Master Thesis Project 2019 Wei Hoow Ong weihoow9@gmail.com Primary Advisor: Professor Eric Helter Secondary Advisor: Professor Ralf Niebergall Dessau International Architecture Graduate School Hochschule Anhalt
FLEXIBILITY FOR THE FUTURE
INTEGRATING AUTOMOTIVE PROCESSES INTO THE BUILT ENVIRONMENT TO ACHIEVE ZERO-WASTE ARCHITECTURE
CONTENTS INTRODUCTION An Honoured Collaboration Lean Philosophy
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LEANSTYLE ARCHITECTURE Our Philosophy Our Approach
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FLEXIBILITY Accommodating the Future Case Studies Four Flexible Elements
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SUSTAINABILITY Standards & Certification Material Selection Green Design Features
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WASTE ELIMINATION Designing Out Waste Takt Planning Lean Team Tools
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INTELLIGENCE Autonomous Construction Autonomous Fabrication
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ADJUST & ADAPT Making the Unmovable Move Flexible Down to the Smallest Detail
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FORM FOLLOWS PROCESS Bauhaus 2.0 Design Grid Standardised Elements
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DESIGN PROPOSAL Spatial Modules Site Master Plan Elevations & Sections Design Features Perspectives
74 94 96 116 124 128
CONCLUSION Let’s Be Lean From Today
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BIBLIOGRAPHY
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INTRODUCTION AN HONOURED COLLABORATION
WHO ARE WE WORKING WITH? Founded in 1916, The Bayerische Motoren Werke Group (BMW) originally developed and manufactured luxury automobiles and motorcycles. BMW also manufactured aircraft engines until 1945. Today the BMW Group lead the luxury automotive industry by pioneering innovative technologies and strategies. To keep ahead of their competitors, BMW Group strives to continually evolve, and on their centenary anniversary they branded their vision for “THE NEXT 100 YEARS”. Their new vision is to not only accelerate their production of innovative and luxury products, but also to eliminate wastes and inefficiencies from their company. To achieve their new goals, BMW group has incorporated a ‘Lean Philosophy’ into their manufacturing and management processes and intends to extend this application into the built environment with their offices, warehouses and workshops. In co-operation with our studio, BMW Group wishes to develop a prototype building which takes the ‘Lean Philosophy’ into consideration.
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WHO ARE WE? Located right next to the world-famous Bauhaus Dessau, the Dessau International Architecture Graduate School (DIA) of Hochschule Anhalt is inspired by the vivid history of the town and driven by innovation to provide current solutions to the architectural problems of today. Our school focuses on the analysis of current questions related to culture and social sciences as well as to the humanities and the environment. We also work to have the latest insights into research and development, new procedures, technologies and materials. On the centenary anniversary of Bauhaus Dessau we will work together with one of the most successful and well known automotive manufacturers in the world to develop prototype buildings considering the ‘Lean Philosophy’. These buildings will have to meet the requirements of BMW Group and be flexible down to the smallest detail. It is our intent to express the ‘Lean Philosophy’ in a new design language and strike a different path that will revolutionise our current way of designing and constructing buildings.
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INTRODUCTION LEAN PHILOSOPHY
WHERE DID LEAN COME FROM? The ‘Lean Philosophy’ was born as a result of Japanese automotive manufacturers competing with their larger and wealthier American counterparts. It all began when Eiji Toyoda and Taiichi Ohno, one of the founders of Toyota and his production specialists visited Henry Ford’s River Rouge Complex in Michigan, America. Both were in awe of the facility’s massive scale and the rate of production it was capable of. With less space and resources back in their homeland of Japan, Toyoda and Ohno developed a new production system called the Toyota Production System (TPS) that expelled the inefficiencies and waste found in the Ford Production System. The TPS was created to be as efficient as possible, and from it the ‘Lean Philosophy’ was derived. This philosophy is now embraced worldwide by manufacturing, production, software companies and even start-up businesses to run as efficiently as possible.
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The 5 Principles of Lean Philosophy vi
James P. Womack and Daniel T. Jones, Lean Thinking
5 PRINCIPLES OF LEAN PHILOSOPHY James P. Womack and Daniel T. Jones founded the Lean Enterprise Institute (LEI) in 1997 and this institute is regarded as the premiere source for Lean wisdom. According to Womack and Jones, there are 5 main principles to the ‘Lean Philosophy’: Value - To identify exactly what the customer puts value on, whether it is products, processes or services. No point providing something that will not be bought or used. Value Stream - To outline all the steps and actions needed to bring value to the customer. All steps that do not create value should be eliminated. Flow - To operate the remaining valuable steps as efficiently and smoothly as possible with no interruptions or mistakes. Pull - To save on inventory by delivering value to the customer exactly when they need it, or ‘just-in-time’. Perfection - To always improve and implement positive change, the market is never static and so businesses should always seek to improve and adapt to these changes. vii
The 7 Wastes viii
Taichi Ohno, Toyota Production System
THE 7 WASTES Eliminating waste is at the heart of the Lean Philosophy. Anything that doesn’t add value should be removed. No one wants to pay more for less. Doing so will increase profits and customer satisfaction, a win-win situation. Here is a list of wastes that can be eliminated: Transport - The process of moving resources increases cost without adding value, as little money should be spent on transport as possible. Inventory - Storing resources costs rent and effort instead of being sold for profit. Resources and items should spend as little time as possible in storage. Motion - Unnecessary motions like navigating poor circulation paths or picking up heavy items can cause stress, interruptions and cost money. Waiting - Not having anything to do disrupts flow and productivity. Over-production - Excess product results in high inventory and means there was wasted money, effort and motion in this overproduction. Over-Processing - Using unsuitable techniques or inappropriate equipment costs time and money. Defects - Every faulty product requires money, time, resources and effort to fix. xi
DMAIC Strategy x
 DMAIC Control Stage, InvisibileConsultant.co.uk
LEAN STRATEGIES Problem solving strategies are quintessential to any process that seeks constant improvement. Regarded as the best improvement cycle for businesses, DMAIC solves problems by identifying the root of issues rather than treating symptoms. The DMAIC strategy is as follows: Define - the customer and their critical requirements. What are the vital business processes that are required to bring the customer what they want? Measure - the current level of performance that is generated from current processes. Analyse - your current processes and identify the source of wasteful and inefficient steps. Improve - by brainstorming for solutions and implement the one that best solves the source of the problem. Then measure for improvement in performance. Control - and maintain improved processes to prevent reverting.
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LEANSTYLE ARCHITECTURE
INTEGRATING LEAN PHILOSOPHY INTO THE ARCHITECTURAL PROCESS
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LEANSTYLE ARCHITECTURE OUR PHILOSOPHY
WHAT IS LEANSTYLE ARCHITECTURE? Since the Lean Philosophy is most effective when implemented throughout an entire process rather than just a few steps, our approach to Leanstyle Architecture is to rethink and apply Lean strategies to every stage of a buildings life. These stages include: Identify - the client’s requirements and program. To find what the client finds valuable so we can produce valuable products, processes and services. Plan - and design spaces, structures and processes that bring value to the client. Anything that doesn’t add value should be excluded. Implement - efficient construction processes and sustainable features and materials. Anything that adds value to the project should be considered. Execute - the planned processes and strategies to be completed ‘just-intime’. Review - how the process performed and identify points of improvement for the future. This also includes maintenance and building operations.
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The 5 Principles of Leanstyle Architecture 3
LEANSTYLE ARCHITECTURE OUR APPROACH
WHAT ARE THE WASTES IN ARCHITECTURE? The Architectural process is littered with wasteful methods and processes. Wastes are introduced even from the first stage of identifying a clients needs. It is all too common for clients and/or investors to request changes to a project design even when the project is almost complete. The time, effort and materials required to make theses changes are wasteful. In the next stage of the process, improper planning of spaces may require fixing later, wasting time, effort, money and materials. Improper planning of construction can cause delays, wasting time, money and efforts. Even more wastes are created by the implementation of sub-optimal construction methods and materials. Mistakes in the execution of construction generates wastes that can snowball if not rectified early. Lastly, inadequate reviewing processes allow for wastes to continue without solutions being developed to continually improve the process.
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The Wastes in Architecture 5
HOW DO WE ELIMINATE THESE WASTES? To find a solution, we must target the problem at its roots. Much of the wastes generated in the Architectural Process can be linked back to the identification stage. Changes to a project mid-construction result in a lot of time, effort, money and materials being wasted. To resolve this issue, we propose the use of flexible structures that can accommodate all valuable requirements, eliminating the need to reconstruct a static structure. Thus providing the main structure of our proposal. Other secondary waste eliminating solutions we propose include: • • •
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the planning of spaces to suit the daily process that a user of the building will go through, removing all unnecessary spaces and encouraging flow. the implementation of lean construction processes and prefabricated structures, greatly reducing the time required for construction and material waste. the use of intelligent systems and artificial intelligence to aid humans in the reviewing stage, removing the chance of human error and accelerating the rate of improvement.
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FLEXIBILITY
RESEARCH INTO LEANSTYLE ARCHITECTURE
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FLEXIBILITY
ACCOMMODATING THE FUTURE
HOW IS FLEXIBILITY LEAN? Traditional construction methods produce static buildings with structural systems that are fixed in place. These buildings struggle to adapt to changes in requirements, especially when these changes involve expansion. Lets take an office project for example. In the design and planning phase, the client may say they require a conference room of approximately xxm2 to cater for xx people. However, this decision only takes into account the current requirements of the company and not taking into consideration that the company will expand and may need a larger conference room in the future. A static buildings would require extension construction which may take a few months. A flexible building on the other hand could change its shape in a matter of a few minutes. This is only one of the many benefits that flexible structures can offer. Precedent studies into recent flexible structures reveals many other benefits which are aligned to the Lean Philosophy and our vision.
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FLEXIBILITY CASE STUDIES
DEE & CHARLES WYLY THEATRE BY REX & OMA Fixed stage configurations limit traditional theaters in the different types of performances they could host. In static theaters, creative directors would often request troublesome alterations to the stage to suit their artistic vision or forgo the venue altogether. These alterations take time and therefore reduce the number of days a theatre could host performances and generate revenue. The materials from the previous construction would also be wasted due to a lack of storage. Joshua Prince-Ramus from REX and Rem Koolhaas of OMA sought to eliminate these wastes with a reconfigurable stage and seating system that could adapt to any performance type. They adopted a modular system of elevating floors plates that work together to define and separate performance from audience spaces and can reconfigure to any stage type required, Shakespearean theatre on a thrust stage one day and Beckett on a flat stage the next day. This flexible system increases the up time of the theatre and caters to more performances and clients, increasing revenue and eliminating wastes.
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Stage is ready for use in a Thrust Configuration.
The seats are stowed away to make space for working.
The floor plates change elevation to adapt to the new requirements.
After reconfiguring, the stage is now ready for use as an exhibition space 13
SUBSTRATE FACTORY AYASE BY AKI HAMADA Faced with the issue of limited space and constantly changing requirements, Hamada planned to design a multipurpose space that could adapt to the active users. The use of lightweight sliding walls allows for a variety of functions to occur in one space, eliminating the need for additional construction or alterations.
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Walls are stowed for an open plan working space.
Some sliding walls are used to define spaces without separation.
More partitions can be used to isolate areas, affording more privacy.
Sliding walls can be stowed again to cater for another configuration. 15
MONK RESTAURANT BY SELIN MANER The floor area requirements of a building can change with season. During warmer months, the Monk Restaurant maximises its outdoor space by retracting its glass greenhouse. Whereas during the cooler months, the glass structure extends to create additional indoor seating, allowing more patrons to dine sheltered from the cold weather.
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TENFOLD TECHNOLOGY BY TENFOLD ENGINEERING When buildings reach the end of their lifetime, they are often demolished and the remains end up in land-fills as they cannot be recycled. Tenfold Engineering has developed mobile, modular , self-deploying structure that can also be repacked into its original container form. This means that when these buildings are no longer required by someone, it can be sold and transported to another location and nothing is wasted or demolished.
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Trailer delivers a container to designated location.
Container begins to expand and unfold.
Interior spaces are created when the structure unfolds.
When fully unfolded, container becomes inhabitable building.
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FLEXIBILITY
FOUR FLEXIBLE ELEMENTS
HOW WILL WE USE FLEXIBILITY? Flexible buildings have proven time and time again that they can adapt to changing requirements and accommodate the future, eliminating wastes from the first stage of the architectural process. Elevating floors offer the possibility to define and change spaces within a building without the use of solid walls just by raising and lowering certain areas. Open, larger spaces that do not benefit from split leveling can be separated with lightweight sliding walls that afford users flexible privacy. Telescopic structures and folding technologies can be used to provide flexibility for spaces that have constantly changing floor area requirements. Our proposal for Leanstyle Architecture will combine elevating floors, sliding walls, telescopic structures and folding technologies into a building system that can adapt to BMW’s current and future requirements for their offices, workshops and warehouses. We will also incorporate other strategies that produce flow in the planning, construction, operation and maintenance of the buildings and maximise the value for both BMW and us.
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Sliding Walls
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Elevating Floors
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Telescopic Structures
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Folding Technologies
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SUSTAINABILITY
RESEARCH INTO LEANSTYLE ARCHITECTURE
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SUSTAINABILITY STANDARDS & CERTIFICATION
Since one of the most fundamental aspects of the Lean Philosophy is waste elimination, we looked to the leading sustainable strategies and programs. These standards help buildings to reduce their negative impact on the environment by reducing wastes and we looked to learn and implement them into our design proposal for Leanstyle Architecture. L.E.E.D. - LEADERSHIP IN ENERGY & ENVIRONMENTAL DESIGN A voluntary rating system to certify sustainable buildings and neighbourhoods. W.E.L.L. - WELL BUILDING STANDARDS A premier standard for buildings, interior spaces and communities seeking to implement, validate and measure features that support and advance human health and wellness. C2C - CRADLE TO CRADLE A biometric approach to create buildings that return nutrients to the environment as a flow of life cycle by maximising the usage of renewable resources and minimising the usage of non-renewable resources.
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SUSTAINABILITY MATERIAL SELECTION
BMW has an established brand identity, and we wish to reflect that in our proposal. We don’t want to design a building that is drastically different from the current aesthetic of BMW buildings as we want their customers to feel familiar when visiting this building. We have chosen a balance between smart and recyclable materials to use in our proposal to meet sustainability requirements and still maintain the visual identity of BMW buildings. RECYCLABLE MATERIALS
Timber
Steel
Aluminium
The use of timber for furniture and interior finishes is one of the more sustainable material choices. As cheap as concrete is, we want to create a concrete free building as concrete is extremely hard to recycle. BMW can use different timbers depending on which is the most available timber in the region they are building in. We also want to use steel as a structural material and aluminium as part of our cladding as both metals are recyclable and will maintain the visual identity of BMW in our design. 28
SMART MATERIALS The features of certain futuristic smart materials can also produce sustainable outcomes. Glass that can change its opacity with a small electrical current removes the need for blinds, the electricity can be generated by the photo-voltaic windows on the facade. Recycled plastics can also be used to print floor, wall and facade elements, taking harmful waste from the environment.
Switchable Glass
Photo-voltaic Windows
3D Printed Bio-plastics 29
SUSTAINABILITY GREEN DESIGN FEATURES
Incorporating as many sustainable and green design features will help our proposal to meet sustainability goals and standards. Our proposal will implement: DAYLIGHT HARVESTING - Using strategic openings to minimise the amount of electrical energy used on artificial lighting NATURAL VENTILATION - Arranging our buildings in a way that maximises the cooling effect of prevailing winds. SOLAR POWER - Using solar panels to turn solar energy into electrical energy. RAINWATER HARVESTING - Storing rainwater to use instead of using water from dams. PORTABLE VEGETATION - Moving shade to where it is needed the most. OCCUPANCY SENSORS - Removing energy waste from servicing unoccupied rooms. WATER EFFICIENT FACILITIES - Reducing the amount of fresh water used. 30
Green Design Features 31
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WASTE ELIMINATION
RESEARCH INTO LEANSTYLE ARCHITECTURE
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WASTE ELIMINATION DESIGNING OUT WASTE
We earlier mentioned that conventional construction methods result in static structures that cannot be deconstructed or reconfigured. These buildings usually end up being demolished and the waste material ends up in landfill. Statistics show that for every 1m2 of construction, 775kg of demolition waste ends up in landfills. This results in 40% of a nations annual waste coming from just construction and demolition. W.R.A.P. - WASTE AND RESOURCES ACTION PROGRAM The W.R.A.P organisation in the United Kingdom identifies there are 9 main sources of waste in the construction industry: Incorrect Acquisition - of materials and services. Material Theft - from vulnerable construction sites that lack security. Poor Quality Control - leads to a build up of mistakes. Weather Damage - to completed work due to lack of protection. Inadequate Storage - for materials which can be stolen or damaged. Unnecessary Conflict - between unsyncronised team members. Improper Work - requiring rework and amendments. Inexperience - leads to mistakes and disruption to flow.
WRAP - Circular Economy & Resource Efficiency Experts
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The 9 Wastes in Construction 36
W.R.A.P. Strategy 37
PREFABRICATED, STANDARDISED & MODULAR CONSTRUCTION The previously mentioned wastes identified by W.R.A.P. can be eliminated by implementing prefabricated, standardised and modular construction into our proposal. Prefabrication removes the risk of materials being stolen or damaged on site as building elements are normally made in a secure factory with security and protection from the elements. Materials that are left over can also be easily recycled or reused in another project, reducing material waste. Standardised design is easy to repeat and therefore it is easier to maintain a high quality of workmanship and workers can quickly gain experience doing the same thing. The incorrect acquisition of materials will be a rare occurrence as quantities will be already specified and just have to be ordered without additional calculations or considerations.
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Prefabrication vs. Custom Construction Timeline 39
In our proposal, we define our prefabrication as the preparation of building elements off site to be transported and assembled on site. These elements will be used to construct standardised modules which will be the same at the beginning, but are flexible and can reconfigure and adapt to many scenarios after construction. WHAT IS A MODULE? The modules in our proposal are pre-designed units that have the flexibility and ability to construct more complex systems. Each individual module is: • • • • • • •
structurally independent self-contained self-sustained movable on the x-y plane stackable on the z axis able to adapt to any global site attachable & detachable to other modules
The modules we pre-design will be used together on a site given to us by BMW and provide them with the office, warehouse and workshop spaces that they require.
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Prefabricated Module Process 41
WASTE ELIMINATION TAKT PLANNING
EFFICIENT CONSTRUCTION PROCESS Our implementation of prefabricated building elements allows for quick assembly of buildings on site. Using takt scheduling, we can shorten the amount of time required to assemble a building even more. Takt scheduling requires the area of construction to be divided into zones. Each trade is given a fixed and appropriate amount of time to complete their task in each zone. For example, lets give workers 3 hours to complete their jobs in each zone. In the first takt block (three hours), workers will install slabs on the ground in Zone 1. Once this is over, these workers will move to Zone 2 and repeat their task, whilst the workers responsible for installing columns will start work in Zone 1 where the slabs were just installed. This method of construction creates flow in the process of work and can be organised in a way where different trades will not be working over the path of another, reducing the chances of conflicts occurring. With such an organised schedule, the process relies on everyone participating to be contributing to its success.
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Z1
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Z6
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Dlouhy, J., Binninger, M., Oprach, S. and Haghsheno, S.,“Three-level Method of Takt Planning” 43
WASTE ELIMINATION LEAN TEAM TOOLS
KAIZEN To make sure flow is achieved in the construction process, everyone must be on the same page and be syncronised in the pursuit of success and improvement. If one link in the chain is weak, then the chain is only as strong as its weakest link. Kaizen is the Japanese word for improvement and is also the process used by many businesses to encourage their employees to refine their work. The process begins with the problem solver identifying the problems they have and then analyse the process to see what is causing the problem. The development and implementation of a solution follows, which then has to be studied to see if the solution is actually working. If it works, the solution should be standardised and used by everyone in the company. If the solution doesn’t work, then the problem solving process begins again and a new solution will be developed
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Kaizen Problem Solving Process Luis, Jorge G.A., Midiala O. Vento, Aide A.M. Macias, “Kaizen Planning�
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INTELLIGENCE
RESEARCH INTO LEANSTYLE ARCHITECTURE
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INTELLIGENCE AUTONOMOUS CONSTRUCTION
SITE PREPARATION Automated equipment can help reduce two of the wastes in construction. Excessive motion and defects can be eliminated when implementing automated machinery into site preparation. Contrary to common belief, humans will not be replaced, rather their jobs will be done by machines and the humans can work in much safer environments, managing and maintaining these automated equipment.
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INTELLIGENCE AUTONOMOUS FABRICATION
PREFABRICATED CONSTRUCTION With Industry 4.0 revolutionising the way we manufacture, we can implement autonomous factories to manufacture the building elements required for our proposal. This will eliminate work place injuries for workers and also greatly reduce the number of defects caused by human error, which wastes resources.
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ADJUST & ADAPT
OUR APPROACH TO LEANSTYLE ARCHITECTURE
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ADJUST & ADAPT MAKING THE UNMOVABLE MOVE
MAKING FIXED ELEMENTS FLEXIBLE Building core elements like lifts, stairs and toilets are traditionally thought of as unmovable. We need to make these elements mobile in order to achieve full flexibility in our proposal and eliminate waste. Usually cast in concrete, lift shafts and stair wells can now be constructed in a modular way which allows them to be flat packed and assembled on site with nothing more than screws and a screwdriver. It is important that the majority, if not all building elements can be prefabricated and transported in shipping containers, to site in order to save time and eliminate wastes. Toilets that rely on fixed plumbing can also be made to be mobile by using self-composting toilet units that not only stop human waste entering the environment but also converts it into something useful that contributes back to the earth. Now that we know it is possible to make static core elements flexible, making the smaller details of our building like furniture and storage will become the focus of our work.
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Lean Lift
Lean Staircase
Exhaust Mixer Motor Waste Compartment Compost Drawer Evaporator
Lean Toilet 53
ADJUST & ADAPT
FLEXIBLE DOWN TO THE SMALLEST DETAIL
MAKING FURNITURE FLEXIBLE After applying Lean Philosophy to the larger aspects of our building, we sought to further this application into furniture design to make the user experience within the building more flexible. Integrated floor storage and furniture that can hide away are just some solutions that make a space more flexible.
Lean Storage
Lean Furniture 54
Lean Auditorium Seating 55
Lean Switchable Wall 1 56
MAXIMISING THE FUNCTION OF WALLS Having a wall that can change materials through sliding or rotating mechanisms allow spaces to gain more value. Acoustic panels can turn an office into a private meeting room. Wall that can be drawn on in meeting rooms can be exposed when needed and hidden when a cleaner appearance is required.
Lean Switchable Walls 2 57
Lean Door 1 58
REDUCING THE TRANSMISSION OF GERMS Door handles are one of the largest culprits when it comes to spreading germs in the office, especially in high traffic areas like toilets and entrances. Developing designs for doorknob-less doors will eliminate the risk of employees contracting illnesses and hence less time is wasted when sick employees have to take time off work to recover.
Lean Door 2 59
ADJUST & ADAPT SOMETHING A BIT MORE RADICAL
RECONFIGURABLE PIER & RAIL FOUNDATIONS The last element to be made flexible is undoubtedly the hardest. Foundations are what make a building stand and should be strong and steady. But castin-situ foundations are damaging and impossible to recycle/disassemble.
Reconfigurable Pier and Rail Foundation System 60
Pier and beam foundations are less harmful on the environment as they can be easily dug up and reused after the structure above them has been removed. We have modified the beams into a set of rails that allow for slabs with omni-directional wheels to slide along them. Structures that are sitting on these reconfigurable slabs can then move according to season, site expansion or reconfiguration, just to name a few reasons.
Omni-directional Wheel Foundation Slab 61
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RECONFIGURABLE VEGETATION Another application for reconfigurable foundation slabs is to move trees and other vegetation around the site to optimise the shade and atmosphere they provide at different times of the year. Trees that line the east side of a building to block morning sun during summer can be moved aways to let more light into the buildings during winter.
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FORM FOLLOWS PROCESS OUR APPROACH TO LEANSTYLE ARCHITECTURE
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FORM FOLLOWS PROCESS BAUHAUS 2.0
COMBINING FLEXIBILITY, SUSTAINABILITY, WASTE ELIMINATION & INTELLIGENCE All the previously mentioned research was carried out to develop a design for BMW’s next generation of offices, workshops and warehouses. All research would be useless however, if our design didn’t cater to the requirements and processes that an employee goes through in a day at work. Each step of a staffs’ daily process will be catered for in our design proposal and nothing more. We want to make sure we provide a design that is valuable to BMW whilst making sure we don not give them anything extra that they won’t need and will waste money buying. Hence we devised a staff process flow diagram that would help us spatially plan our modules and organise their arrangement on a site provided to us. First we will design an entrance module for the arrival of staff and guests alike. A communal area for causal socialising and dining will be close to the entrance. Staff can then proceed to a central circulation gallery where they will split into their respective offices per department or team (open plan/ enclosed). They will then take a lunch break before returning to work until the work day ends and they can socialise, eat, drink and/or exercise. Formal events such as press conferences, theatre and formal meetings can happen at any time and a space for convocation should also be provided. 66
(routine)
(occasional) BMW Staff Daily Process 67
FORM FOLLOWS PROCESS DESIGN GRID
FITTING PROCESSES INTO A STANDARDISED MODULES After establishing the different modules we would be designing, we had to consider the restrictions of standardised construction. Modular construction requires a consistent grid to which all building elements adhere to and can work together in. So before designing the modules and figuring out how to construct them we decided to standardise our module designs to fit within a 1.5m x 1.5m grid. This decision was based on a study of the space required by human in various positions and doing various task, either alone or together in a group of people. The average space required for comfortable working and moving spaces from this study is 1.5m and hence why we used this dimension as our design grid for designing our modules. Not only is this dimension suitable for humans, but if you double the grid to 3.0m x 3.0m, it’s perfect to fit vehicles and humans in comfortably.
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Neufert Study of Human Space Requirements Ernst Neufert and Peter Neufert, “Architects Data”
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Neufert Study of Vehicular Space Requirements 70
Ernst Neufert and Peter Neufert, “Architects Data”
FORM FOLLOWS PROCESS STANDARDISED ELEMENTS
STANDARDISED STRUCTURE AND OTHER BUILDING ELEMENTS Construction is simpler and more efficient when there is less variation as you can then repeat the same/similar tasks quickly and easily. Our design will utilise as many standardised building elements as possible.
Standardised I-Beam, T-Beam and I-Beam Crosswise 71
Standardised Floor Plate Panels 72
DESIGN PROPOSAL
OUR APPROACH TO LEANSTYLE ARCHITECTURE
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DESIGN PROPOSAL SPATIAL MODULES
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First Floor & Above
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Ground Floor 74
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1. Foyer 2. Lobby Lounge 3. Reception 4. Security Room 5. Central Corridor 6. M & E Services
ENTRANCE MODULE, E Primarily used as a waiting point for visitors, the entrance module is a single purpose module that serves as a gateway to the other facilities used on the site.
Entrance Module 75
1. Restaurant 2. Cafe 3. Al Fresco 4. Exhibition 5. Event Hall 6. M & E Services 7. Toilet 8. Storage
COMMUNAL MODULE, U Containing a telescopic structure, sliding walls and elevating floors, the communal module serves as a casual, multipurpose area for staff to take their breaks, socialise and eat.
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Scenario A 76
Scenario B
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Scenario B 77
ADMINISTRATION MODULE, A More aligned to traditional office spaces, administration modules provide more private working spaces for the legal, human resources and administration staff. The offices are isolated in this way to make sure sensitive and confidential information remains secure. Telescopic meeting rooms allow for larger meetings to be held in a space that was initially smaller.
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Scenario A 9
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Scenario B 78
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1. Printing Room 2. IT Server Room 3. Multipurpose Room 4. Discussion Room 5. Meeting Room 6. M & E Services 7. Toilet 8. Archive Room 9. Cubicle Office
Corner Corridor Connection 79
Scenario A
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INNOVATION & RECREATION HUB MODULE, I 6
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A more modern take on the open plan office, the innovation and recreation module utilises elevating floors to define separate work areas just by changing the floor elevation level.
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This eliminates the need for partitioning walls and encourages an open, transparent work environment.
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Other fun elements like a ball pit, swings and beanbags make for a more engaging work environment.
Scenario A
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Scenario C
1. Staff Lounge 2. Game Room 3. Gym 4. Open Plan Office 5. Studio & Workshop 6. M & E Services 7. Toilet
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1. Foyer 2. Meeting Room 3. Conference Room 4. Training Room 5. Auditorium 6. M & E Services
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Ground Floor - Scenario A 86
Ground Floor - Scenario B
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CONVOCATION MODULE, V Designed to cater towards more formal meetings, the convocation utilises telescopic structures, sliding walls and lean auditourium seating to provide formal conference rooms, press conference spaces, private meeting rooms and an auditorium.
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First Floor - Scenario B 87
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Ground Floor - Scenario B
WAREHOUSE MODULE, W 1. Loading Bay 2. Warehouse 3. External Warehouse 4. Office 5. Meeting Room 6. M & E Services
A place to store archived documents, materials for developing prototypes and equipment, the warehouse module has a telescopic structure that increase the total floor area inside the warehouse to accommodate the need for extra storage, eliminating the wastes that come from inadequate and improper storage.
5 4
First Floor - Scenario A
4
First Floor - Scenario B 91
Scenario A
92
Scenario B
93
DESIGN PROPOSAL SITE
REAL WORLD APPLICATION We designed the modules to have the ability to adapt to any site in the world. A change in region would mean the implementation of different materials in the construction, but the overall method remains the same. For the purpose of this Thesis Project, we propose to build on a site already owned by BMW and is currently unbuilt on.
Munich, Germany 94
KnorrsraĂ&#x;e 147
100m 150m
BMW Group Research and Innovation Center FIZ, 80788 Munich, Germany. 95
DESIGN PROPOSAL MASTER PLAN
IV
I
III V
VI
VI VI
VI III
II
Spring - Summer Site Plan: Roof SUMMER VS WINTER With reconfigurable buildings that move on rails, we propose different master plans for the warmer and cooler seasons. In the warmer months we spread the buildings out to maximise natural ventilation and solar panel exposure during the warmer months. Whilst during the cooler months, we group the buildings closer together to provide a larger mass to retain heat more efficiently. 96
IV VI
III V VI
I III
II
Autumn - Winter Site Plan: Roof I II III IV V VI VII
Entrance Module, E Communal Module, U Innovation & Recreation Hub Module, I Convocation Module, V Warehouse Module, W Administration Module, A Carparking Module, C 97
Spring - Summer Site Plan: Typical Basement Floor 98
Autumn - Winter Site Plan: Typical Basement Floor 99
Spring - Summer Site Plan: Ground Floor - Scenario A 100
Spring - Summer Site Plan: Ground Floor - Scenario B 101
Spring - Summer Site Plan: First Floor - Scenario A 102
Spring - Summer Site Plan: First Floor - Scenario B 103
Spring - Summer Site Plan: Second Floor 104
Spring - Summer Site Plan: Third Floor 105
Spring - Summer Site Plan: Fourth Floor 106
Spring - Summer Site Plan: Fifth Floor 107
Autumn - Winter Site Plan: Ground Floor - Scenario A 108
Autumn - Winter Site Plan: Ground Floor - Scenario B 109
Autumn - Winter Site Plan: First Floor - Scenario A 110
Autumn - Winter Site Plan: First Floor - Scenario B 111
Autumn - Winter Site Plan: Second Floor 112
Autumn - Winter Site Plan: Third Floor 113
Autumn - Winter Site Plan: Fourth Floor 114
Autumn - Winter Site Plan: Fifth Floor 115
DESIGN PROPOSAL ELEVATIONS & SECTIONS
Spring - Summer North Elevation
Spring - Summer East Elevation 116
Spring - Summer South Elevation
Spring - Summer West Elevation 117
Autumn - Winter North Elevation
Autumn - Winter East Elevation 118
Autumn - Winter South Elevation
Autumn - Winter West Elevation 119
To Wall Detail Section 1
To Wall Detail Section 1
120
top of roof level
FFL + 24.80
fifth floor level
FFL + 20.50
fourth floor level
FFL + 16.50
third floor level
FFL + 12.50
second floor level
FFL + 8.50
first floor level
FFL + 4.50
ground floor level
To Wall Detail Section 3
FFL +/- 0.00
basement level
FFL - 4.00
top of roof level
FFL + 24.80
fifth floor level
FFL + 20.50
fourth floor level
FFL + 16.50
third floor level
FFL + 12.50
second floor level
FFL + 8.50
first floor level
FFL + 4.50
ground floor level basement level
FFL +/- 0.00 FFL - 4.00
Spring - Summer Section A-A’
Autumn - Winter Section A-A’ 121
top of roof level
FFL + 24.80
fifth floor level
FFL + 20.50
fourth floor level
FFL + 16.50
third floor level
FFL + 12.50
second floor level
FFL + 8.50
first floor level
FFL + 4.50
ground floor level basement level
FFL +/- 0.00 FFL - 4.00
Spring - Summer Section A-A’
122
To Wall Detail Section 3
To Wall Detail Section 2
To Wall Detail Section 2
Autumn - Winter Section A-A’
123
DESIGN PROPOSAL DESIGN FEATURES
280mm thick Prefabricated Ceramic Brick Wall(Redbloc®) with 10mm thick Plastering on both sides Parapet Capping 150mm x 300mm Steel I-beam to engineer’s detail Insulation Board Upstand Flashing and Joints sealed with Welding Strip 150mm thick Prefabricated Single Ply Membrane Roof Panel (QuadCore™Topdek)
50mm thick Laminated Timber Flooring 3mm thick Damp Proof Membrane (DPM) 20mm thick Timber Skirting Thermal Insulation Dry Timber Block Timber Cassette Floor System (PosiStrut®)
Wall Detail Section 1 124
130mm thick Prefabricated Ceramic Brick Wall(Redbloc®) with 10mm thick Plastering on both sides
50mm thick Laminated Timber Flooring Powder Coated Frame Sill Window Sill Metal Flashing
Timber Cassette Floor System (PosiStrut®) Powder Coated Frame Head Thermal Insulation
25mm thick Clear Tempered Glass Center Meeting Rail Outdoor
Indoor
3mm thick Damp Proof Membrane (DPM) 20mm thick Timber Skirting 150mm x 300mm Steel I-beam to engineer’s detail 130mm thick Prefabricated Ceramic Brick Wall(Redbloc®) with 10mm thick Plastering on both sides
Wall Detail Section 2 125
Wall Detail Section 3 126
Retractable Structure (Libart) to engineer’s detail 20mm thick Ceramics Tiles 3mm thick Latex Portland Cement Mortar Bond 15mm thick Cementitious Backer Unit (CBU) with Taped Joints
3mm thick Dry Set Mortar Stainless Steel V-wheel (Librart) 150mm thick Exterior Glue Plywood Subfloor Continuous V-track with countersunk fasteners (Libart) to engineer’s detail
0
100
200
400
600
mm
127
128
DESIGN PROPOSAL PERSPECTIVES
129
130
131
Spring - Summer Entrance Perspective
132
Autumn - Winter Entrance Perspective
133
Spring - Summer Scenario A
134
Spring - Summer Scenario B
135
Spring - Summer Scenario A
136
Spring - Summer Scenario B
137
Autumn - Winter Scenario A
138
Autumn - Winter Scenario B
139
Autumn - Winter Scenario A
140
Autumn - Winter Scenario B
141
Facade Scenario A
142
Facade Scenario B
143
144
CONCLUSION LET’S BE LEAN FROM TODAY
+1
0
OUR FINDINGS Learning about automotive manufacturing processes has been an eye opening experience for the both of us. It introduced us to new methods of construction and design that eliminate wastes from the architectural process. It has changed the way we think and analyse every part of our lives that involves process, from spending time more efficiently to working more efficiently, the application of Lean Philosophy is unlimited. We believe that this project is a great starting point for Leanstyle Architecture and we wish to further implementing Lean Philosophy into even deeper detail in our future work. In a world of finite resources and wasteful methods, it is important that we strive to eliminate wastes everywhere we can, to preserve the world that we live on. So from this day on, we will seek to not only eliminate (0) as much waste from our lives and work, but to also contribute back to Mother Earth (+1). 145
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