When modularizing a heavy industrial project, you’re taking a major step toward improving efficiency and reducing on-site labor. But for all the benefits, there’s a challenge that can derail even the best modularization plan: coordination between disciplines. In a project involving civil, structural, process, mechanical, piping electrical, instrumentation and controls engineers, every piece of the puzzle must fit together perfectly. If it doesn’t, you risk costly delays, rework, and safety issues.
At DyCat Solutions, we’ve been through this process many times and understand that poor coordination can become a serious barrier to success. Our approach focuses on removing those barriers early on—helping you streamline the process, improve communication between disciplines, and ensure a smoother project overall.
The Challenge: Coordinating Multiple Disciplines in Modular Projects
Modularization means fabricating and assembling large components within a structure off-site and installing them at the project site location. The tricky part is that this process requires collaboration from several engineering teams—each with its own technical standards, design needs, and timelines.
In a modular heavy industrial project, structural engineers focus on the structural frames and supports, while process engineers design the process systems. Mechanical engineers develop equipment to align with the process requirements, and piping designers arrange the equipment and piping systems within the module. Electrical engineers handle power distribution systems across the module(s), and instrumentation and controls engineers design instrumentation based on process and safety requirements, managing the overall distribution of controls within the module.
When these teams don’t coordinate, you can end up with design clashes, misaligned equipment, piping, electrical, instrumentation and controls that don’t fit within the module. These issues can lead to rework that costs time and money.
But the good news? These challenges are solvable. With the right strategies and tools, we can help ensure that everyone is on the same page from the start.
Addressing the Complexity: Differing Requirements and Miscommunication
Every discipline in a modular project comes with its own set of technical requirements. Without proper coordination, these differing requirements can lead to conflicts during module integration. What happens then? You end up with incompatible designs, and fixing these issues in the module fabrication and assembly facility or on-site is much more expensive than getting it right from the start.
On top of that, many teams operate in silos, which leads to incomplete communication between disciplines. When teams don’t communicate effectively, critical design details can slip through the cracks, leading to misaligned equipment or incompatible systems causing rework in the module fabrication and assembly facility or on-site.
At DyCat Solutions, we work to break down those silos and build better communication pathways, ensuring that your engineering, design, module and construction teams are always in sync.
How Poor Coordination Impacts Your Project
When different teams don’t coordinate, the consequences can quickly add up. Common issues include:
Increased Rework: If modules are fabricated and assembled with design errors, you may need to redo work at the fabrication and assembly facility or on-site. This adds time and costs to the project.
Delays: A misalignment between mechanical, piping or electrical systems can stall progress for days or weeks, pushing your schedule off track.
Cost Overruns: When errors and rework pile up, budgets start to expand. The cost-saving potential of modularization is lost if these issues aren’t addressed early.
Safety Risks: Poorly coordinated designs can also lead to operational hazards like leaks, electrical faults, or equipment failures, increasing the risk of accidents.
Solutions for Improving Coordination in Modular Projects
At DyCat Solutions, we’ve helped many clients tackle these challenges head-on. Here are some of the strategies we implement to ensure smooth interdisciplinary coordination in modular projects.
Integrated Project Delivery (IPD) Models
One of the most effective ways to foster collaboration is through Integrated Project Delivery (IPD). This model brings all key players—owners, engineering, procurement, module fabrication and assembly and construction contractors, suppliers—into the project from the very beginning. By working together to develop a shared project plan, teams can identify and resolve potential conflicts early, ensuring smoother collaboration as the project moves forward.
Smart 3D Model (CAD)
Another powerful tool for solving coordination challenges is Smart 3D Model (CAD). CAD creates a digital 3D model of the project that incorporates designs from all disciplines. This allows engineers and designers to see how each system will fit together long before construction begins, preventing design conflicts that would otherwise cause delays and rework. At DyCat Solutions, we utilize CAD to improve collaboration, increase visibility, and reduce the risk of errors.
Cross-Disciplinary Teams and Communication Tools
Creating cross-disciplinary or horizontal organized teams ensures that everyone involved works together throughout the entire project. These teams meet regularly, using cloud-based project management platforms to stay connected and informed. Tools like these enable real-time updates, making it easier for teams to adjust designs or timelines as needed.
Early Detection of Interface Issues
We also focus on detecting interface issues early in the project. By addressing potential conflicts between systems before modules are fabricated and assembled, we help prevent costly rework down the line. Our interface management systems track and resolve issues as they arise, keeping the project on track and minimizing delays.
Why DyCat Solutions?
At DyCat Solutions, we’ve developed a reputation for guiding modular heavy industrial projects with precision and attention to detail. Our approach emphasizes collaboration, early problem detection, and the use of advanced tools like CAD to help teams stay coordinated.
We know that poor coordination can throw a wrench into your modularization plans, but with our experience, we can help ensure your project stays on track—delivered on time, on budget, and with the high quality you expect.
Contact DyCat Solutions today to learn how we can help streamline your modular project and solve coordination challenges before they become costly issues.