An Owner's Perspective on Lean Construction IPD and BIM

SAN DIEGO COMMUNITY COLLEGE DISTRICT

An Owner’s Perspective on Lean Construction, IPD, and BIM

Presented to ASCE San Diego Section Younger Member Forum January 15, 2013| San Diego, CA

Lean Construction

A World View – Ueber Lean!

http://www.youtube.com/watch?v=rwvmru5JmXk

San Diego Community College District (SDCCD)

Overview  The Second Largest Community College District in California

 Sixth Largest in Nation  Three Colleges - City, Mesa and Miramar  Six Continuing Education Campuses  District Square Footage - 2,218,031

City College

Mesa College

Miramar College

Continuing Education

San Diego Community College District

Why Go Lean? 

Reduced operating budgets of $46 million in past four years (-16%)



Increased build environment footprint of 1.3 million square feet (+65%)



Capital funding from locally approved and funded general obligation bonds



Reduce waste, create greater value

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San Diego Community College District

About the District (Current State) Current Square Footage (As of September 2012)

Buildings = 2,560,187 gross square feet Parking = 377,712 gross square feet

Current Acres of Landscape = 199.2 Current Utilities Consumption Electric = $4,119,936 Gas = $334,632 Water = $790,322 Total = $5,244,890

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San Diego Community College District

About the District (Future State) Projected Square Footage Additional Building GSF = 720,608 Total Building GSF = 3,280,795 Additional Parking GSF = 279,265 Total Parking GSF = 1,372,622

Grand Total GSF = 5,653,290

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San Diego Community College District

Construction Productivity in the U.S. Figure 1: Construction (1964 – 2003)

and Non-farm Labor Productivity Index

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San Diego Community College District

Construction Waste in the U.S. Current Manufacturing Support Activity 12%

Waste 26%

Value Added 62%

Current Construction Support Activity 33%

Waste 57%

Value Added 10% Source: Construction Industry Institute

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San Diego Community College District

Total Cost of Ownership  50-year design life

 100,000 square foot classroom building  Design and construction cost - $30 million

 Capital Renewal: 2% of current replacement value (APPA benchmark)  O&M Budget $5.69/square foot  Inflation: 3%

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San Diego Community College District

Total Cost of Ownership Total Cost of Ownership Save 5% in Cap. Renewal

Savings

11% D&C: Cap. R.: O&M: Total:

36% 53%

$30M Total $101M $ 5M $149M $15M $280M $20M

NPV $1.1M $3.4M $4.4M

Save 10% in O&M

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San Diego Community College District

Target Costing

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San Diego Community College District

Practicing the Toyota Way Business Principles

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San Diego Community College District

The Toyota Way Business Tools • The Machine that Changed the World – James Womack • The Toyota Way – Jeffrey Liker

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San Diego Community College District

Early (and continued) Attitudes Toward Lean We’ve tried that.

We already do that.

We don’t need it.

It won’t work here.

We don’t build cars.

We’re different.

The other guy needs it, not me.

We’re doing well, so why change?

Credit: Lean Construction Institute

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San Diego Community College District

“Rainbow” Report

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San Diego Community College District

Schedule Performance Traditional Design-Bid-Build Change Order Rate

Project Delay

Average = 10.8%

Average = 43.5 Days

CM Multi-Prime Change Order Rate

Project Delay

Average = 7.1%

Average = 19.5 Days

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San Diego Community College District

Integrated Project Delivery (IPD)

http://www.aia.org/ipdg 17

San Diego Community College District

IPD – What Is It?  Project delivery approach that integrates people, systems, business structures, and practices to optimize project results, increase value to the owner, reduce waste and maximize efficiency of project delivery.  Distinguished by highly effective collaboration among the owner, prime designer and prime constructor commencing at early design through project completion.

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San Diego Community College District

IPD – Why Do It? An integrated design process allows decisions to be made early when the opportunity for change is maximized and the cost of changes are minimized.

MacLeamy Curve 19

San Diego Community College District

Integrated Project Delivery Charter

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San Diego Community College District

Schedule Performance

Is Critical Path Scheduling Obsolete?

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San Diego Community College District

Pull vs. Push

http://www.youtube.com/watch?v=frhk6gkSCbs

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San Diego Community College District

Pull Planning

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San Diego Community College District

Pull Planning –Miron Construction

http://vimeo.com/13195662

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San Diego Community College District

Pull Planning

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San Diego Community College District

Target Costing – Project Budget Development  Space Programming  Efficiency  Targeted Cost Per Sq. Ft.

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San Diego Community College District

BIM Standards

http://public.sdccdprops-n.com/Design/SDCCD%20%20Building%20Design%20Standards/SDCCD%20BIM%20Standards%20Version%202.pdf 27

San Diego Community College District

BIM Clash Detection Building Construction Mechanical piping hits cable tray and fire protection piping in ceiling space

 Survey Average Results Man-hour Savings = 61 Delay Savings = 3 Days Cost Savings = $30,349.00

 Number of Clashes Shown in Example = 9  Savings per Clash Resolved = $3,372.00 28

San Diego Community College District

Change Order Metrics – BIM vs. No BIM Change Orders Errors & Omissions BIM: 1.1% No BIM 3.3%

Total 4.1% 8.6%

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San Diego Community College District

Schedule Impacts – BIM vs. No BIM Average Days of Delay BIM: 24.5 No BIM: 79.6 BIM - Math & Social Science Bldg.

Original Schedule – 1217 days Actual Schedule 1037 days

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San Diego Community College District BIM Integration: Mesa College Social & Behavioral Sciences Building

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San Diego Community College District MacLeamy – Buildings Are Assembled Not Built

http://www.youtube.com/watch?v=UnXG2q8tbyY

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San Diego Community College District

Off-site Fabrication Trends

Exterior skin – Mesa College Math & Science Building

Columns and Double Ts – City College Arts & Humanities Building 33

San Diego Community College District

Off-site Pre-Fabrication Trends Mechanical systems off-site racking – Mesa College Math & Science Building

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San Diego Community College District

Off-site Pre-Fabrication Trends

Pre-fabrication warehouse – University Mechanical & Engineering 35

San Diego Community College District (SDCCD)

A3 Problem Solving – Risk/Benefit Analysis

San Diego Community College District (SDCCD)

A3 Problem Solving – HVAC Design

San Diego Community College District

A3 Reporting System Design – Structural

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San Diego Community College District

Value Stream Mapping – Change Order Process START Resolution to CM

1 Working Day

15 Working Days

CM Creates RFP; Issues to Contractor

Contractor Issues Price, CM Reviews Price, Issues COR

Determine entitlement Before proceeding From this point

Old Change Order Process

Price Fair and Reasonable?

5 Working Days

5 Working Days

Contractor Signs

A/E Signs

YES

15 Working Days

END

1 Working Day Negotiate

Distribution

NO

0 Working Day

District Admin.

Receives and Processes

CM Creates Change Order 1 Working Day

Total Process Duration: 67 Working Days With Negotiation

CM Signs

IOR Signs

CPM Signs

Richard B Signs

Dave U Signs

5 Working Days

5 Working Days

5 Working Days

5 Working Days

5 Working Days

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San Diego Community College District

Value Stream Mapping – Change Order Process 1 Working Day

START Resolution to CM

CM Requests Pricing from Contractor via Fax/Email

5 Working Days Contractor Issues Price, CM Reviews & Prepares Change Order

7 Working Days

Negotiate

Determine entitlement Before proceeding From this point

New Change Order Process Effective January 2011

Price Fair and Reasonable?

7 Working Days

Total Process Duration: 28 Working Days With Negotiation

NO

YES

CPM Signs

A/E, IOR, Contractor, CM Sign Separate CO Cover Sheet

Richard B Dave U Sign

District Admin.

Receives and Processes

7 Working Days

1 Working Day

END Distribution 1 Working Day

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San Diego Community College District

Safety – Root Cause Analysis of Repeated Incidents City College Campus Safety Report – February 2012 Overall Safety Comments

Overall Safety Issues

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San Diego Community College District (SDCCD)

Safety – Root Cause Analysis of Repeated Incidents Central Plant

Math & Social Science

Business & Humanities

Science

San Diego Community College District

Safety – Root Cause Analysis of Repeated Incidents • Required fall protection refresher training • Enhanced training for spotters • Enhanced focus on safety culture

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San Diego Community College District

Genchi Genbutsu

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San Diego Community College District

Hourensou

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San Diego Community College District

Questions?

David Umstot, PE Vice Chancellor, Facilities Management San Diego Community College District dumstot@sdccd.edu

(619) 388-6546