optimizing material-related costs using dynamic site ... · incorporating lean tools along with the...
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Optimizing Material-Related Costs Using Dynamic Site Layout and
Supply Chain PlanningSarah Abou Dargham1 | Karim Faour2 |Sena Assaf1 | Farook Hamzeh3
Presenting Co-Author: Sena Assaf
1 Graduate Student, Civil and Environmental Engineering Department, American University of Beirut, Lebanon2 Civil Engineering Graduate, Civil and Environmental Engineering Department, American University of Beirut, Lebanon3 Associate Professor, Civil and Environmental Engineering Department, University of Alberta, Canada
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Outline
1Topic Introduction
3Methodology
5Discussion
2 Problem Statement
4 Simulation Results
Conclusion6
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Space in a Construction Site
Temporary facilitiesMaterial storage
areasOngoing construction
works
(Said & El-Rayes, 2013), (Mossman, 2007)
Often Considered LIMITED
Introduction3
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Seven groups of resource flow needed to complete a certain task
Construction Design
Components and Materials
Workers
Equipment
Space
Connecting Works
Addition to External Conditions
Right Time
Right Quantity
Desired Quality
Cost Reduction&
Value Addition
Introduction
(Koskela, 2000), (Lange & Schilling, 2015)
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When Are Material-Related Costs Incurred on Site?
Material movement into the site from laydown areas or storage facilities
Push nature of activitiesMaterial transportation to installation area
Introduction
(Tommelein, 1994), (Alves, Tommelein, & Ballard, 2006)
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Why Dynamic Site Layouts?
Introduction
(Said & El-Rayes, 2013)
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Gap Statement
(El-Rayes 2013) , (Turanoglu & Akkaya, 2017), (Bascoul and Tommelein, 2017), (Tommelein and Zouein 1993)
Different methods and models in the academic literature addressing material handling ina construction site have focused on:
- On-site congestion- Logistics cost- Project schedule- Material flow to the site- Dynamic site layout planning
The impact of how all those individual factorsact and interact with one another in a singleproduction system to incur material movingcosts has been understudied.
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What’s the Main Problem?
How can we decrease material-related costs on site throughthe use of dynamic site layout and supply chain strategies?
Research Objective8
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23
45
Case StudyConceptual
Model
Base Case Scenario
Improved Scenario
1
Gathering Intel
Methodology9
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GRC units Held on Rack
Zone 1
GRC Installation Zones
Case Study10
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Zone
number
Number of
GRC units
(Qzi, i = 1:8)
Total GRC
area
per zone
(m2)
Installation
period
(weeks)
Zones 1,3,5 350 4550 8
Zones 2,4,6 700 9100 8
Zones 7,8 175
4550 6
GRC Quantities and Equivalent Areas per Zone GRC Installation Schedule
Case Study11
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800
Available storage area for GRC units equivalent to 100 units
Site Layout Plan
Case Study12
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One delivery = ¼ of the quantity
per zone
Bi-weekly delivery per
zone W0 W2 W4 W6
Conceptual Model13
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On Site
Conceptual Model14
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Conceptual Model15
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W0 W2 W4 W6
Conceptual Model16
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On Site
(1/8) QZn+1
(1/8) QZn+1
(1/8) QZn+1
(1/8) QZn+1
Conceptual Model17
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Base Model18
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Material Deterioration
Costs
No Space for Other Material
Trucks Accumulating
on Site Hindering Movement
Storage Costs
Labor Overutilization
Base Model Concerns 19
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- Decrease the # of trucks from 4 to 2- Make deliveries weekly instead ofbiweekly
- Crane moves a GRC rack (10 units) insteadof moving one unit- Labors of both activities should work at thesame time- Requires less time than if the activities wereseparated (less movement)
Pull SystemDecrease Lead Time
of Trucks on Site
Merging ActivitiesCombine the
activities “Clean GRC” and “Install
GRC” into one
Improved Model20
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0
Improved Model21
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Model A
• Reduced L.T. = 1 Week(pull system)
Model B• Merging activities• Longer L.T. = 2 Weeks
Model AB
• Merging activities• Reduced L.T. = 1 Week
Models Developed
Developed Models22
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Total hours
The Truck Delay Cost ($)
Deterioration Cost ($)
Turnover Rate (hours/occurrence)
Total Cost ($)
Model simulation time
Cost incurred by trucks waiting to be unloaded instead of performinganother delivery
Cost of the total time a GRC unit spends on site before its final installation
Time needed for the storage space on site to be replenished by a newGRC rack.
Cost of the trucks, labour, crane, the GRC units’ deterioration cost, andtruck delay cost.
Assessment Criteria23
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Simulation Results & Analysis24
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Simulation Results & Analysis25
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Reducing Lead Time Effect Combining Activity Effect
Decreased transportation delay cost
Satisfy site and schedule demand
Reduced site congestion
Decreased total material handling cost
Increased space utilization
Decease unneeded movement
Simulation Results & Analysis26
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Conclusions & Future Work27
Incorporating lean tools along with the proper supply chain
---> Reduced the material related costs on site by 15-16%---> Reduced the process time by 15%
Future work aims at improving the existing model to better reflectthe actual site conditions regarding labour productivity and truckcapacity of the site.
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Thank you for your time!
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