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The Precast Concrete Industry

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.

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The Precast Concrete Industry

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  1. The Precast Concrete Industry A proposal for the adoption of advanced Information Technologies

  2. Introduction • Existing processes and business environment. • Available and suitable information technologies. • A framework target plan, including assessment of potential benefits. • Assess the expected costs of achieving the plan. • Analysis of the readiness for implementation of the framework plan. • A detailed plan for the next incremental step.

  3. 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

  4. 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.

  5. Part 1: Environment - Scope An economic review • approximately 380 plants in Canada, the US and Mexico, operated by some 160 producer companies.

  6. Part 1: Environment - Scope

  7. Part 1: Environment - Scope

  8. 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

  9. Part 1: Environment - Process What activities are there ? • Win contract and acquire project • Assembly design • Detailed design • Planning and Scheduling • Production • Handling - Storage and Shipping • Erection

  10. 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

  11. Part 1: EnvironmentA High Level Process Model

  12. 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

  13. 41% of producers reported encountering problems in production due to ambiguities in design “often” or “very often”. Part 2: Computerization for Design (PCI/CPCI Survey 2001) (Arditi et al. 2000, ASCE Journal of Architectural Engineering)

  14. 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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  19. Prison Complex

  20. Arena

  21. 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

  22. 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

  23. Part 3:Long-term IT goalIntegration Formwork fabricator Architect or contractor Material suppliers Outside Exchanges Design Stage “B2B” exchanges Design application Integrated Precast/ Prestressed Data model Analysis application Enterprise Applications Shop drawing Application Internal Exchanges Materials order/ tracking app. Scheduling and workflow app. Production Stage Process planning application Mold design application Logistics and production app. Rebar bending application Robotics applications (Eastman & Augenbroe, 2000, presentation to PCI)

  24. Part 3:Short-term IT goal3-D Modeling Design Stage 3D Modeling of Precast Buildings Design application Analysis application Enterprise Applications Shop drawing Application Internal Exchanges Materials order/ tracking app. Scheduling and workflow app. Production Stage Process planning application Mold design application Logistics and production app. Rebar bending application Robotics applications (Eastman & Augenbroe, 2000, presentation to PCI)

  25. 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.

  26. 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.

  27. Part 3: A future process model Precast Process Model

  28. Part 4: Expected Costs • What are the ‘hard’ costs ? • Initial investment in hardware and software • Annual maintenance fees • Training fees and salaries • Equipment

  29. 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

  30. 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?

  31. Preconditions Conditions Necessary Developments Part 5: What conditions must exist ? • Significant value-added portion • Perceived economic benefits • Available production automation technology • Computerization in the business environment • IT integration in external environment • Modeling software • Product model integration

  32. Part 5: Industry Readiness • Which conditions are currently satisfied ? • Significant value-added portion • Perceived economic benefits • Available production automation technology • Computerization in the business environment • IT integration in external environment • Modeling software • 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

  33. Part 5: Industry Readiness • Which conditions can be satisfied in the short-term? • Significant value-added portion • Perceived economic benefits • Available production automation technology • Computerization in the business environment • IT integration in external environment • Modeling software • Product model integration  Yes; development is now under way by Tekla. For example…  Yes; development is now under way by Georgia Tech

  34. Part 5: Industry Readiness • Which conditions can be satisfied in the long-term? • Significant value-added portion • Perceived economic benefits • Available production automation technology • Computerization in the business environment • IT integration in external environment • Modeling software • Product model integration  Through the IAI ?

  35. 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.

  36. Summary • Existing processes and business environment. • Available and suitable information technologies. • A framework target plan, including assessment of potential benefits. • Assess the expected costs of achieving the plan. • Analysis of the readiness for implementation of the framework plan. • A detailed plan for the next incremental step.

  37. 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

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