building information modelling (bim) workshopciria.org/buildoffsite/pdf/taylor woodrow bim 6...

11 May 20091

Building Information Modelling (BIM) Workshop6th April 2009Department for Business and Enterprise’s Conference Centre

Case Study 3Information Model used on the Open ManuBuild System Platform

Jeff Stephens jeff.stephens@taylorwoodrow.comDavid Leonard david.leonard@taylorwoodrow.com

11 May 20092

What is ManuBuild?

3 6th May 2009

ManuBuild Consortium

4 6th May 2009

ManuBuild Technical topics

Building system concepts

Architectural typology

Building templates

Smart components

Multi-functional integrated modules

Innovative connections and interfaces

Multi-functional materials

Business Models

New manufacturing technologies

Autonomous fixed factories

Flexible, mobile and autonomous factories

Logistics solutions

Rapid connection and assembly methods

ICT and other system architectures

Intelligent component catalogues

Design configuration, manufacturing configuration and sales office tools

Logistics, management & assembly and monitoring tools

Training and simulation

11 May 20095

ICT tools and services

6 6th May 2009

Simplified Demonstration Process

7 6th May 2009

ManuBuild configurators

ManuBuild Configurator

Building Templates

(early design)

Design Configurator

Sales Configurator

Manufacturing Configurator

Manufacturing Configurator

Manufacturing Configurator

1

3

Building Configuration

(Customer options)

Product informationIncl. design constraints

Building Component information

(various sources)

Building LogisticsData passed on:

1: Building design in the form of drawings, 2D and 3D CAD files

2: Design details, options parameters and their acceptable values, 3D models, dwelling unit model

3: Architectural spaces, configurations, component and performance specifications

4: Parts list, component information

Sales Person/

Customer

Manufacturer/Supplier

Template/Building Designer

Configurators in the ManuBuild business process scenario

Manufacturing configurator

Design configurator

Sales configurator

Supply chain management and assembly

planning

Building component information

Building templates

8 6th May 2009

Demonstration Process Diagramusing Business Process Modelling Notation

11 May 20099

Creating a Catalogue Item: Shower Unit

Create GDL catalogue itemExport GDL catalogue item to PMO View PMO model using PMO-Viewer

10 6th May 2009

Create catalogue itemProcess

11 6th May 2009

Create catalogue itemSelect corresponding GDL objects

12 6th May 2009

Create catalogue itemparameter list - tray

13 6th May 2009

Create catalogue itemparameter list - enclosure

14 6th May 2009

Create catalogue itemSimplified parameter list - tray

15 6th May 2009

Create catalogue itemSimplified parameter list - enclosure

16 6th May 2009

Create catalogue itemSimplify GDL script, convert to PMO,

17 6th May 2009

Create catalogue itemAdd other parameters and combine scripts & test

18 6th May 2009

Create catalogue itemSelect default colours

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Catalogue Server

Upload to catalogue ServerSearch for component in Catalogue ServerOverview of other catalogue server services

20 6th May 2009

Catalogue Server:Searching catalogue

21 6th May 2009

Catalogue Server:Uploading catalogue

22 6th May 2009

Catalogue Server:Services available

23 6th May 2009

Catalogue Server:Browsing catalogue

24 6th May 2009

Catalogue Server:Browsing catalogue

25 6th May 2009

Catalogue Server:Browsing catalogue

26 6th May 2009

Accessing catalogue information using Manufacturing Configurator

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Create Architectural Model using the Design Configurator

28 6th May 2009

Creation of the Architectural Building Model Design Configurator - Process

29 6th May 2009

Apartment Building

30 6th May 2009

Building Template created from a CAD model

31 6th May 2009

Adding rules to a Building Template

32 6th May 2009

Checking the rules:a constrained internal wall being moved

11 May 200933

Create manufactured solution using theManufacturing Configurator

Corus: Corner supported volumetric units

34 6th May 2009

Create Manufactured SolutionProcess

35 6th May 2009

Creation of dwelling templatesLight steel wall panel

36 6th May 2009

Creation of dwelling templatesLight steel floor panel

37 6th May 2009

Creation of dwelling templates8 post module

38 6th May 2009

Creation of dwelling templates8 post corner supported module

39 6th May 2009

Creation of dwelling templatesOne bed dwelling – 2 modules

40 6th May 2009

Creation of dwelling templatesOne bed dwelling – 3 modules

41 6th May 2009

Creation of dwelling templatesTwo bed duplex dwelling – 4 modules

42 6th May 2009

Architectural Building Model

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Create manufactured solution using theManufacturing Configurator

Mostostal: Fibre Reinforced Polymer partitions

44 6th May 2009

Architectural Building Model2 Bedroom Dwelling

45 6th May 2009

Architectural Building Model1 Bedroom Dwelling

46 6th May 2009

Light steel wall manufacturer – Corus1 Bedroom Dwelling

47 6th May 2009

Light steel wall manufacturer – Corus2 Bedroom Dwelling

48 6th May 2009

GRP wall manufacturer - Mostostal1 Bedroom Dwelling

49 6th May 2009

GRP wall manufacturer - Mostostal2 Bedroom Dwelling

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Demonstration Building

Use of the Corus ManuBuild building system for medium rise residential projects

51 6th May 2009

Proposed site of development

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Apartments in the development scheme

53 6th May 2009

Apartments in the development scheme

54 6th May 2009

Apartments within the development

55 6th May 2009

Apartments broken down into Volumetric Modules

56 6th May 2009

3 Module Apartment

57 6th May 2009

Typical Hallway Module

58 6th May 2009

Contractors Construction Sequence –Install Volumetric Modules

59 6th May 2009

Construction Sequence: Apartment modules installed

60 6th May 2009

Linking Logistics data

61 6th May 2009

Progress monitoring using the Enterprixe Explorer Client

62 6th May 2009

Project details

959 modules- 211 apartments [44 variants]- 584 open sided volumetric modules [117 variants ignoring customisation] (generally 2 per trailer)- 187 roof panels [32 variants] (up to 8 per trailer depending on sizes for stacking)- Corridor roof panels (possibly 8 per trailer)- 140 corridor floor panels [25 variants] (possibly 8 per trailer)- 48 balcony units [12 variants] (possibly 8 per trailer)- Manufactured on Deeside in North Wales

Congested site- Suburban South London- 2 unloading bays- Local secure holding area

10 week assembly period- 20 modules per day to avoid weekend working- 2 per hour for a 10 hour day- Could be 10 trailers to unload per day (20 truck movements)- Restricted STGO-Cat1 truck movements (07h30 ~10h00, 16h00~19h00)- At least 20 trailers in use at any time

Current manufacturing rate of 10 modules per day- Buffer stocks required - Module manufacturing might have to start 10 weeks before start of site assembly

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Lessons learnt

64 6th May 2009

Lessons: Architectural Design

Controlling the number of variants of manufactured modular parts is a challenge for designers.

But, too much standardisation produces boring buildings.

Corner areas are difficult to modularise especially where the corners are not at 90 degrees.

System suppliers need to consider reference arrangements for corners areas.

Ideally, the system for construction should be identified for the early design for planning application so that the design can exploit the positive attributes of the proposed system.

The structural philosophy, assembly method, transportation and lifting considerations have to be understood by the architect.

Strategic decisions have to be made early in the process. Leaving decisions site workers is not an option.

Effective off-site-manufacturing requires 10 times more information than that required for in-situ construction and that information is required early in the process.

Many architects are not familiar with the disciplined ways of working demanded by off-site-manufacturing- Much architectural design work has to be re-done by the contractor and manufacturers.

ManuBuild defined effective ways for using the various levels of technical information from design through to assembly.

There is a need for Design For Manufacture and Assembly (DFMA) iterations involving the architectural designers, contractors and manufacturers.

Care is required to create naming conventions to help interoperability down the information chain.

Corner supported modules have architectural benefits.

The benefits of off-site-manufacturing are not being realised with the results being similar to conventional construction in terms of cost and time.

65 6th May 2009

Lessons: Manufacturing

Manufacturing plants require serious investment in the order of £5 million+.

Choosing a manufacturer early has benefits but also includes big risks.

Manufacturers are line-of-balance process driven and construction projects are one-off project driven. Manufacturers need to keep their manufacturing assets busy which means that they will be juggling the bidding, design, planning and production of a number of projects simultaneously.

The scope for production runs of identical modules is limited.

Production rates for manufacturing for individual projects are likely to be less than the site assembly rate. This limits the scope for late customisation and requires more finance.

There needs to be an effective exchange of technical information between contractors, manufacturers and contractors.

ManuBuild explored economies of scale. It was noted that after 1000 units per year, the rate of increase in benefit to unit cost reduced. However , at the higher rates of production the discounts from component and material suppliers increases.

- Suppliers need to deliver on trucks loaded to their maximum capacity. - Suppliers and customers need to automate their trading systems and to plan production together. - Suppliers need to invest in production methods to meet customer needs. - (Deep discounting requires reduced risk, trust, business confidence and possibly national agreements across the

supply chain.)

Off site manufacturing still appears to be more expensive than in-situ construction.

Final customers do not want to take risks on their projects.

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Lessons: Logistics and Assembly

Volumetric modules can be very fast to assemble on site. One every 30 minutes is feasible.

Fast rates of site assembly need the methods and logistics to be worked out meticulously.

Careful detailing reduces localised damage.

Assembly sequences need to be 100% complete and 100% accurate. This requires much more detail than is traditionally included on construction project programmes.

Adding programme detail is very boring and requires skill. Better software tools are required.

The construction friendly logistics solutions already exist.

The access required during module assembly needs to be fast to adjust for a rapidly changing building. Mast climbing platforms are ideal for this. However, cladding sub-contractors are not keen on this method and prefer conventional scaffolding because they work on at least three levels simultaneously.

Fast assembly requires close collaboration between contractor, manufacturer and transportation contractors.

Much more discipline is required from both companies and individual workers.

Information used by the site people needs to be complete, accessible and very easy to use.

Training for supervisors and operatives is definitely needed.