DMOC – Distributed Manufacturing for Offsite Construction
Cloud-based task allocation so networks of manufacturers can become distributed assembly lines.
Summary
The move towards modern methods of construction is helping to deliver greater efficiency, reduced waste and better performing assets. Smaller manufacturers, however, faces challenges. Major investment in programming expertise or new machinery is often required, and many developers are investing in their own manufacturing capabilities. At the heart of the Distributed Manufacturing for Offsite Construction solution (DMOC) is a cloud-based orchestrator that allows offsite manufacturing to be coordinated across multiple sites; distributing workloads, reassigning tasks and ensuring continuity. This allows a network of smaller manufacturers to work together as a distributed assembly line, with tasks being allocated based on criteria such as capacity, capability, materials and location.
Innovation type: Digital, Offsite
Organisation type: Innovative SME
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Project pioneers
aLL Design is an internationally renowned collective of young and established architects and designers, founded by Marcos Rosello and the late Professor Will Alsop OBE RA. Its work focuses on innovation, driven by curiosity across a broad range of specialisms. Conversations with automation software specialists HAL Robotics and business technology provider Konica Minolta sparked aLL Design's interest in what cloud-based distribution and orchestration could mean for construction.
The problem
The traditional construction manufacturing supply chain is made up of a diverse range of smaller manufacturers. The move towards modern methods of construction (MMC), with an assembly line approach guided by digital design, is helping to deliver greater efficiency, reduced waste and better performing assets.
In 2018 research conducted by the National House Building Council found that 69% of developers were already using MMC (such as volumetric construction and panelised systems) and 92% had plans to expand the use of MMC over the next few years. However, nearly 30% of developers were investing in their own manufacturing facilities and over 25% in their own systems. This risks many smaller manufacturers being pushed out of supply chains.
Even where smaller suppliers are providing parts to MMC assembly lines, both the Royal Institution of Chartered Surveyors and the NHBC identified a lack of capacity in the supply chain as a key barrier to housebuilders using MMC.
Vision
At the heart of the Distributed Manufacturing for Offsite Construction solution (DMOC) is a cloud-based orchestrator that allows offsite manufacturing to be coordinated across multiple sites; distributing workloads, reassigning tasks and ensuring continuity.
This enables a network of smaller manufacturers to work together as a distributed assembly line. Work packages can be allocated or reallocated based on criteria such as capacity, capability, materials and location; providing a more robust supply chain.
The data for each task is converted directly to machine toolpaths, removing the need for suppliers to have manual programming expertise. Lowering this barrier, while providing access to a digital tendering framework, helps to incentivise automation in the supply chain.
The coordination provided by DMOC allows supply chains to provide the just-in-time delivery of components, reducing onsite storage requirements and incorporating last-minute changes to minimise rework.
Key Insight
In 2019, aLL Design was sharing office space with automation software company HAL Robotics. HAL Robotics was working with business technology provider, Konica Minolta, who was looking at cloud-based distribution and orchestration for other manufacturing sectors. This sparked aLL Design's interest in what this technology could mean for construction, especially with the industry's adoption of Building Information Modelling.
First step
aLL Design proposed collaborating with Hal Robotics and Konica Minolta on a system to extract information from BIM and automatically dispatch production tasks to distributed facilities based on capacity, capabilities and location. With We Design For adding their building engineering expertise the Distributed Manufacturing for Offsite Construction (DMOC) project was born.
Barrier
The high entry costs to modern methods of construction for smaller manufacturers and the lack of supply chain agility based on capacity, capabilities or proximity.
Process innovation
By creating an automated tendering framework based on criteria such as capability and capacity, DMOC helps save time and money in both design and manufacturing.
Knowing that there is access to a potential client base through this platform, will incentivise smaller manufacturers to invest in new technologies or propose novel approaches that will give them a competitive advantage.
The coordination provided by DMOC also allows supply chains to provide the just-in-time delivery of components, reducing onsite storage requirements and incorporating last-minute changes to minimise rework.
Digital Innovation
At the heart of the Distributed Manufacturing for Offsite Construction solution (DMOC) is a cloud-based orchestrator that allows offsite manufacturing to be coordinated across multiple sites; distributing workloads, reassigning tasks and ensuring continuity.
It also enables work packages to be allocated based on criteria such as capacity, capability, materials, location, standards and certificates; providing a more robust supply chain. If production faults or facility issues occur, tasks can be reallocated, ensuring continuity and increasing efficiency.
DMOC compliments existing Design for Manufacture and Assembly (DfMA) approaches by embedding process data in digitally designed components and assemblies. This data is converted directly to machine toolpaths that automatically program robots on the production line. This removes the need for manual programming and enables automation for small batch production typical of a construction supply chain.
Every DMOC facility contains an Edge computing device, ensuring production data is processed more efficiently at the point where it is created. This data is communicated back to the central orchestrator and robotic hardware controllers. Each production cell simulates tasks to ensure they are executed safely and to program the required mechanical configuration for the specific job.
Collaborators
HAL Robotics - automation software specialists Konica Minolta - cloud-based distribution and orchestration expertise We Design For - building engineering knowledge
- HAL Robotics
- Konica Minolta
- We Design For
Lead support
While Transforming Construction Challenge funding will enable a virtual demonstration of Distributed Manufacturing for Offsite Construction; there is a potential opportunity to produce a physical demonstration, manufacturing cladding across distributed sites, with the Manufacturing Technology Centre (MTC). The MTC is part of the Construction Innovation Hub (CIH), funded under the Transforming Construction Challenge.
Long Term Vision
At the heart of the Distributed Manufacturing for Offsite Construction solution (DMOC) is a cloud-based orchestrator that allows offsite manufacturing to be coordinated across multiple sites; distributing workloads, reassigning tasks and ensuring continuity.
This allows a network of smaller manufacturers to work together as a distributed assembly line; providing the just-in-time delivery of components, reducing onsite storage requirements and incorporating last-minute changes to minimise rework.
Human Stories
In 2019, aLL Design was sharing office space with automation software company HAL Robotics. HAL was working with business technology provider, Konica Minolta, who was looking at cloud-based distribution and orchestration for other manufacturing sectors.
It was a conversation with HAL Robotics that sparked aLL Design's interest in what cloud-orchestration could mean for construction, especially with the industry's adoption of Building Information Modelling.
Powerful Processes
At the heart of the Distributed Manufacturing for Offsite Construction solution (DMOC) is a cloud-based orchestrator that allows offsite manufacturing to be coordinated across multiple sites; distributing workloads, reassigning tasks and ensuring continuity.
It also enables work packages to be allocated based on criteria such as capacity, capability, materials, location, standards and certificates; providing a more robust supply chain. If production faults or facility issues occur, tasks can be reallocated, ensuring continuity and increasing efficiency.
DMOC compliments existing Design for Manufacture and Assembly (DfMA) approaches by embedding process data in digitally designed components and assemblies. This data is converted directly to machine toolpaths that automatically program robots on the production line. This removes the need for manual programming and enables automation for small batch production typical of a construction supply chain.
Every DMOC facility contains an Edge computing device, ensuring production data is processed more efficiently at the point where it is created. This data is communicated back to the central orchestrator and robotic hardware controllers. Each production cell simulates tasks to ensure they are executed safely and to program the required mechanical configuration for the specific job.
Fascinating Facts
In 2018 research conducted by the National House Building Council found that 69% of developers were already using modern methods of construction (MMC) and 92% had plans to expand the use of MMC over the next few years. However, nearly 30% of developers were investing in their own manufacturing facilities and over 25% in their own systems. This risked many smaller manufacturers being pushed out of the industry.
Even where smaller suppliers are providing parts to MMC assembly lines, both the Royal Institution of Chartered Surveyors and the NHBC identified a lack of capacity in the supply chain as a key barrier to housebuilders using MMC.
Benefits
Cost
The DMOC orchestrator, alongside automated manufacturing, will help to create more accurate timelines. This should enable cost-savings from the just-in-time delivery of components, shorter construction programmes, and reduced time on site.
By using existing manufacturing capability, without the need for manual programming expertise, DMOC can reduce the CapEx required for many manufacturers to start using more automation.
Emissions
DMOC can be calibrated to assign a greater weighting to local manufacturers in order to reduce emissions from the transport of components or companies who meet certain sustainability criteria such as ISO 14001.
Time
DMOC uses a hybrid-cloud orchestrator to communicate with connected production cells and efficiently distribute workloads. By constantly monitoring available manufacturing resources DMOC can maximise the productivity of the networked offsite facilities. The platform can also orchestrate and monitor multiple work packages from one project, coordinating them to arrive onsite at the time they are needed, reducing construction programmes, time spent onsite, and onsite storage. The ability to reallocate tasks within the network also mitigates any delays that could be caused by one individual facility being unable to deliver on time.