CHANGING THE WAY WE BUILD THROUGH INNOVATION ADOPTION - THE DFMA STORY - DR. JOHN KEUNG EMERITUS FELLOW, BCA ACADEMY 19 DECEMBER 2019 2019 ...
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Changing the Way We Build Through Innovation Adoption
– the DfMA Story
Dr. John Keung
Emeritus Fellow, BCA Academy
19 December 2019
Driving Innovation through Technology Adaptation
Source: mirror.co.uk Source: https://negosentro.com/ Source: Teambuild
Design for Manufacturing and Assembly (DfMA)
Driving Innovation through Technology Adaptation
Design for Manufacturing and Assembly (DfMA)
Design for Manufacturing and Assembly
(off-site and (on-site)
automation)
Moving work offsite will improve productivity in 3 ways
•Controlled offsite environment
•Scope for automation of offsite work
•Scope for offshoring of offsite work
Changing the Way We Build – WHY?
The wastage and hack
1 Ever rising
construction
2 Labour shortage 3 and rework tradition
accidents/fatalities
Defects Over Production Inventory Unnecessary
Motion
Waiting Time Inefficient Over Employees
Transport Processing underutilized
4 Noise and dust nuisances
from construction sites 5 Rising construction costs
Mega developments
Noise & Dust Hazard Smart townships Infrastructures
Changing the Way We Build – WHY?
Benefits of DfMA
For the industry For the public
Greater automation in factory Less dust
Faster construction
Less noise
Conducive Working Environment Fewer delivery trips
High quality
Less workers on site
DfMA Continuum
Integrated Assemblies:
Components: Incremental Improvement Game-Changing Improvement
Prefab Components Advanced Prefab Systems Integrated Sub-assemblies Fully Integrated Assemblies
Structural Steel / Mass Engineered Timber
Precast Advanced Precast / Hybrid PPVC
(MET) / Hybrid
Structural
10% 20% 35% 40%
Manpower Savings [Project Level]
Prefab kitchens/
On-site Dry Applied Finishes Prefinished Surfaces PBU PPVC
Architectural
Common Toilets
Wallpaper Engineered timber floor
30% 45%Common Toilet Kitchen PBU 60% 70%
Manpower Savings [Trade Level]
MEP
Prefab Plant Prefab MEP Deck
Flexible Water Pipe/ Prefab Ceiling Module/
Sprinkler Dropper Prefab Plant Prefab Module with Platform/ Catwalk PPVC
How other advanced countries have embraced DfMA
3 Mass Engineered Timber 1 Mass Engineered Timber
2 Advanced precast
6-Storey
concrete system
Tamedia, Zurich (Switzerland)
Completed in 2013
2
DfMA 5-Storey 3XGRUN, Berlin
Bella Sky’, Denmark
(Germany)
7-day cycle time 5 DfMA Completed in 2011
5 Mass Engineered Timber 1 DfMA 6 Prefab pre-finished
3 volumetric construction
DfMA Little Hero (Australia)
7 DfMA
VDC
8
DfMA 4 Mass Engineered Timber
8 Virtual Design and 7 Prefab Mechanical, 6 10-Storey
Brock Commons,
University of British
Construction (VDC) Electrical & Plumbing 4 Forte, Melbourne
System (Australia)
Columbia (UBC) DfMA
17-storey MET building Expo 2020 (Dubai) Completed in 2012
Chrysalis Amphitheatre (US)
How other advanced countries have embraced DfMA
Launching of Hong Kong’s DfMA Alliance on 18 Mar 2019
• Organisation comprising industry stakeholders across construction value chain, government, professional bodies,
trade associations and academia to co-create an ecosystem for adoption of DfMA in Hong Kong
DfMA, a low hanging fruit?
Going DfMA, a no-brainer?
Image Source: https://insights.som.yale.edu/insights/can-low-hanging-fruit-drive-earnings-growth
DfMA in Singapore? It’s easier said than done
What were the Key Hurdles?
Hurdle No. 1 :
SKEPTICISM
over innovation
Source: https://www.aciworldwide.com/insights/expert-view/2017/october/in-the-digital-era-banks-must-ask-why-not
Doubt over whether if innovation really works or brings the promised benefitsDfMA in Singapore? It’s easier said than done
What were the Key Hurdles?
Hurdle No. 2 :
FEAR of the Unknown. FEAR of being the first mover
?
Source: https://www.roycastle.org/campaigns/face-your-fear/
https://business-ethics.com/2011/09/05/7721-the-better-light-bulb-debate/
Doubt over the potential of innovation; fear of making mistakesDfMA in Singapore? It’s easier said than done
What were the Key Hurdles?
Hurdle No. 3 :
COST of Change
Source: https://medium.com/@weiking/step-by-step-guide-on-how-to-earn-interest-
lending-with-defi-481ec385b48a
Concerns over the affordability and effectiveness of innovationDfMA in Singapore? It’s easier said than done
What were the Key Hurdles?
Hurdle No. 4 :
The Industry is NOT READY
Source: https://www.ai-maxtools.com/company
The rest of the value chain is not ready and not capable of providing support for innovationDfMA in Singapore? It’s easier said than done
What were the Key Hurdles?
Hurdle No. 5 :
REGULATORY Hurdles
Source: https://www.hoopla.net/summer-sales-competitions-to-boost-your-teams-numbers/
The regulators are not ready. The current rules are rigidWhat did we do?
Building Up the DfMA Ecosystem
STEP
STEP 04 Build Industry Capability
Create the demand and
supply ecosystem 03
STEP
STEP 02 Secure stakeholders’ buy-in
Raise Awareness 01
Making the Impossible PossibleDfMA: Making the Impossible Possible!!!
Step 1A: Raise awareness
International Panel of Experts (IPE) Interactive and informative platforms
A barrier free learning and sharing platform
on the advanced productive technologies Publications
International BIM competition
Participants from over 250 industry leaders
>3000 visitors to BCA Construction Productivity Gallery showcasing BIM, DfMA and
other advanced technologiesDfMA: Making the Impossible Possible!!!
Step 1B: Raise awareness
>25,000 participants in significant outreach activities Provide an Immersive and Experiential Learning Facility
CLVC
Centre for Lean and Virtual Construction
Demonstration of building with
MET at Skilled Builders’ Project
during the BuildTech Asia (BTA) BCA Award 2015 (BIM Award) Public Sector Productivity
2015 exhibition Leadership 2018
Singapore Construction Productivity Week 2017 BCA-REDAS Quality and Productivity Seminar 2017DfMA: Making the Impossible Possible!!!
Industry Government
Step 2A:
2B: Secure stakeholders’ buy-in
>20 overseas learning journeys since 2010 Establish links with overseas counterparts
Greyform Pte Ltd, an ICPH under Teambuild ICPH
Prefab MEP in the UK, 2016 Prefab Bathroom Unit in the UK, 2016 Source: straitstimes.com
Straits Construction Group
RATEC GmbH - Specialist in
adjustable moulds for production
Partnering of Straits Construction Singapore Pte Ltd
of monolithic 3D concrete PPVC
and Bathsystem S.p.A. in the supply of drywall PBU
Prefab Bathroom Unit in Italy, 2014 Stadthaus at Murray Grove, UK, 2013 modules
and lightweight concrete PBU in SingaporeDfMA: Making the Impossible Possible!!!
Government
Step 2B: Secure stakeholders’ buy-in
Building Innovation Panel Review of Regulatory Requirements
A One-Stop Multi-Agency Platform for All Innovative Construction Regulatory hurdles resolved to widen the application of DfMA and reduce
Technologies to secure Speedy Clearance of All Regulatory Requirements compliance cost
Max. height of MET buildings allowed by Fire Safety and
Shelter Department
Storeys
No height limit
24
(except healthcare occupancy)
(or 12 for
healthcare)
Examples of systems cleared by BIP are PPVC and PBU 4
0*
2012 May 2013 Mar 2014 Aug 2016
*MET is not allowed as structural element before 2012
10-sty high Forte, Melbourne,
AustraliaDfMA: Making the Impossible Possible!!!
Step 3A: Create the demand and supply ecosystem
Specifying DfMA technology adoption in land
Public Sector Taking the Lead
tender conditions
Adoption of DfMA technologies PPVC
PPVC (25 projects) Prefab MEP (8 projects) 29 GLS sites
(24 residential, 4 mixed
developments, 1 hotel
Structural Steel /
NTU Hostel Healthcare Hub
Minimum Prefab Level
MET (14 projects) Structural Steel (12 projects)
2 Commercial GLS and 50
Industrial GLS sites
Sport Hall State Court
*GLS refers to Government Land Sales (GLS)DfMA: Making the Impossible Possible!!!
Step 3B: Create the demand and supply ecosystem
Carrot and Stick Approach
Mandatory Requirement Incentive Funding
• Public Sector Construction
Productivity Fund (PSCPF)
Carrot
– S$154 million
• Construction Productivity
Stick and Capability Fund (CPCF)
– ~S$800 million
• Bonus GFA schemeDfMA: Making the Impossible Possible!!!
Step 3C: Create the demand and supply ecosystem
Integrated Construction and Prefabrication Hubs (ICPHs)
Pulau Punggol Barat (PPB)
Jalan Gali Batu
Tiong Seng Prefab Hub
Kaki Bukit 1
Completed ICPH Teambuild Soilbuild Greyform
(Straits Construction)
ICPH under planningDfMA: Making the Impossible Possible!!!
Step 4: Build Industry Capability
Training for Transformative Skills
Building Control Industry Development Capability Building
Green BIM / VDC DfMA
• Masters • Diploma
• Bachelor • CET Programmes
Institutes of
Higher Learning:
Training Area Current (Personnel trained by BCAA) Target: 2025
Green Design and Engineering 10,000 25,000
Integrated Digital Delivery 11,900 20,000
DfMA 11,150 35,000The Success Stories
PPVC Project Highlights
Changi Airport Crowne Plaza Hotel
• Time savings of 3 months; Construction Productivity Awards 2017
• On-site manpower savings 44% Project Category Platinum Award
10 storeys completed in 26 days
Transport trips reduced by 70%PPVC Project Highlights
NTU Nanyang Crescent Hostel
784 PPVC Modules used
Only 7 workers were required to install
a module in 30 minutes.
6-8 modules were installed each day
Only 6 months of on-site works
Project Information
Steel PPVC
Gross Floor Area 48,500 m2
(GFA) Construction Productivity Awards 2018
Number of Storeys 11 to 13 (4 blocks) Project Category Platinum Award
Number of Rooms 1527PPVC Project Highlights
The Brownstone Executive Condominium
~5,000 Building Modules used
Likely the World’s Largest and First-of-its-kind
application of Full Concrete PPVC for a Large-
Scale Private Residential Development
City Development Limited clinched
Construction Productivity Awards 2017
Developer Category Platinum Award
Builder Teambuild clinched
Construction Productivity Awards 2017
Builder (Open) Category Platinum AwardPPVC Project Highlights
Clement Canopy Condominium
World’s tallest Concrete PPVC building
(40 storeys)
Superstructure EdgeProp Singapore Excellence Awards 2018
completed in 14 months • Landscape Excellence Award
• Top Development Excellence AwardsMET Project Highlights
NTU The Wave
No internal columns or pillars required to support the
weight of the roof
First large-scale building in South-east Onsite manhour savings:
Asia built with MET Technology • Took only 14 workers ~5 weeks Green Mark
to complete the roof Platinum Award
72m roof made of seven timber archesMET Project Highlights
SMU Tahir Foundation Connexion
Shorten Construction time from Green Mark
24 months to 15 months Platinum Award
Use of myriad DfMA technologies – MET, modular +
façade, modular MEP Net Zero Energy BuildingBeyond DfMA
Source:
https://www.youtube.co
m/watch?v=pL-c00M2CnI
Source: Technical University of Munich Source: Doka Source: Fira
Human-Robot Collaboration (HRC) Robots Formwork 3D Printing A.I. in Workplace Safety Harnessing IOT for Information Sharing
Source: https://riskandinsurance.com/algorithms-and-
Source: Technical University of Munich Source: Sika Technology Centre artificial-intelligence-can-make-construction-more-efficient/ Source: Fira
Welding Robots Architectural Feature 3D Printing A.I. in Facilities Management Full Digitalisation of All Building Services
Source:
https://www.roboticsbusinessreview.com/constructio
Source: ETH Zurich Source: ETH Zurich n/komatsu-ai-construction-sites/ Source: Kira
Robots for Digital Fabrication 3D Printed Slabs A.I. in Construction Management Managing Concrete Curing via IOT
Harness Digitalisation though
Automation & Robotics 3D Printing A.I. Technology R&DFood for Thought
Changing the Way We Build Through Innovation Adoption
- the DfMA Story
40%
The Big Questions
22% Do we have the mechanism
to proliferate and entrench
0% DfMA to the point of no
2010 2018 2020
DfMA Adoption Rate in Singapore return?Food for Thought
Changing the Way We Build Through Innovation Adoption
- the DfMA Story
The Big Questions
Have we done enough to
make innovation and
ecosystem building part of the
DNA of the Built Environment
Sector from now on?Food for Thought
Changing the Way We Build Through Innovation Adoption
- the DfMA Story
The Big Questions
How do we groom and
nurture future leaders to
bring about innovation and
innovation adoption in the
industry?Food for Thought
Changing theGreen
Way We Build Through Innovation Adoption
- the DfMA Story
Digitalized
DfMA The Big Questions
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beyond a green, digitalized
and technologically
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