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Applying a DFMA Approach in the Redesign of Steel Bracket - a Case Study in Post and Beam System
Jönköping University, School of Engineering, JTH, Industrial Product Development, Production and Design, JTH, Product design and development (PDD).ORCID iD: 0000-0003-2239-973x
Jönköping University, School of Engineering, JTH, Industrial Product Development, Production and Design, JTH, Product design and development (PDD).ORCID iD: 0000-0002-3677-8311
Jönköping University, School of Engineering, JTH, Industrial Product Development, Production and Design, JTH, Product design and development (PDD).ORCID iD: 0000-0002-6619-7489
2022 (English)In: Proceedings of the 30th Annual Conference of the International Group for Lean Construction (IGLC), Edmonton, Canada, July 25-31, 2022, 2022, p. 564-575Conference paper, Published paper (Refereed)
Sustainable development
00. Sustainable Development
Abstract [en]

Design for manufacturing and assembly (DfMA) has gained increased attention in the construction industry as the process has been industrialized and shifting towards a combination of factory prefabrication and assembly on site. The aim of this study is two-fold. Firstly, to apply the DfMA approach in the redesign of a steel bracket from a post and beam building system to simplify the design for reducing the cost and improving manufacturability. Secondly, to experimentally evaluate the mechanical properties of the redesigned bracket for implementation. An experimental case study has been conducted in a multistorey post and beam building system. The empirical data were collected from five semi-structured interviews and two workshops.

The result shows that the DfMA approach has the potential to improve the manufacturability and cost of building components in Industrialized house building (IHB) and is comparable to lean design. Moreover, the proposed steel bracket offers satisfactory load-bearing capacities and shows an improvement with a reduction of cost by 15%, lead time by 50%, and material efficiency by 25%. DFMA can be used as a promising approach for aligning the design phases of IHB with the production and assembly by improving cross-functional collaboration.

Place, publisher, year, edition, pages
2022. p. 564-575
Keywords [en]
Off-site construction, Design management, design for manufacturing, design for assembly, lean construction
National Category
Production Engineering, Human Work Science and Ergonomics Construction Management
Identifiers
URN: urn:nbn:se:hj:diva-58406DOI: 10.24928/2022/0161Scopus ID: 2-s2.0-85170370314OAI: oai:DiVA.org:hj-58406DiVA, id: diva2:1692582
Conference
30th Annual Conference of the International Group for Lean Construction (IGLC), Edmonton, Canada, July 25-31, 2022
Available from: 2022-09-02 Created: 2022-09-02 Last updated: 2023-09-20Bibliographically approved
In thesis
1. A product platform approach to support the design phase of industrialised house building: A framework conceptualisation when using mixed production strategies
Open this publication in new window or tab >>A product platform approach to support the design phase of industrialised house building: A framework conceptualisation when using mixed production strategies
2023 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The ability to offer unique solutions that meet customer demands has been considered a competitive advantage in the industrialised house building (IHB) industry. However, IHB companies are struggling due to varying customer needs and the simultaneous need to fulfil legal regulations, market demands, and production constraints. This has forced companies to develop unique solutions for every housing project to satisfy individual requirements, which automatically drives them to follow an engineer-to-order (ETO)-based strategy. The high involvement of customers in the design process results in the need for considerable engineering activities to validate and adjust to the customer demands, thereby providing individualised solutions. Moreover, designers adopt different production strategies based on the degree of pre-engineering. Product platform approaches have been acknowledged as one of the prominent means to improve both internal and external efficiencies. However, the use of traditional platform-based strategies does not suffice for the design of ETO-based components in an IHB system. A systematic approach is required to align the product platform and different production strategies so that customer requirements can be easily managed. Thus, this research aims to outline the means to support the design phase of IHB by applying a product platform approach when using a mixed production strategy.

A Swedish multi-storey house building company that uses a glulam-based post and beam building system was used as the main case in this research. Empirical data were collected mainly from interviews, observations, workshops, and document analysis. This research proposes a framework for the systematic development and use of the product platform by following an inductive approach. Further, a parametric design platform method is proposed to achieve a platform-based development for ETO-based components by identifying, formalising, and reusing the design assets. The findings reveal how the transition of production strategies can be managed with supporting tools and methods. Moreover, this thesis emphasizes the importance of adopting the design for manufacturing and assembly (DfMA) in IHB. In addition, the research contributes to the existing knowledge on product platforms in IHB by providing the context of mixed production strategies and best practices to improve the IHB design process.

Abstract [sv]

Förmågan att erbjuda unika lösningar som möter kundernas krav har ansetts vara en konkurrensfördel inom industriellt husbyggande (IHB). Dock, utmaningen för IHB-företag handlar om att kunna balansera varierande kundbehov med behovet att uppfylla juridiska regler, marknadskrav och produktionsbegränsningar. Följden är att företag har tvingats att utveckla unika lösningar för varje nytt bostadsprojekt för att därigenom tillgodose individuella krav, vilket automatiskt driver dem till att följa en Engineer-toorder (ETO)-baserad strategi. Kundernas engagemang i projekteringsprocessen kräver ingenjörsmässiga aktiviteter för att bekräfta och anpassa sig till kraven och erbjuda kundunika lösningar. Dessutom,beroende på nivån av förprojektering antar projektörerna olika produktionsstrategier. Produktplattformar har accepterats som ett sätt för att förbättra både intern och extern effektivitet. Användningen av traditionella plattformsbaserade strategier räcker dock inte för framtagning av ETO-baserade komponenter i ett industriellt byggsystem. Det krävs ett systematiskt tillvägagångssätt för att anpassa produktplattformen och de olika produktionsstrategierna så att kundernas krav kan hanteras. Därför syftar denna avhandling till att bestämma de resurser som krävs för att stödja projekteringsfasen av IHB genom att tillämpa produktplattformar när en mixad produktionsstrategi tillämpas.

Ett svenskt industriellt husföretag med flervåningshus som använder ett limträbaserat pelar-balkbyggsystem har varit huvudfall. Empiriska data har samlats in från intervjuer, observationer, workshops och dokumentanalyser. Resultaten tar fram ett ramverk för systematisk utveckling och användning av produktplattformar genom att följa ett induktivt tillvägagångssätt. Vidare föreslås en parametrisk designplattformsmetod för att uppnå en plattformsbaserad utveckling för ETO-baserade komponenter genom att identifiera, formalisera och återanvända tillgångarna från projekteringen. Resultaten visar hur övergången av produktionsstrategier kan hanteras med stödjande verktyg och metoder. Dessutom betonar denna avhandling vikten av att anta design för tillverkning och montering (DfMA) inom IHB. Forskningen bidrar också till den befintliga kunskapsbasen om produktplattformar inom IHB i kontexten med blandade produktionsstrategier och best pratice för att förbättra projekteringsprocessen inom IHB.

Place, publisher, year, edition, pages
Jönköping: School of Engineering, Jönköping University, 2023. p. 75
Series
JTH Dissertation Series ; 074
Keywords
Industrialised house building, product platform, design platform, engineer-to-order, design for manufacturing and assembly, Industriellt husbyggande, produktplattform, designplattformar, engineer-to-order, design för tillverkning och montering
National Category
Building Technologies
Identifiers
urn:nbn:se:hj:diva-59820 (URN)978-91-87289-80-4 (ISBN)978-91-87289-81-1 (ISBN)
Public defence
2023-03-17, Gjuterisalen (E1405), School of Engineering, Jönköping, 10:00 (English)
Opponent
Supervisors
Available from: 2023-02-14 Created: 2023-02-14 Last updated: 2023-02-14Bibliographically approved

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Thajudeen, ShamnathElgh, FredrikLennartsson, Martin

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