BIM to support DfMA and Lean Construction
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Transcript of BIM to support DfMA and Lean Construction
BIM to support DfMA & Lean Construction
Proposed Activity
Richard Kelly, buildingSMART International
Agenda
• What is DfMA (Design for Manufacture & Assembly)?• Benefits delivered through DfMA• DfMA links to other initiatives and enablers• Issues holding back universal adoption of DfMA• Discussion
• how can open sharable BIM standards enable DfMA?
What is DfMA in the Built Environment?
What is DfMA in building design?
• DfMA: developed since the 1970s in several industries• Led by US National Science Foundation,
Salford University, IBM, Xerox, Ford, GM, Lucas & others
• DfMA is the combination of Design for Manufacture (DfM) and Design for Assembly (DfA)
• It is a structured process• It is a primary driver of reduced lead
times, whole life cost and quality improvement
Image courtesy of Heathrow Ltd
Designing for Manufacture
• Understand manufacturing processes, capabilities & cost drivers
• Select materials & processes• Estimate cost of designs
suggested by the DfA stage• Refine designs, model, simulate
and prototype
A new lounge designedwithin manufacturingcapabilities of steel and panelised systemssuppliers
Image courtesy of Heathrow Ltd
Designing for Assembly• Does a part need to move
independently of others?• Does the part need to be made of a
different material or be isolated?• Does it need to be separate to
enable assembly of other parts?• Would combining it with others
exceed limitations for transport or lifting?
• Does the part’s assembly time exceed the time allocated in the build rhythm?
If “No” to any of these look to combine it with other components or eliminate it
BEFORE
AFTER
Source: Boothroyd, Dewhurst & Knight Source: BAA T5
BEFORE
AFTER
Source: Boothroyd, Dewhurst & Knight Source: BAA T5
Modularity & mass customisation
Image courtesy of Heathrow LtdModularity definitions from Joseph Pine II, Mass CustomisationHavard Business School Press
DfMA in summary
• A way of looking at the whole facility or product and determining the optimal way of making the parts and assembling them
• Applies equally to on-site & off-site• A methodology that the (whole) design team needs to
engage with• Can be applied to bespoke buildings or mass production• An enabler of “mass customisation”
Benefits of DfMA
The objectives of a DfMA approachThe optimised design enables a more efficient build phase.• Cost less• Schedule duration less• Quality and maintainability improved• No of site trades less• Impact on operations & the public less• Safety improved
NOT value engineering which is often:• scope reduced• suppliers squeezed
Image courtesy of Heathrow Ltd
Benefits of DfMA
Modular and innovative design combined volumetric and flat-pack solutions.Cost savings through:• Optimised and improved tolerance• Minimised interfaces• Shorter schedule by 75% (100 weeks of stand availability saved)• Factory predictability • Modular standard design• Fewer on site trades – 33,000 hours removed from site• Minimal stand closure (only 2 weeks per stand)
Capex 11% less than traditional build. Opex savings c. £2.5million due to schedule reduction
12 large buildings assembled in a complex, time constrained environment with ZERO accidents
Safety
Quality
WL Cost Time
Courtesy of Heathrow Ltd
Heathrow T5CNodes
Aspects influenced
Procurement
Installation
Operational
Maintenance
Risk
Training
• Less components• Trades offsite• Low level working• Tighter tolerances therefore more predictable fit• Better capabilities• Repeatable processes• Reduced schedule
• Better ergonomics in use (specification & orientation)• Access for maintenance, refurb & renewal
• Optimised decisions for• Maintenance access & frequency• Renewal / replacement access• End of and through life asset failure behaviour
• Visual instructions direct from the design
DfMA opportunitiesDfMA elements
Aspects influenced
Facility / asset life - years
Disposal
Procurement
Installation
Operational
Maintenance
Risk
Training
Opex
Capex
Links to other initiatives
Quicker, Better (Q & CO2), Cheaper (wlv), Safer
Linking the built environment initiatives
DfM
A
Contractual mandate
Lean
6 s
igm
a
Offs
ite
Cap
abilit
y
Some GovernmentsSome clients
Much has been done since “Rethinking Construction” but in pockets of excellence.Linking it together remains a problem.AM
(ISO
550
01)
The goal
Lean constructionDesign for Manufacture, Assembly and Commissioning (DfMA+C)• Determines the constraints• Analyses the build sequence and determine the optimal rhythm• Identifies opportunities for offsite (in lean factories)• Ensures rapid integration for the offsite elements to interface well onsite• Identifies opportunities to eliminate componentsBuild phase establishes lean, continuous flow conditions onsite (& offsite)
Applies to bespoke buildings or mass produced “boxes”An enabler of “mass customisation”
The Traditional vs DfMA approach
Traditional DfMA
Collaboration between trades & disciplines to:• Manage interfaces• Eliminate clashes• Use innovative offsite practices effectively• Reduce components• Provide visual instructions for assembly and
maintenance• Optimise for operational use & maintenance• Predict through life and end of life behaviour
• Different disciplines designed in isolation• Risk managed at company interfaces not
collectively • Risk mitigated through high intensity at build
phase• Opportunities to remove constraints from
project not able to be taken• Whole life value measurement not possible at
the design stage
Improvement in WLC is through reduced schedules and optimised decision making NOT scope reduction or squeezing supply chain margins
Applying a DfMA StrategyStrategy from the supplier is expected to remove wasteful aspects.WORMPITT
14 tools provided for guidance.
1. Commercial considerations – contracts that drive collaboration & flow.
2. Design for productivity3. Design for logistics4. Design for modularity5. Simulation & correlation
(BIM)6. Process capabilities
8. Use of common parts9. Reduce parts10.Reduce assembly risks11.Make fabrication easy12.Make handling easy13.Reduce interfaces14.Efficient methods of
jointingDfMA in Construction Strategy Richard Kelly Nigel Fraser
Collaboration between trades
Progressive application through facility lifecycleConcept Definition Development Implement DisposeHand
overStrategy Operation
Project constraints identifiedBuild rhythm to meet schedule1. Commercial considerations2. Design for:
3. productivity4. logistics5. modularity
6. Simulation & correlation7. Process capabilities
DfMA
8. Use of common parts9. Reduce parts10. Reduce assembly risks11. Make fabrication easy12. Make handling easy13. Reduce interfaces14. Efficient methods of jointing
Facility data
Continuous improvement
DfMA in Construction Strategy Richard Kelly Nigel Fraser
Issues holding back universal adoption of DfMA
Quicker, Better (Q & CO2), Cheaper (wlv), Safer
Linking the built environment initiatives
DfM
A
Contractual mandate
Lean
6 s
igm
a
Offs
ite
Cap
abilit
y
Some GovernmentsSome clients
Much has been done since “Rethinking Construction” but in pockets of excellence.Linking it together remains a problem.AM
(ISO
550
01)
The goal
Linking the built environment initiatives
Some GovernmentsSome clientsMore required
Open data has come of age.• Open standards• Technology• Cohesive
community
The goalQuicker, Better (Q & CO2), Cheaper (wlv), Safer
DfM
A
Contractual mandate
Lean
6 s
igm
a
Offs
ite
Cap
abilit
y
AM (I
SO 5
5001
)
The Procurement dichotomy
Early engagement of specialist• Solution lock-in• Lack of commercial tension• Is the client prescribing the
solution?• Off-site solution that supply chain
can provide efficiently• Reduced schedule duration
Engagement of specialist after scheme design• Non-optimised solution for offsite• Design duration extended due to
rework for offsite• Can test the market prices thoroughly• Client not prescribing the solution
Next steps
DfMA / Lean / Offsite
Supply chains rationalisedFlowlines in offsite facilitiesUse of semi skilled labourQuality improvementsReduction in trades on siteSafer site workingReduced lead time for facility deliveryLess CO2 in construction and operation
Digital Engineering
Project software providers not rationalisedInformation sharing protocols not rationalised
Without Digital Engineering improvements the DfMA capabilities cannot be achieved; holistically, routinely or consistently.Facility whole life value will not be realised.Capability is being created
X Capability is missing
ProposalHow can open sharable BIM Standards enable the universal adoption of DfMA & Lean construction?
IFCIndustry
Foundation Class