SCHEDULING ON TRANSPORTATION FOR INDUSTRIALIZED BUILDING SYSTEMS

Transcription

1 SCHEDULING ON TRANSPORTATION FOR INDUSTRIALIZED BUILDING SYSTEMS FOONG KOK LI This project report is submitted as a fulfilment of the requirements for the award of the degree of Master of Science (Construction Management) Faculty of Civil Engineering Universiti Teknologi Malaysia APRIL 2006

2 PSZ 19:16 (Pind. 1/97) UNIVERSITI TEKNOLOGI MALAYSIA BORANG PENGESAHAN STATUS TESIS JUDUL : SCHEDULING ON TRANSPORTATION FOR INDUSTRIALIZED BUILDING SYSTEMS SESI PENGAJIAN : 2005 / 2006 Saya FOONG KOK LI (HURUF BESAR) mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah)* ini disimpan di Perpustakaan Universiti Teknologi Malaysia dengan syarat-syarat kegunaan seperti berikut: 1. Tesis adalah hakmilik Universiti Teknologi Malaysia. 2. Perpustakaan Universiti Teknologi Malaysia dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. ** Sila tanda ( ) SULIT TERHAD (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktud di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat yang TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) TIDAK TERHAD Disahkan oleh (TANDATANGAN PENULIS) (TANDATANGAN PENYELIA) Alamat Tetap: PROF. MADYA DR. ABDUL KADIR 88, JALAN KELAPA BALI, MARSONO TAMAN SOGA Nama Penyelia BATU PAHAT, JOHOR. Tarikh: 28 April 2006 Tarikh: 28 April 2006 CATATAN: * Potong yang tidak berkenaan. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD. Tesis dimaksudkan sebagai tesis bagi ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertai bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM).

3 Status Declaration Letter Date : April, 2006 Librarian Perpustakaan Sultanah Zanariah UTM, Skudai Johor Sir, CLASSIFICATION OF THESIS AS RESTRICTED SCHEDULING ON TRANSPORTATION FOR INDUSTRIALIZED BUILDING SYSTEMS FOONG KOK LI Please be informed that the above mentioned thesis entitled SCHEDULING ON TRANSPORTATION FOR INDUSTRIALIZED BUILDING SYSTEMS be classified as RESTRICTED for a period of three (3) years from the date of this letter. The reasons for this classification are (i) (ii) (iii) COMMERCIALIZATION OF RESEARCH PRODUCT NEGOTIATION STAGE WITH UTSB SDN. BHD AS BUSINESS CONSULTANT NICHE IBS PRODUCT COMPONENT ARE WAITING TO BE MANUFACTURED Thank you. Sincerely yours, ASSOC. PROF. DR. ABDUL KADIR MARSONO M

4 I/We* hereby declare that I/we* have read this project report and in my/our* opinion this project report is sufficient in terms of scope and quality for the award of the Master of Science (Construction Management) Signature Name of Supervisor I : : PM. DR. ABDUL KADIR MARSONO Date : 28 APRIL 2006 Signature :. Name of Supervisor II : DR. MASINE MD. TAP Date : 28 APRIL 2006 * Delete as necessary

5 ii I declare that this project report entitled Scheduling On Transportation for Industrialized Buildings Systems is the result of my own research except as cited in the references. The project report has not been accepted for any degree and is not currently submitted in candidature of any other degree. Signature : Name : FOONG KOK LI Date : 28 APRIL 2006

6 iii Dedication To my beloved father and mother

7 iv ACKNOWLEDGEMENT At first, I would like to express my sincere appreciation to my supervisor, Associate Professor Dr. Abdul Kadir Marsono for his guidance and encouragement. Without his guidance and support, this project would not have been completed. Other than that, I am also very grateful to my parents and friends for their support and encouragement throughout this project. I would to thank Mr Cheng from Country View Sdn Bhd for giving me the key plan and architectural drawings for the shop houses at Taman Universiti.

8 v ABSTRACT Now, the construction is facing the challenges from the four main aspects, which are quality, cost, time and safety. However, by implementing the industrialized building system (IBS), all those challenges can be faced easily. In this study, double storey shop houses will be used as a model to illustrate the management of IBS transportation for fabricators. Besides, the number of trucks required each day will be discussed here based on proper scheduling using project management software. Other than that, this study focuses on the scheduling by optimization. This project highlights a proper management of the trucks used in the delivery of IBS components for construction.

9 vi ABSTRAK Kini, industri pembinaan sedang menghadapi cabaran daripada empat aspek iaitu kualiti, kos, masa dan, keselamatan. Namun demikian, melalui pelaksanaan sistem bangunan secara berindustri (IBS), semua cabaran dapat dihadapi dengan mudahnya. Dalam kajian ini, rumah kedai dua tingkat akan digunakan sebagai model untuk mengilustrasi pengurusan bagi pengangkutan IBS untuk pembuat-pembuat IBS. Selain itu, bilangan trak yang diperlukan bagi setiap hari akan dibincangkan bergantung kepada penjadualan yang sistematik dengan penggunaan pengurusan projek perisian. Di samping itu, kajian ini menumpu kepada penjadualan dengan menggunakan kaedah optimum. Projek ini menitikberatkan pengurusan yang sistematik dalam penghantaran komponen IBS untuk pembinaan.

10 vii TABLE OF CONTENTS CHAPTER TITLE PAGE TITLE OF PROJECT DECLARATION DEDICATION ACKNOWLEDGEMENTS ABSTRACT ABSTRAK i ii iii iv v vi CHAPTER I INTRODUCTION Introduction Problem Statement Objectives Scope of Study Significant of the Study 4 CHAPTER II LITERATURE REVIEW Definition of Industrialization 6

11 viii 2.2 Characteristics of Industrialization 6 Process 2.3 Industrialized Building Systems Advantages of Industrialized 8 Building Systems Limitations of Industrialized 9 Building Systems Aspects Considered in the 11 Selection of an Industrialised System Precast Units Materials Management Just-in-time Management Principles of Just-in-time Management Philosophy JIT and Lean Production Production Management Classification of Inventories Cost of Keeping Inventory Prefabrication Planning Transportation of Precast Components Precast Concrete Handling Unloading at Site Production Planning and Control Process Planning Loading Scheduling Project Planning Methods 32

12 ix Planning in the Delivery and Erection Facility Management Queing Theory Optimization 40 CHAPTER III METHODOLOGY Introduction Selection on Type of Buildings Determination Location of Study Data Sources Determination Location and Number of 44 Shop Houses 3.6 Determination of Precast Components Scheduling Demands for Precast 44 Components 3.8 Transportation Scheduling Analysis Conclusion 45 CHAPTER IV RESULTS AND ANALYSES Introduction Problem Definition Benefits of Scheduling 48

13 x 4.4 Scheduling Software General Description Description of Site Description of Fabrication Plant Description of Shop Houses Scheduling Demand at Site Assumptions Detail Scheduling of Demands at Site Transportation Scheduling Assumptions Detail Scheduling of Transportation Analysis Case 1: 50 km Distance Time Estimation Rescheduling (50 km) Case 2: 100 km Distance Time Estimation Rescheduling (100 km) Analysis Cases of Transportation Break Down Analysis for Case 100 km Analysis for Case 50 km 114

14 xi CHAPTER V CONCLUSION AND SUGGESTION Introduction Discussion on the Study General Conclusion Suggestions for Future Study 121 REFERENCES 123 APPENDICES Appendix A 125 Appendix B 132 Appendix C 133 Appendix D 134 Appendix E 138 Appendix F 142

15 xii LIST OF TABLES TABLE NO. TITLE PAGE 2.1 Relative Advantage and Disadvantage of 10 Industrialization Under Various Conditions 4.1 No of Shop Houses for Each Site Number of Components for One Shop House Description of Symbol Used in the Scheduling Explanation of Symbols in An Example Assumptions for the Weight of Components Number of Components per Truck Time Estimation for 1 st Truck (50 km) Time Estimation for 2 nd Truck (50 km) Time Estimation for 3 rd Truck (50 km) Time Estimation for 4 th Truck (50 km) Time Estimation for 5 th Truck (50 km) Time Estimation for 1 st Truck (100 km) Time Estimation for 2 nd Truck (100 km) Time Estimation for 3 rd Truck (100 km) Time Estimation for 4 th Truck (100 km) Time Estimation for 5 th Truck (100 km) Time Estimation for 1 st & 2 nd Trucks (Case 1: km) 4.18 Time Estimation for 3 rd & 4 th Trucks (Case1: km) 4.19 Time Estimation for 1 st & 2 nd Trucks (Case 2: km) 4.20 Time Estimation for 1 st & 2 nd Trucks (Case 1:50 km) 114

16 xiii 4.21 Time Estimation for 3 rd & 4 th Trucks (Case 1:50 km) Time Estimation for 1 st & 2 nd Trucks (Case 2:50 km) Time Estimation for 1 st & 2 nd Trucks (Case 3:50 km) 117

17 xiv LIST OF FIGURES FIGURE NO TITLE PAGE 2.1 Flowchart for JIT Deliveries Without Buffer Stocks Modified JIT Deliveries With 2 Days Buffer: Production 21 to Installation 2.3 Critical Path Diagram. Numbers Correspond to Events, 33 and Letters Correspond to Activities and The Time Taken to Complete the Activity 2.4 Facility Management Overview Busy Periods, Idle Periods and Interarrival Times Decomposition of Busy Period Into Sub-busy Periods Evolution to high-order facility Research Methodology Example of Demands Scheduling Demands at Site 2 (Day 1) Demands at Site 2 (Day 14) Demands at Site 2 (Day 25) Demands at Site 2 (Day 27) Demands at Site 2 (Day 52) Demands at Site 2 (Day 69) Example 1 of Scheduling the Trucks Required Example 2 of Scheduling the Trucks Required Example 3 of Scheduling the Trucks Required Example 4 of Scheduling the Trucks Required Example 5 of Scheduling the Trucks Required Example 6 of Scheduling the Trucks Required a Example 1 of General Scheduling 74

18 xv 4.14b Example 1 of Rescheduling a Example 2 of General Scheduling b Example 2 of Rescheduling a Example 3 of General Scheduling b Example 3 of Rescheduling a Example 4 of General Scheduling b Example 4 of Rescheduling a Example 5 of General Scheduling b Example 5 of Rescheduling a Example 6 of General Scheduling b Example 6 of Rescheduling a Example 7 of General Scheduling b Example 7 of Rescheduling a Example 8 of General Scheduling b Example 8 of Rescheduling a Example 9 of General Scheduling b Example 9 of Rescheduling a Example 10 of General Scheduling b Example 10 of Rescheduling a Example 11 of General Scheduling b Example 11 of Rescheduling a Example 12 of General Scheduling b Example 12 of Rescheduling a Example 13 of General Scheduling b Example 13 of Rescheduling a Example 14 of General Scheduling b Example 14 of Rescheduling a Example 15 of General Scheduling b Example 15 of Rescheduling a Example 16 of General Scheduling b Example 16 of Rescheduling a c Example 16 of Rescheduling b a Example 17 of General Scheduling 102

19 xvi 4.30b Example 17 of Rescheduling a Example 18 of General Scheduling b Example 18 of Rescheduling a Example 19 of General Scheduling b Example 19 of Rescheduling a c Example 19 of Rescheduling b a Example 20 of General Scheduling b Example 20 of Rescheduling a Example 21 of General Scheduling b Example 21 of Rescheduling a Example 22 of General Scheduling b Example 22 of Rescheduling 110

20 xvii LIST OF SYMBOLS ג - Intensity coefficient ρ - Probability t - Time Y - Length of the full busy period G(y) - Busy period distribution G (s) - Moment generating function f(w) - Cost of building a road w - Width F(w) - Capacity D - Minimum capacity N - Minimum number of roads S1 - Site 1 S2 - Site 2 S3 - Site 3 S4 - Site 4 SB - Short beam LB - Long beam C - Column ( ) - Day

21 xviii LIST OF APPENDICES APPENDIX TITLE PAGE A Architectural drawings for double 125 storey shop houses B Key plan for Taman Universiti 132 C Drawing for double storey shop 133 houses using IBS. D General Scheduling 134 E Rescheduling for 50 km case 138 F Rescheduling for 100 km case 142

22 CHAPTER I INTRODUCTION 1.1 Introduction The construction industry plays a very vital role in the economic growth besides providing basic necessity for everyone. Besides, it also provides various types of job opportunities to the Malaysian. However, due to the advancement in the science and technology, the construction industry now is very competitive and also facing the challenges. Besides, according to the concrete association of India (1973), the use traditional building materials and construction practices has become rather costly due to one or more of the following reasons such as substantial increase in the cost of materials, uneconomical structural designs, slow and laborious process of construction, comparatively shorter life or higher cost of maintenance. In fact, the construction industry now is unlike the past twenty years ago. Now, the construction industry put more emphasis on the aspects of time, cost, quality and safety. It can be said that each construction process is related to the four aspects as stated earlier. Time is a significant aspect in the construction in which every project should be completed on time or earlier in order to prevent the undesirable losses of money. Therefore, the control of time in each construction process is very important. Other than that, each project now ought to be controlled within the estimated cost. The quality of the construction product is also a common issue that be disputed. In this case, quality control is a very important aspect in this industry. Besides, the construction industry also faces the challenge of safety. For instance, how to prevent accident and implementing safety regulations at site are the

23 2 issues that always been emphasis on. Those four aspects are the most challenges that construction industry has to face today. In order to achieve those aspects, the construction method used must progressing. The traditional method of construction that always been adopted in Malaysia is cast-in-situ method. Although this construction practice has been used for a long time, however, it is found that this method still has its own weakness. Hence, a systematic system, which is the industrialized building system (IBS), should be used in the construction industry in Malaysia in order to supplement the traditional method. IBS or precast concrete has been in the use since the latter part of the 19 th century (Joseph J. Waddell, 1974). However, it is seldom been utilized in Malaysia. According to Fazlur R. Khan (1976), the early use precast construction for structural members of multi-storey buildings was mostly dictated by the need for quality control of construction constraints due to extreme bad weather and unusual location of construction. Industrialization of building or system building is a term in the building industry which indicates the industrialized process by which components of a building are conceived, planned, fabricated, transported and erected on site (Syed Mansur Syed Junid, 1986). Generally, by using this system in the construction industry, a lot advantages can be gained compared to the conventional method. In this rapid development of science and technology era, the demand of houses also quite high and sometimes it cannot fulfil the demands. However, by using the IBS, this problem can directly be solved. It is because with the IBS system, it can help to reduce the time that normally required building a house. It means that the total construction time of a building will become shorter by implementing the IBS. Other than that, comprehensive prefabricated elements that are produced in the plant considerably reduce both the amount of work on site. Moreover, it also reduces the dependence on the weather and the skill of available labour. Therefore it is no doubt to implement industrialized building system in the construction industry

24 3 can make the construction faster, economy, and the product of the construction is more quality. Besides, prefabrication also offered a wealth of architectural shapes and finishes. In this paper, the industrialized building system and its transportation used in the shop houses will be discussed. 1.2 Problem Statement In these few years, the demand for houses and shop houses are quite high. By using the conventional method, the speed of the construction is quite slow. Nowadays, a lot of construction cannot be completed on time as required in the contract document. It can lead losses to the contractors due to the late finish of the construction. Other than that, by using the conventional method, the quality in the end of the construction is not so good. For instance, after removing of formworks, there are existence of honey comb in the beams and columns. Therefore, industrialized building systems have been introduced in order to solve those problems. However, by using industrialized building systems, there also some problems exist. For instance, the late delivery of the precast components to the site and as a result, the construction progress is affected. Besides, sometimes the precast components delivered to the site are not in the right quantity or not in the right types of precast components. The fabricator has to redeliver the components to the site. It is waste of time and also money. In addition, in some cases, the delivery of precast components to the site is too much early. The space at the site is so limited and therefore causing congestion of precast components at site. Moreover, there are high probability that the damages may occur on the precast components if there is no proper storage area for them. All

25 4 these problems occur are due to the improper management of fabricator who do not have a detail scheduling on it. 1.3 Objectives The objectives of this master project are: To optimize the number of trucks by scheduling it at specific distance and quantity. To find out the number of trucks that should be controlled in the condition of break down. To introduce a proper management of the delivery of IBS componenet for fabricator. 1.4 Scope of Study The scopes of this study are: Emphasis on the study in shop houses on prescribed IBS building components Sites at Taman Universiti, Skudai, Johor. Do the scheduling for site demands and rescheduling to optimise the delivery process. 1.5 Significant of the Study As the construction industry now is facing the challenges of four aspects; time, cost, quality and safety, it is crucial to have a systematic system or method to be used in this industry. In this study, an industrialised building system used in the shop houses will be introduced.

26 5 Other than that, this study will be a model for the fabricator of the precast components as a guidelines or ideas in order to know how to manage their trucks in the delivery to the site. Besides, this study will show the fabricator how to optimise their schedules in the delivery. The idea of this study of may help the fabricators to prevent unnecessary problems. In addition, the progress of construction at site will not be affected due to the late problem of delivery in terms of types and quantity. It is because proper scheduling will make the delivery smoothly. Moreover, it is also a way to accomplish the vision of 2020.

27 6 CHAPTER II LITERATURE REVIEW 2.1 Definition of Industrialization According to Abraham Warszawski (1999), an industrialization process is defined as an investment in equipment, facilities, and technology with the purpose of increasing output, saving manual labour and improving quality. 2.2 Characteristics of Industrialization Process There are six characteristics in order to a successful industrialization. There are standardization, specialization, centralization of production, mass production, good organization and integration. For standardization, if the output is standardized, production resources can be used in the most efficient manner. Besides, the production process, workers training and machinery can be adapted to the particular characteristics of the product in the best condition. For specialization, due to the large volume and standardization, it allows a high degree of labour specialization within the production system. Moreover, the process can be broken down into a large number of small homogeneous tasks. Hence, the workers able to work at the high productivity level attained with the specialization.

28 7 As for the centralization of production, it means that from the central location, the product is shipped to the various consumer areas. It is only feasible to utilize the expensive equipment and facilities if the production is at a single location. In this case, the process will use the economics of scale with respect to the management, capital management and also the auxiliary services. Other than that, a successful industrialization process should have a good organization. A capable and sophisticated organization is needed in the planning, coordination and control functions with respect to the production and distribution of the products. Centralization of production, specialization of work teams and high volume really need a good organization. In the aspect of mass production, it is only can justify the investment in equipment and facilities associated with an industrialization process economically if only the large production volume considered. It is because such big volume allows a distribution of the fixed investment charge over a large number of units. Besides, it will also not to inflate the ultimate cost. One of the important aspects that must be taken account into is integration. In a good industrialization process, a very high degree of coordination must exist between design, production and marketing of the product. Therefore, within an integrated system, a good coordination between those processes can be obtained as it is under unified authority. 2.3 Industrialized Building Systems A building system can be defined as a set of interrelated elements that act together to enable the designated performance of a building (Abraham Warszawski, 1999). In an industrialized building system, all the buildings elements are prefabricated offsite, which is in a central facility. Then, the components of the buildings are sent to the site from the prefabrication yard.

29 8 Other than that, by using the industrialized building systems, the erection works at site can be reduced to the minimum. The jointing and finishing work on site can also be minimising. Besides, the design, production and on site of the buildings components such as beam, column, wall and so on are strongly interrelated. In this case, those components must be planned and coordinated accordingly as they are viewed as parts of an integrated process Advantages of Industrialized Building Systems There are many advantages of implementing industrialized building systems. One of the advantages is making the construction process faster. It means that the projects can be completed much earlier than before, which used the conventional method. Faster completion of works can bring a lot of benefits especially in the housing projects. The houses can be built within a short time and handover to the owners. It is quite crucial when the population increase and demands of houses are quite high. The construction time that be reduced due to that system has an economic value both to the owner and the contractor. In addition, there is a big saving in the aspect of labours. According to Abraham Warszawski (1999), the labour savings in prefabricated elements may amount to about 80% of their conventional requirement, or to about 40%-60% of the total labour on site. It is due to the savings of the labours in the masonry, plastering, painting, carpentry, formwork, tiling and pipe laying (electrical and water supply) at site. Therefore, it faster for the turnover of working capital and also save in the lifecycle costs of the finished buildings. In fact, the economic value of labour saving due to the prefabrication depends on the total labour saved in this manner and the prevailing cost of the labour. Besides, it is also depends on the wage difference between work done on site and in the plant. The work in plant is usually given lower wages as it is usually done in the better conditions compared to the works done on site.

30 9 Compared to the conventional method, which is cast-in-situ, the quality of the building components prefabricated in the plant is much better. It may due to the strict and well organised quality control at the prefabrication yard. Moreover, it is much easier to control the quality at the prefabrication yard than casting at site. The using of advanced technology of production tools also allow the producing of high quality products in the batching and casting process. It means that every component is designed in the view of the particular technology and know how employed by the plant. In addition, in the large volume of production, it enables more careful choice of materials and materials suppliers if compared to single construction site. The prefabricated components of building usually have the longer economic service life. A higher quality of the components will serve longer before having to be replaced. Other than that, good quality ensures that less defects such as spots, cracks or blemishes. There is also lower input of finish works such as screed, plaster, sand mortar and stucco due to the tighter tolerances in the execution of wall surfaces and the top and bottom surfaces of floor slabs. Furthermore, it also helps to reduce the maintenance expenses. It is because prefabricated components require less repair and preventive maintenance Limitations of Industrialized Building Systems Although there are a lot of advantages of industrialized building systems, however there are limitations for this system to be used too, for instance, most of the modules or subjects that be conducted in the universities do not emphasis on the design of prefabricated building systems, the potential and the problems associated with the industrialization in building. As a result, the builders and the designers more tendency to use the conventional method which is familiar to them. In fact, the industrialized systems are quite rigid with respect to changes that might be required in the building over its economic life. It is true when the small span room size prefabrication is employed. Besides, in the developed countries, as

31 10 the demand for large public housing projects decrease due to the volatility of the building market, it is quite risky to use the industrialised building systems if compared to the conventional labour intensive method. Moreover, there is abundant supply of cheap labourers in the most developed country. It makes the limitations use if industrialised building systems. Other than that, the weakness of the industrialised building systems is still in their cumbersome connection and jointing methods. These methods are very sensitive to the errors and sloppy work. Moreover, for the place where industrialization is widely used, it will produce more monotonous barrack-like complexes that very often turned into dilapidated slums within several years due to the excessive tendency toward repetitiveness and standardization in public projects. Another limitation of the prefabricated systems with respect to the conventional method is the higher sensitivity of their cost to the various factors. These factors include distance between the fabrication plant and the construction site, volume of demand, which is not under the control of the fabricator. The transportation cost of prefabricated elements form plant to their construction site, amounts to 3%-5% of their total cost for distances not exceeding 50km-100km Abraham Warszawski (1999). Hence, prefabrication is at disadvantage when asked to compete for work at locations far from the fabrication yard. Table 2.1 shows the relative advantages and disadvantages of industrialization under various conditions. Table 2.1: Relative advantages and disadvantage of industrialization under various conditions. Conditions General market conditions Industrialized Methods Advantage to Conventional Method High volume and stability of demand for buildings High construction wages Lack of skilled workers Centralized planning of building supply