this project included a four-month concept development phase, a Lean review of the operation’s logistics model, optimization of a previously completed feasibility design, and preparation of preliminary planning/permitting submissions. This was our first opportunity to demonstrate the dramatic benefits of applying Lean principles on a true pharmaceutical project, helping significantly reduce the footprint of the facility. Using supply chain planning, we achieved a 66% reduction in raw materials and packaging inventories, point-of-use delivery for bottles, 30% reduction in shipping receiving area, introduced changeover kit carts and rapid changeover teams, visible factory tools and techniques, elimination of glass ampoule inventory through point-of-use delivery and in-line inspection, labeling, and packaging for ampoules to further meet site utilization code and reduce both capital and long-term operating costs. The project is located in Shanghai Zhanjiang High-Tech Park, a massive 2.5-square-kilometer high-tech campus that our company master planned in 2009. It is an “innovation campus” supporting research, development and prototype-to-market space for biopharmaceutical, nanotechnology, microelectronics and other emerging technologies. We impressed BI through delivery of diverse services within an integrated team, our extensive pharmaceutical experience, our Lean capabilities, our strong local knowledge of regulatory and permitting issues, our detailed understanding of their manufacturing process, and the quality of our ideas to optimize operational flows—all from a single source. The combined Boehringer Ingelheim–CH2M HILL project team was multinational and multicultural with members from China, Germany, Singapore, US, France, Spain, Wales and Ireland.
Carrier Site Reuse Plan Carrier Corporation has been a significant presence in the Syracuse community for over 50 years. Historically, Syracuse site operations included manufacturing, research and development (R&D), and administration, with the site serving as the company’s corporate headquarters. In recent years, manufacturing and administration functions ceased, and the site has become one of several Carrier R&D centers (global design centers) located around the globe. The site supported a Carrier employee population of approximately 7,000 persons at an operational peak in the 1970s, and by 2006, the Syracuse R&D center employed roughly 1,600 persons. While the existing building area totaled over 3,000,000 square feet in 2006, only 2,000,000 square feet was actually occupied for Carrier operations. In 2005, Carrier partnered with state economic development to form a Community Advisory Committee (CAC) to sponsor preparation of a comprehensive plan for reuse of the site. The initiative was funded by a grant from the U.S. Department of Commerce Economic Development Administration, and other local agencies comprising the CAC included the Onondaga County Office of Economic Development, the Syracuse Metropolitan Development Association, the Greater Syracuse Chamber of Commerce, and regional utility provider National Grid. The master plan was built around a vision of the site as a world-class technology park with a consolidated Carrier Global Design Center at its core. The plan consolidated Carrier operations into the central portion of the site and proposed redevelopment of the east and west portions of the site as non-Carrier R&D uses, and included a re-image the public face of the site to create a “gateway” to a potential technology corridor south of the site. A business plan was developed to aid in Carrier evaluation of the master plan for consistency with Carrier corporate goals and policies, including: • Ownership / management options • Pro forma analysis and financial plan • Marketing plan • Economic impact analysis
Life Technologies Campus Development CH2M HILL understands the needs of the bioscience industry. To be competitive in biomedical research, manufacturers must develop new product lines that enable scientific researchers to make ground-breaking discoveries. Manufacturers also need the ability to grow through the acquisition of smaller companies to capture significant market share. For Life Technologies, an opportunity to expand its research and manufacturing base became available on its campus in Eugene, Oregon. We sought to support this client’s dramatic growth. As a bioscience corporation supporting the international scientific community, our client offers more than 25,000 products, from genetic studies through protein identification, drug discovery, and process development. When this Life Technologies engaged CH2M HILL to perform a site analysis of nearly 20 acres in 2004, the campus consisted of approximately 136,000 SF of research, production, administration, and support space distributed among eight buildings. CH2M HILL’s site master plan increased the north campus building area from 136,000 GSF to 289,000 GSF. In addition, the master plan recommended approximately 192,000 GSF of facilities with the addition of a south campus. CH2M HILL’s site analysis resulted in a master plan with several key benefits. A dramatic site sequence offered visitors a main entry from the adjacent street to the central office, parking service for staff located at the rear of the facility, and centralized service access. Additionally, CH2M HILL’s master plan offered contiguous green space with simplified circulation, and multiple configurations to enable future siting of an operations building. Among the features proposed to enhance the campus were: an outdoor plaza with a pavilion; a grand exterior stair from the plaza to the upper courtyard; Building D cafeteria with outdoor terrace; full site fencing; and an additional entry to Building C, separating the childcare area from the employee area. Since 1998, CH2M HILL has collaborated closely with this bioscience client on its campus in Eugene, helping to achieve its mission of serving the international scientific community. Our contribution to this client’s long-range planning with this pivotal master plan helped to define the goals and the full potential for the site.
Science & Technology Advanced Manufacturing Park The central aim of the first project planning phase, completed in late 2008, was to assess the feasibility of a Science & Technology Advanced Manufacturing Park (STAMP) to serve the Western New York region. Working closely with the Genesee Gateway Local Development Corporation, CH2M HILL (through our architectural entity, IDC Architects) led a planning process that involved extensive stakeholder participation and engagement. Over the course of the project, several town hall meetings were held with the general public, and a community-wide survey was conducted to assess community views towards the development. Upon receipt of very favorable survey results, IDC Architects prepared a feasibility study for STAMP that included a high-tech market analysis, a physical master plan, cost projections and an estimate of direct jobs potentially created by the project. A key technology park theme that emerged during the feasibility study is “Renewable Energy,” which aims to focus on photovoltaic manufacturing as a target market and which would complement a wind farm project proposed adjacent to the STAMP site. IDC Architects led the second project planning phase, which intends to bring the site to market-ready status as a major technology manufacturing campus. The second phase consisted of preparing/processing State Environmental Quality Review Act (SEQRA) documentation, which included conducting benchmarking trips to comparable technology communities for STAMP representatives, continued the dialog with local community stakeholders, and developed marketing strategies with Genesee Gateway Local Development Corporation. The process has now entered the infrastructure planning and development stage and funding is in place. Water, waste water, power and other essential utility systems are being developed to support high tech development at the site which has been recognized as a key element of the Governor’s ‘Start-up NY’ program.
About CH2M HILL Employee-owned CH2M HILL is a global leader in full-service consulting, design, design-build, operations and program management services for public and private clients. With US$6.6 billion in revenue and over 26,000 employees worldwide, we deliver innovative, practical, sustainable solutions-helping clients develop and manage infrastructure and facilities that improve efficiency, safety and quality of life. CH2M HILL has long been recognized as an industry-leading program management, construction management and design firm as ranked by Engineering News-Record (2013) and has been named a leader in sustainable engineering and environmental services providers by Verdantix. Visit us at www.ch2mhill.com, twitter.com/ch2mhill and facebook.com/ch2mhill.
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