Optimizing Prefabrication with Lean

Optimizing Prefabrication Jessica Kelley with Lean Who is Southland?

Southland Industries is one of the US's largest MEP building systems experts. Taking a holistic approach to building performance, we specialize in the design, construction, and operation of mechanical, electrical, plumbing, fire protection, process piping, automation and controls systems, as well as comprehensive energy services.

Capabilities

DESIGN-BUILD SERVICES TRADES • HVAC • Pipefitting • Process piping • Sheet metal • Plumbing • Plumbing • Fire protection • Sprinkler-fitting • Controls and automation • Energy • Electrical Markets Served

Healthcare Mission Critical Biotechnologies Sports/Entertainment

Industrial/Manufacturing Commercial Education Government

Safety Quality Productivity Labor Shifting

Laydown space Schedule Cost

• New vs Renovation • Tight Timelines • Lack of Repetition • Wrong Team • Wrong Owner • Distance from Shop • Site Access Project Delivery Method Matters

Southland Workflow Ideas Come From Anywhere

Fab Shop Crew Engineer

Detailer Field Crew

Group Planning Meetings Project Manager

Leveraging BIM

1 9 BIM… not a guarantee: Understand your Tolerances

20” gap between segments RECEIVING LOGISTICS FABRICATION SHEETMETAL PLUMBING ASSEMBLY PIPING PIPING ASSEMBLY ASSEMBLY SM DESIGN TEAM STAGING TOOLS

SHIPPING Offsite Prefab Facilities Too Many Carts Universal Cart

Universal Cart Closed Cage Conversion Material Handling Options

Transport Safety Stackable for Shipping/Storage Planning: Last Planner® informs Project Schedule

• Who develops the Design Schedule? • Who develops the Construction Schedule? • Are they aligned?

Planning: Pull Schedule (Internal)

Hanger Fabrication and Delivery

OLD NEW

Eliminate the Risk

Ex Mod Rate .46

Van Ness & Geary Hospital

San Francisco, CA

Engineering and Construction

25% Labor Reduction

• 15 Jigs for Lavatory and Shower Assemblies • 75% increase in detailing labor • 14% overall labor savings Manufacturing

Procter & Gamble

West Virginia

Engineering, Construction

Innovation Preassembled Ductwork (AHU-204) Description The supply and return ductwork for AHU-204 was designed to be installed between roof joists and steel grid. The ductwork was fabricated and preassembled in (3) large sections and installed with the structural contractor’s crane. Rather than installing the duct run in 5’ pieces, this allowed 110’ run to be installed ahead of the construction schedule saving time and production costs. Safety/Risk The duct runs were installed in larger sections, thus limiting the amount overhead work. impact Quality impact: The larger sections allowed for the QC team to inspect the ductwork fully on the ground rather than inspecting only visible sections in the air. Schedule impact: Allowed this work to be installed in advance of the building construction.

Cost impact: Allowed Southland to install 60% of the ductwork utilizing only 40% of the labor for a savings of 20% of labor costs. Piping Racks Improved Piping Racks

Multi-Disciplinary Savings: Struct: $200K of $400K saved Mech: $250K of $1.8M saved Safety: 7,800 hours moved to shop Schedule: 3 of 40 weeks saved Healthcare

Penn Medicine

Philadelphia, PA

Engineering, Construction

• Curb-to-curb construction • Active medical campus • Limited laydown area • Heavy traffic and limited parking Prefabrication Maps

Conceptualize prefabricated elements before design is completed.

Mechanical layout supports prefabrication on day 1

Effective communication tool to show architectural team construction constraints

Visual guide to % of off site manufacturing (OSM)

Coordination of Pod Types

Project Award ~2015 Struct/Arch Coordination Clinical Mockup

Prototypes A3’ G 2016 Functionality Mockup Constructability Mockup Fabrication

• 1 Finish Schemes • 504 Pods • 2 Layouts • 10% reduced onsite labor, projected • 7 Plumbing Variations • 10 less deliveries, weekly Penn Medicine Metrics - Piping

Total Pipe Length [Miles]

35 Miles of Piping Patient Floors (L7-L14)

10 %

10,5; 30 % Prefab Pipe 20 % Bathroom Pod Piping Onsite 70 % 25; 70 %

Excludes 3 pipe Med Gas racks

Prefab Pipe Onsite Interventional/OR (L4-L6) Penn Medicine Metrics - Sheetmetal

Total Project Sheetmetal [Tons] OSM 46 % 1100 tons (2.2 Million lbs) of Sheetmetal Onsite 54 %

220; 20 %

50; 5 % Patient Floors (L7-L14) 830; 75 %

OSM 49 % Onsite 51 %

Fitout Duct C&S Headers Onsite Labor Shift Peak Manpower (Traditional): 1,200 Peak Manpower (w/ Prefabrication): 1000

5 8 Metrics

• Month over Month Trend • By Division • By Market • Project Specific

I ’ h lifecycle and our connections to our ’ h y differentiate us. Questions Jessica Kelley, PE [email protected] www.southlandind.com