The mission
A leading second-level building supplier has developed an innovative modular construction process, leveraging never-before-seen offsite pre-manufacturing. This process offers significant advantages, including reduced lead times, improved safety, and efficient waste management. To maximize its potential, the company needs to:
- Demonstrate and improve the profitability of the new modular industrial process
- Define applicability of the new process (what projects should be addressed with the modular process vs usual method)
- Structure the ramp-up of the process and ensure its correct implementation for the upcoming projects
The challenges
- Very low level of process maturity, highly relying on the knowledge of few experts
- High impact on work habits and a strong need for change management activities
- Need to define a relevant “averaged” cost baseline to demonstrate process profitability, as each project has very specific cost breakdown
- Very limited return of experience of the modular process, with few datapoints collected from a restricted number of past & ongoing projects
The approach
We implemented a comprehensive strategy to unlock the full potential of the innovative modular process:
- Identification of single replicable modules
- Complete cost-breakdown assesment of the new modular method for comparison versus usual method, including non-recurring costs
- Implementation of the economic comparison within a parametric model, and implementation of the parametric model to an upcoming project
- Anticipation of manufacturing issues towards process optimization
- Assessment of all non-economic benefits for customer communication
The impacts
- Set-up of a parametric model allowing quick assessments of economic relevance of the modular process
- Structuration of the modular process implementation roadmap aiming for 20% costs savings
- Definition of the new process to follow while applying this new modular method to a project
