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Design for Manufacture + Offsite

Using the full power of off-site thinking

There are new pressures on the industry to maintain quality at lower cost, with less environmental impact. The UK government has set some key targets* for 2025 of 33% lower cost, 50% lower emissions, 50% faster delivery and 50% improvement in exports.

Achieving these targets will mean reducing changes and delays. Analysis** shows that 30% of them
are due to poor productivity, lack of materials, lack of design information and man power.
To address these challenges the question within the building industry is not why consider
Off-site and DfMA, but how to incorporate them.

* Construction 2025 - Industrial Strategy: Government and Industry in partnership

** HM Government Capital Delivery Projects Framework

Applying off-site thinking to find smarter ways to standardise and optimise

After 20 years of experience, DfMA is a way of thinking at Bryden Wood. We do not sell a single “system” or “product”, but instead look to rationalise, standardise and optimise any project or scheme - traditional or hi-tech. We might automate the production of repetitious components, for example, to save resource without reducing value. Our architects can then focus on bespoke elements, applying their skills where they are most valuable.

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Working with your current systems and processes

We design for existing supply chains with no preference for one material or technology over another. You'll find steel, concrete and timber in the range of system-build, flat-pack and modular solutions we have designed. Alternatively, we can help you create new solutions, using existing suppliers. With both options, the key is to understand the risks and benefits of different procurement strategies (construction management and early contractor involvement (ECI), for example); or identify the companies with the right capabilities.

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Delivering benefits at scale

We have now developed our off-site thinking to a point where we can deliver systemisation benefits on large scale and mega projects. Bryden Wood can create site or location-specific assets with flexible, repeatable components, allowing mass customisation that works within the confines of the architectural design.
It's a practicable, real-world solution that works with the existing supply chain, procurement, manufacture, logistics and assembly processes.

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Flexible and widely applicable

For us, DfMA is a way of thinking, so we can apply it at any level, from traditional construction  to advanced prefabrication techniques.
You can enter the process at different points and adopt as few, or as many, solutions as you like to gain business benefit.

Adoption Scale

Increasing improvments in site productivity

Increasing efficiency of BIM workflows

Reduced reliance on skilled labour

Traditional build

Traditional build with standard interface

Traditional build with off site manufactured (OSM) elements

Project specific OSM

Product

System build

Component build

Proof Points

Achievement

Project / Comments

Applying factory quality assurance and testing procedures, reduces on-site commissioning and defect rectification; This can result in an improvement of up to 70% in reworking and ‘snagging’;

Crossrail

The MTC recommends adoption of the Advanced Product Quality Planning methodology proven out over more than 30 years to increase competitiveness, save both time and money, reduce waste, manage risk and ensure customer satisfaction. The APQP methodology also ensures designs are fit for purpose, that non-conforming product does not reach the client-site and that the safety and reliability of the finished product are not compromised.

Crossrail

Achievement

Project / Comments

Taking items off the ‘critical path’ reduces time on site;

London Heathrow - T3 Link Bridge

Fewer deliveries, trades and activities to plan increases certainty in the programme.

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Installation and assembly (as opposed to ‘construction’) sequences are more capable of precise execution;

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Lack of design information typically accounts for up to 8%of delays on site in traditional ‘construction; this is mitigated substantially by DfMA.

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Achievement

Project / Comments

Poor productivity and manpower shortage account for up to 37% of delays on site, a DfMA approach reduces hours on site and increases productivity of those hours;

Heathrow & Gatwick - Pier Segregation

The productivity of factory staff is 80% relative to 20% productivity of on-site workers. Staff based on site typically cost up to twice as much as factory personnel.

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Achievement

Project / Comments

By limiting the number of hours on site, adverse consequences are reduced resulting in an 80% reduction in incidents;

Spine House

Reduced traffic movements to and from sites leads to improved neighbourhood road safety - up to 20% reduction in road accident data within 0.5km of site;

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The adoption of these methods can only assist neighbourhood consultation and reduce disturbance due to construction.

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Achievement

Project / Comments

DfMA components allows waste reduction through better stock control;

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Research data suggests DfMA reduces site waste by 70 -90%.

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Achievement

Project / Comments

Fewer traffic movements to / from site reduces neighbourhood pollution / congestion by up to 20%;

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Reduced site labour site results in up to 50% saving in renting, heating and lighting of temporary site accommodation;

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Improved performance-in-use of environmental controls (better assembly and factory-based commissioning) results in up to 30% reduction in carbon dioxide.

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  • Quality

  • Programme

  • Labour

  • Health + Safety

  • Waste

  • Environmental Gains

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100 Gray's Inn Road, London, WC1X 8AL