the precast concrete industry
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The Precast Concrete Industry. A proposal for the adoption of advanced Information Technologies. Introduction. Existing processes and business environment. Available and suitable information technologies. A framework target plan, including assessment of potential benefits. - PowerPoint PPT PresentationTRANSCRIPT
Str
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for
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e B
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Pro
f. C
.M. E
astm
an &
Dr.
R. S
acks
The Precast Concrete Industry
A proposal for the adoption of advanced Information Technologies
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Pro
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Dr.
R. S
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Introduction1. Existing processes and business environment.
2. Available and suitable information technologies.
3. A framework target plan, including assessment of potential benefits.
4. Assess the expected costs of achieving the plan.
5. Analysis of the readiness for implementation of the framework plan.
6. A detailed plan for the next incremental step.
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Part 1: Environment - Scope
What is Precast Concrete Construction ? • Construction of buildings and other
facilities using precast concrete elements;
• Precast concrete elements are reinforced concrete elements produced in a dedicated plant. They are transported and erected after curing.
• For examples - Precast Concrete Institute
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Part 1: Environment - Scope
What sub-sectors are there ? • Architectural Precast generally includes the
production and erection of precast panels for facades of buildings.
• Structural Precast generally includes production and erection of structural systems (assemblies of precast elements), and in certain instances of complete buildings.
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Part 1: Environment - Scope
An economic review
• approximately 380 plants in Canada, the US and Mexico, operated by some 160 producer companies.
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Part 1: Environment - Scope
Units $ '000 000 Precast Total New Construction Share
Public and Commercial Buildings 3,346$ 143,297$ 2.3%
Hotels, Motels and Housing 352$ 38,356$ 0.9%
Bridges 640$ 10,209$ 6.3%
Other 443$ 46,063$ 1.0%
Single Family Houses 13$ 175,296$ 0.0%
Total 4,794$ 413,221$ 1.2%
w/o houses 4,781$ 237,925$ 2.0%
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Part 1: Environment - Scope
28%26%
20%18%
13%
6%
1%
56%
0%
10%
20%
30%
40%
50%
60%
Finland Germany UK Spain France Italy USA Turkey
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Part 1: Environment - Scope
Who is involved ?
• Owners/Clients• Architects• Structural Engineers• Precast Concrete Producers and Erectors• General Contractors• Material Suppliers• Designers and providers of other building systems
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Part 1: Environment - ProcessWhat activities are there ?
• Win contract and acquire project• Assembly design• Detailed design• Planning and Scheduling• Production• Handling - Storage and Shipping• Erection
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Part 1: Environment - Process
What are the information dependencies ?
• Building design (geometry & systems)• Product design• Materials Procurement• Plan, Schedule and Production• Erection• Company Management information
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A High Level Process Model
Top-level External Activity
Top-level Internal Activity
complete project
abandon project
Acquire Project Do Detail Design Fabricate
Check Quality Assurance
Prepare Molds Check Quality No.2
Move to Yard
Schedule Engr. Staff
Material Cost Database
Labor Cost Database
Plant Scheduling
Prepare Project Schedule
Billing for Project
Deliver to Site Erect Structure
Yard Layout Planning
Prepare Reinf. & Hardware
Prepare/track bill of Material
Prepare Batch Instructions
LEGEND
Static Info Source
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Part 2: Information Technologies
What is in use ?
• CAD – 2-D drafting e.g. Precast Drawings
• Structural Design applications e.g. LEAP
• ERP software (production planning, materials management, human resources, accounting, etc.)
• Scheduling software
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Part 2: Computerization for Design
Use of CAD in Precast Concrete Companies
AutoCAD81%
Outsource4%
Other CAD15%
92% 8%
(PCI/CPCI Survey 2001) (Arditi et al. 2000, ASCE Journal of Architectural Engineering)
59%
41%
41% of producersreported encountering
problems in production due to ambiguities in
design “often” or “very often”.
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Part 2: Information Technologies
What is the effectiveness of IT use ?
• Errors are commonplace.
• No integration – data is re-entered for each application.
• Examples…
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Office Building
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Parking Deck 1
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Parking Deck 2
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Parking Deck 2
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Prison Complex
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Arena
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Part 2: Information Technologies
What else is available ?
• CAD: 3-D Modeling
• Rendering, Animation and Virtual Reality,
• CAM and Robotics,
• B2B, collaboration portals,
• Product Model based integration,
• Automated data collection and monitoring
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Part 3: A Framework Target Plan
• What are the long-term IT goals ?
• What are the short-term IT goals ?
• Potential local benefits – activities and cost-centers
• Potential system benefits in the supply chain
• A future process model
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acksPart 3:Long-term IT goal
Integration
Process planningapplication
Design application
Analysis application
Shop drawingApplication
IntegratedPrecast/
PrestressedData model
Rebar bending application
Design Stage
Architect or contractor
Mold design application
Production Stage
Robotics applications
Logistics and production app.
Scheduling and workflow app.
Materials order/ tracking app.
EnterpriseApplications
Material suppliers
“B2B”exchanges
Formwork fabricator
Outside
Exchanges
Internal
Exchanges
(Eastman & Augenbroe, 2000, presentation to PCI)
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3-D Modeling
Process planningapplication
Design application
Analysis application
Shop drawingApplication
3D Modeling
of Precast
Buildings
Rebar bending application
Design Stage
Mold design application
Production Stage
Robotics applications
Logistics and production app.
Scheduling and workflow app.
Materials order/ tracking app.
EnterpriseApplications
Internal
Exchanges
(Eastman & Augenbroe, 2000, presentation to PCI)
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Part 3: Local benefits
• Reduced drafting hours/salaries
• Reduced drafting and production errors
• Shortened sales response time
• Shortened time to erection
• Improved management information flows
All of the above = Increased Market Share.
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Part 3: Supply chain benefits
• Improved coordination with and support for project architects and engineers.
• Shorter activity times for GC.
• Lower overall cost for Owner.
• Shorter overall duration – benefits all.
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Part 3: A future process model
Precast Process Model
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Part 4: Expected Costs
• What are the ‘hard’ costs ?– Initial investment in hardware and software– Annual maintenance fees– Training fees and salaries– Equipment
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Part 4: Expected Costs
What are the ‘soft’ costs ?– Business re-organization and adaptation– Decreased productivity during ‘learning-curve’
period.– Management time (salaries)– Opportunity cost
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Part 5: Industry Readiness
• What are the conditions that must exist ?
• Which conditions are presently satisfied ?
• Which conditions can be satisfied in the short-term?
• Which conditions can be satisfied in the long-term?
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Part 5: What conditions must exist ?
1) Significant value-added portion
2) Perceived economic benefits
3) Available production automation technology
4) Computerization in the business environment
5) IT integration in external environment
6) Modeling software
7) Product model integration
Preconditions
Conditions
Necessary Developments
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Part 5: Industry Readiness• Which conditions are currently satisfied ?1) Significant value-added portion
2) Perceived economic benefits
3) Available production automation technology
4) Computerization in the business environment
5) IT integration in external environment6) Modeling software7) Product model integration
Materials are 15-20% of product cost
Yes; especially schedule, error reduction and market share
Yes; rebar, mold, casting and finish automation is available
Yes; enterprise management systems are common
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Part 5: Industry Readiness• Which conditions can be satisfied in the
short-term?1) Significant value-added portion
2) Perceived economic benefits3) Available production automation technology4) Computerization in the business environment5) IT integration in external environment
6) Modeling software
7) Product model integration
Yes; development is now under way by Tekla. For example…
Yes; development is now under way by Georgia Tech
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Part 5: Industry Readiness• Which conditions can be satisfied in the
long-term?1) Significant value-added portion
2) Perceived economic benefits3) Available production automation technology4) Computerization in the business environment
5) IT integration in external environment
6) Modeling software7) Product model integration
Through the IAI ?
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Part 6: The Next Step• What technologies and resources are
required ?– 3-D Modeling Software and Product Model– software and model development teams– industry technical working teams– financing
• What short term benefits are expected ?– reduced errors,– reduced lead times,– reduced engineering costs.
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Summary
1. Existing processes and business environment.
2. Available and suitable information technologies.
3. A framework target plan, including assessment of potential benefits.
4. Assess the expected costs of achieving the plan.
5. Analysis of the readiness for implementation of the framework plan.
6. A detailed plan for the next incremental step.
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Precast Concrete Industry - Role 1
Welcome.
As you listen to this presentation, try to consider the issues from the point of view of an imaginary interested party. Try to protect your interests by asking questions and asserting your views ! To help you prepare, here is a description of your role:
You are the CEO and president of a medium sized precast concrete production company. The company specializes