CH2M HILL provides manufacturing integration and consulting services for photovoltaic (PV) cell and module production. They have experience across crystalline silicon, thin film technologies like cadmium telluride and CIGS. Their services include manufacturing layout, material handling design, line optimization, and implementation of manufacturing execution systems. They take a tailored, simulation-based approach to evaluate and optimize solutions for clients' PV manufacturing needs.

1. Manufacturing Integration,
Productivity and
Technology Services
Tailored Solutions to Your Individual
PV Operations Requuirements

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

3. Company Overview
CH2M 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 Glance Recognized for Industry At CH2M HILL, we strive to
Founded in 1946 and headquartered Excellence “outperform,” exceeding
near Denver, Colorado, employee- CH2M HILL earned 13 Number your expectations and our
owned CH2M HILL is a global firm One rankings and multiple Top 10 industry’s standards.
providing consulting, engineering, rankings from Engineering News- It’s not the exception here.
construction, operations, and related Record in 2009. These rankings
technical services to public and It’s the rule.
include:
private clients. Each of our clients demands and
• #1 of Top 20 Manufacturing Design deserves a completely satisfying
• More than 23,500 employees in Firms
solution on every project, regardless
offices worldwide
• #2 of Top 100 Construction of complexity.
• 100 percent employee owned Management Firms
• Broadly diversified across 10 • #1 of Top Five Design Firms in
business sectors: Semiconductor Industry
» Energy & Chemicals
Performance Excellence -
» Environmental Recognized Across Industries
» Government Facilities & As a result of our processes and
Infrastructure systems, we have won many industry
» Industrial & Advanced awards from our customers for
Technology project quality, health and safety, and
» Industrial Systems customer satisfaction. With an EMR
of 0.74, our safety record is among
» Nuclear
the best in the industry.
» Operations & Maintenance
» Power
Fortune Magazine ranked
CH2M HILL
» Transportation
» Water
• $6.3 billion in revenue (2009)
100 BEST www.ethisphere.com ranked
Companies to Work For
CH2MMost HILL
2009 World’s
ETHICAL Companies
2009

4. CH2M HILL Manufacturing Solutions - Overview
The 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.
Improving Performance
and Profit
Global 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

5. Manufacturing Integration, Technology & Productivity Services
Manufacturing/Facilities • Productivity studies
Planning • Manufacturing excellence/lean
• Strategic planning constraint analysis
• Support area requirements Manufacturing Operational
Systems
• Flow analysis
• Warehousing/logistics • Systems assessment, refinement,
selection and integration
• Utility requirements definition
• Manufacturing execution system
• Micro level manufacturing layout
(MES)
planning
• Controls systems (PLCs, AB, GE,
• Macro level manufacturing layout
Siemens, Mitsubishi, etc.)
planning
• Motion controllers
• Tool list development
CH2M HILL Manufacturing • Vision systems
Integration engineers enter the • Capacity modeling/planning
• SCADA systems (GE Proficy, RS
project early in the pre-planning • Manufacturing process definition
View, Wonderware, etc.)
phase, to define and integrate the • Manufacturing production plan
• SQL, Oracle and other database
facility, systems, process equipment, definition
systems
and operational activities.
• Operating procedures
• Ethernet networks
• Staffing plans
• Industrial PCs
• Manufacturing/process simulation
Automated Material Handling
• Workplace design Systems (AMHS)
• Microcontamination design
• Turnkey solutions
Strategic Planning/Risk • Automation simulation and
Assessment modeling
• Business risk analysis • Conveyors (belts, links, rollers)
• Profitability analysis • Robots (SCARA, r- -z, Cartesian)
• Asset management • Warehouse layout planning
• Operational goaling • General material handling design
• Financial modeling • Sustaining engineering
• Cost of ownership model • Facility planning support
• Facility cost model • Layout services
Factory/Line Optimization/ • Construction modifications
Modeling • Equipment installation and
• Line/equipment layout integration
• Static and dynamic modeling Equipment Install Planning
• Production flow modeling • Production tools integration and
• Failure mode and effects analysis production readiness
(FMEA) • Line audit for factory acceptance
• Production equipment layouts • Equipment source inspection
• Layout optimization

6. Photovoltaic Manufacturing
CRYSTALLINE SILICON
polysilicon wafer cell module
Mitsubishi REC Spectrawatt Trina Solar
THIN FILM
silicon CdTe CIGS
CH2M HILL has
worked with developers of
solar/PV products in all cell various turnkey vendors
and their customers First Solar Solyndra
technologies and has more
than 10 years of experience
in both crystalline and thin CH2M HILL provides a single
film technology. Our portfolio includes customers point of responsibility for the
ranging from start-ups to companies complete life cycle of your
in the top 20 list of manufacturers. project.
We have provided design-build,
design only, and consulting work in
Engineers, designers, and technical
Asia, Europe, and North America.
specialists make up the core of
Our experience base encompasses our firm — professionals with
the full spectrum of PV unparalleled experience in all
manufacturing processes, from the phases of the planning, design, and
initial production of polysilicon, installation operations that support
including monocrystalline, to the development of wafer and thin
polycrystalline casting, amorphous, film manufacturing systems.
cadmium telluride (CdTe), CIGS and
multijunction technology.

7. In-house Experience and Tools
PV Automation Expertise Process Technology Experience Solution Evaluation and
Optimization
• Automated storage and retrieval • Mono- and polycrystalline silicon
systems • Cadmium telluride (CdTe) • Lean planning for concept
• Automatic guided development
• Amorphous silicon
vehicle (AGV) • Business process mapping
• Copper indium gallium (di)selenide
• Rail guided vehicle (RGV) supporting optimized methods
(CIGS)
• Stack and single wafer handling • Dynamic capacity models for
Production Line Layout and production line evaluation
• Wafer buffering Material Handling Applications (standardized models)
• Raw wafer handling • Single, stack and cassette wafer • Material handling simulation
• Manufacturing execution systems handling models to validate material
• Cassette and stack • Inline and batch wafer processing handling solutions (standardized
loading and unloading models)
• Wafer buffering
• Process tool loading and unloading Manufacturing Operations
• Large glass thin film single sheet and
Systems
batch processing configurations
• Alternate media applications (glass • Requirements definition – controls/
tubes, flexible media, wafer) manufacturing execution systems
(MES)/material control systems
• Raw materials and finished goods
(MCS)/enterprise
logistics
• 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

8. Photo: Aleo Solar
Approach
CH2M HILL combines our process, Our approach includes the following
material handling, and engineering activities, with the flexibility to tailor
experience when evaluating and a solution to fit your needs and
optimizing potential solutions. budget:
The figure on the next page
• Develop processing requirements • Develop alternate and potential
demonstrates the execution of the
as defined by the client team, solutions.
basic evaluation process.
creating a manufacturing
• Evaluate potential solutions
requirements document. This
statically to eliminate options
process utilizes Lean methods
that will not support efficiency
to quickly converge on the
improvements.
appropriate definition.
• Perform dynamic evaluation of
• Execute a baseline process where
best case options as defined by the
existing concepts are evaluated
static process; rank solutions per
both statically and dynamically,
criteria.
creating a validated baseline where
alternative solutions and changes
can be ranked.

9. Material Handling Modeling
STATIC
Simulation The hybrid approach of static
and dynamic analysis offers a
comprehensive evaluation of all
possible options yielding optimal
solutions while minimizing time From developing system
and effort. requirements through the request
for qualification, bid, selection and
construction/integration, CH2M HILL
Layout vendor management for both
material handling and manufacturing
system solutions minimizes capital
expenses while optimizing PV facility
operations. We deliver cost effective,
OPTIMIZED turnkey automation systems to
DYNAMIC material handling
system design meet your needs, not a supplier
Simulation
Requirements
specification sheet.
Vendor Submittal, Review
Requirements Concepts & Recommendation
Equipment
Validation and Concepts & Solutions
Modeling Validation
Management
Approval
Bid Package Construction
Bids
Award Contract Development & Integration
Client
CH2M HILL
Install
Construct Equipment
Software
Systems
STARTUP Deploy & Integrate
ramp factory Software Systems

10. Representative Client Projects
The 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 Material Handling Design
Layout Design Amorphous Silicon
Amorphous Silicon CH2M HILL developed
CH2M HILL developed the manufacturing facility design options.
manufacturing facility design and MI services were used to create and
included the following MI services to test layouts adapted to support the
validate the manufacturing space and site and facility constraints:
production requirements:
• Simulation modeling was used
• Dynamic capacity modeling to evaluate potential material
was used to evaluate delivery handling system approaches.
and work in progress (WIP) • We developed alternate layout
requirements affected by planned configurations that supported
and unplanned production tool the selected material handling
schedules. approach that supported facility
• Simulation modeling was used to constraints.
support evaluation of potential • Simulation and layout activities
material handling solutions and included overlapping RGV
their impact on production operation, ASRS stacking, batch
capacity. transportation of WIP and single
• Simulation included the use of sheet conveyor transport of WIP.
six-axis robotics, glass conveyance,
tool loading robots and bulk sheet
buffering.

11. Module Manufacturing Module Manufacturing
Empty Container Return
Wafer Manufacturing
Material to Cell
Cell Manufacturing Cell Manufacturing
Ingot In
Line Layout Optimization Manufacturing Layout Material Handling
Cadmium Telluride (CdTe) Design & Implementation Flow Analysis
CH2M HILL conducted detailed Polycrystalline Silicon Amorphous Silicon
manufacturing efficiency studies Materials CH2M HILL conducted detailed
to support the client’s analysis CH2M HILL developed the complete analysis of materials and production
of potential manufacturing line manufacturing facility design for material handling requirements
configurations. CH2M HILL further a multiphase polysilicon ingot and to resolve both traffic and space
recommended potential material wafering facility, including the limitations associated with a retrofit
handling solutions to support the following services: facility.
recommended line configurations:
• Evaluation of multiple sites in • Conducted logistics studies
• Provided dynamic capacity support of the client’s production supporting general material
modeling of production lines to process and manufacturing plans;
handling between production lines.
determine the most efficient line the resulting facility fit the client’s
plan and accelerated the project • Simulated potential solutions
combinations.
schedule. and recommended changes to
• Identified detailed production warehousing layout, production
line layout testing to desired • Complete design-build activities for
layout, and associated space
production line configurations. multiple production lines, including
requirements.
vendor coordination, utility planning
• Provided simulation modeling and modeling, equipment layout, • Simulation and layout activities
of finalized material handling and material handling planning. included forklift transport of glass A
configurations and production frames, conveors, ASRS, and logic
• Significant coordination into
layouts. supporting conveyor operation.
facility and systems planning with
• Simulation and layout activities the client’s Lean manufacturing
included pick and place glass team for the new manufacturing
robotics, conveyors and conveyor approaches.
logic, ASRS, and sheet buffers.
• 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.

12. Manufacturing Equipment
& Operation Systems/MES
Integration
Amorphous Silicon
CH2M HILL had total responsibility
Photo: Solarworld
for manufacturing operations
systems, including equipment
control, production tracking,
maintenance management and
quality control.
Material Handling • Developed equipment
Strategy specifications to drive standard
operations and interface of vendor
Copper Indium Gallium
equipment.
(Di)Selenide (CIGS)
CH2M HILL supported the analysis • Worked with equipment vendors to
ensure specifications were met.
and identification of the corporate
material handling strategy of the new • Developed equipment software
production line as follows: to manage automated material
transfer between production
• Studied and recommended equipment.
material handling strategy for the • Developed tool control software
new production lines. to upgrade or replace vendor
• Developed detailed layout options supplied software.
supporting the new strategy and • Developed production tracking
testing facility, including layout software for genealogy and
constraints. production reporting.
• Simulated final solution, • Developed production dashboards
validating final hardware system and reports for operations
requirements. management.
• Simulation and layout activities
included ASRS, AGV, six-axis
robotics, and various conveyor
configurations.

13. Manufacturing Basis of
Design
Manufacturing
Layout Design CdTe, CIGS
CH2M HILL supported this clients
Monocrystalline Silicon in the process of scaling from a
CH2M HILL developed the complete prototype line to the first high
Gap Analysis on manufacturing facility design for volume manufacturing line.
Manufacturing Operations a multiphase facility, including the
• Performed industrial engineering
Systems following MI services:
analysis of the manufacturing line
Amorphous & • Utility modeling, tracking and configuration and defined optimal
Polycrystalline Silicon analysis to determine the effects layout.
of different vendor selections on • Performed engineering analysis of
This client had a polysilicon factory
the overall design of the facility factory warehousing requirements;
and an amorphous silicon (a-Si)
and the start-up/commissioning proposed solutions including
factory; CH2M HILL performed a gap
ramp. warehousing sizing requirements,
analysis on manufacturing operations
systems: • Coordination of vendor design identification of storage and
activities across different vendors handling concepts and selection
• Studied each factory and and process steps, including criteria.
documented existing production automation transporting
tracking methods. • Established process equipment
product between major process utility matrix and identified utility
• Met with stakeholders to operations, process loading loading for the new building.
determine priorities for and unloading, and space
improvements and additional management within the facility. • Reviewed the logistical flows of
functionality. raw materials and finished goods
• Equipment layout and planning to to, from, and within the site/
• Developed gap analysis including ensure proper material, personnel, building, including comparison of
development plan, priorities, and and maintenance activities. process manufacturing equipment
investment requirements. • Warehouse design, layout and with process flow methodology,
flow planning. identification of bottlenecks.
ERP
Application Server
Production Quality Inventory Maintenance
Management Management Management Management
Equipment Interface
Human/Machine Historian
Interface
Equipment Equipment Equipment Equipment
Interface Interface Interface Interface
consume
consume
consume
produce
produce
produce
consume
produce
process process material process
control control storage control
Process Equipment Process Equipment Material Handling Process Equipment

14. Summary
CH2M HILL’s Manufacturing
Integration group provides
CH2M HILL’s extensive
focused services to support the PV
experience across the PV
manufacturing industry.
industry includes:
• Facility design of monocrystalline
These services include:
and polycrystalline wafer,
• Manufacturing planning amorphous silicon (a-Si), cadmium
• Risk assessment telluride (CdTe), and copper indium
gallium (di)selenide (CIGS) based The unique experience of the
• Factory/line optimization
systems. CH2M HILL Manufacturing
• Material handling turnkey solutions
• Manufacturing and optimization Integration team, with both
• Manufacturing execution systems/ studies of various systems facility and manufacturing
solutions including mono- and systems, provides a
• Equipment installation and polycrystalline wafers. strong foundation for the
integration • Simulation modeling of various development and evaluation
By combining traditional industrial production lines and material of systems optimized for PV
engineering and design with handling systems; material manufacturing.
business process planning, handling systems studied include
simulation, and Lean strategies, ASRS, AGV, robotics, conveyor,
Manufacturing Integration develops sheet buggers, lifters, fork truck,
integrated solutions and systems to and loading dock areas.
optimize the production line.

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

16. About CH2M HILL
Headquartered near Denver, Colorado, employee-owned CH2M HILL is a
global leader in full-service engineering, procurement, construction, and
operations for public and private clients. With $6.3 billion in revenue and
more than 23,500 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, including being named by FORTUNE magazine as one
of the 100 Best Companies to Work For (2009).
Web Address: www.ch2m.com/solarpv
Email: solarpv@ch2m.com
CH2M HILL operates out of more than 200 offices worldwide. For a complete
list of office locations in your area, please visit us at ch2mhill.com.
Global Headquarters
9191 South Jamaica Street
Englewood, CO 80112
USA
Toll-free: 888.CH2M.HILL
Tel: +1 303.771.0900
Fax: +1 720.286.9250
North America North Asia South Asia Europe
2020 SW 4th Avenue 8F, Tower 1, Grand Gateway 150 Beach Road, 34th Floor Optima Building, Level 1 North
Third Floor 1 Hong Qiao Road Gateway West 58 Robertson Street
Portland, OR 97201 Shanghai, 200030 Singapore, 189720 Glasgow, G2 8DU
USA People’s Republic of China Republic of Singapore Scotland, U.K.
Tel: +1 503.235.5000 Tel: +86 21.6113.2000 Tel: +65 6391.0350 Tel: +44 (0) 141.204.2333
Fax: +1 503.736.2000 Fax: +86 21.6113.2199 Fax: +65 6299.4379 Fax: +44 (0) 141.204.2033
Mexico Brazil Argentina Middle East/North Africa
AV. Xola 535 Vila Olimpia Azara 841, 1 Floor Star Holding Building
Piso 23 Col. del Valle Rua do Rocio, 351 - conj. Ciudad Autonoma de Ground Floor #2
Del. Benito Juarez Suite 11, 12, 21, 22, 52, 61 e 62 Buenos Aires, 1267 Dubai Internet City
Mexico City, 03100 Sao Paulo, 04552-000 Argentina PO Box 500554
Mexico Brazil Tel: +54 114 309 0201 Dubai, United Arab Emirates
Tel: +52 55 5999 0400 Tel: +55-11 3040 0800 Fax +54 114 303 3954 Tel: +971 4.427.7600
Fax: +52 55 5999 0410 Fax +55-11 3040 0802 Fax: +971 4.427.7601