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Optimizing Prefabrication with Lean

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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. Southland Industries ©2019 All rights reserved. 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 Southland Industries ©2019 All rights reserved. Why Prefabrication? Safety Quality Productivity Labor Shifting Laydown space Schedule Cost Southland Industries ©2019 All rights reserved. Culture Shift Southland Industries ©2019 All rights reserved. Project Type and Environment Matter • New vs Renovation • Tight Timelines • Lack of Repetition • Wrong Team • Wrong Owner • Distance from Shop • Site Access Project Delivery Method Matters Southland Industries ©2019 All rights reserved. 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 LOGISTICS PLUMBING ASSEMBLY TOOLS SHEETMETAL SM FABRICATION ASSEMBLY STAGING SHIPPING RECEIVING PIPING ASSEMBLY DESIGN TEAM 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 Southland Industries ©2019 All rights reserved. Recordable Incident Rate .63 Ex Mod Rate .46 Southland Industries ©2019 All rights reserved. What does Integrated Project Delivery enable? Healthcare Van Ness & Geary Hospital San Francisco, CA Engineering and Construction Southland Industries ©2019 All rights reserved. Sheetmetal 15% Detailing Increase 25% Labor Reduction Southland Industries ©2019 All rights reserved. Plumbing • 15 Jigs for Lavatory and Shower Assemblies • 75% increase in detailing labor • 14% overall labor savings Manufacturing Procter & Gamble West Virginia Engineering, Construction Southland Industries ©2019 All rights reserved. Highly Restricted 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 Southland Industries ©2019 All rights reserved. Site Logistics • 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) Southland Industries ©2019 All rights reserved. 46 Multi-Trade Pipe Racks Wall Assemblies Bathroom Pods Coordination of Pod Types Project Award ~2015 Struct/Arch Coordination Clinical Mockup Prototypes A3’ G 2016 Functionality Mockup Constructability Mockup Fabrication Southland Industries ©2019 All rights reserved. 49 From Shop to Field • 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 Southland Industries ©2019 All rights reserved. Sharing Strategies REVIT UNIFI Prefab Playbook Prefab Strategy Meeting Prefab Playbook 5 8 Metrics • Month over Month Trend • By Division • By Market • Project Specific Southland Industries ©2019 All rights reserved. We know the best value is delivered for our customers when we connect all of our services in an integrated design- build-operate process. I ’ h lifecycle and our connections to our ’ h y differentiate us. Questions Jessica Kelley, PE [email protected] www.southlandind.com.
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