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Optimizing Prefabrication with Lean

Jessica Kelley

Southland Industries ©2019 All rights reserved.

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

• HVAC

• Process piping

• Plumbing

• Fire protection

• Controls and automation

• Energy

• Electrical

TRADES

• Pipefitting

• Sheet metal

• Plumbing

• Sprinkler-fitting


Markets Served

Healthcare Mission Critical Biotechnologies Sports/Entertainment

Industrial/Manufacturing Commercial Education Government


Why Prefabrication?

Safety

Quality

Productivity

Labor Shifting

Laydown space

Schedule

Cost


Culture Shift

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 Workflow

Ideas Come From Anywhere

Engineer

Detailer

Fab Shop

Crew

Group Planning Meetings Project Manager

Field Crew

1

9

Leveraging BIM

BIM… not a guarantee: Understand your Tolerances

20” gap between

segments

RE

CE

IVIN

G

SHEETMETAL

FABRICATION

PLUMBING ASSEMBLY

PIPING ASSEMBLY

DESIGN TEAM

SM

ASSEMBLY

SH

IPP

ING

TOOLSLOGISTICS

STAGING

Offsite Prefab Facilities

Too Many Carts

Universal Cart

Universal Cart Closed Cage Conversion

Transport Safety Stackable for Shipping/Storage

Material Handling Options

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


Recordable Incident Rate

.63

Ex Mod Rate

.46

What does Integrated Project Delivery enable?


Van Ness & Geary Hospital

San Francisco, CA

Engineering and Construction

Healthcare


15% Detailing Increase

25% Labor

Reduction

Sheetmetal

Plumbing

• 15 Jigs for Lavatory and Shower Assemblies

• 75% increase in detailing labor

• 14% overall labor savings


Procter & Gamble

West Virginia

Engineering, Construction

Manufacturing

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 impact

The duct runs were installed in larger sections, thus limiting the amount overhead work.

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


Penn Medicine

Philadelphia, PA

Engineering, Construction

Healthcare

Site Logistics

• Curb-to-curb construction

• Active medical campus

• Limited laydown area

• Heavy traffic and limited parking


Prefabrication Maps

46

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)

Multi-Trade Pipe Racks

Wall Assemblies


Bathroom Pods

49

Project Award ~2015

Functionality MockupA3’ G 2016

Struct/Arch Coordination Clinical Mockup

Constructability Mockup

Coordination of Pod Types

FabricationPrototypes

From Shop to Field

• 1 Finish Schemes

• 2 Layouts

• 7 Plumbing Variations

• 504 Pods

• 10% reduced onsite labor, projected

• 10 less deliveries, weekly

Penn Medicine Metrics - Piping

10,5; 30 %

25; 70 %

Total Pipe Length [Miles]

Prefab Pipe Onsite

10 %

20 %

70 %

Patient Floors (L7-L14)

Prefab Pipe

Bathroom Pod Piping

Onsite

35 Miles of Piping

Excludes 3 pipe Med Gas racks

Penn Medicine Metrics - Sheetmetal

220; 20 %

50; 5 %

830; 75 %

Total Project Sheetmetal [Tons]

Fitout Duct C&S Headers Onsite

46 %

54 %

Interventional/OR (L4-L6)

OSM

Onsite

49 %

51 %

Patient Floors (L7-L14)

OSM

Onsite

1100 tons (2.2 Million lbs) of Sheetmetal


Labor Shift

Peak Manpower (w/ Prefabrication): 1000Peak Manpower (Traditional): 1,200

Sharing Strategies

REVIT UNIFI

Prefab Playbook

Prefab Strategy Meeting

Prefab Playbook

5

8


Metrics

• Month over Month Trend

• By Division

• By Market

• Project Specific

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

mailto:[email protected]

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