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Configuration of Modularised Building Systems ISSN: 1402-1757 ISBN 978-91-7439-XXX-X Se i listan och fyll i siffror där kryssen är LICENTIATE T H E SI S Department of Civil, Mining and Environmental Engineering Division of Architechture and Infrastructure Patrik Jensen Configuration of Modularised Building Systems Configuration of Modularised ISSN: 1402-1757 ISBN 978-91-7439-108-4 Building Systems Luleå University of Technology 2010 Patrik Jensen LICENTIATE THESIS CONFIGURATION OF MODULARISED BUILDING SYSTEMS Patrik Jensen Luleå, May 2010 Division of Architechture and Infrastructure Department of Civil, Mining and Environmental Engineering Luleå University of Technology SE - 971 87 LULEÅ www.ltu.se/shb Configuration of Modularised Building Systems ”there is nothing wrong with change, if it just goes in the right direction” Winston Churchill Printed by Universitetstryckeriet, Luleå 2010 ISSN: 1402-1757 ISBN 978-91-7439-108-4 Luleå 2010 www.ltu.se Preface Preface As the statement explains; change is of nothing bad, it helps us want to learn more. This thesis concludes the joint venture between Tyréns AB and Luleå University of Technology, and somewhere there between myself. Over the last three years I have been challenged to wear two vastly but complimentary hats; one academic, the other as a consultant. In the academic world the focus was education while as a consultant the focus was business. My fellow Ph.D. students called me ”Structural phone engineer” because I was always on my cell phone conducting business while studying. I would like to express my deepest gratitude to my Professor Thomas Olofsson for always pushing me in the right direction and never stop surprising me with your knowledge. Docent Helena Johnsson, you always have a clear and straight forward approach how to tackle the academic. Also the true visionary Vice President Tomas Alsmarker is acknowledged, this journey couldn’t have started without you. My colleagues and friends at Tyréns, LTU and Ph.D. students at the Lean Wood Engineering program are truly appreciated, especially Linus Malmgren and Emile Hamon my former colleges at Tyréns. A special thanks to Tyréns AB for financing the project. Finally I would like to thank my family and wonderful wife Lina. ƉYou are the sunshine of my lifeƉ Patrik Jensen Stockholm, May 2010 I Abstract Abstract Swedish building industry is mainly project-oriented where the design process is sequential involving various disciplines separated both in time and space. During the last decades the industry has been criticised and accused of having problems with quality and low productivity. One cause is believed to be deficiencies in information transfer between different functional teams in the project organisation. A more product-oriented approach has been proposed by some as one solution that can improve quality and productivity. Several construction companies have started to develop platforms consisting of standardized technical solutions and processes that can be adapted and used in specific projects. However, the current practice of involved disciplines need to adapt to new methods and processes and the question is; Is it possible to apply principles based on mass customisation in the one-of-a kind project dominated construction industry? In the shift to mass customization, the manufacturing industry is developing product platforms from which customized products can be configured in a so called configuration process. A product platform in the manufacturing industry consists of modules that can be combined into customized products using a configuration system. Modularization is the method used to organize the components of a product family with the aim to simplify and minimize the number of component variants to improve customization without compromising the productivity of the manufacturing process. Erixon (1998) defines modularization as; ”Decomposition of a product into building blocks (modules) with specified interfaces, driven by company specific reasons”. The aim of the thesis is to study and propose solutions of the integration between architectural design, engineering and production using mass III Configuration of Modularised Building Systems customisation principles without changing the traditional structure of the AEC industry. The author's background as practising structural design engineer in an AEC consultancy company has made it possible to study, propose and apply methods in two real-life industrial cases and in one development project of a building system for multi-storey wooden houses. The research performed mainly relies on qualitative research methods combined with action research. The result of the thesis is a configuration demonstration, in which four product views been identified; the customer, the engineering, the production and the assembly view. Constraints and rules of the building system is transferred upstream while design information is transferred downstream the value chain using design automation and design guides embedded in the different disciplines CAD applications. The process has been illustrated for a cut-to-fit configurable wooden slab module in which a design guide is used in the architect tool transferring dimensional information via XML to the knowledge based engineering tool where the detailed design is automated. The result, including shop floor drawings, bill of quantities and CNC files is then used in the prefabrication of the customized floor slab module. The knowledge based engineering tool used in the demonstration is a product configurator integrated into a 3D CAD system mainly used in the mechanical industry. To implement configuration processes in the construction industry it is evident that constraints and rules of the building system needs to be transferred upstream to disciplines working early in the specification process. Otherwise the risk is high that "ad-hoc" solutions violating the rules of the building system will be transferred downstream to engineering and production causing quality issues and lower productivity as a result. Implementing configuration processes will also require new business models. AEC consultants with competence in engineering and advanced design tools can develop new modularised building systems and configuration tools rather than selling engineering hours in design of specific buildings. This can also foster the development of more open and flexible building systems on the market. Keywords: Building system, Modularization, Configuration, Parameterization IV Sammanfattning Sammanfattning Svensk byggindustri är i huvudsak projektbaserad med en sekventiell projekteringsprocess där olika discipliner är separerade i både tid och rum. Detta arbetssätt har utsatts för hård kritik och blivit beskyllt för att ha låg produktivitetsutveckling med brister i informationsöverföring mellan de olika aktörerna som sedan får stora konsekvenser på byggplatsen. Ett produktorienterat arbetssätt har av vissa ansetts som lösningen som kan förbättra kvaliteten och produktiviteten. Genom att utveckla standardiserade byggsystem kopplat till standardiserade arbetsprocesser skapas en produktiv plattform som sedermera kan utvecklas till att konfigurera projektanpassade byggnader. Med nya arbetssätt kommer dagens aktörer att behöva anpassa sig till nya förhållanden och frågan som uppkommer, är det möjligt att införa industriella konfigureringsmetoder i byggandet? Denna avhandling är inriktad på att studera och föreslå metoder för att modularisera och konfigurera byggsystem med hjälp av IT-verktyg. Metoder som kan ersätta dagens projekteringsprocess med en konfigureringsprocess av utvecklade byggsystem. Konfigureringsmetodik kan sammanfattas som ett strukturerat arbetssätt att åstadkomma kundanpassning med bibehållen standardisering med avseende på produktion. För att lyckas med kundanpassningen krävs det att produkten är uppbygga kring moduler och att konfigureringsverktyg utvecklas som stödjer byggsystemets möjlighet att kundanpassas. Modularisering är en metod som har använts inom många olika industrier med syftet att förenkla och minimera antalet komponentvarianter med bibehållen möjlighet för kundanpassning och produktionseffektivitet. En parallellisering av produktion ökar samtidigt produktiviteten för själva tillverkningsprocessen. Erixon (1998) sammanfattar Modularisering som; “indelning av produkter till byggblock (moduler) med V Configuration of Modularised Building Systems specificerade gränssnitt och utvecklade med företagets speciella förutsättningar”. Syftet med avhandlingen är att studera och föreslå lösningar för integration mellan arkitektonisk design, konstruktion och produktion baserade på metoder hämtade ifrån ”Mass Customisation” utan att ändra den traditionella strukturen inom byggindustrin. Författaren är verksam som konstruktör i ett konsultföretag som verkar inom dagens projektbaserade byggande, vilket gjort det möjligt att studera, föreslå och tillämpa metoder i två verkliga industriella fall och i ett utvecklingsprojekt av ett byggsystem för flervåningshus trähus. Den forskning som har bedrivits bygger i huvudsak på kvalitativa forskningsmetoder i kombination med aktionsforskning. Från fallstudierna har ett IT-baserat CAD verktyg tagits fram, där 4 vyer av produkten har definierats; Kund-, Ingenjörs-, Produktions- och Montagevy. Byggsystemets regler kan illustreras i arkitekters IT- verktyg och sedermera överföras till produktions och montagevyn via parametrisering i ingenjörsverktyget. Regler för byggsystemet definieras i ingenjörsvyn och byggsystemets förutsättningar överförs mellan olika
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