mep offsite manufacturing kaizen panel 12-labrecque.pdf · day 1 the first day is spent on a quick...

© LEAN CONSTRUCTION

INSTITUTE

CAPTURE AND LEVERAGE THE LEAN ADVANTAGE


MEP Offsite Manufacturing Kaizen

October 2017

Kevin Labrecque, HarperJustin Brockenbrough, HarperStephen Gibson, I.C. Thomasson

© LEAN CONSTRUCTION INSTITUTE


Agenda

Harper Offsite Manufacturing History

3D Rack Deep Dive

Next Steps - Manufacturing Kaizen

Who We Are

Closing Thoughts



Who We Are

Kevin LabrecqueSenior Vice President

Justin

BrockenbroughFabrication Manager

Stephen Gibson, P.E. CSCP, PMP

Continuous Improvement Project

Manager



Who We AreLimbach - 116 years, DB MEP Firm operating from 14 offices in New England, the Mid-Atlantic,

the Southeast, the Midwest and California.

ICT - 75 years, employee-owned, multidisciplinary engineering consulting firm providing designs

for healthcare, commercial, hospitality, recreation, education, institutional clients.



Agenda


3D Rack Deep Dive


Who We Are

Closing Thoughts



Who We Are

7 7

“Virtually every other major

industry has been automated in

the last 100 years, except

construction. Imagine ordering a

car, and having thousands of parts

delivered to your driveway, from

hundreds of suppliers, for on site

assembly. This happens in

construction everyday.”

Tim McDonaldPresident & CEO of Onion Flatsgb&d, volume 1, issue 1 July/August 2010



Gathering the Facts

MEP Solutions

Lang O’Rourke

NG Bailey

Ormandy

M-Tech

Armstrong Balfour Beatty

Skanska

Heron Tower

Converging Themes

North American Growth

in Prefabricated

Elements

Global Movement Towards

Manufactured

Enabling

Tools



“What’s New is Old”, or is it “What’s Old is New”?



What is Offsite?

Level 1

Sub Assemblies

Level 2

Non-Volumetric

Level 3

Volumetric

Level 4

Modular Building



Agenda


3D Rack Deep Dive


Who We Are

Closing Thoughts



Offsite Manufacturing Experience

Phase 1

Tradition Medical Center

Phase I - 2013

● 190k sf, 82 bed Acute Care Facility

in Port St. Lucie, FL

● Patient floors (3, 4 & 5) corridors

racked

● Fabrication facility 140 miles away

in Sanford

● 80’ of corridor per delivery

● Each floor took < two weeks to

install on site



Offsite Manufacturing Experience

Tradition Medical Center

Phase II – 2016

● Expansion (Floors 6, 7 & 8)

● 50% of overall mechanical systems

prefabricated

● New fabrication facility in Lake Mary

Phase 2



Offsite Manufacturing Process

Step One: Engineering Design

Identify Rack Systems &

Locations

Coordinate Systems then

Fit with Racks

Generate Module

Fabrication Drawings

Step Two: Factory

Assembly




Step Three: System Install

All Testing: Pressure

Tests

Insulating, Labeling &

Final Inspections

Step Four: Receive at Job

Site




Step Five: Install at Job Site

● Raised into Place

● Connected to

Hanger Rods

● Connections

Made Between

Racks

Final Product



Lessons Learned - Outcomes

Phase 1

Phase 2

● Optimize systems, then fit the racks

● Intra-module dimensions key, inter-

module over done

● Local inspections brought on board

early - get parties on board early

● Fewer personnel on site, less waste,

safer, faster install

● Ergonomic strike zone in shop

● Quality - 360 degree view of install

● Learning curve – after first few racks,

team was asking “should we

continue”, by the third floor, time

savings were significant

● Schedule Time Savings - with

Optimized Shop Crew



Offsite Innovations & Tools

In Wall Specialty Tools 2D Racks

Multi-Trade 2D Racks

2D Racks Installed

Best Practice



Agenda


3D Rack Deep Dive


Who We Are

Closing Thoughts



The Concept: Production to Mass Customization

20

1903to

Today



The Start: Limbach SoCal Shop Reviews

1200 Sq. Ft.

Opportunities:

• Changed Rack layout – More storage in less floor space

• Opportunities to use AGV’s to move goods to person

• Use vacuum lift system to improve safety and reduce manpower



The Plan: During The Kaizen Event

Day 1 The first day is spent on a quick review of lean concepts and strategy. A map of

the current process is developed to determine the path of parts or raw materials.

Day 2 Training continues. Then team members collect data. Team goals are written

on Day 2 and an opportunity chart is compiled.

Day 3 The opportunity chart is completed, and solutions are developed to key issues.

A floor plan is created. Equipment is moved where necessary to create a better flow.

Day 4 Improvements are finished, and operators are trained on new processes.

Production using the new methods begins. Measurements are again taken.

Day 5 A 5S/visual workplace activity makes sure the workplace is well organized and

tools, cabinets and storage areas are labeled. Standard operating procedures are

updated. A summary report is prepared for upper management. It includes team goals,

floor plan before and after, key results and savings.



The Future: Flexible Manufacturing Near/ On-Site

23



Agenda


3D Rack Deep Dive


Who We Are

Closing Thoughts



Changing The Question

How you phrase the question is important:

• What parts of this project can we prefabricate?

Versus – Starting with the Assumption of 100% Prefabrication and Asking

• What parts of this project won’t we be able to prefabricate?

“What if the dashboard was the duct?”



Rhythm, Meter & Measure



The Tyranny of Common Sense

“Innovation is hard, because it means challenging what we take for granted,

things we think are obvious. The great problem for transformation is the tyranny of

common sense.”

Sir Ken Robinson: Bring on the learning revolution! TED, February 2010



Thank You!

MEP Offsite Manufacturing Kaizen

mep offsite manufacturing kaizen panel 12-labrecque.pdf · day 1 the first day is spent on a quick...

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