A construction project for a plant in a new industry had begun. The products manufactured with this equipment were very special, since this client was the only manufacturer in Japan. Plus, it was a chemical manufacturer that handles various hazardous materials. When signing the contract, as a project manager, I told the client “we have basically no experience constructing this type of plant. Let us combine our knowledge to proceed with each other.”

　Typically, when trying to build something from scratch, nothing is as difficult as the beginning, conceptualizing what we will create and how we will create it. The same can be said for plant design, and the initial basic design is crucial. For this plant, we decided to start by understanding what it is that will be manufactured. To start designing, the team in charge had to dive into numerous documents to understand the whole equipment fully and properly.

　It was necessary to create many blueprints, including product creation procedures, equipment and device selection procedures, and equipment storage and layout procedures. In addition, it was necessary to check related legal measures for the equipment and consider them in the plan. I wonder, how many times did I visit the fire department to inquire and consult? Laws, such as those regarding hazardous material leaking, dealing with gas generated on-sites, fire alarms and sprinklers, obviously must be respected. The types of hazardous materials vary, so it is crucial that countermeasures are appropriate. If anything should happen, it could lead to a catastrophic situation, so we took appropriate steps accordingly.

　What made this project particularly difficult was that there were multiple products to be manufactured. This was a multi-plant which manufactured six or seven products in the same production line. The system was very complex, and versatile equipment was required. Although the client decided the equipment specifications, we spent an enormous amount of time comparing each piece of equipment and device, joined the meeting between our client and an equipment manufacturer, and jointly considered the options. We continued to make the best decisions using our expertise, even if was not what the client wanted to hear. little did we know, we would later receive an email thanking us for our cooperation during the design stage.

　Although basic plans and equipment selection were important, the design was particularly vital for this project. Of course, it is not sufficient to satisfy only the function as an equipment. We needed to design a comprehensive layout incorporating machinery, electricity, and construction aspects while leaving space for maintenance, operators, and future equipment. Given the size of the building, this facility had a lots of machinery and electricity equipment. For that reason, the interior design was extremely complex. On site, designs that looked great on paper did not appear as expected. I often tell young managers to always check designs at the physical construction site, never has that been so true as in this project.

　Every day, I faced my work head on, knowing that my decisions would determine the success of the design. Challenges included working in an industry I was inexperienced in, taking on tasks in a complex system, and considering numerous safety measures, but after a year of collaboration with the client, we completed the design after a year. Now, construction is ready to begin.