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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
Southland Industries ©2019 All rights reserved.
Markets Served
Healthcare Mission Critical Biotechnologies Sports/Entertainment
Industrial/Manufacturing Commercial Education Government
Southland Industries ©2019 All rights reserved.
Why Prefabrication?
Safety
Quality
Productivity
Labor Shifting
Laydown space
Schedule
Cost
Southland Industries ©2019 All rights reserved.
Culture Shift
Project Type and Environment Matter
• New vs Renovation
• Tight Timelines
• Lack of Repetition
• Wrong Team
• Wrong Owner
• Distance from Shop
• Site Access
Southland Industries ©2019 All rights reserved.
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
Southland Industries ©2019 All rights reserved.
Eliminate the Risk
Southland Industries ©2019 All rights reserved.
Recordable Incident Rate
.63
Ex Mod Rate
.46
What does Integrated Project Delivery enable?
Southland Industries ©2019 All rights reserved.
Van Ness & Geary Hospital
San Francisco, CA
Engineering and Construction
Healthcare
Southland Industries ©2019 All rights reserved.
15% Detailing Increase
25% Labor
Reduction
Sheetmetal
Plumbing
• 15 Jigs for Lavatory and Shower Assemblies
• 75% increase in detailing labor
• 14% overall labor savings
Southland Industries ©2019 All rights reserved.
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
Southland Industries ©2019 All rights reserved.
Penn Medicine
Philadelphia, PA
Engineering, Construction
Healthcare
Site Logistics
• Curb-to-curb construction
• Active medical campus
• Limited laydown area
• Heavy traffic and limited parking
Southland Industries ©2019 All rights reserved.
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
Southland Industries ©2019 All rights reserved.
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
Southland Industries ©2019 All rights reserved.
Labor Shift
Peak Manpower (w/ Prefabrication): 1000Peak Manpower (Traditional): 1,200
Sharing Strategies
REVIT UNIFI
Prefab Playbook
Prefab Strategy Meeting
Prefab Playbook
5
8
Southland Industries ©2019 All rights reserved.
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
JKelley@southlandind.com
www.southlandind.com
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