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GOVERNING CONSTRUCTION PROJECTS in WHICH 3D PRINTING IS APPLIED an Integration of Traditional Project Governance, Product Design and Innovation

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GOVERNING CONSTRUCTION PROJECTS in WHICH 3D PRINTING IS APPLIED an Integration of Traditional Project Governance, Product Design and Innovation GOVERNING CONSTRUCTION PROJECTS IN WHICH 3D PRINTING IS APPLIED An integration of traditional project governance, product design and innovation Rik Tersteeg | 4095928 MSc Construction Management and Engineering Delft University of Technology i Author Name Rik Tersteeg Student Number 4095928 Graduation Thesis University Delft University of Technology Faculty Civil Engineering and Geosciences Master Construction Management and Engineering (CME) Graduation Committee Chairman Prof.dr.ir. M.J.C.M. Hertogh Faculty of Civil Engineering and Geosciences Supervisor Dr.ir. H.H. Bier Faculty of Architecture Supervisor F. Setaki Faculty of Architecture Company Supervisor J. Hutten Senior Project Manager Arup Company Supervisor R. Kluwer Senior Project Manager Arup Commissioned by Company Arup (Amsterdam office) Naritaweg 118 1043 CA Amsterdam ii Preface The process of conducting this research shows strong similarities to the 3D printing projects that it aimed to investigate. It involved many experts from different disciplines and industries, lots of initial unknowns, and was highly iterative. The lessons I learned therefore, are interestingly similar to what is required to bring 3D printing technology forward. Skills to manage uncertainty, looking across industry boundaries and disciplines, deal with the resulting conflicting perspectives, and bringing them together in a final deliverable. I think this approach embodies the spirit and added value of the MSc Construction Management and Engineering, and have worked on this project with great enthusiasm. I would like to thank my committee members for their active support, the experts in Arup who were happy to share their expertise with me, and all interviewees that enthusiastically shared their vision and perspectives. Henriette, thank you for introducing me to this fascinating topic. Throughout the research you continuously exposed me to new ideas which allowed me to see the bigger picture of what 3D printing might mean for the construction industry. Understanding why and how my research was contributing gave me a lot of motivation. Jeroen, I enjoyed working with you a lot due to our conversations, your enthusiasm and way of providing feedback. You encouraged me to take charge of my project, and gave feedback in a way that empowered me to build on my own ideas. Particularly in the initial phases when I was in an ocean of different perspectives this was extremely helpful and motivating. Marcel, thank you for the clear advice during the formal meetings. You added a sharp critical eye to the direction of the overall project, and gave very clear feedback that was understandable. Your genuine interest in my personal opinion on the topic encouraged me to develop my individual perspective between the many experts I encountered. Rinke, I appreciate the time you made for supervising me during the final stages of the research. Your feedback was always very helpful, clear and understandable. You encouraged me to think critically about my conclusions and how the different aspects of the research fit together. Foteini, the many conversations we had really helped to structure my thoughts. You were very approachable and provided clear feedback, particularly from a methodological point of view. iii iv Executive Summary Introduction 3D printing is a manufacturing technology that is rapidly developing. Key differences to traditional manufacturing methods are that highly complex objects can be manufactured at lower cost and that the same (automated) manufacturing process can be used to manufacture a wide variety of objects. Its first mature applications can be seen in the aerospace and automotive industry, where it is used to rapidly manufacture small scale prototypes and tools. Driven by large private and public capital investments, a transition towards manufacturing end products is now being made. The advantages of applying this manufacturing technology include integrated products which require little assembly, weight reductions, increased functionality, increased manufacturing flexibility, shorter lead time of new products, and a simplified supply chain. In the more conservative construction industry the technology is in a research and prototyping stage, though the first construction projects in which it is applied are emerging. These projects can be classified in two main scenario’s: 1) A construction project in which 3D printed components are applied 2) A building in which the majority is 3D printed In scientific literature little is known about how to govern such projects. The objective of this research is to fill this knowledge gap, by designing a project governance structure for both scenario’s. Project governance is defined as the collection of processes and methods to successfully steer projects. Changes from the governance of traditional construction projects are expected because 3D printing introduces new organizations, roles, and activities. Additionally, it requires close collaboration between many disciplines, where a traditional construction project is fragmented. The main research question is therefore stated as follows: “What is the impact of large scale freeform 3D printing on the governance of construction projects?” Project governance structures for both application scenario’s are designed for the phases inception to construction. (excluding operation and maintenance). The governance structure for the first scenario in which 3D printed components are applied is valid for the current situation and is fully operationalized. The governance structure for the second scenario in which the majority of the building is 3D printed is designed for the future and therefore explorative and generically described. Research methodology A broad, empirical, qualitative, practice oriented approach was chosen. A literature review was first done to evaluate the state of the art of 3D printing and operationalize project governance into its elements. Based on this literature study, an interview framework was created and criteria for case studies were defined. Based on these criteria, 7 case studies in which 3D printing was applied were selected. Qualitative empirical data on the governance elements of these case studies was obtained through conducting interviews with key players involved in the project. Results were analyzed and compared to existing governance approaches for traditional construction projects, product design and innovation. Best practices and challenges were extracted and an analysis was done on the differences to traditional construction projects. Based on these insights, the first governance structure for applying 3D printed components was designed. The results were validated against an expert panel. To obtain data on the potential future development, the panel was asked to react against statements regarding the future development of 3D printing. As a final synthesis, an explorative governance structure for the second scenario in which the majority of a building is 3D printed was designed. Results 4 case studies suited the first scenario in which 3D printing was used for components in a construction project. Its governance approach was a combination of elements from traditional construction projects, product design and innovation. The similarities to product design include an early involvement of the v manufacturer, iterations between the design phases, and network relationships between project stakeholders. The different disciplines collaborated closely towards realization of the 3D printed component. Similarities to innovation were the dynamic unstructured process, iterative experimentation with the technology, an ad-hoc style of management, and changing composition of project teams. 2 case studies suited the second scenario in which 3D printing was used to manufacture the majority of the building. Its governance approach was a combination of product design and innovation. From this it can be concluded that the governance of traditional construction projects is not valid for design, engineering and manufacturing of a 3D printed object, regardless of whether it is a small component or a building. Once 3D printing technology is mature in the future, the governance domain innovation will drastically reduce, meaning the governance approach for this type of project will converge to that of product design. Several differences can be observed when comparing the governance of a project in which 3D printing is applied to a traditional construction project. Standard contracts and design phases are not applicable, there is a central role for the manufacturer, increased uncertainty and risk, an alternative building permit acquisition procedure, additional information system, and new skills are required for project stakeholders. The changes in governance that are therefore required are: - Adopting a product design approach for the 3D printed object - Early involvement of the manufacturer - A new type of contract between manufacturer and project team is required - A new approach towards communicating progress to higher management layers in the project - An increased emphasis on risk management - Early involvement of the municipality to agree on alternative requirements for the grant of the building permit - Reserving time for education and development of required skills - Alignment of the different communication systems (2D drawings and 3D models) Design governance structure 3D printed components A project in which 3D printed components are applied should be decoupled in three layers: the overall
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