Lean Construction Ireland Annual Book of Cases 2021 66 Case 18 DPS Group is a global consulting,engineering, and construction management company serving high-tech industries around the world. DPS has sector experts in key locations in Europe, the US, Asia, and the Middle East, bringing world-class resources and the latest innovative technologies to every project.Our sector expertise spans many markets, including Biotechnology, Pharmaceutical, Medical Technologies,Oil and Gas,AdvancedTechnology, Food & Beverage, Energy, Science & Education. DPS delivers full-service Engineering with a Client-first mentality and personal touch across a range of disciplines: Project and Programme Management, Procurement, Design, Construction Management, Health & Safety Management, Commissioning,Qualification, and Start-up.DPS employ more than 1,800 people worldwide. This case study examines how process and value stream mapping can be utilised to optimise the hand-offs and quality checks required for an Off-Site Manufacturing (OSM) workflow. DPS Applied Technology Group (ATG) was engaged to design and develop the required structure to manage the OSM of a portion of a large client program.While the client wished to move to an OSM process, the changes required and the implications of the transition were not fully understood.DPSATG worked closely with the client to determine the steps involved and the changes required to the client’s existing systems and structures to implement the OSM process. Whilst OSM is a move towards the implementation of a manufacturing-based system to improve construction productivity, the change in project infrastructures required to enable OSM can also be optimised by the implementation of Lean principles. DPS utilised a number of key Lean techniques to enable the development of an OSM structure for a large client.This case study outlines the main principles considered in developing the program and the Lean thinking and techniques utilised for its optimisation. Development of an OSM Framework In the initial stages of developing an OSM framework, a number of considerations must be taken into account when setting up anOSM process for construction projects, including: • Identification of OSM opportunities. • Ability for trades to meet the OSM requirements. • The establishment of a new framework for the project. • Establishment of new standard operating procedures (SOPs). It was determined that the DMAIC process could be utilised as the best methodology for the development of the OSM framework. Define While OSM can be applied in many stages across a project, one of the first determinations needs to be the establishment of what sections of the projects can be moved off-site, how much of the project can realistically be manufactured in a OSM environment, and what are the most value-adding OSM activities for the client. It was decided to complete an OSM reviewwith the client, coupled with a brainstorming session to determine the most value-add opportunities. A number of standard industry-recognised OSM definitions were drawn up, and the following categories were identified: • Pre-Assembled Unit (PAU) – Unit fully designed and delivered to site for hook up. • Supplier Package Unit (SPU) –An SPU designed and supplied by a supplier and delivered pre-assembled to the maximum extent possible.This often includes on-board automation allowing off-site FAT. • Supplier Assembled Unit (SAU) –An SAU is a unit in which a supplier’s normal scope of work is extended. • Pre-Assembled Rack (PAR) – A PAR would be designed by the design contractor and comprise a pipe rack complete with piping, valves, cable trays, access walkways, tracing, insulation, and painting where applicable. • Pre-Assembled Structure (PAS) – A complex structural assembly with a high weight-to-volume ratio and a large number of connections is designed, and it can often be more economically fabricated away from the project site. • Rooms Module Unit (RMU) – An RMU is where rooms or suites of rooms are modularised as Pods.Typically, they should include all Mechanical & Electrical and Life Safety Systems that can be tied in at the site. Company Overview DPS ATG dpsgroupglobal.com Overview & Background to the Lean Initiative Lean Initiative Undertaken – Lean Thinking, Tools, Techniques Richard Casey Author
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