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There’s a well-known business principle known as the “Cost of Quality.†It illustrates that the closer a project gets to completion, the more expensive it becomes to correct quality issues. This concept is crucial in any project lifecycle, especially in complex industries like solar energy, where design and construction must be carefully balanced.
Quality isn't just about performance—it's also about time and cost. Project management literature often refers to these as the "triple constraints," represented by a triangle that shows how time, cost, and quality are interdependent. The idea is that you can optimize two of them, but you’ll have to compromise on the third.
In the solar industry, every project goes through a design and construction cycle where these three factors must be managed. As an Independent Engineer (IE), our goal is always to maintain high-quality standards. However, we often find that quality is compromised when projects are rushed or run out of budget—especially when we're brought in too late.
Conducting an independent engineering review at the end of a project is problematic. Developers typically bring in engineers to satisfy the owner or lender’s need for risk mitigation and quality assurance. But this is often done as a final sign-off, long after key decisions have been made. At this stage, fixing issues means sacrificing either time or money, because most of the budget and schedule has already been committed.
For example, if a mistake is discovered late in the process, such as a miscalculation in string length, the cost and effort required to fix it increase dramatically. Here’s how:
1. **Design Phase**: If the error is caught early, it can be corrected without affecting cost or schedule. A simple revision to the design and racking table is all that’s needed.
2. **Procurement Phase**: Once equipment is ordered, changing the string length could require reordering inverters or adjusting configurations. This might lead to delays or increased costs.
3. **Installation Phase**: If the issue is found during installation, it may require removing and reinstalling conductors, adding extra work and potentially delaying project completion.
The later the problem is detected, the higher the cost and time required to fix it. That’s why early involvement of an Independent Engineer is so valuable.
When an IE is brought in early, they can identify potential issues before they become costly or time-consuming. This allows for timely corrections with minimal impact on the project timeline or budget. Stakeholders appreciate this proactive approach, as it helps avoid surprises later on.
On the other hand, if the IE review is conducted too late, it often feels like a "check-the-box" exercise. The value of the review diminishes, and stakeholders may feel frustrated by the number of issues identified at a point where fixing them is expensive and disruptive.
Some may argue that the EPC (Engineering, Procurement, and Construction) company should bear the cost of fixes. While that may be true for direct expenses, all parties still face indirect impacts—like extra meetings, communication challenges, and delays. EPCs may also resist some IE recommendations due to cost concerns, leading to compromises that affect long-term performance.
In conclusion, involving an Independent Engineer early in the project lifecycle adds real value. It allows for better decision-making, reduces risks, and ensures that quality is maintained without unnecessary cost or time overruns. If you’re going to invest in an IE, make sure to do it early to get the most benefit from their expertise.