Managing Construction Parts From Manufacturing to Construction Researchers Principal
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Managing Construction Parts – From Manufacturing to Construction Managing Construction Parts From Manufacturing to Construction Principal Investigators Industry Collaborators Researchers (CIFE) Dr. Martin Fischer (CIFE) Dr. Calvin Kam (CIFE) Dr. Ben Schwegler (Disney) Dr. Guangbin Wang (Tongji) Helen Chen (Disney) Dean Towl (Mortenson) Daniel Hall Nanyu Zhao Sijia Tao Other Researchers Cheryl Chi Chi Zhang (Tracy) Dan Tan Huiming Zhou Jieming Wei Kai Zha Meiyan Fan Pengfei Wang Peng Zhao Raj Padachuri Tong Liu Weihong Yuan (Baron) Xiao Ma (Matt) Xinghao Shen (Mecsi) Yanping Wang Yong Sun 1 CIFE TAC 2014 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction POINT OF DEPARTURE Six Million Parts in A380 (Weight = Fuel = Money) Carbon Fiber Planes “[Using Composites] we will mould all the parts together at the same time, so our perception of what a single part is will change" (BBC news, 2014) 2 CIFE TAC 2014 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction THE BIG IDEA What is a Part for Construction? 3 CIFE TAC 2014 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction THE BIG IDEA “An integral feature of a building critical to structural stability and usage” “A combination of systems that work together to provide function” The “An object installed as one piece” Construction does have “Single building Industry component such as anot stud or a nail” “A discrete object or object a Uniform Definition for aassembly Part that occupies space and time in the building lifecycle with semantic connectivity to other objects” CIFE TAC 2014 “The logic level at which a piece of design/construction data is irreducible and unique, both geometrically and 4 parametrically” Copyright 2012 Managing Construction Parts – From Manufacturing to Construction THE BIG IDEA How many Parts in a Hotel Project? 7 floors 420 rooms 430,000 sf Industry Estimation 10 CIFE TAC 2014 1,000 100,000 Part Range 10,000,000 1 Billion 5 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction POINT OF DEPARTURE Bill of Materials (BOM) Design Engineering Support EBOM Synchronized BOM Formally structured list of “items or raw materials that go into the product” Production Supply MBOM BOM Regulation BOM CIFE TAC 2014 (Source: PLM Think Tank website) 6 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction POINT OF DEPARTURE What is Value? Toyota Production System • VALUE is only what the customer will pay for • The only people who add VALUE are those who “touch, transform, or transport” a physical part of the final product • People who do not touch the material do not add VALUE 7 CIFE TAC 2014 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction YEAR ONE RESULT Part \ˈpärt\ noun Any entity requiring act(s) of installation that composes the final building product 8 CIFE TAC 2014 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction YEAR ONE RESULT Part \ˈpärt\ 9 CIFE TAC 2014 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction YEAR ONE RESULT Part \ˈpärt\ 10 CIFE TAC 2014 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction YEAR ONE RESULT How many “Parts” in the Hotel Study Case? Blue Sky Feasibility Concept 100% CD 30% DD Schematic 60% CD Parts Approach Construction 3.2 -4.6 Million 60% CD BIM 110,000 Industry Estimation 10 CIFE TAC 2014 1,000 100,000 Part Range 10,000,000 1 Billion 11 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction YEAR ONE RESULT Number of Parts in Hospital Case 440 prefabricated bathrooms Blue Sky Feasibility Concept 100% CD 30% DD Schematic 60% CD Construction • 3% overall cost saving • 7 month (20%) schedule saving • 150,000 hrs moved to offsite Mortenson Construction Part Approach 10 CIFE TAC 2014 1,000 Innovative Prefab 25,000 100,000 Part Range Conventional Practice 1.7 Million 10,000,000 1 Billion 12 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction RESEARCH METHOD 1 Continue to Develop Part Ontology 2 Apply Part Ontology to Develop BOM 3 Use Parts as New Metric for Lean Construction 13 CIFE TAC 2014 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction RESEARCH METHOD 1 Continue to Develop Part Ontology • Expand Study Cases • Hotel and Office Building Retrofit • Determine Part Number, Type, Category • Examine Part Count Variance & Consistency across Projects • Extend Operational Definitions 14 CIFE TAC 2014 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction RESEARCH METHOD 1 Continue to Develop Part Ontology Part Component Assembly & Enabling & In Situ CIFE TAC 2014 https://flic.kr/p/adEmYB http://mcdmag.com/ Count By Piece & Volume https://flic.kr/p/5EoYEA 15 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction RESEARCH METHOD 2 Apply Part Ontology to Develop BOM • Determine Criteria of a Good Bill of Materials (BOM) • Study Industrialized Construction Use of BOM • Draft BOM for two Study Cases • Critique the Existing Construction Information Exchange Method and Part Ontology 16 CIFE TAC 2014 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction RESEARCH METHOD 3 • Use Parts as New Metric for Lean Construction Can the Part Number serve as an indicator of prefabrication rate? Part Offsite Temporary Intermediate CIFE TAC 2014 Mortenson Construction 17 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction RESEARCH METHOD 3 • Use Parts as New Metric for Lean Construction Can we use Parts to estimate the impact of design iterations? MacLeamy Shift of Paulson curve CIFE TAC 2014 Image courtesy sefaira.com 18 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction RESEARCH METHOD 3 • Use Parts as New Metric for Lean Construction What else can we use Part for? • Parts per area / volume • Parts by physical size • Parts by construction time / equipment • Parts installed / delivered per day • Number / Types of Parts with no accident / injury 19 CIFE TAC 2014 Copyright 2012 INDUSTRY Managing Construction Parts – From Manufacturing to Construction INVOLVEMENT Lead Research Team Researchers from Shanghai Shanghai Research Lab Additional Study Cases 20 CIFE TAC 2014 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction RESEARCH PLAN Schedule 2014 Jun Summer Internship Sep Study of BOM, Part Applications Dec 2015 Mar Critique of Construction Practice & Part Ontology Jun Build BOM Framework Milestone Initial Preparation 2014 Jun Industry Workshop Sep Part Ontology Diagram Sep and Draft BOM Dec 2015 Mar Jun Journal Jul Publication 21 CIFE TAC 2014 Copyright 2012 RELATIONSHIP TO CIFE Managing Construction Parts – From Manufacturing to Construction GLOBALIZATION Research Focus SCHEDULE Breakthrough Objectives • • • COST Metric for Project Performance Integrating VDC and decision analysis Manage data from BIM through project life cycle 22 CIFE TAC 2014 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction REFERENCES • Kam, C., & Fischer, M. (2004). Capitalizing on early project decisionmaking opportunities to improve facility design, construction, and lifecycle performance—POP, PM4D, and decision dashboard approaches. Automation in construction, 13(1), 53-65. • A Similar Window Detail in Brussels, Belgium. https://flic.kr/p/6rDJbu • Chang, H. (2009). Operationalism. • Sijia Tao (2012). BIM parts library. CEE 212B • Mark J. Clayton, Paul Teicholz, Martin Fischer, John Kunz (1999). Virtual components consisting of form, function and behavior. Elsevier Science B.V. • Toyota Production System http://artoflean.com/tps_history.htm • Schonberger, R. J. (2007). Japanese production management: An evolution—With mixed success. Journal of Operations Management, 25(2), 403-419. • Molloy, O., Tilley, S., & Warman, E. A. (1998). Design for Manufacturing and Assembly: Concepts, architectures and implementation. Springer. • Carbon fibre planes: Lighter and stronger by design http://www.bbc.com/news/business-25833264 • MacLeamy Curve http://www.msa-ipd.com/MacleamyCurve.pdf 23 CIFE TAC 2014 Copyright 2012 Managing Construction Parts – From Manufacturing to Construction Thank You! Questions 24 CIFE TAC 2014 Copyright 2012
