BIM and Lean Construction Can BIM remove waste from construction processes?

Transcription

1 Tekla European BIM Forum 2014 BIM and Lean Construction Can BIM remove waste from construction processes? Assoc. Professor Rafael Sacks

2 What is Lean Construction? Waste in construction? Lean and BIM Synergies Lean and BIM Education Examples from practice Tools and techniques Conclusions 2

3 Research Scope, Goals and Methods To study, model, experiment with and understand the flow of work and teams in complex construction projects. - Observations, action research, process mapping and modeling, management games (LEAPCON), discrete event simulation To study and develop Building Information Modeling (BIM) - IFC and BIM standards development, BIM tools, virtual reality, BIM education, BIM for earthquake rescue and recovery To propose, define, develop and test BIM-enabled systems to support production planning and day to day production control on construction sites. - Prototyping, field experiments, Virtual Construction Site experiments 3

4 CAVE (Cave Automatic Virtual Environment) 4

5 The PCSC Project and Evaluating Economic Benefits (PCSC = Precast Concrete Software Consortium) Dr. Rafael Sacks Technion Israel Institute of Technology Technion - Israel Institute of Technology Tekla Global Business Forum Prague, June 10-11th,

6 What is Lean Construction? Lean Construction is an innovative approach to management that translates the successful principles of the Toyota Production System (TPS) to construction. See 6

7 What is Lean Construction? Creating value for clients Removing waste Smooth flow of operations See 7

8 Waste 8

9 Waste 9

10 Waste 10

11 Flow 11

12 Quantifying the Waste Typical apartment baseline 12

13 Quantifying the Waste Work Hours Changes 7% Move between floors 0% Moving blocks 4% Fixing ends 3% Cleaning 10% Rework 11% Cutting blocks 24% Laying blocks 32% Scaffold 2% Marking out 7% 13

14 Transformation Inputs Process Outputs 14 14

15 Decomposition Inputs Process Outputs Process A Process B Decomposition makes a powerful assumption: decomposed subprocesses are mutually independent! Thus, the whole production effort can be integrated in an additive manner: by minimizing the costs of each department, function, section, and work station the total costs will be minimized

16 Flow Moving Moving Waiting Waiting Process A Process B Inspection Inspection Scrap Scrap 16

17 Empire State Building 17

18 Empire State Building Completed in 410 days with no critical path! 18

19 Lean Construction Principles Area Principle Flow process Reduce variability Reduce cycle times Reduce batch sizes (strive for single piece flow) Increase flexibility Select an appropriate production control approach Standardize Institute continuous improvement Use visual management Design the production system for flow and value Value generation Ensure comprehensive requirements capture process Focus on concept selection Ensure requirement flowdown Verify and validate Problem-solving Go and see for yourself Decide by consensus, consider all options Developing Cultivate an extended network of partners partners 19

20 Lean and BIM Synergy Lean Construction Building Information Modeling (BIM) Sacks, R., Koskela, L., Dave, B. and Owen, R.L., (2010). The Interaction of Lean and Building Information Modeling in Construction, Journal of Construction Engineering and Management, Vol. 136 No. 9 pp

21 BIM Functionality Stage Design Design and Fabrication Detailing Pre-construction and Construction Functional area and function Visualization of form Rapid generation and evaluation of multiple design alternatives Maintenance of information and design model integrity Automated generation of drawings and documents Collaboration in design and construction Rapid generation and evaluation of construction plan alternatives Online/electronic object-based communication 21

22 BIM Functionality Lean - BIM Interaction Matrix Lean Principles Reduce Variability Reduce cycle times Reduce batch sizes Increase flexibility Select an appropriate production control approach Standardize Institute continuous improvement Use visual management Design the production system for flow and value Ensure comprehensive requirements capture Focus on concept selection Ensure requirements flowdown Verify and Validate Go and see for yourself Decide by consensus consider all options Cultivate an extended network of partners A B C D E F G H I J K L M N O P Q R S T U V W X Visualization of form 1 1, Rapid generation and evaluation of multiple design alternatives , Maintenance of information and design model integrity Automated generation of drawings and documents (52) Collaboration in design and construction , Rapid generation and evaluation of multiple construction plan alternatives (29) 31 (41) (29) 37 (41) (29) (42) Online/electronic objectbased communication (42) (42) (42) 47 48

23 Information related Waste Project managers on high-end projects reported spending up to 60% of their time managing client changes and the resulting complexity of instructions to specialty contractors. Sacks, R., and Goldin, M., (2007). Lean Management Model for Construction of High-rise Apartment Buildings, ASCE Journal of Construction Engineering and Management, Vol. 133 No. 5 pp

24 Seeing the Waste as an opportunity Growing the Margin Value in the design brief Standardization Operational excellence (lean) BIM Processes and information systems 24

25 The Targets Achieve a 5% added-value gain in apartment sales prices Increase the profit margin on construction operations by 15% within four years Reduce the construction overhead to 4% within four years by increasing volume 25

26 Why Lean and BIM? Had tried TQM, ISO 9000, planning and control, etc. Influence of lean construction in the US and Europe Deep dissatisfaction with the quality of information - arrival of BIM as an alternative to CAD Exposure to Lean Construction and to BIM through academia at the Technion 26

27 BIM tools and techniques Standardization of design leads to standardization of work 27

28 22 types of exterior wall

29 Program Schematic Design BIM tools and techniques Licensing Standardization of modeling process - LOD Detailed Design Contracting Construction Detailing Manufacturing BIM Maturity Level Construction on Site Building Operation and Maintenance 29

30 BIM tools and techniques MEP Coordination Dawn Tower example 30

31 BIM tools and techniques MEP Coordination Dawn Tower example 31

32 BIM tools and techniques MEP Coordination Dawn Tower example 32

33 BIM tools and techniques MEP Coordination Dawn Tower example 33

34 Rosh HaAyin project Flagship Lean and BIM transformation project Co-location Reduced lead time for permits Model collaboration Client changes managed using models 34

35 Rosh HaAyin project Over 1,000 apartments ~ 800 million NIS (US $ 235 million) 35

36 Rosh HaAyin project Modeled fully by a collaborative team 36

37 Rosh HaAyin project Modeled fully by a collaborative team 37

38 BIM Collaboration with Co-location Big Room 38

39 BIM Collaboration with Co-location Big Room 39

40 BIM Collaboration with Co-location Big Room 40

41 Lean and BIM Synergies Information flow improvements in incremental steps: From 2D to Building Modeling (BIM) From BIM to Virtual Design and Construction (VDC) From VDC to Lean (pull) VDC Reducing cycle times for Reinforced Concrete works Lagoon example Product configuration and information flows 41

42 Traditional Information Flow Architectural Design Architectural Detailing Structural Design Drawings Structural Detailing Drawings Construction Systems Design Systems Detailing Legend General Contractor (Tidhar) 2D Coordination Designer or Supplier 42

43 BIM Information Flow Architectural Design Architectural Detailing Structural Design Drawings/ Models Structural Detailing Drawings/ Models Construction Systems Design Systems Detailing 3D Coordination Legend General Contractor (Tidhar) Building Modeling Designer or Supplier 43

44 VDC* Information Flow Architectural Design Architectural Detailing Structural Design Drawings/ Models Structural Detailing Drawings/ Models Construction Systems Design Systems Detailing 3D Coordination Building Modeling Drawings *Virtual Design and Construction 44

45 Lean (pull) VDC Information Flow Architectural Design Architectural Detailing Structural Design Drawings/ Models Structural Detailing Drawings/ Models Systems Design Systems Detailing 3D Coordination Construction *Phase planning and Look Ahead planning Building Modeling Pull signals* Drawings 45

46 Lean and BIM Synergies CU Office Park case study 46

47 Lean and BIM Synergies Fully detailed curtain wall model 47

48 CU Curtain walls pilot 30% reduction in quantities for curtain wall subcontract 48

49 Lean and BIM Synergies Reducing cycle time for Reinforced Concrete works Lagoon project Two 21 story apartment buildings 252 apartments 49

50 Lean and BIM Synergies Reducing cycle time for Reinforced Concrete works 50

51 Lean and BIM Synergies Reducing cycle time for Reinforced Concrete works 51

52 Lean and BIM Synergies Reducing cycle time for Reinforced Concrete works Conclusions Lack of balance between workers tasks excessive waiting at the stone cladding workshop on the ground floor Inefficient use of steel formwork window negatives Clashes between steel mesh and formwork closure bolts Results Reduced cycle time from 9 days per floor to 8 days per floor Reduced crew from 26 to 24 workers 52

53 Customer changes Choosing the team Modeler Customer coordination representative Customer coordination team leader Learning current tools and practice Off-line pilot by the modeler Preparing the families and templates Preparing one example Full pilot by the customer coordination representative Using Revit process with real customers 53

54 Modeling the apartment 54

55 Modeling the apartment 55

56 Electrical Drawings 56

57 AC Drawings 57

58 KanBIM Aim: To propose, define, develop and test a BIM-enabled system to support production planning and day to day production control on construction sites. Kanban (pull flow control in lean production management) + BIM (Building Information Modeling) = KanBIM 58

59 Prepare and pour topping Floor 5 Grids A1 to D8 Strip and clean Floor 5 Grids A1 to D8 Erect Hollowcore Floor 5 Grids A1 to D4 Erect columns Floor 6 Grids E5 to H8 Erect columns Floor 6 Grids E1 to H4 Sprinkler pipes Floor 4 Erect Hollowcore Floor 5 Grids A5 to D8 Support installation of hoist South side facade Lintels and ring beams Basement 1 Framing West side Basement 1 Main ducts Ducts Side A West side Basement 1 Cut HVAC access holes Floor 4 Grid B3- C4 Main ducts Ducts Sprinkler pipes Floor 3 Secondary ducts Ducts 10a-20a Main ducts Ducts End Units Zone 1 Testing HVAC - Zone 1 Electrical connection HVAC end unit zone 1 Main distribution board Wiring Entrance floor Lobby Framing for false ceiling Entrance floor Lobby Complete to ceiling Basement 1 Partitions Basement 1 Close openings above HVAC Stairwell 2 Basement 1 Framing East side Basement 1 Side A East side Basement 1 Pipe installation in drywalls West side basement 1 Duct installation in drywalls West side Basement 1 Lintels and ring beams Basement 2 Partition walls Storerooms Basement 3 Partitions Basement 2 Install main lines Basement 2 Fire fighting pump room Install main lines Basement 3 Fire fighting pump room Complete to ceiling Basement 2 Fix cracks West side basement 3 W12 59

60 Plumber avatar in the VCS Gurevich, U., and Sacks, R., (2014). Examination of the Effects of a KanBIM Production Control System on Subcontractors' Task Selections in Interior Works, Automation in Construction, Vol. 37, pp

61 Test Subject Video 61

62 Typical results Gross production without KanBIM Gross production with KanBIM Net value-earned without KanBIM Net value-earned with KanBIM 62

63 Commercial Break 63

64 Commercial Break 64

65 Conclusion Lean Construction Building Information Modeling (BIM) Can BIM remove waste from construction processes? Yes There are significant synergies between Lean Construction and BIM. BIM makes construction leaner even when lean is not the explicit intent. BIM can significantly enhance any lean construction transformation. 65

66 Tekla European BIM Forum 2014 BIM and Lean Construction Can BIM remove waste from construction processes? Assoc. Professor Rafael Sacks Questions, discussion? 66