Reducing Waste in Sainsbury s Supermarket Refits through off site fabrication

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1 WAS031 Off site Construction Case Study Reducing Waste in Sainsbury s Supermarket Refits through off site fabrication Sainsbury s have made effective use of the Fit Out UK / RG s off site fabrication and consolidation centre leading to a reduction of up to 40% in the amount of waste produced while fitting out superstores. Project code: WAS031 ISBN: Research date: October 2007 Date: May 2008

2 WRAP works in partnership to encourage and enable businesses and consumers to be more efficient in their use of materials and recycle more things more often. This helps to minimise landfill, reduce carbon emissions and improve our environment. Written by: Halina Mason of Mace, with the support of Mark Tipton (Mace) Chris Gaze (BRE), Andrew Morrissey (Fit Out UK) and Tuval Rockman (Sainsbury s) Front cover photography: Photo1 Final backwall product assembled and installed in Sainsbury s Supermarket. WRAP and (Consultants Name) believe the content of this report to be correct as at the date of writing. However, factors such as prices, levels of recycled content and regulatory requirements are subject to change and users of the report should check with their suppliers to confirm the current situation. In addition, care should be taken in using any of the cost information provided as it is based upon numerous project-specific assumptions (such as scale, location, tender context, etc.). The report does not claim to be exhaustive, nor does it claim to cover all relevant products and specifications available on the market. While steps have been taken to ensure accuracy, WRAP cannot accept responsibility or be held liable to any person for any loss or damage arising out of or in connection with this information being inaccurate, incomplete or misleading. It is the responsibility of the potential user of a material or product to consult with the supplier or manufacturer and ascertain whether a particular product will satisfy their specific requirements. The listing or featuring of a particular product or company does not constitute an endorsement by WRAP and WRAP cannot guarantee the performance of individual products or materials. This material is copyrighted. It may be reproduced free of charge subject to the material being accurate and not used in misleading context. The source of the material must be identified and the copyright status acknowledged. This material must not be used to endorse or used to suggest WRAP s endorsement of a commercial product or service. For more detail, please refer to WRAP s Terms & Conditions on its web site:

3 Executive summary Supermarket group Sainsbury's has an ongoing programme of store fit out and refitting. An integral part of these refits is the use of mounted images and graphics on areas know as backwalls. Sainsbury s has identified the refurbishment of backwalls in retail departments as a critical element in the successful delivery of store refurbishment and extension projects. Sainsbury s, together with RG Group and Fit Out (UK) Ltd have identified a number of initiatives to maximise the off site consolidation and fabrication of backwall elements. Consolidation of key materials and off site fabrication of the backwall components has had a direct effect in reducing construction waste by up to 40%, as well as reducing construction cost, the duration of departmental closures and disruption to the trading store. The consolidation process maximises the efficiency of distribution vehicles and leads to a substantial reduction in overall vehicle numbers delivering into restricted and congested environments, such as supermarket car parks. By fabricating the partition panels in the workshop, the number of on site activities and programme timescales are further reduced. Wastage is also reduced through savings of 16.25% on average, realised in materials due to improved design, material procurement, storage and manufacturing. In addition, the minimal amount of waste which is not reused on site is sent to a nearby waste processing facility along with 100% of packaging for separation and recycling. Reducing Waste in Sainsbury s Supermarket Refits through off site fabrication 1

4 Contents 1.0 The use of off site Backwall fabrication in store fit out programme Background to the project - Backwall consolidation and off site fabrication Backwall off site fabrication lower cost with continuous improvement The Factory and Construction Process The off site fabrication manufacturing process Key features of the off site fabrication facility Waste Comparisons with Traditional Build Material saving and waste generation data The reasons for reduced waste generation Supply chain benefits from the associated consolidation centre The environmental benefits of using the consolidation centre to support off site construction Sainsbury s, RG Group and Fit Out (UK) further innovation in off site fabrication Backwall Off site Fabrication Further Opportunities...11 Conclusion Conclusion..12 Reducing Waste in Sainsbury s Supermarket Refits through off site fabrication 2

5 1.0 The use of off site Backwall fabrication in store fit out programme 1.1 Background to the project - Backwall consolidation and off site fabrication Supermarket group Sainsbury's has an ongoing programme of store fit out and refitting. This work is important to maintain a high quality shopping environment for customers and to ensure that the quality produce for sale in store is displayed to its best advantage. The use of wall mounted images and graphics is an integral part of this approach to marketing. Sainsbury s has identified the refurbishment of these areas (known as backwalls) in several retail departments as a critical element in the successful delivery of store refurbishment and extension projects. Backwall systems (for the display and sale of Meat, Fish, Delicatessen and Bakery products etc) are core to the customer offer and tend to be re-branded and refurbished in all store development projects. The off site fabrication of the backwall panels use a range of materials including timber, MDF, ceramic tiles as well as materials such as plastic poly wrap and cardboard for packaging. Historically, a large number of on site trades and equipment suppliers (some 40+) have been involved in refurbishing these backwall departments. The large supply chain, combined with the location of the departments within the store and the confined spaces involved were identified as a critical path to the successful delivery of a project. This risk has historically been managed by the main contractors and store delivery team, requiring a disproportionate amount of management time and associated cost. Driven by Sainsbury s Green Agenda, the RG Group, Fit Out (UK) Ltd and Sainsbury s have collaborated on a number of initiatives to maximise the off site fabrication of these backwall elements. By adopting a method of consolidation and off site fabrication of the backwall components the time, cost and waste associated with the refurbishment of these areas can be drastically reduced. The main drivers for adopting this type of process is the direct effect it has in reducing construction waste, construction cost, the duration of departmental closures and disruption to the trading store. The product is developed in bulk at an off site factory in a controlled environment and delivered as modules to the supermarket where installation is simple and efficient. 1.2 Backwall off site fabrication lower cost with continuous improvement Sainsbury s, the RG Group and Fit Out (UK) Ltd originally collaborated to develop a process for modularising brand wall panels (the panels that display graphics of the goods as large colour displays in customer facing areas). Based on the success of the process and realisation of cost and waste efficiencies which could be transferred to a similar product further opportunities have been identified for off site fabrication, particularly with regards the use of backwalls, the customer facing panels in Meat, Fish, Delicatessen and Bakery areas (Photo 1 on title page ) in Sainsbury s departments. RG and Fit Out (UK) Ltd have developed pre-finished modular partition panels which are fabricated off site. These modular partition panels are delivered to site in pre-finished form, together with the required containment in place for electrical cabling and pipe work. By assembling and pre-finishing the partition panels in the workshop, the number of on site activities and programme timescales are significantly reduced. This reduced on site construction, together with the corresponding reduction in dust and noise, is a significant benefit to trading stores, particularly in view of the location of these departments. Following a competitive tender in late 2006, Fit Out (UK) was appointed by Sainsbury s as preferred supplier for the supply and installation of a sales area perimeter wall boarding (i.e. a perimeter boarding and brandwall package). Fit Out (UK) was able to offer a significant cost saving (22%) compared to previous suppliers by adopting off site fabrication solutions. This was achieved using a process that not only reduced cost, but also reduced material wastage through design and manufacturing achieving savings on the amount of waste produced by up 40% (see section 3). The system developed by Fit Out (UK) involves the use of V jointed modular panels with prefixed split battens. This off site process reduced on site installation times involving premium rate night working, together with a reduction in cutting, dust, noise and general disruption to the store. Reducing Waste in Sainsbury s Supermarket Refits through off site fabrication 3

6 2.0 The Factory and Construction Process Panels can be made up as perimeter boarding and brand walls or backwalls. Brand walls are composed mainly of oak and are generally used behind checkouts. This make up allows the panels to be customer facing and facilitates the display of special offers and advertising. Backwall panels are generally composed of tiles and oak and are used in deli, meat and fish areas. 2.1 The off site fabrication manufacturing process The off site fabrication of the backwall system is described below through a series of pictures which demonstrate the simple, streamlined process from component delivery, tracking and storage at the factory site, processing and assembly, and finally transportation of the product and installation on site. Stage 1 Components are delivered to the consolidation centre and booked in to the computer system. Stage 2 Component deliveries are allocated to a specific location in the warehouse. Stage 3 Bulk dry Component storage at consolidation centre. Stage 4 Components are formed at the factory using state of the art technology for accurate machining. Stage 5 Tiles added to frames in a bulk panel manufacturing process. Stage 6 Finished modular panels ready for assembly. Reducing Waste in Sainsbury s Supermarket Refits through off site fabrication 4

7 Stage 7 Finished products are transported as modules to the site. Stage 8 Site delivery of modules Stage 9 Completed modules are installed at the site. Stage 10 Ready for business The installation of the end product as shown above is the final action in the fabrication of a composite panel made up of a number of different materials: Timber (oak), tiles (ceramic), trim strips (aluminium), and the necessary adhesive and grout for a clean finish. Details can be seen in the figure below (figure 2). The end product is designed for straight-forward and swift fitting and is modular to permit any necessary site alterations that may be required. Figure 2. The technical specification for the modular backwall panels used in store fit out. 2.2 Key features of the off site fabrication facility The facility has some key features that allow the off site fabrication process to be environmentally sound as well as effective. The facility is: Reducing Waste in Sainsbury s Supermarket Refits through off site fabrication 5

8 spacious and secure with a 60,000 square ft warehouse with 350 tonne storage capacity; modern and monitored has an effective track and trace computer system for material location; efficient and accessible employees have access to all required material, tools and machinery in one location reducing time between destinations and minimising potential for damage or inaccuracy; water considerate employs a 15,000 litre rain harvester which feeds jet washers, showers and toilets; energy considerate employs a wood burner heats 80% of warehouse (recovering site waste wood); and materials considerate Recycling 100% of packaging used. The minimal amount of waste which is not reused on site is sent to a nearby waste processing facility operated by Powerday for separation and recycling. The Powerday facility and the consolidation centre are located in the same factory, thereby ensuring that energy and transportation, as well as CO 2 emissions are minimised. 3.0 Waste Comparisons with Traditional Build Waste reduction is a key benefit of backwall off site fabrication. Data collected by Fit Out UK has shown that there are number of significant benefits overall 1. These include: 40% saving in MDF material use due to design (off-cuts are reusable as components); 5% saving on materials (overall) due to reduced on site damage by assembling components in a controlled factory environment (dry factory storage); 5% saving in wood during manufacturing due to pre-programme panel cuts (accurate controlled cutting); and 15% saving on oak veneer and tiling materials due to processes (afforded by off site fabrication). Material savings are also made in the perimeter boarding and brand walls. Details are shown in the tables 1 and 2 (sec 3.1). This is an average saving of 16.25% overall. In addition to this, 100% of the packaging (the packaging used to supply both components for the off site fabrication and the protection used on the finished product when transported to site for installation) is returned to the consolidation centre for reuse. This compares very favourably with the large amount of packaging waste generated when traditional in-situ (on site) construction occurs and all packaging material is sent to landfill via on site skips 2. Site operations for baling pre-assembly and post delivery packaging and other off cut material for recycling as well as the on site wood burner, which reuses off cut oak and recovered sawdust are shown below. Recycling 100% of all packaging is recycled Recovery Fit Out s waste-wood power plant 1 Fit Out UK figures October Fit Out UK information October 2007 Reducing Waste in Sainsbury s Supermarket Refits through off site fabrication 6

9 3.1 Material saving and waste generation data In the off site fabrication of both the backwall and associated brandwall panels, there are savings in materials due to improved design, material procurement, storage and manufacturing. The following tables (tables 1 and 2) show data collected for the two part system of backwall panel off site fabrication and the perimeter boarding and brand wall. The tables show the percentage of material saved compared with traditional in situ (on site) construction. Table 1. Part one of the prefabricated unit - Backwall Partitions. A Summary of Saved Material and Waste Generated Compared to Traditional In Situ Construction Activities Waste Waste Disposal (%) Generated Type % Reuse Recycle Landfill Saved Material (%) Design Modular panel design / standard detailing Optimum panel sizing / minimising off cuts Off site Manufacture / CAD Workshop Drawings Mdf % - 40% Procurement Bulk purchase of materials Materials delivered to dry 'factory' storage All 0% % Manufacturing CNC pre programmed panel Cutting List Composite panels manufactured & assembled c/w 1st Fix M&E containment Composite panels prefinished off site, c/w oak veneer & ceramic tiling Split batten pre fixed to simplify site install Wood burning off cuts to heat Factory Shipping Prefinished composite partition panels shipped to site, minimal packaging required Packaging collected & returned for re-use Single delivery, fixing team c/w panels Install Single trade required for on site installation No on site cutting or waste generation Timber 0% % All % Mdf % Plastic - 0% 100% 0% 100% CO Vehicle Movements -50% Reducing Waste in Sainsbury s Supermarket Refits through off site fabrication 7

10 Table 2. Part two of the prefabricated unit - Perimeter Boarding & Brand Wall. A summary of Saved Material and Waste Generated Compared to Traditional In Situ Construction Activities Waste Waste Disposal (%) Generated Type % Reuse Recycle Landfill Saved Material (%) Design Modular panel design / standard detailing Optimum panel sizing / minimising off cuts Off site Manufacture / CAD Workshop Drawings Mdf % - 40% Procurement Bulk purchase of materials Materials delivered to dry 'factory' storage Mdf 0% - - 0% 5% Manufacturing CNC pre programmed cutting patterns Precision off cuts re-used for split battens etc Split batten pre fixed to simplify site install Wood burning off cuts to heat Factory Shipping Prefinished panels delivered to site, minimal packaging required Packaging collected & returned for re-use Single delivery, fixing team c/w panels Install Single trade required for on site installation No on site cutting or waste generation Mdf 0% % Mdf - 100% Mdf % - - Plastic - 0% 100% 0% 100% Vehicle Movements -50% 3.2 The reasons for reduced waste generation The reasons for material savings are manifest from the tables above. Through intelligent design, where off-cut material can be reused within the product manufacturing process, MDF is saved and thereby waste generation is reduced. This is achieved through optimum sizing and accurate manufacturing systems. With the off site fabrication of several panel systems at one time, the reuse of materials (for example adhesive) is possible when manufacturing the oak veneer and tiled elements of the backwall panels. Reducing Waste in Sainsbury s Supermarket Refits through off site fabrication 8

11 With the secure, dry and organised storage of materials in a temperature controlled warehouse, materials quality is not compromised and waste is reduced. Timber off-cuts can be recovered (if not reusable) when off site fabrication occurs, with all suitable material being processed on site to temperature control the factory environment. Other benefits are also achieved due to the consolidation centre and this is detailed in the next section 3.3 Supply chain benefits from the associated consolidation centre Fit Out (UK) Ltd is currently operating a 60,000 square ft Consolidation Centre on behalf of RG Group and Sainsbury s. RG Group and Fit Out (UK) Ltd have applied the Consolidation logistics model to the Sainsbury s store development programme and have expanded the concept to include the supply of all retail fixtures and fittings, termed as turnkey equipment. Photo 2. The consolidation centre, showing the office frontage. The manufacturing facility is behind the office. Consolidation Centres have proven to be an effective supply chain management solution in delivering construction materials, plant and equipment to multiple construction sites. The centres facilitate the efficient flow of goods from supply chain source to on site installation, goods are delivered in bulk to the centre and are then consolidated, which means multiple part loads (e.g. blocks, tiles, cable tray etc) are combined into a single daily delivery to site. Reducing Waste in Sainsbury s Supermarket Refits through off site fabrication 9

12 The consolidation centre approach is represented in the chart shown below. This shows the traditional approach to Backwall production above, with the alternative approach using the consolidation centre shown below. Figure 1a. The traditional approach to store fit out (10+ deliveries per department). Bakery Meat & Fish FoodToGo Delicatessen Figure 1b. The consolidation centre approach to store fit out. Bakery Recycling Centre Equipment Consolidation Centre Recovered Waste Equipment Waste Meat & Fish Food To Go Delicatessen The consolidation process maximises the efficiency of distribution vehicles and leads to a substantial reduction in overall vehicle numbers delivering into restricted and congested environments, such as supermarket car parks. The facility is located well for store fit out in the South East. It is close to North Circular Road in London as well as the main roads the A40/M40 and the London Orbital, the M25. Fit Out (UK) Ltd have allocated circa 15,000 square ft within the Consolidation Centre for the storage and consolidation of Backwall department equipment. 3.4 The environmental benefits of using the consolidation centre to support off site construction. In addition to the waste generation reduction shown in this case study, Fit Out (UK) Ltd and Sainsbury s have engaged an expert consultancy 3 to calculate the carbon emission reduction in consolidating turnkey equipment, such as the backwall panel for use in stores. Some of the information they have gathered is shown below. The calculation, based on a sample of 5 suppliers, delivering via the Consolidation Centre rather than individually to 20 individual projects, achieved a carbon saving of 143 tonnes (or 169,445 km travelled). The estimated carbon saving for 5 suppliers delivering to 20 stores equates to the energy required to heat, power and light 26 houses. The above carbon saving could be multiplied 50 fold if all suppliers and all Sainsbury s projects were to use the Consolidation Centre for equipment deliveries. In conclusion, the initial evidence suggests that the combination of off site fabrication and consolidation can have a significant impact on the carbon, waste and overall environmental impact of superstore fixtures and fittings manufacture and installation. 3 dcarbon8 a consultancy who specialise in carbon mapping, Reducing Waste in Sainsbury s Supermarket Refits through off site fabrication 10

13 4.0 Sainsbury s, RG Group and Fit Out (UK) further innovation in off site fabrication 4.1 Backwall Off site Fabrication Further Opportunities While the number of on site tasks and disruption to the store has significantly reduced, there is still a large supply chain, a ll of whom who are key to the successful handover and operation of each Backwall department. Fit Out (UK) and RG Group are currently trialling a one stop shop on a number of Sainsbury s projects, whereby Fit Out (UK) are responsible for co-ordinating and delivering all Backwall tables, together with all the equipment required to operate the Backwall departments. By consolidating the delivery of all the departmental equipment, and maximising off site manufacturing opportunities, RG Group aim to significantly reduce the risk and also the time required to refurbish Backwall departments. 5.0 Conclusion By maximising the opportunities offered by the off site consolidation and off site fabrication of backwall elements Sainsbu ry s, together with RG Group and Fit Out (UK) Ltd have achieved reductions in construction waste, construction cost, the duration of departmental closures and disruption to the trading store. The successful a combination of the consolidation process, which has led to a substantial reduction in overall vehicle numbers delivering into supermarket car parks, and the off site fabrication of partition panels, leading to a reduction of the number of on site activities and programme timescales have resulted in measurable benefits. Wastage is also reduced through savings realised in materials due to improved design (40%), material procurement (5%), storage and manufacturing (5-15%). Reducing Waste in Sainsbury s Supermarket Refits through off site fabrication 11

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