KitConnect Reduced Bathroom Pod Design Times by 40%

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Background

A global General Contractor located in Europe, is utilizing bathroom pods in almost 75% of its projects. For these projects, there are often four design variations of the pods – single stalls, double stalls, family stalls and handicapped stalls. A bathroom pod, is built in a factory setting and delivered to the construction site ready to be connected to the core structure. The entire process delivers a much more efficient construction practice in terms of safety, quality, labor, cost, materials, waste and speed.

The challenge: Reduce time in design to manufacture to delivery of the pods

GC was looking for a solution to reduce the time it takes from design to manufacture to delivery of the bathroom pods to the construction site. The GC has noticed every time a new project started, the bathroom pods were being re-generated within the design models from scratch. Each project could have a new team of stakeholders trying to understand the design constraints of the bathroom pods, keeping countless documents organized and updated, with changes applied whenever design guidelines were changed. The team members had to open all the files and manually make the necessary changes. It is difficult to track and guarantee that all the changes have been implemented all over. In addition to the manual changes, the design choices were also being artificially limited due to difficulty to scale choices in production. Without that flexibility, scalability was limited by default.igning and building customer data center projects, Project Frog faced two major hurdles that affected workflow and increased the time required to design each project.


With multiple documents needing to be manually updated, projects were seeing significant delays, and in some instances, inaccuracies, instead of being streamlined due to the lack of a feedback loop or connection to manufacturing constraints and DfMA needs. In some cases, the simple act of removing a single object from the design was generating an incomplete, or inaccurate, Bill of Materials (BOM) for the manufacturing plant. There was no control over the fact if someone removed an object resulting in an insufficient BOM. In addition, the plant was also receiving incorrect designs that did not meet design, fabrication floor or assembly requirements, exposing the organization to risk and stoppage of the assembly line.


The solution: KitConnect linked design, manufacturing and construction

By using KitConnect, Project Frog started by breaking the five pod options into a defined Kit-of-Parts (a repository of reusable components that can be mixed and matched to create an almost endless array of building types and design options) and then publishing that kit-of-parts to KitConnect library. By publishing the DfMA constraints directly with the content, not only the bathroom pod itself was part of the library but the variations in which it could be configured were also made available within the library.



With a KitConnect library loaded with this valuable content, the design teams are now enabled to start all the new projects utilizing the latest pods and variations. They are able to pull the latest designs from the library and place them within the designated floor plans wherever necessary. If a change occurs to the pod itself, including regulatory changes in ADA requirements, in the course of a project, the team is able to make the change within the KitConnect library, allowing each project manager to grab the latest content and be confident it matched the requirements coming from the factory floor. Doing so allowed all the projects, even the in-flight ones to grab the latest content. Additionally, automated audits of the Revit model ensured a high-fidelity hand-off to manufacturing with a highly accurate BOM.

Results:

  • Immediate starts on new projects involving Bathroom pods
  • 40% design time reductions because design teams on any new project were able to get started immediately when it came to the usage of the Bathroom pods
  • 65% reduction in loopbacks from the factory floor to the design team due to the audit capabilities offered by KitConnect. With KitConnect audit, design intent was withheld and the provided design met the given constraints.
  • Assurance of a complete and accurate BOM. KitConnect ensured a BOM (Bill of Materials) fully representative of the Kit-of-Parts placed.