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The Cost of Quality – A Solar IE’s perspective
There’s a well-known business principle called the “Cost of Quality.†It illustrates a simple yet powerful idea: the closer a project gets to completion, the more expensive it becomes to fix quality issues. This concept is especially relevant in industries like solar energy, where design and construction phases must carefully balance time, cost, and quality.
In project management, these three factors are often referred to as the “triple constraints,†represented by a triangle that shows how each element influences the others. You can optimize two, but you’ll always have to compromise on the third. For example, if you want to reduce costs, you may need to extend the timeline or lower the quality standard.
The challenge with solar projects is that they involve complex systems, and any oversight during the early stages can lead to costly fixes later. That’s why many developers bring in independent engineers (IEs) at the end of the project, often as a final check before handover. But this late-stage review comes with its own set of problems.
When an IE is brought in too late, the opportunity to correct errors without major disruptions is lost. By this point, the design is already finalized, materials have been purchased, and labor has been invested. Any changes required at this stage could mean reordering equipment, adjusting installation plans, or even delaying project completion. These adjustments not only increase costs but also add time and complexity to the project.
Let’s take an example of a string length miscalculation, which is a common issue in solar design. The impact of this mistake depends on when it's discovered:
1. **During the Design Phase**: If the error is caught early, it’s relatively easy to correct. The engineer can simply revise the design, and there’s minimal impact on time or budget.
2. **During Procurement**: Once equipment is ordered, changing the string length might require swapping out inverters or reworking the layout. This can lead to delays, additional costs, or even the need to reorder parts.
3. **During Installation**: If the mistake is found after installation, the consequences are the most severe. Wires may need to be removed and reinstalled, leading to extra labor, potential delays, and a less efficient system overall.
This highlights why early involvement of an independent engineer is so valuable. When an IE reviews the project in the early stages, they can identify and resolve issues before they escalate into costly problems. This proactive approach helps maintain quality while keeping time and cost under control.
On the other hand, a late IE review often feels like a “check-the-box†exercise. Stakeholders may feel frustrated because the IE’s findings come too late to make meaningful changes without significant financial or scheduling impacts. While EPCs may be responsible for some direct costs, all parties still face indirect challenges—like increased communication, meetings, and conflicts over change orders.
In short, the value of an independent engineering review is maximized when it’s done early in the project lifecycle. Don’t wait until the last minute to bring in your IE. Instead, involve them from the start to ensure quality, avoid unnecessary costs, and keep the project on track. After all, fixing a problem early is always better than dealing with the aftermath later.