Energy efficient industrialized housing research program

CERTAINDATA C0NTA!N'ED IN THIS DOCUMENTMAYBE DIFFICULTTO READ IN MICROFICHE PRODUCTS. ENERGY EFFICIENT INDUSTRIALIZED HOUSING RESEARCH PROGRAM i VOLUME II APPENDICES FY 1989 _i'ASK REPORTS CENTER FOR HOUSING LNNOVATION UNIVERSITY OF OREGON AND FLORIDA -p SOLAR ENERGY CENTER ,, DOE/SF/17 DE9] 96 0--T4-Vol 0001]] AUTHORS Center For Housing Innovation Rudy Berg Research Assistant G.Z. Brown Project Director, Professor of Amhitec,'xa_ Jerry Fintow Principal Investigator, Professor of Architegmm Ron Kellett Principal Investigator, Asst. Professor of Architecture Margot McDonald Research Assistant Barry McGinn Reseamh Assistant Pat Ryan Research Assistant Tomogo Seldguchi Senior Research Assistant Florida Solar Energy Center I Subrato K. Chandra Abroad Elshennawy Project Dire.ct*_rof R:e._.arch & Development Di,Hs-ion AssistantDirector, Professor, Deparancnt of Industrial Engine.,erir,g, UCF Philip Faimy John Harrison Principal Program Dir_ctor_ R&D Division Research Investigator, Assistant Lawreace Maxwell Senior Research Architect Jim Roland Director, Testing & Operation Division W521iam Swart Chairman & Professor, Dept. of Industrial Engineering, iii, • i {:l _,_ UCF .2 STEERING COMMITTEE b J. Wayne Beighle Executive Vice President The Charles WayneGroup Daytona Beach, Florida LarryJordan Manager, Manufactured Housing CodesandStandards Department of CommunityAffairs Tanahassee, Florida Don Carlson Editor and Publisher Automatc_ Builder Carpenteria, California Michael Dickens Mmager,Advanced Design& Development GE Plastics Pittsfield, Massachusetts John Elizalde Chief, Residential ProgramBranch Bonneville Power Administration Portland" On;gon Mark KcUey Energy Engineer AcornStructures Acton, Massachusetts JonNord Senior VicePresident Fleetwood Enterprises Riverside, California Ed Sheets Executive 851 Northwest Power Planning Coum,-il Portland, Oregon Stan Floyd Manager, Structural Materials Corporate Research & Engineering Weyerhaeuser Company Federal Way, Washington John SlaymDirector, Research & Engineering Ryland Group Columbia, Marylmld BarbaraHarwood President BBH Enterprises Dallas, Texas United States Depknment of Energy MarvinGorclick Project Manager Building FnergyResearch Division U,S. Department of Energy Washington, D.C. . v. RandyChang ProgramManager U.S.Department ofEnergy Oakland, Caiifomia .... ii _l ,,Jll i INDUSTRY COSPONSORS AND COLLABORATORS Michael Tobin, Executive Director/V.P. AFM- fR-Control) Excelsior, Minnesota Michael Busich, President American Ingenuity Mclbournc, Florida Kenneth Franklin, Project Lender Dow Chemical Granville, Ohio Van Pope, Corporate Director of Operations Phil Tanner, General Manager Haines City Plant Fleetwood Industries MichaelJ. Dickens, Manager AdvancedDesignandDevelopment GE Hastics Pittsfield, Massachusetts , II ACKNOWLEDGEMENTS Center for Housing Innovation Beth Holmes , Word Processing Joyce Deters Word Processing Matt Meacham Research, ILlustration, and Pasteup Diane Fellows Gunnar Hubbard Research,/]]ustration, andPasteup Research, Illustration Kimberly Kaufman Curt Wilson Illustration Research and Illustration Marian Fincher Librarian Florida Solar Energy Center and Department of Inaustriai Engineering, UCF I Robert Abemethy Timothy Branson Construction Research I Bidyut Chakraborty Computer ' Mable Flumm Alan Garentt Word Processing Construction Leader Elvis Gumbs Instrumentation Gloria Hill Word Processing Jeanette Holder Word Processing Lorenzo Young Research FSEC Graphics Photo Pasteup FSEC Library Library Services FSEC Testing & Operations Construction, Instrumentation I ! , , , , , L CONTENTS VOLUME II 1. TRIP REPORTS 2. SOFTWARE BIBLIOGRAPHY 3. COST COMPARISON OF SWEDISH & U.S. HOUSING 4. CONTACTS 5. LIBRARY 6. INDUSTRIALIZED HOUSING MANUFACTURING SYSTEMS ..Fleetwood VOLUME I 1. ABSTRACT 2. INTRODUCTION 2.1 Research Context 2.2 Research Goals 2.3 Overview of FY89 Research 2.4 ProjectTeam 2.5, Industry Participation 2.6 3. Project Funding ANALYSIS OF U.S. INDUSTRIALIZED HOUSING 3.1 Definitions and Characterisiticsof Industrializing Housing 3.2 Statistics and Trends in IndustrializextHousing 3.3 Field Observations ofHUD Code,ModularandPanelize, d HousingManufacturers 3.4 Case Study: Fleetwood Homes 3.5 Current Status of Energy Efficiency 3.6 U.S. and Foreign Building Codes viii. ,4. ASSESSMENT OF FOREIGN TECHNOLOGY 4.1 Current Status of Design, Manufacturing, Marketing and LnstallatJonin Industrialized Housing in Sw,eden 4.2 Current Status of Design, Manufactunng, Marketing and Installation in IndustriaLized Housing in Other Western and Northern European Countries 4.3 ' 5. Ill ! I ' 6. i Current Status of Design, Manufacturing, Marketing and InstaJlation in Industrialized Housing in Jap_ AssESSMENT OF INDUSTRIALIZATION APPLICATIONS _.1 Statistical Analysis of Industrialized Housing Production by Climate Zone 5.2 Climate Response of Industri"aliz_lHousing by Climate Region 5.3 Analysis of Domestic and Foreign Industrialized Housing Costs and Energy Performance 5.4 5,5 Towards 21st Century Manufacturing: the GE Plastics Panelizing Plant for the Future Emerging Components and Subsystems COMPUTERIZED DESIGN AND EVALUATION TOOLS 6.1 Evaluation of Computerized Design Tools Used by Industrialized Housing Manufacturers 6.2 Analysis o_f _e EnergyDecision MakingProcess m Industrializexl Housing 6.3 I 7. ASSESSMENT OF ENERGY PERFORMANCE OF BASELINE AND ADVANCED INDUSTRIALIZED HOUSING CONCEPTS 7.1 I ! Prctowpe-E)esign Tool - R-Control Panel Side by Side House Comparisons 7.2 Artificial Sky 7.3 Wind Tunnel 8. OBSERVATIONSAND 9. REFERENCES RECOMMENDATIONS , 1. TRIP REPORTS i 1. TRIP REPORTS UNITED STATES i Palm Harbor Homes (ENERGMISER) Plant City, Florida Bill Nolan, President, Orlando Homebuilders Assn. Orlando, Florida PeaseCompany, Inc. Benchmark Homes Hamilton, Ohio Brookvill¢, Ohio Unibilt Industries Vandalia, Ohio Ali American Homes, Inc. Decatur, Indiana Nationwide Homes Mar_svilIe, Virginia National Building Systems Collinsville, Virginia Titan Manufacturing Co. Orlando, Florida RylandHomes Columbia, Maryland AmericanStandard Building Systems Maxdasville,Virginia Cardinal Homes Williesburg, Virginia Fleetwood Enterprises, Inc. Acorn Structures Haianes City, Florida Concord, Massachusetts RyanHomes Plant City, Florida MOD-U-KRAF Homes Inc. MeadowoodIndustries RockyMount,Virginia Lebanon, Oregon Western Insulfoam/R-Control Panels DesCon'89 A/E/C SystemsConference Kent, Washington Anaheim, California FlectwoodEnterprises, HousingGroup Riverside, California Automated Builder Magazine Carpcnt_ria, California Blazer Industries , RylandModularHomes Silverton, Oregon New Windsor, Maryland • RylandConsmacjtion Systems(Panelized) Manufacturing PlantColumbia, Maryland , "Modular Housing: The Trendforthe90's" Conference PennState University AdvancedBuilding Systems Bennington, Vermont Key-LocHomes (Division ofHodgsoaHousesInc.) Suncook, New Hampshire National Association ofHome Builders AnnualMeeting Atlanta, Georgia '89Rcpon/Vol 2 Disk I-I SWEDEN ' M ulti.familyProject Prefab Housing Project Ingebo Stockholm Atrium Project Housing Project Stockholm Kejsaren, Stockholm Apartments Energy Efficient Multifamily Project Sjukskoferskan, Shockholm Konsolem Skogsalmen, Stockholm Stockholm Multifamily Project Bodbetjanten SFC Housing Project South Linkoping Lambohov. Project Myresjofonster Plant Linkoping Vetlanda Myresjohus Plant , Veflanda 4 Flex Veflanda GuUringshus Plant Hultsfreds - Hus Gullringen Hultsfred Will House , + Gullringer_ Burmek Boro AB Nassjo Landsbro Myresjohus Under Construction Vetland DENMARK Architecm_ Museum and Bookstore Hosby Hus a/s Copenhagen Juelsminde Roslev Hus Skive Ebbeltofi Recreational Housing Community Housing Project Northeast of Aarhus Aarhus, Denmark Energy Efficient Ca>HousingProject _ca Byg and Bo Housing Exhibition Slite Odense T'mggardenHousing Project Koge Holmebaek Housing Project Herfloge Sun, W'md and Light Co. Housing Project Koge TastrupHof Development Area West of Copenhagen Retrofit Housing Project DamgardscrealetProject North of Copenhagen Alber',slund '89Report/Col2 Disk 1-2 + Sibelius. Parken Project West Copenhagen Urban Mixed Use Building Copenhagen Martin Rubow et. al, Office Copenhagen Vandkunsten Office Copenhagen Norgards Plantage Project Hesselbo Fuglsangpaken Forum Graese Bakkeby Modulbeton Plant Copenhagen Torstorp Skoven Interview C°l_,nhagen Copenhagen Brondby JAPAN I Kyoto University Waseda University Kyoto Tokyo *Meiji University Tokyo *OsakaCity University Misawa Homes Co, Ltd. Headquarters Osaka Tokyo Misawa Homes Co. Ltd. Plant Nagoya *Mitsui Home Company Limited *Sekisui Chemical Tokyo Tokyo, Hasuda _;SekisuiHouse *Building Cente.rof Japan Tokyo, Koga, Osaka Tokyo *Building Research Institute *Federation of Home Contractors Tsukuba Tokyo *Issiki Architects and Partners Tokyo *Housing Parks Tokyo Shin-yurigaoka Takaido Hasuda Koga Osaka Kusatsui Nagoya * Visits _mde, trip reports incomplete '89 R_ol 2 Disk 1- 3 Energy Eff,_c_ent Industrialized TRIP Faciility visited: Palm Harbor homes(ENERGMISER) 605 S.Frozl.ta;e Rd. P_an!t C_ty, FL 33566 ,, Project Housing REPORT Visit October (takeexlt 13or 14 from _s offered Date: 17, 1989 I-4) Host_,: Took!the standard the i;ubllc Fro_ect Staff: Subrato Prepared Report guided By: plant tour which routinely to Chandra Subrato Chandra Compa!n_y Profile They are a HUD code manufacturer and the only one that I know of which emphasizes energy c6ns_rvation as their top marketing too_. They have a neat "warning" slgn _n all their mode_ homes saying the buyer will _ose $7244 in h_gher ut_llty bills over the llfetlme of the home if they bought from a competitor. They emphaslze their better construction of their quality over competitors every step the way from models to the p_ant tour. See attached materials descr'Iblng the company. Business ? Design Volume and StaffAn_ - milllon/year S_:aff 500-700 - ? Admlnlstrat_ve Staff Sales Staff = quite to the factory Deslgn ? Procedure Energy Design homeS/year Production Staff - ? - ? a few, about 25 in their model center Decls_ons_ For many years, they have advertised their product quality energy efflclent manufactured home. The words mobile home are never mentioned. Automation I and attached Computerization as a h_gh HUD code and level _s comparable to Benchmark homes Products Manufactured See attached Raw Ma_erlal and Inventory Qu_te slgn_flcant. Huge plant. I would guess _t at three weeks. Plant accomodates about 14 modules and throughput is 6 to 8 modules per day (one sh_ft) Manufacturlnq Methods Plant was well laid out w_th vertical spaces well ut_llzed by ho_sts and cranes. Pneumatic hand tools. Level of manufacturing sophistication was close to better moduZar builders such as Benchmark. Some interesting features: I. get Frame built gets they a built in are level. 2. Chassis painting space requirement. 3. Carpet f_nlshlng as is an Is done Minimal field option. 4. Last manufaturlng ammonia for 12 hours 5. Various module Ouallty Control camber welding so holdlng chassis paint overspray installed step to get shapes by and so that when vertically noted. is modules to m_nlmlze drywall taping and is gassing each module with anhydrous tld of 90_ of the formaldehyde. were _n production at the same t_me. In general the quallty control appeared to be superior. See attached materials. They use white rather than yellow pine throughout. 2 x 4 construction with full top and bottom 2 x 4 plates. Good application of insulation in knee wall areas and over ce_llng. Uses 235 lb. shingle. V_nyl s_dlng Is _nstalled w_th room to move to prevent warping. Each module _nspectors. Energy goes thru a 16 step inspection procedure. 4 plant Performance Should be qu_te superior to standard HUD code homes. to modulars. See attached for spec_. Heating equipment se_ectlon _s upto the builder/dealer. Comments IMPRESSIVE for a HUD code home. Comparable and cooling 5. In general, If done rlght0 rate of return for manufacturers can be pretty high, 18_-2Z_ per year plus perks. So th_s is a lucrat_ve business and f_IrZy slmpZe to do. The reason GM and Boelng have not gone into mobile home manufacturing Is that they dldnot have a home bullder mentality. That _s to keep things low tech and slmpl_, H_ also agreed with Phillp'e hypothesis that it le very dlff_cult to patent or otherwise protect a manufacturing process or Innovatlve idea in this business. That's why the big boys are not in it. 6. Home manufacturi:_g falls apar_ when there _s too much flexibility. He c_te_ t_o efforts _n Florida -- one by contlnental homes _n Haines clty and another by benchmark In Tallahassee who trled to make modulate the way the customer wanted, and folded In one to tWO years, ?. OperatiOn Breakthrough had number of good effects, For the flrst time _eople saw'_hat good homes (better than mobile ) can be made {n the factory. Secondly it spawned the existing modular codes in 30+ states and therefore created the modular housing Industry. He agreed w2th Philip that we could make a case that operation breakthrough was a success. 8. Statew_de modular codes can be enforced at the local level if one is prepared to f_ght. Cardinal never, was stopped at the local level although it had to engage the law a few t_mes to do _t. Local zoning laws can keep the mobile homes out because they do not meet the national codes (SBCCI, BOCA e_c.). Thoughta a. in Saw the wet core b. Thought where they wou_d test future modules. (next five about years) Pro_e¢_ _n larger components, perhaps industry would be interested _n doing cost shared R&D get govt. to pay for about half the_ costs. Then the prototype products for performance. c. Men_1oned an Idea Have PVC plpe _nstead wlr_ng and plumbing. a Texas prof. had for opera,ion of 2 x 4, Then use the p_pes We should follow thls up with breakthrough. as chases for GE plastics. Energy Efficient Indu_rialized Housing Project TRIP REPORT Facility visited: Pease Company, Inc ._j_: 900 Laurel Ave. Hamilton, Ohio 45023-0001 (513)867-3382 j proiect Staff: Lawrence Maxwell, SubratoChandra (BSC FallPlantTour) t Revort Prepared B_. Lawrence Maxwell Sept. 15, 1989 PeaseCompany has been a manufacturer and supplier of home building materials ever sinceitwas established iu 1893.The companybeganasa smallwholesale sashand door (_0mvanvProfile company selling to retail lumber yardswithinthe "horseand buggy"distanceof its Cincinnati, Ohio,business. or Pease was one of the earlymanufac_'uzers of pre-cu_ prefabricated homes in the country, and one of the first in the industry to utilize assembly.line production techniques to produce homes_ The first Pease home, produced in 1939, was a one and one-half story Cape called the"Peaseway" and was designed tobe built offour variations. The homesCod businessexpanded x_pidly and 1940,and the inany company moved its homes manufacturing toHamilton,Ohio. The adventofnew materials and the desireformore flexibility in designbroughtabout the development in 1950 of the _Pease-Fab System'. This system allowed the home owner to customize the home to his individual taste. In 1959, the company successfully directed the research and development of the Ever. Strait Door System.Thiswarp-free, insulated and magnetically weatherstripped product was accepted so well that in 1966 a separate manufacturing division was formed. In 1982, the division, with plants in Fairfield, Ohio, Denver, Colorado, and New Castle, Indiana, was spun-off and became Pease Industriea Today,PasseCompany employs260 peopleand rrmn-f-cturers and distributes buildinB " products throughout Ohio,IndiA,_,. Kentucky and West V_ The compauyJspackagehomes are designed forsingle-family and multi-family aswellu forlight commercial buildings. The aremanufactured atthe360,000s.fplantinHamilton, 1 A Ohio, with the capacity for producing and shipping 2,500 units a .v_:ar. PeaseCompany alsosells a widerangeofbuilding products tothe c_nstruction industry. There are fourPease Showrooms and DesignCentersin the great, er Cincinnati area, Cheviot, Kenwood,Hamilton, and Sharonville. Full-sized displays exhibit thePeaseProduct Line,as wellas providing fullkitchenplannerson staff'. The companiesHazrilton, Ohio plantappearsto be a fairly old heavy industrytype manufactvxing complex,which Pease has acquiredand ispresently u_|izlng for both component,and paneliza_on production as wellas productstorage. Business Volurae and StafRue ? . million/year up to 2,500 homes/year Design Sta_ = 8 Production Staff. = -150 Arlmi,_strative St, afr= -42 Sales Staff = -25 DesienProcedure PeaseCompany hasa designstaff whichincludes 2 registered Architects, The companyhas introduced AutoCadintothedesignprocessThe companycontinuously creates new single and multi.family housingunits.Further,designsare acceptedfrom builders and home buyers,iftheycan be effectively producedinthe manufacturing plant.The design_tff willreviewand revise a designasnecessary towork inthe factory production mode. The designs created by thecompany arewithinthestandard designtypesnotedthroughout the industry, Le.capes, ranches, colonials, etc., aswellasmore contemporary, and larger custom homes, EnerevDesiL,n DecisiQns Energy related design decisions are based on requirements of the local energy codes where a home willbe located. No additional designforpassive energystrategies areincorporated intothe home1_ An energyefficiency upgradepackageisavailable, which consists of increased insulation levels in th_ walls and ceiling. Automationand ComDuteri_tio,_ PeaseCompany utilizes AutoCad Softwarefordesignand drafting function_AutoCadis also utilized to prepare wall panel frAmi,_udiagrams for the manufacturing planL Materials takeoffs and quantity control isnot monitoredor control by use ofcomputers.Hewlett Packard computerhardwareisusedtorun theAu_ drafting functions, with 8 statiozm _ t operating, The computers are not netw6rked, but are buffered for printing on a single printing de_'ice, Other soft.'are used is "The Plan" software package and Alpine Truss software and eqtL'pment for truss configuration and production, A larger networked computer system is utilized for corporate business functions, such as bookkeeping, inventory, and order processing and control. The industrialized housingcomponentofthecompanyincorporates wallpaneljigsand laser controlled automatic nailing bridges, roller bridges forpanelmovement,Alpine_ rolling trusspresses, automatedventedsoffit manufacturing equipment, automatedstair stringer manufacturing equipment, and automatic wood finish trimroutingequipment. ..Product_ Manufactured Peaseisa manufacturer aswellasa majordistributor ofbuilding products selling lumber, building components, millwork,windowsand doors, and kitchenand bath cabinetry. The companyhasa doormanufacturing company withseveral manufacturing plants around I the country-. The industrialized housingportion ofthecompanyproduces openwallpanelsforsingle and multi-f_m_ly and light commercial construction. The companyalsoproduces pre-engineered permanent systems. roofand floortrusses, and wood foundation ..Raw Material and Inventory As Pease Company is both a house pauelizeroperationas well as a components I and components.Approximately one halfof the manufact_'mgplantisgivenoverto manu£_cturer, supplier, and retailer, thecompanymaintains a largeinventory, ofmaterials inventory storage. Mauufacturine Methods | I Peaseincorporates cad generated wallframingconfigurations to themanufacturing plant. Initial cutting isperformedwithmanuallyfedand positioned cutting equipment,and all measurementsand markingsforstudlocations, openings, member identification, etc,is performedby hand and markerpen. Once individual members arecut and marked,they are sortedintobinsforuse on the assemblyline.The panelsarethen configured on jig tables, with manual member selection from bins,and manual member placementand alignmentintothejigstopa Fastening ofstudstoplat_and headersisaccomplished with pneumatic nailing guns which are suspended from the ceiling on cables to eliminate the continuous lifting of the heavy guns used. The panels are shifted, to the next station on a roller bridge, which requires only that the panel be pushed manually to the next _ttion. Exterior sub-sheathing ismanuallyplacedon thewan panelandpositioned, and tackedinto position.An electric routerisutilized to cut window and door openingsout of the sheathing after placementbutpriortofallattachment ofthesheathing tothepanel.Then a laser guidedautomatic nailing bridgestaples the sheathing tothepanel.The panelsare thenloadeddirectly on totrucksfortransport to the construction site. OualitvControl i,sopen wallpanels,and floorand panelsare the productproduced,jigsand automated nai]Lngbridgesare the main method ofq_alitycontrol No additional QC personnelwere noted,or additional QC measures observed. Znerev Performance J Itisassumed thatthe energy performanceof the homes constructedwould be similarin natureto a sitebuiltho_zsewhich isconstructedwith the same levelsof insulation and buildingcomponents incorporatedintothe finalproduct.However, the ability to produce wallpanelswith closertolerances, willlikelyprovidea betterconstructedproductwhich couldhelp increasethe energy ,ef_ciency of the home. Comments Pease Company is possibly one of the largest companies in the business, with business interests in ali facets of the construction of homes, from the production and distribution of materials and components, to the manufacture of panelized homes themselves. Numerous contributions to the construction industry as well as the industrialized housing has been brought about by the company. The potentis! for fun.her contributions to quality, affordability, and energy ef_ciency exists within the structure of the company. Energy Efficient Industrialized Housing Project TRIP REPORT Facilit7 visited: J I_t_: I ProiectSta_: Benchmark Homes, Inc. 630 Hay Avenue Brookville, Ohio 45309 i____: Sept. 13,1989 GeorgeKirby, Jr,(President) (513) 833-4091 LawrenceMaxwell,SubratoChandra (BSC FallPlantTour) Re___port Preum'ed B,_',Lawrence Maxwell ComDanv Profile Benchnmrk Homes isa fully integrated building companywhichisone ofthe pioneers in the modularbuilding industry,The company has been in the modularhome building industry for 45 years. Benchnmrk homes builds single-family, homes through the Benchmark builder dealer network. Ali homes manufactured by Benchmark are transported, installed, and finished by Benchmark crews. The builder/dealers are responsible only for site and foundation work and the plumb' and electrical connections outside of the home. The company utilizes sub-contractors '_'de the plant for all of the construction of their product, Benchmark Communities, Inc. is another arm of the company which is involved in design, site planning, full approval processes, construction," and mA,_A_ement of multi.family residential projects. The same plant is utilized for both the _ngle and multi.family modular units construction. The plant comprises 95,000 s.£ Business Volume _ud S_fFm_ .million/year DesignStaff= ! 750-1200living units/year .-6designers Production Staff= 175 + 4 engineers (-7 on payroll and 7 majorsubcontractors) A_rnlniJrtrative Staff= -40 _les Staff = De_i_n Procedure Benchmark Homes has a complete design dept. with 6 designers and 4 engineers. Ali design work is accomplished in house. The company works both from standard plans for single fan_y homes and custom designs for multi-family. A large portion of Benchmark's work is for mul_i.fa_-nilyprojects, and the company will provide the complete package, from design of the units, to site design, engineering, and code approval, The company has designs ranging from fairly standard product, to very high quality designed projects. Much care is taken in the design and construction of the projects to avoid the look or indications that the product is modular in nature, lt appears that once a project program is developed by Ben_k or by a separate client, the design staff is given the design leeway to produce what they feel is appropriate. However, much of the product is a variation on a theme which they have found to be successful For example , a standard floor plan arrangement may be utilized, with slight modifications, and the exterior elevations changed to suit the specific project_ EnQrev Desi_m Decisio_ The energy design decisions appear to be made to meet code requirements of the local where the project will be built. No Sl_cific enhancements beyond code minimums were noted in the design or construction of the single or multi-family units. Automation and Comv_teri_tion Benchmarkutilizes AutoCadforthe designand drafting oftheirnew projects. The system has been in operation foraboutone year.Presently the usersarejustbecomingfamiliar enoughwith the systemto be ableto utilize iteffectively. The hardwareutilized isan Acer system with approximately 30 stations operatingboth the AutoCad as well as accounting and word processing operations throughthe use ofan Ethernetnetworking setup. . "Low techinplant, hightechinengineering" ishow GeorgeKirbydescribes Benchmark's approach to manufacturing. The plant does not incorporate any automation in its manufacturing operation. One of the reasons for the lack of automation is the fact that Benchmark utilizes all sub-contractors to perform the labor roles in the plant_ The subcontractors provid_ most allthetools*hey requireforthe performance oftheirwork_ Pro_lucts Manufactured Benchmark ls a manufacturer of modular single and multi.family homes and apartment complexeL For the ]ast five years, the company concentrated totally on multi-family rental and condomimum complexes. This year the company is again producing single family homes, which comprises approximately 25% of their production. The typical single or multi-family unit is approximately 1200 s.f. to 2600 sJ: The multi-family structures are bufldh_ up to 3 stories in height, Single family are produced and sold to Benchnmrk builder\dealer network,multi-family are developedthroughBenchmark Cornrnlmiti_L Raw Mat e.rial and Inventory Benchmark practices Just.In-Time (JIT) inventory acquisition and control, All raw materials and component inventories are provided to the subcontractors on the production line, Agreements with materials and components suppliers are setup so that necessary materials arrive within one day of use. Due to Jrr, very little inventory is maintained on hand, reducing storage requirements, pilferage, and overhead cost. MRnufacturin_ Methods Benchmark has a very low tech manufacturing operation. The company incorporat_ subcontractors for ali the trades on the _job. The subcontractors are actual field construction crews that bid for and work in the company's production plant. It is the subcontractors responsibility to add to or deduct from his cre_ es necessary to maintain the amount of manpower necessary to perform the work required. Simple jig tables are utilized for the framing of floors and walls. The rest of the production is directly related to similar site construction techniques. _tv Control Quality Control sign off forms follows each module as it moves through the plant. The among quality control inspectors are the few people who are on the actual payroll of the company. They are required to sign off at each stage of work before it proceeds to the next step, The subcontractor does not g,_t paid until hk work is finished and approved. I Benchmark also installs the modules on the foundations and ,performs ali finish work. If a discrepancy is discovered in a subcont_ractors work, the subcontractor responsible has a repairs and subcontractor be backcharged accordingly. specific timethe period in which will to rectify the deficiency or Benchmark crews will do the Ener_ Performance The units designed by Benchm.rk do not incorporate any special energy efficiency design, seal and the all top units and insulation, bottom plates, etc, areand based all receptacle on code requirements. boxes to reduce However, infiltration, the company and coupled does with the tighter construction tolerances, is most likely producing a more energy efficient product then its site build counterpart. | _om_ments . i I Benchmark is fully integrated company which is involved in every aspect of the single and multi.family development proces& The business sense of the company is very impressive. The integration of production, development, land planning, marketing, property management, Jr/' inventory management, and labor controk through subconU_ labor, is vastly different from about every other Industrialized housing manufacturer visited. The company takes great pains to avoid the "modular" stigma, or the "M"word es they put it. In the design and manufacture of the homes, the company goes to lengths to eliminate the telltale signs of a modular unit such as a too thick marriage wall or variations in the floor at the door opening in a marriage wall Further, no mention is • made to modularwhen goingforzoningapproval, or formarketingofthe units,Ifthe topicisbroughtup,they stress the quality control benefits and the costbenJ.flt.s of the factory producedunits. To ensurethe quality of theirproduct, the company maintainstheirown erection and finishing crews, instead ofleaving thisaspect tothebuilder/dealer. They alsomake every efl'ort to rectify any problema home ownermay havewithin2 daysofthe receipt ofthe complaint. LM Energy Ef_cient Industrialized Housing Project / TRIP REPORT Fa¢_i_ vis_ted_ _: Unibflt Industries, Inc. Van_ Ohio _: Sept. 14,1989 BSC Plant Tour Pro,jec_ Staff: Lawrence Maxwell, Subrato Chandra (BSC Plant Tour) Re uor_ PreDated BY: Lawrence Maxwell ComDau_ profile: Unibilt In& is a priva_ly held corporation (management owai_ 92% of company) which was 1969. The senior management has been the company 1972, The incorporated company is ainmodular home .ms:, .u, ufacturer, which beg._with production in a since 14,000 shf. warehouse building. Presently, Unibilt's manufacturing fjCilities consist of 49,000 s,f. of production space, warehouse 4,500site. s.f. of office space, sells and 2,300 s.f. of garage space, for 24,500 a total s.£ of of 80,300 s.f. on space, a 7 acre The company exclusively through a builder network, with 90% of the homes sold in the state of Ohio, with the other 10% going to Indiana, Kentucky and Tennessee. The product manufactured is singlefamily homes consist/ng of ranches, cape cods, and _wo story homea The product selection is from over 100 standard plans. Business Volume s_d S__ . million/year Design Staff 425 homes/year - 1 Architect Production Staff - 70 persons day shi_2 draftsmen 30 persons night Administrative Staff - 13 DelivexT crews - I0 persons Sales Staff - 4 ,q, ,, ..... | Desizn P.rQced_ Product design is based on perceived market desires. Input is also generated by of requests of the builders. Most new p,_duct design consists of revising existing plans through a method of 'cut and paste'. Where exist_ing plans are revised _white out' and pasting revisions over existing drawings then creating reproducible with a 'Xerox" machine. the type standard utilizing drawings When a completely new product is desired, the architect will develop the design based on input from marketing and administratiom J En_errv DesjLm Decisions Unibilt Industries strives to market energy efficiency, and to this end, most of their product is constructed with energy upgrade packages. The designs of the homes themselves are not such that they attempt to derive heating or cooling from natural or passive means However, the adage of 'more is better' is utilized in selecting insulation levels for the homes. That is, the perceived impro,rements in energy efficiency, more than the actual cost optimized increases in insulation levels for example, are opted for by the home buyers. Interestingly, the home buyers are typically selecting improved energy ef_ciency over increased amount of amenity or size house. Unlbilt is also providing Anderson Windows as a standard in all their homes, a_ it is felt that they provide the energy e_ciency levels desired along with reduced inventory requirements of carrying only one grade of window. The same concept is utilized for doors, etr. Au_mation and Comuut_rizat:ion The use of computerization at Unibilt is extremely limi_ PC's are utilized for bookkeeping operations and for general business word processing. Computers are not utilized for design or _ at all. As mentioned under design procedure, the method of _cut and paste' is utilized for revise' plans for manufacturing. This operation would lend itself very well to a CAD application. No automation is incorporated into the m_ufac_-ing opera,iota Produe_s Msnu__ Unibflt Industries man_es single family modular homes exclusively. of ranches, capes, and two story units, from over 100 standard plans currently produces 18 to 20 'floors' per week. Homes consist The company l_awMater'_al a,ud Invento_ Raw material is stored in a warehouse separate from the manu_ facili_ and not available for viewing. The amount of materiak stored or the rate of inventory turnover is unknow_ M_nufacturin_ Method.s Unibilt constructs wall panel assemblies on RL Industries wall table jigs. Floor platforms are produced on jig tables, placed on roller assemblies and manually moved from station to station on tracks. The manufacturing process closely follows site construction techzuques and sequences throughout the production process. The manufacturing process is low tech in nature and resembles that seen at most plantJ. The emphasis is on utilizing relatively unskilled to semi.skilled labor in-lieu of automation or higher technologies, or fewer higher skilled laborers. Ou_lity Control Unibflt has one Quality Control inspector at the plant. The inspector will check each portion of the work before it is covered up by subsequent construction. ]_nerev Performance The energyperxbrmance ofthetypical Unibilt home isexpected tobe higherthanthatof a typical comparablehome. The reasonis due to the increased levels of insulation installed 'inthe construction of the unC.ts as wellas the tighter levelof construction tolerances overa sitebuilt product.The homes aretypical inotherrespects inthatthey do not incorporate any sitespecific designsor orientations nor do they incorporate any passive heatingorcooling designstrategies. I manu_cturing.They a,-e essentially builtunderawith roofutilizing the advantages of Unibiltis a typical modular homesite manufacturer, a low tech approach to improvedproductivity throughassemblylineoperation, volumepurchasing, and protection fromthe elementsduringconstruction. The advantages ofautomation orcomputerization or exploited process production explored opera_ionofthe has not been in their The assemblylineoperation at the plantconsists of a L shapedconfiguration, with the turnoccurring about2/3oftheway down the line.Thisrequires eachmodule tobe lifted withjacksoffofitsrollers and thenhave rollers thatmove inthe otherdirection placed underthe unit.The modulesmove "sideways:_down thefirst portion ofthe assemblyline, and then after the switch, move "endwise" down the remainder ofthe line. At the end of the assemblyline, the module isrolled out ofthe building and directly ontothe backof a awaiting trailer tobe transported to its final destination. LM Energy '_ Ef_cient Industrialized Housing Project TRIP REPORT Faci_tv Ali American Homes, In_ Decatur, Indiana visited: _T.9_: Mike Research and Development ProiectStaff: Reuort • V__: Sept. 13,1989 Preuared Lawrence Maxwell CBSC FallPlant Tour) _.Lawrence Maxwell o' Company Profile Ali American Homes is a producer of modular homes. The company is presently operating in a new 142,t)00 s.f. plant which they began production in March 1, 1989. The company is producing approximately 3 homes or 6 'floors' per day. Ali American Homes are sold through builder/dealers in Ohio, Indi,_,_ Michigan, DJinois, Kentucky, and West Virgin_ The corapany produces homes from approximately not produce any homes not from their plan_ 80 standard plans of their own, and does BusinessVolume and S_t_,,_5 - million/year Design Staff,,4 -800 ' ProductionStaff= i00 + AdministrativeStaff- 35 Sales Staff= 7 homes/year ° Design Procedure AllAmericandoesnot havea designsta_,but rathera drafting department.Each year approximately 2 new modelsaredeveloped.New modelsarecreated toprovidea product sind/ar towhat isbeingbuilt by sitebuilt contractors inthearea.The balance ofthework ismodifications to existing designs. Enerev, D_si_ Energy decisions are b_d on compliance with energy codes at the location where the final home isbeingbuiltfor.E:th_,mcements to the basicenergyincludes changingthe roof insulation from R-25 to R-40,changingwallsfrom R-11 to R-19,and allhomes receive AndersonWindows. Autom_ti0nand Comvuterization The drafting departmentutilizes AutoCadSoftware on a IBM 286 and a Compaq 386.The computerisutilized tochangeand upgradeplansforproduction. No materials orinventory control or takeoffsareperformedon the computer.Production scheduling isperformed manually, as wellas allproduction procedures.Computersare utilized forbookkeeping functions as wellasword processing. P.___actured All American Homes produces all modular single family homes from a sto_ of approximately 80 standard plans. The mix consists of 864 s.f. to 2400 s,f homes with the 2largest box or group 4 box beinghomes. approximately The mix 1.800 of s.f. homes The isfloors about are 80% a standard 2 box, 12' andor 20% 13'-6"wide 4 box configurations_ Raw Material and Inventory_ All raw materials and inventoryiskept under the same roofas the manufacturing operation. The manufacturing operation is in a linearconfigtcation, with the manufacturing taking up halfofthewidthofthebuilding, and thesub-assembly (plumbing trees, etc,) down the middle of the building, and the materials storage _m,_ng parallel to the manufacturing line and taking up about one third of the width of the building. Inventory turn around is approximately once a month, with a two week turn around desired. A vast quantity of inventory is on hand at any given time, adding to overhead and carrying costs, along with storage cost¢ Manufa_e I Methods Of the 142,000s.f. forr, he entire plant,135,000s.f._is production and materials sCorap space, withapproximately 2/3giventoproduction, and 1/3giventomaterials storage. The production areaconsists ofa L shapedcoafiguration. In thelowerlegoftheL,wallpanek and floor platforms are constructed. ClarT. wall and floor jigs are utilized in assembly. An Alpine Truss machine is utilized to fabricat.e roof trusses. The wall and floors are then moved to the main assembly line by the use of overhead cranes, the floor is placed on trolley wheels, and the walls, roofs, and subsequent construction takes place. , Foam glue is used to attach ceiling gypsum board to roof trusses, and the finished roof structure is placed on top of the assembled walls. After the walls are erected, and the roof structure attached, the module moves down the assembly line. Plumbing and electrical lines are routed, interior gyp. b& is attached, and insulzLtionin the exterior walls and roof is installed. Exterior wall sub-sheathing and roof decking is installed. Windows and doors are installed utilizing a split jamb system which allows installation of the door or window from one side and insertion of the other frame half from the other. Doors and windows and frames are pre-finished at the component manufacturers prior to shipping to the modular plant. This eliminates several fivi_hing steps as well as the need to use materials that will generate EPA scrutinized hazardous wastes. The construction practices utilized in the plant closely resemble field techniques for the balance of the work. No automation or special procedures or techniques were noted in the construction. At the end of the assembly line, the finished products are lifted off"the trolley rollers by the use of motorized lift _milAr to what is used a marinas to lift boats out of the water. The lift straddles the module, straps are placed under the box, it is lifted off. the trolleys and rolled outside and placed on concrete blocks until such times as it is to be loaded on a truck for shipment. Q_mlit_ Control A quality control check list is attached to each module along with a copy of the floor plan for the module. The worker responsible for each portion of the work _ the sheet when his work is finished, the work is reviewed by a QC inspector and sJ_Taedoff"on when the work is considered acceptable. Enerev Performance No special design consideration is given to the modules to allow for any passive heating or cooling strategies. The materials used and the tighter tolerances that were noted in the construction of th_ modules would help in producing a home that is more energy efficient than a _mil,,,. standard house that was site built. The Ali American Homes present manufacturing plant is new and in its first year of operation. The building and the configuration of the assembly line were created for the manufacturing of modular homes versus most plants visited that had developed their manufacturing operation in existing industrialized buildings that were deemed to be suitable for the purpose. The manufacturing operation does not deviate from the standard method of operation noted in other plants, Le. low tech_and low levels of automation, and high use of a low or semi-skilled labor force. 8 @ ) A verylargeinventory ofmaterials was on hand atthe plant, and overi/3ofthe entire plantfloorspacewas usedto storeit. The investment inplantfacilities isamong the largest seenatany plantvisited, however, the investment in designstaffand productdesignwas veryminimal, ltappearedthat much lessthanoptimalstudywas putintorethinking theproduction process atthetime the designofa new production facility tookplace.The companydirection was toprovide a product[zlmilnr tO what a typical builder was providing inthe area,but to builditin a factory to benefit from the advantages inherent in that type of operation. The potential benefits of restarting a production process "from scratch" don't seem to have been explored or exploited in the creation of this new facility. I I Energy EfficientIndustrialized Housing Project TRIP REPORT Fa_ility visited: _: NationwideHomes P.O.Box 5511 _e, VA 24115 VisitD_t_: 1 June 1989 (revised 7/14/89) James Love,Productiofi Manager Pr_ectStaff:Jim Roland,BillSwart,Abroad Elshennawy ReportPreparedBN Jim Roland Company Pro_e Nationwideisa modularhousingmanufacturerproducing12 and 14 feetmodels. The company has two modularplants, and a separate building forcomponentsand storage. Nationwidesells througha dealernetwork. Nationwidewas recently purchasedby seniorplantmanagement. BusinQssVolume and $_ - million/year 680 homes/year DesignSta_ = 6 Production Staff= A_mi_tzativeStaff= SalesStaff= t Totalstuff is approximately 350 Designprocedure They have a standarddesignfor 37 homes. However, Nationwide,as allother manufacturers, pointedoutthattheyareinthe customhousebusiness.They buildwhat the marketwantsand designsforthe individual buyer.A Vemacod systemisused for design.I didnot gettosee the engineering ofSce ofthisplant. Automationand Comuutcrizat_qn No automatiomUse computersfordesingand costing. Computersystemisnotintegrated withproduction. Products M_ufactured Modular homes from 800 to 3000 square feet, They also assemble their own cabinets. ,Raw M.ateri_ and !nventor_ Materials are stored inside. control. Quality appears good. There was no sophisticated inventory Manufa..fturine Methods I Two manufacturing lines in separate plants 14 footmodels. also assemble cabinets and doors.Much work by for12 hand -foot moreand apparent wastethanThey expected. Modelsare stickbuiltunderroof. OualityControl Reportedtohave Quality Controlinspectors who reporttoGeneralManagement. Quality ofcontruction appearedgood. Enerev Performance I Nationwide a standard nergypackagewithfeatures greater thatrequired by code andprovides provided by some eof the othermodularbuilders. Thethan standard package includes insulation valuesofR30,Rf3 and Rf9 in theattic, wallsand floors respectively. i standardpackageincludes double pane windowswithstormwindowsassn option. UpgradestoR38 inthe attic isoffered. Foam boardcan alsobe addedtothe walls.The Heat isprovidedby baseboardelectric heaters.Ifthecustomerdesires a heatpump,the factory providesand openingand pre-wires the thermostat.The owner/local builder is responsible forthe heatpump and installation. Two gradesofappliances (GE)are offered, but the difference isinfinish and/orsizenot energy consumption. ' The hotwaterheaterisan electric, 50 gallonenergyefficient unit. A designcommitteeconsisting of threeseniormanagement personsmake decisions on features tooffer.When a customerrequests, througha builder anythinkdifferent from standard or standardoptions, an engineering and productioncommitteedecideit8 feasibility and cost, Comments / ! 2 'Energy Efficient Industrialized Housing Project TRIP REPORT Fac'flitv visited: National Building Systems P,O, Box 8578 ColLinsville, VA 24078-8578 .Yj.__: 1 June 1989 (text revised 7/12/89) _[9._:Don Peck Project Staff: Jim Roland,BillSwart,AbroadElshennawy RevortPreparedB_ Jim Roland CQmuanv Profile National isa largepanelized home builder (over6000 housingunitsperyear)located in Lafayette, Indlana_ Martinsv_e,Virginia; and Thomson, Georgia. Homes are soldto builders. National usesa salesforce(17people). They aremarketdriven.Almostevery home iscustomized. National recently reorganized, putting allengineering atthe Martinsvflle plant.Business is20% single familydetached, 75% multi-family and 5% commercial. Business Vohune and S_e 70- million/year t_00 homes/yeartotal At thisplaz_t 800 DesignStaff= Produ_on Staff= 120 Ad.minJstrative Staff= ,C_ies Staff = 17 Desien Procedttr_ National offers design services or will build to other's plans, Although they have standard designs almost every unit is customized. They build what the customer wants, They have a computerized materials take off and estimating system. They receive order for 16% of the estimates they do, Automationand Compu._tefi_ti_0_ No automation.Nationalisprogressive in use of computers.They use ICG software (walls), Merlin(trusses) and Advanced Construction Technologyforestimating.Their system will eventually control inventory, Computer produced tickets are used on the plant floor to specify all cutting and construction, Products Man,, ufactured Open panels with or without exterior siding, with doors and windows, trusses, cabinets, Have ceased dosed panel construction because of code problems, Raw Material and Inventory The computerized design system they are using will eventually also be used to control inventory, Part numbers are assigned now. _.tmufoctt_ine Method_ National has seven production lines at the Virginia plant, Cutters using radial amn saws " cut and mark all pieces using computer generated instructions. Cut materials loaded on part costs and delivered to the lines, Oua_iW Control 1 Quality Control reports to general management. a function of the local builder. Enerev Performance National builds what the customer wants. insulation. ! Final quality control, in this case, is more Their panels are not closed and contain no Continents National is operating in a very old plant in _e. computer usage of any of the plants we visited. - They had the most advanced National can deliver a typical 3 bedroom, 2 bath house on one truckload. Their trucks have cranes for set-up and en air compressor for use by the builder in assembly oi' walls and roof. The National plant is unionized. Average labor rate is $7.64 per hour which k substantially higher than any other plant on the Virginia tour. At other plants the labor rates were $5.00 to $6.00 per hour. ' National estimated materials cost to be 50% and labor 10 to 15% of total cost of house, 1 | ! 2 Energy Efficient industrialized Housing Project TRIP REPORT Facility '' v_mted: _: TitanManufacturing Co. 10901Rhema Road Orlando; Florida 32821 VisitDat_: March 2,1989 Mx. Tom Nelson,President (407)851-8450 Project Staff: LawrenceMaxwell,Jim Roland ReportPreDatedBy_ LawrenceMaxweLl Comvanv Profile TitanManufacturing Co,isa produceroflight gaugesteelstudframedpanelized housing components, whichincludes wallassemblies and rooftrusses, The manufacturer isworking on developing innovative panelized housingcomponentsand systemsutilizing metalstud framingin lieuofwood studframing,Currently, TitanManufacturing has 22 patents or patentspending for variousinnovations developedfor metal stud framed panelized construction. Mx. Nelsonisresponsible (aided by an outside engineer), forthe creation and development ofthe innovations that]_avepatentsappliedfororpatentsobtained, Titanhas been developing new studshapesand formsforvariousportions oftheirwork The new shapes and forms are to facilitate the manufacturing and construction process. At the present time, Titan does not have the capability to form shapes that they utilize from roll steel, however, the company is involved in retooling to increase their manufacturing process as well as enable them to form the shapes they need, as they requirethem. i i Business Vole.meand St_['m_ _. .5-million/yes.r DesignStaff= 0 60 homes/year Production Staff= 6 Administrative Staff= I SalesStaff= I (Presently organizing salesstaff) Desien ]_rocedu_ At present, there is no in.house design work. All work is bid _om outside home builders. i f En,er_ Desi_n, Decisi.on_ All work preformed by the company is to plans provided by outside contractors, as such, there is no energy related decisions made, but rather the panels manufactured are per the requirements of the builder, Automation .and Computerization Computers are utilized for word processing and administrative c_mpany is presently investigating computers for cost estimating, structural analysis, functions only. The truss configuring, and Roboticweldingsystemsarebeing[n_cstigated forwallpaneland trussmember welding, Further, an auto-pnuematic screwdriving systemin-lieu-of weldingisbeinginvestigated. The robotic weldingsystemisby Hobart, Inc., and theauto-pneumatic screwsystemiJby K_:met_,_c, _0.ductsMan_a.ctured Open panelexterior and interior steel studframedwallsystemsand steel studframedroof trusses, foroutside home builders, i O_ I ]_ Material a Invento_ Raw material cn_l onsists of galvanized steelstudsofvariousgaugesand stud thicknessea Material inventories are maintained and obtained on an as required basis, Manufacturin_ Methods Wall panels constructed built are on company jigs,Wallpanelsconsist ofvariousgauge steel studswhichconfigured inthejigand then connections aremade by welding.At the weldpoint, (thepointwhere studmeetstoporsill track), a continuous weldthe lengthof thesideofthe studisapplied, Even thoughspotweldingmay be sufficient, the company provides full weldsateachlocation. Treesmembers areformedon a plantfabricated metal brake.Then theindividual truss members arearrangedina truss jig, (also in.plant built), and weldedtogether, Ifany additional work isrequired on thepanels, suchasattachment ofexterior sheathing orinstallation ofwindows,theseoperations areperformedofftothe .., sideofthe main assemblylinearea, _Oual]_ Control Quality control measuresconsisl; oftheuse ofalignment jigsand fixtures toinsureplumb and squarepenels, and the insistence thatallweldsbe full weldsversusspotwelds. j Enere_, Performance designs broughtinto plant.However, asbuyer the plantcan provide wall framing suchas The plantprovides tthe o the buyerwhat the has specified as all work isbasedon O_ ! '- 6" framing for less cost than which allows for increased tolerances in the wall panels and erection, that a tighter, 2x4 wood framing, ,many clients opt for the greater thickness wall insulation capabilities, Further, consistantly tighter and panel openings are rnalnt_ined throughout manufacturing and more precise building envelope can be obtained, Comments The innovations being developed by Mr, Nelson appear to be directed towards reducing the cost of as well as the amount of time spent manufactu._g of and in erection of the components in the field, The innovations are a direct, spin.off of the metal stud framing _stem, but at least some could have direct application to wood framed construction. Interestingly enough, the innovations developed by Mr. Nelson, would benefit both industrialized as well as conventionally (site) built housing. The following are some of the innovations that Titan Manufacturing is working on: ._ ' - A 'truss shoe" which is attached in the plant to the top of a panelized wall assembly that eliminates several time consuming steps in the field; measuring and location of trusses and final attachment of the truss. The truss shoe is such that the truss is placed into the shoe and snapped into position, once snapped in, the shoe is capable of permanently holding the truss without any further mechanical fastening. - A 'truss plumb block' which allows the installer to plumb the truss as well provide X.bracing to adjacent trtmses at the same time. The plumb block eliminates the need for any additional tools or equipment to phunb or brace the truss as the plumb block will not snap into position until the truss is plumb. Further, once the plumb block is snapped into position, no further mechanical fastening is required to secure it to the trusses. - A 'panel clamp' which allows two wall panels to be mated and snap locked together without any further mechaz\ical fastening required. • New shapes for various structural members to either provide greater structural capabilities or ease of assembly in the field. • Pre-formed facia and soffit assemblies that require only a snap on attachment in the field, and which also allows for painting before or after installation as well as allowing for the attachment of various other finishes over it such as wood if desired. Titan Manufacturing presently gafus economic advantage in construction through the _avings m material costs as outlined earlier_ However, Mr. Nelson feels that steel stud framing can very easily be cost competitive with wood framing using 'full cost', steel with even a small quantity of homes being produced, Presently, he contents that his costs for manufacturing and erecting a home are significantly lower than a conventional rough framing, crew on the same house, and with any sort of quantity at all, there would be no comparmon in costs between the two systems. To date, Titan has been able to compete in the market place not because of volume of work produced, but rather by being cost competitive through the cost savings of t_ raw materials used. Mr. Nelso_ of Titan will typically travel to various steel operations in the state and purchase sheet metal of the gauges required for _uck. The sheet metal purchased is reject material obtained at very low prices due to it being visually blemished 3 i i and therefore not acceptable for use by the supplier, The supplier Is typically utilizing the sheet metal to roll form metal wall and roof panels, Titan manufacturing will typically have the seller roll the sheet metal into the stud shapes he requires for his work as part of the purchase, as Titan does not have the capability to roll the shapes they require presently, When posed the question of what is the perceived benefits of producing homes in this manner, Mr,' Nelson noted, interestingly enough; 1.cost savings through quantity materials purchasing, 2-inexpensive labor force (the manufacturing operation can utilize completely untrained people, an employee can be trained in two days to perform the tasks required), 3-ability to produce components in a controlled environment (out of the weather, and with the ability to utilize quality assuring machines such as jigs), The two perceived hurdles to acceptance of metal stud framing in a home are home owner misconceptions of metal stud systems (sometimes perceived as being somehow inferior to wood framing) as well as some builders reluctance to utilize metal studs instead of wood. The advantage of reduced costs appeals to the builder, However, in most cases to date, these cost savings have not been passed on the homeowners, The homeowners who, after having lived in the homes, have been queried about their concerns over the metal stud systems, had no complaints about the system. 4 / I _r i , , Energy Efficient Industrialized Housing Project TRIP REPORT Facility visited: _: Ryland Homes Visit Date: Feb,2,1989 NortheastDivision 7120 OaklandMillsRd, Columbia,Maryland21046 John Slayter, V.P.research ', engineering, techsupport(301)730-7222 P.R.(Dick)Drass, plantmanager (301)381-1300 Proiec_Staff: Phillip Fairey, LawrenceMaxwell,BillSwart, John Rivera, CarlaKish,MarvinGorelick RevortpreparedBw, LawrenceMaxwell Company profile RylandHomes isa 20 + yearoldcorporation whichproducesbothmodularand panel_zed homes forre'ali sale. The company alsohas mortgagesubsidiary, as partof itsgroupof operations. The company has operations in the Mid-Atlantic region, Florida, Southwest, Central region, and California Rylandsells primarily to.thefirst timeand move-uphome buyerinthemarketrangeof$70,000to$325,000price range.The companybuilds mainly single familydetachedhousing, but doesbuildsome multi.family attached housing. The plantvisited in Columbia,Maryland,isa open-panel wallassemblyand rooftruss fabrication plant. Business Volume and SmfFme " $800. million/yeL, x(companywide) over9,000homes/year(company) DesignStaff= Production Staff= 75 Administrative Staff= SalesStaff= Desien Procedure . RylandHomes builds homes froma file ofstandard planswhichmay be occasionally altered froma list ofoptions available tothe prospective buyers. Majorrevisions orcustomdesigns aretypically avoided. When the company makes a determination that a new product is desirable, the new design is initiated by the head office. Within the head office_ a group consisting of sales, marketing, financial, and design personnel get together to determine what the new product should be. The design is created, drawings are produced, including specific manuiacturing drawings, and then distributed to the manufacturing plants that may produce it. Enere_ DesienDecisions ,' RylandHomes buildshomes to meet codeenergyefficiency requirements. A "Super-E" upgradedenergyefficiency packageisavailable as an optiontothebuyer. A..utomation a_d Computerization The amount and typeofcomputerization utilized atthe corporate levelisunknown. At theplantlevel (theplantvisited), computersareusedintwoareas; administrative: functions and production. The administrative functions aretypically forpayroll, accounting, etc.,for production thecomputerisutilized toprovide a printoutofpanels required forproduction ofa home,alongwitha listing ofthe materials required. Computersare not utilized forproject scheduling, or work orderscheduling, nor isany computerization or automationincorporated inthe manufacturing operation. ProductsMan.ufactur_d At theplantvisited, wood framedopenwallpanelsand rooftrusses areconstructed. Both exterior and interior wallsaremanufactured, withexterior panelshavingtheexterior subl sheathing attached atthe plantand the interior wallshavingonlytheframingproduced. ! l_w Material and Inventory Lumber ispurchasedinlargequantities, withinventory turn-ow;r occurring about12 times a year. All lumber materials are storedin an open yard,and unprotected from the weather.Allthe additional materials requiredforthe home suchas siding, sheathing, roofing, etc., arepurchasedin quantity by the plantand senttothe siteasrequired. Manufacturing Methods ' I Manufacturing is performedin a {}0,000 s.f. plant. Computer generatedprintouts of requiredwallassemblies are utilized to produceallwallpanelsrequiredfora home. Material isassembledfrom the yardand cut down utilizing hand operated power tools, Door and window openingsubassemblies are constructed and moved to the main wall assembly line.Wallsareconstructed on setuptables, allmaterial ismanuallyplacedinthe jigsand allnailing isperformedby hand heldpneumaticnailers. The wallpanelsare then moved by hand to the sheathing application table.The sheathingisplacedand positioned by hand,then a automaticstapling bridgeattaches the sheathing to the wall framing. The wallassemblyis then moved mAmml]y and placedon the trailer for transportation to the construction site.While the loadingofwallassemblies istaking place, otherconstruction materials arealsoloadedon to the trailer insucha faahional toinsurethetransportability oftheentire Ioa& Adjacenttothewa_lassemblyline, isthe 2 truss assembly line. Similar to the wall assembly operation, all materials are manually cut, positioned, and the truss press is manually positioned at each connection plate prior to pressing of the plates. The trusses are then manually carried to the trailer and loaded for transportation. Quality Control A quality control position has been created in the plant to determine where a field identified problem may have _curred, or if the problem occurred after an assembly left the plant. No other quality control measures were identified. Enerev Perform_ce No energy emciency improvement measures appear to be implemented in the plant. Further, since all the remainder of the construction in the field is conventional construction practice, it is assumed that the energy performance of the finished product is comparable to a s'mlilar site constructed home. Comments Energy Efficient Industrialized Housing Project TRIP REPORT Facility visited: AmericanStandardBuilding Systems 700 Commerce Court Martinsville, VA .Visit Date: 1 June 1989 (textrevised 7/14/89) Project Staff:Jim Roland,BillSwart,Ahmad Elshennawy R.epo_ PrevaredB_ Jim Roland Company PrPffl_ American Standard is a twenty-year old manufacturer of open panels. Their plant was the newest and most modern of those seen on the Virginia tour. They are producing 15 housing units per week and have a capacity of 30. t BusinessVolume and $taff'me 19. mLllion/year 800 homes/year DesignStaff- Production Staff- Administrative Staffffi SalesStaff= 17 TotalStaffis180 Desien Procedure . American Standardhas a largenumber of standardplans,but as in the caseof all manufacturers, eachproject isunique.AmericanStandardusesa CAD programfordesign ofwallsand trusses. They arenotasadvancedasNational inuse ofcomputers, butmuch more advancedin tools inthe plant. Aut@n_tiQnand Com])uterization Thisplanthad the highestdegreeofautomation.They have many operational s;.ations thatuse automaticsaws,routers, punches,etc. ProductsManufa.ctured • i 1 Open panels with or without exterior siding, with doors, windows, etc. American Standard also manufactures doors, stairs and other components. Raw Material and _ventor:y ', ,. Manufact_ M_th0cls Probably asclosetoautomation asany Americanhousingcompany.They construct panels, trusses, doors, moldings, etc.usingmodern equipmentand inmany casesautomatictools. Qusli_ Control Probably has tighter construction quality thansome ofthe otherplants.QualityControl Jza concernand exercised inthe plantwithinspectors and a manual. EnerzvPerformance No special concernforenergy. Constructing open panelsonlyand building what the market. Energy decisions are made at the local levelbetweenthe purchaserand local builder. Most modern lookingimpressive plant.Still heavyuseroflabor, but has many aut,_matic tools. AmericanStandarddelivers tobuilders, butdoesnotprovide craneservice asNational does. # Energy Efficient Industrialized Housing Project TRIP REPORT Facility visited: Cardinal Homes VisitDate: 31 May 1989 P.O.Box 10 1:30-3:30PM Williesburg, VA 23976 (text revised 7/12/89) (Notassociated withCardinal Industries) Host: Don Cappaert Project Staff: Jim Roland,BillSwart,Ahmad Elshennawy ReportPreparedBr.JimRoland Comuanv Profile I CardinalHomes, Inc.isa private company constructing modularhomes. They sellin Virginia, West Virginia, NorthCarolina and Maryland.The facility includes a 42,500square footplant(Butler building type).They sell tobuilders, developers. Modulesareeither12 feetor 14 feetwide. Business V...olum. e andSmfrnne - million/year 250 homes/year(approx. I house/day) DesignStaff= Acim_ni_trative Staff = Production Staff= 90 SalesStaff= Desien Pr.ocedure Cardinal has a number of standard designs of 24 feet and 27 feet width. They also offer options and acceptcustomeroptions. .' Automationand C. omputeriz_tign No automation was evidentinthe factory. ProductsManufactured ' ! Modularhousesusingmodules12 feetor14 feetwide lengths up to56 feet, one storyand two stories. Wood construction, 2x4 studscoveredwith plywoodand varioussidinga Interior smooth drywallwalls, stipled ceilings withmoldingatthe floor and ceiling. l Raw Material and Invento_ Material is stored under roof. Quality appeared good, All material trucked m. Inventory set, based on deUvery expectations, e.g. if it takes 4 weeks to obtain a particular product they keep at least 4 weeks supply. ..Manufac.turine Methods They use various self-built jigs and fmtures. No automation is used, Very little pre.cutting and pre-drilling is done. For example, the electrician does his job (from the outside) hauling a drill and 100 foot extension cord, drilling studs and plates as necessary, QualiW Control A Quality Control inspector who reports to general management is used, A quality control manual is used. The quality inspector inspects at each station and reports any problem to the foreman of that shop. In case of conflict, tha inspector can go directly to management. Energy Performance No special energyfeatures areincluded.They can be orderedas options,See attached features and optionssheets. Co_ents At thisplantand atallthe plantscomments were made tothe effect that'youcan't sell energythesedays,no one isintereste&" Qualityand features ofthe basichouse atthisplantisjudgedtobe OIL but,not great. One of the othervisitors saidtheirunitswere somewhere betweenmobilehomes and modularunits.Theirmodel home 1080ftz sells toa builder dealerfor$25,000, Laborratesat thisplantaveragearound $S.00per hour. Keepingqualified l_l_or was reported as a mai0rproblem. Code approvals were reported as no problemexceptinNorth Carolina. .. Sizesare from 900 ft2 toabout1800ftz. My tourguidesaidmost oftheirs arebetween 900 and 1200ftz. b Energy Efficient Industrialized Housing Project TRIP REPORT ,,J Fac_tv vis'ted.l' ': Fleetwood Enterprises, Inc, 1603 Grove Ave. P,O, 37 Haines City, F1. 33844 (813) 422-7591 Visit Date: Mar. 25, 1989 Host: Phill Tanner, Plant manager _ProjectStaff: Subrato Chandra, Jim Roland, Bill Swart, Lawrence Maxwell, Tim Branson Report Prepared By; Lawrence Maxwell Company Profile Fleetwood Enterprises is the largest manufactured home builder in the U.S., with production facilities throughout the country. The company manufactures both HUD code (mobile homes) as well some recreational vehicles. Fleetwood has two manufacturing plants in Florida. The plant visited manufactures for the retiree market, while the other Florida plant manufactures homes for the family market. The corporate offices of Fleetwood Enterprises are located in California. I Busin_Volume ,and S_g $26-mfllion/year 1300 homes/year(this plant) DesignStaff= unavailable Production Staff= 145 to 185 Administrative Staff= ? SalesStaff= (salesstaffconsists of mobile home dealerswho purchaseunitsfrom Fleetwoodforretail sale) Design Procedure The design of new homes by Fleetwood occurs at the corporate level and is undertaken in California, even though the new product may be for a specific market such as the Florida retiree market. The localmanufacturing groupwilldeterminethata new productis desired either by the typeofrequests received from the dealers thatmarketthe homes, or based on observations of productsmanufacturedand soldby competitors. information isrelayedtothe corporate offices inCalifornia where the decision todevelop a new productwillbe determined.Ifthe decision ismade to createa new productor changeand existing one,the designand developmentwilltakeplacein the California offices. | | 1 wiring, The roof assembly, which consists of trusses, ceiling, insulations, and HVAC ducts, is moved as a complete unit from its assembly area and attached to the top of the walls, Roof sheathing, felts, and shingles are attached to the roof assembly after the assembly has been attached to the main structure, Exterior wall finishes and the balance of interior wall finishes, are applied, By this time, the plumbing and electrical work is completed and testing of the wiring as well as pressure testing of the plumbing systems is carried out, Finish trim and molding os attached, and doors are adjusted for proper closure,, At this time the production is complete and the unit is ready to be moved out of the assembly building, / QualityControl Third party code inspectors (DOT inspectors) are on hand at the plant to confrere code compliance. In-house QC measures were not detailed during visit, Enerevperforce The unitsmanufacturedby Fleetwoodare designedto HUD requirements. code energyperformance Co!_l_en_..8 Automationisnot incorporated in tothe manufacturing process.The use ofpneumatic stapling gunsrepresents thelevelofmechanizedeqttipment utilized inthe manufacturing process.All materials control, handling, cuttingconfiguring, fastening, or assemblies movement isperformedmanually.Inventory control, production r-An_gement and control, and scheduling areperformedmanually.Thisplantwas stated tobe fairly representative ofFleetwood's manufacturing operations aroundthe country. i Energy Efficient ' Industrialized Housing Project Trip Report Facility Visited: Acorn Structures 1 Rear Keef Road Acton, MA 01720 _: Visit Date: March 2, 1989 3:45. 5:00 p,m, Mark Kelley, Energy Engineer, (508) 369-4111 4 Project Staff:SubratoChandra,PhilipFairey, BillSwart ReportPreparedb_ SubratoChandra Comvanv Profile Acornisa 41 yearoldpanelized (open)builder catering to the custom home market ($100/sqft+ range).Acornsells primm-fly intheNortheastand theWashington, DC area_ althoughtheyhave shippedhomes alltheway toCalifornial The Acornfacility iscomposedofo_cv and manufacturing facilities aswellasa salesand model center.Acornworks directly with affluent homebuyerswho want customhomes. AcornusesAcorntrained builders tobuildthe home. Acornhas a distinguished history ofbuilding energyef_cient housing.They havea direct D their homes, They have 600+ active s olara housesand many more passive solar houses gainsolar houseasa model houseand offer ctive solarheating/water heating options on operating inthe field. ! BusinessVolume and 8tatTm_ ~ $13 - million/year - 200 to400 homes/year Designstaff= 22 Production staff= 8 to 10 Administrative staff = 12 (including fmance,dat_processing, R&D, Marketing) ._, SalesStaff= 39 DesignPr.ocedure There arethreelevels ofdesignservice: • Standardplan,as in catalog w/minor modifications - MAjoradditions or modifications tocatalog designs - Architecture from scratch. Acornworkswiththe homeowner todesignthehouse.The houseplanand elevations are done manually.A graphics computer(ortwo?)isexclusively used toupdateconstruction detail bookscommon toAcorn houses. ! | i Energy D_si_ Decisions Fleetwood energy design decisions are market driven, If the market demands increased energy efficency, Fleet_ood is willing to provide it, Otherwise, Fleetwood works to meet HUD code minimum standards, Automation and Comput_rizat_ Computers are not utilized in the plant other than for some clerical and administrati,e functions, Inventory and production scheduling and control are performed manually, Products Man_/actur_ Fleetwood manufactures HUD code homes in the Haines City plant, The units mauufactured are single and double wide mobile home units targeted for the retiree market, The assemblylinewillhave I0 unitson the lineat different stagesof const_ction ata giventj.me, and production issetup sothatina run,theywillproduce a pre-determined number ofidentlcal models,Thisallows theproduction staff toproduce a number ofidentical unitssimultaneously, insteadofworkingon 4 or 5 different model types at the same time, Raw Material and l_vento_ Fleet'wood purchasestheirmaterials in largequantities, The purchasingagentswill typically purchaseitemssuchaslumberfor2 or3 plants atone timeensuring thegreatest possible ,pricing advantages,Bulk itemssuch as lumber willbe broughtin by railin quantities thatwillinsurea 2 week supplyofstockto avoidany shortages ofmaterials wbJch couldpotentially stopproduction. Allmaterials are keptin enclosed building_ to maintainmoisturecontentlimits and preventdeterioration. Construction inventories are turnedoverapproximately 24 timesa year,Material wasteisnot monitoredortrackedin the production processand figures forthe quantities or material lostto wastewere not available. _anufacturing Methods .. The manufacturing ofa unitbeginswith the construction ofthe steel chassis, The steel members forthe chassis areconfigured on a jigand welded,When the chassis assembly iscompleted, itistakenoutsideforpainting.Once painted, the chassis isbroughtback intotheplant,, placedon a dolly whichfacilitates itstravel sideways throughtheproduction _quence,and be'gins itsjourneydown theassemblyline,The assemblythinbeginswith theconstructmn ofthe floor platform on the cha_is,The floor joists areattached tothe chassis and the plywoodsubflooring isgluedand stapled tothejoists. Floorcoverings are appliedto the platform.During the assemblyof the floorplatform, in_erior walk, cabinetry, and roof assemblies are constructed in areas on either side of the main production line. As the main assembly moves down the production line, the subassemblies are moved, over the main production line and attached to the platform. Nearly all subassemblies are hand carried to the production line, except for the roof system, which tstoo largeto be manuallylifted,Exterior wall_ isattachedto the platform, electrical wiringisrouted,and exterior insulation ismstslledand fishedthroughthe E_ner_ Desi_ Decisions Acorn makes a conscientious effort to design and build very energy efficient homes. This is by utilizing architects and engineers who are very well versed i_ both passive and active solar energy technologies as well as energy efficient design and construction techniques. At_omation and Computerization They have a VAX duster and three VAX minicomputers to perform management tasks (accounting, payroll), A net'worked PC running VersaCAD is used to draw panels, They strive to design to a 4 ft x 8 ft panel, A complete set of blueprints of the house fs used to prepare shop drawings for panels, Even with the VAX, there is a lot of manual counting and checking, About 3.man days are required to produce material take.offs, The computers are not run at night, They are in the process of examining ICG's computer software in hopes that it can better integrate their operation, Products Manufactured Acorn uses a traditional frame structure using ra/tar assemblies rather than trusses for roofs. They pre-cut the roof rafters and pre.assemble open wall panels in the factory, They assemble their own fixed windows and buy operable windows and doors, The manufactured products are trucked to the site. !_w Material and In:rento_ Ali lumber used kiln dried, the best quality available. All lumber is stored under a roof. Raw material inventory is typically 1 to 1 1/2 months. I Manufacturine Methods Manufacturing is done in a 60,000 sq ft factory. Radial arm saws cut the lumber for roofs and wall panels. The wall panels and windows are assembled on two separate lines on workstations having j'i gs. The material is moved everywhere manually by handtruck, forklift and cranes. The plant gets custom drawings for each panel manufactured from the design department. Theso drawings are stapled to, the panels as they. go down the production line and are removed by the stacker who checks the construction quality. _uali_ Contr_l In the plant, the supervisor checks to see that the panels are correctly made as per the drawing. The builders are trained and preapproved b_, Acorn. Acorn personnel,in field, erform quality control checks and educate the builder about properly installing infiltration arners, caulking, etc. Measured infiltration rates in Acorn homes are 0.1 to 0,4 airchanges per hour, These are very tight homes and thus Acorn installs air.to.air heat recovery ventilators in most homes. Acorn houses are very energy efficient and have an overall heating requirement of about 3,5 Btu/DD/sq ft, Typically their passive solar direct gain homes have a backup fos_l | ,,. J ' energy consumption of 2,5 Btu/sq ft/DD and their hybrid homes have backup requirements of about 1 Btu/sq ft/DD, This high level of energy efficiency Is_achieved with a high level of design expertise, use of R.19 walls, R.30 ceilings, low.E glass, an imCiltration control package, builders _traLuedin low infLltration construction techniques, use of high quality materials and tight tolerances in manufacturing (1/lY in all wood cutting operations). However, this is achieved with skilled production crews and a very low level of factory automation, Acorn design buyers ethics is committed to building a very of Acorn houses m aesthetics, buy energy efficiency and solar is a strong motivation in many high quality and very energy efficient product, Tho amenities, and space layout is outstanding, Their not totally due to economic reasons, Environmental Acorn buyers, Acorn used to manufacture closed panels (insulated, wired, plumbed, etc,) which would be erected in the field in a tilt-up mode, They have abandoned that because of diff, culty in getting inspection approval, Acorn is very supportive of the EEIH project, They are willing to work with the project team. They are especially interested in air distribution systems research and technology, and in design for microloads. I June 21, 1989 INDUSTRIALIZED HOUSING PLANT VISIT Title: Acorn StructuresPlant Visit Date: April 18, 1989 Location: Concord, Massachusetts Attending: BarryMcGinn, Center for Housing Innovation, University of Oregon Purpose: To view an industrialized housing plant. Sponsor: Energy Efficient Industrialized Housing Research Program Supporting Documents: Annapolis House Plan On April 18, 1989, a representativeof the C.enterfor Housing Innovation at the University of Oregon visited theplant andoffice ofAcornStrucRn'es m Concord Massachusetts. Acornmanufactures a 4x8 openpanelhousing system, whichallows thema gooddealofflexibility indeveloping varied house plansandmassing, | Acorn hasattractively a standard catalogue 45 plans whichcolor fall into five major families house offerings. These are set forth inoftheir extensive brochure"The Art of anofAcorn." The house families arc categorized as pcr their s_tltentarchitectural massing features, such as shed roof forms, wraparoundhiproofs, andsaltbox forms.Theyarefurther elaborated oninseparate family brochures, whichexplain indetail eachmodelinthefamily. Theirmodelhouses arelocated inActon, MA andMorristown, NJ. Inaddition, display offices arelocated inWestport CT,Annapolis MI:), andFalrfax VA. Approximately 30% ofAcornpanelized housebuyers purchase straight catalogue houses, 20% purchase totally new deslgns, and 50% purchase modified catalogue house designs. The professional architects and designers on staff at Acorn have a plan library of standard changes to catalogue houses that number in the several hundreds. Their market goals are to reach out to new builders and building dealers. The plant operates with three standard 4x8 panel lines and two 8x8 special sub-assembly panel lines. Special jigs for frame alignment and racking are employed, as well as hand held pneumatic nailing guns. , •. I their own fixed windows. Theyusestandard PeUaoperable windows.This affords them Acornstock a large number ofsealed glazed units ofvarious configtwations fromwhich theybuild considerable flexibility inconfiguring windowlayouts andwindowwalls anditisobvious they capitalize on this feature intheir housedesigns. Theirscaled units am purchased witha 13/16in. airspace asopposedtotheusual 3/16inairspaceforimproved energyperformance. Low emissiv_ Acorn Plant Visit 1 . glass is used exclusively for the same reason, The in-hour's:,millwork shop fabricates all the sash, window frame, and trim, The window units are assembled into a frame on the 8x8 sub-assembly panel line and shipped to the site as a panel, The floor decks are stick built on site; apparently floor cassettes proved too costly for the complex house designs used. The panels are simply nailed together and to the deck with the aid of a lever gadget for alignment that was invented for the purpose, The wall panels are se'lfsupporting while the roof is supported by an internal heavy timber frame of fir posts and glue-lain beams, A 4x10 solid fir header is utilized for external wall openings. A special vent spacer detail for the open ceilings has also been developed, , CAD and Ener_ In 1974, Acorn developed and Commenced manufacture of a large formaVlarse volume active solar system incorporating their own flat plate collector design. As well as the actave system, many of their house destgns incorporate passive solar heating elements such as solariums with mass heat storage in the floors. They perfo,rm energy performance analysis on a separate computer from the CAD for the various active/passl_,e solar systems used as well as site conditions, They are presently reassessing their CAD system m,qutrements and are not using the CAD system for design. They simply track house construction (plant panel fabrication) on a wall, similar to what you might find in a construction site office. The proclucdon department does a take-off with a separate computer which generates a cutting list and a packing list, Many of the Acorn designs incorporate extznsive vertical, o_n planning but do not seem to bc ,taking vantage ofthestack ventilation potential inherent inthis des2gn approach. Them tsalsotheissue of winter.tame heatstratification whichmustalsoaccompanythis spatial design strategy andwhichdoes notseemtohavebeenaddressed. Mostofthesmaller homesinthevarious family housecategories start atabout$140,000withthe exception oftheluxury family group, andrangeuptoabout$360,000, Ac,or'n, builds aquality panelize_ home anddefinitely seemstohaveextende.d theaesthetic possibihties ofthis production mode. Acorn Plant Visit 2 Energy Efficient I_dustria]ized Housing Project TRIP REPORT FaciLity visited: Ryan Homes 4408 N. Airport Rd. Plant City, Florida 33566 Visit Date: Mar.24,1989 Host: Daniel J. Ball A.LA. (813) 754-0555 Project Staff: Subrato Chandra, Jim Roland, Lawrence Maxwell, Bill Swart, Tim Branson Rewort Prepared Bw. Lawrence Maxwell Company Profile ' Ryan Homes is a home builder utilizing a factory setting to produce open wall panel assemblies. The company produces both homes from a file of designs as well as custom homes and homes from plans brought to them by builders and home buyers. The homes built range in cost, from $60,000 to $250,000 each including land costs. Ryan Homes facility consists of Administration building, 3 buildings for production, and a materials storage facility. I Business Volume and StaWme - million/year homes/year Market:Move up home buyers $70,000 to $350,000 DesignStaff= 9 f Production Staff= 30 Admini_txative Staff = 7 SalesStaff,, Desien Procedure Ryan Homes design department consists of arcb.itects, engineers and draftsmen. The group is continuously developing new home designs. Through an independent m_ket research company, potential h,_me buyers are quizzed as to what they are looking for in a home, eventhough theyarenot informed asthe actual company who isdeveloping thebdesignL theyarealsoaskedtocomment on and criticize designs that arebeingdeveloped y Ryan, The comments received fromtheprospective buyersareincorporated intothedesigns and the homes are built.Most of the actualdesignwork isaccomplishedin the more traditional manner,i.e. sketching v.s. by computers. ! Z Ener_ Design Decisions Energy decisions are derived by providing complaince with the local code requirements in themost costeffective manner. Decisions aredeveloped by the designers alongwiththe market managers.No energyupgradeoptionisoffered, but can be provided ifinsisted upon by thebuyer.Equipmentsuchashvacunitsaresizedbasedon worsecasescenerio, and withagreements withequipmentmanufacturers, theactual unitsinstalled will be sized bythemechanical contractor, and areusually downsizedfromthe_mitspecified. Upgrades foritemssuch as kitchenapplainces willbe basedon addedamenitiesin the unitv.s. incorporating a more energyef_cient unit., The companywantstobe fully marketdrivenintheir decision process. The companydoes notprovidea energyefficiency upgradeoptionatthepresenttime.The optionwouldbe offered ifthe market expressed a desireforsuch. Automationand 0om])ut_rizatio.n Ryan Homes utilizes computersforadministrative functions and foradvancedproduct designand engineering. At theadministrative level, computersareutilized foraccounting, payroll,and _irniIAr ftl.Ilctions. At thedesignand engineering level, computeraideddrafting isutilized to producethe final production drawingswhich includesuchthingsas panel configurations materials rake-offs and costestimating.The computersin house are networkedtogether and have the capability tointeract withthe central computersystem atRyans home office. Computers are not utilized in the manufacturing process, or in scheduling ofwork but isutilized forinventory control There islimited use ofautomationin the assemblyplant.An automatedtrussmember cutting machineisutilized, however,theactual trussfabrication machinerequires manual setup, material placement, and traasassemblyremoval.The balanceofthemanufacturing operation inthe plantisnonautomated. .P.r0ducts Manufactured Ryan Homes manufacturesopen wallpanelsand rooftrussesfor construction of their speculatively built homes. The company alsoproducespre-hungdoorsutilizing purchased doorblanks, and producestairs and railings intheirmillwork shop.On occasion, they_dll producewallpanelsforbuilders from the builders drawingson a bidperjobbasis. ._Raw Materialand Inventory The plantinventory ischangedoverapproximately 12 timesa year.Allwood products are storedundera shedroofto protect, from weather,but humiditycontrol isnot provided. Doorsarestoredasblanksand pre-hungon a asneededbasis. Windows areprepurchased and utilized as require& Kitchenand bath cabinetry arepurchasedknockeddown and assembledintheplantforuseinthe new construction astheyarerequired. Countertops areproducedin the plant. Mauufacturin¢ Methoc_ Manufacturing isaccomplished in 3 buildings, one of approx_20,000s.£forwallsand 2 = millwork, one of approx, 15,000 s,f, for trusses and casework, and one of approx, 8,000 s,f. where rough cutting of material for the truss fabrication operation occurs, Walls are produced on jig tables with manual cutting and placing of materials, and pneumatic nailing of materials. Exterior sheathing is attached in the plant as required, windows may be assembled into the wall panel at the plant. Trusses are produced on a truss plate press which requires manual set-up and materials placement, and manual truss removal, Several different sized truss presses are utilized in the plant. In the millwork shop section of the wall assembly plant, pre-hung doors are produced along with such iter-. asstairs and stair r_gs, Theseareproducedby hand and withsome conventional finiah carpentry equipment. i _ualitvControl Duringthe manufacturing process, the foremancheckspanelsto ensurethatthey are correctly constructed and aresquare.As thisisan openpaneloperation utilized tospeed up field construction and reducesitelosses, the construction tolerances arenot perceived tobe necessarily critical. The tolerances arewhat isreasonably required toallowerection in the field witha acceptable levelof quality. EnergyPerformance Ryan Homes willprovidean upgradedenergyefficiency packageconsisting ofincreased insulation thicknesses and higherquality windowsifrequestedby a buyer. However, Energy efficiency throughfactorytechnologies isnot the p_zrpose of the operation. Furthermore,the tolerances established in the manufacturingoperationis to allow reasonable construction quality inthe field ratherthanimprovementofenergyefficiency. I | (_omm{_nts Ryan Homes started theirmanufacturing operation producing closed wallpanelsystemsand 3 dimensional wet cores.However theyhaveabandonedthisapproachbemuse thesystem preventedthe flexibility thatwas required by marketconditions. At thistime,theyare producingopen wallpanelsto reducecodeinspection problems, and increase flexibility. They desire to be more marketdrivenand lesstechnology driven. t Energy EfficientIndustrialized Housing Project TRIP REPORT _Facihty visited: MOD-U-KRt.F Homes Inc. P.O, Box 573 Rocky Mount, VA 24151 Visit.. Date: 2 June 1989 (text revised 7/14/89) H_p._:RobertFitts, President DalePowell, VP Operations _.. Jim Roland,BillSwart,AbroadElshennawy Rcuort PreuaredBw. Jim Roland .CompanyProfile Mod-U-Krafisa publicly heldmodularbuilder formed in 1971. The facility includes an office (contained inthe plant) and a very,verytight20,000ft'plant.The marketareais Virginia and thesurrounding states. House sizevaries fromabout900 ft'up to3000 ft2. Salesaretolocal builders withhouseprices inthe mid-range. The modelhome we visited inRoanokewas reportedtosellat$129,000completeon a lottherewith septic tank or hook-ups.Thathouseconsisted offivemodulesand totalled 2230ft.(Seeattached photo). _Business VoIw:neand Staff_e 7.2- million/year 250 homes/year DesignStaff= 5 ProductionStaff= 90 Administrative Staff= SalesStaff= DesignProcedure The company has 76 standardmodels. Almost everyhouse is,however,customized. Re-design and drafting isdone manuallynow. The companyjustinstalled an AutoCad ' systemand istraining personnel on itsuse. The modulesareconstructed intheplantusingstandard drawings suchasa stickbt_ilder would_e. Automationand Computerization No Automation.Plantsizeisverysmalland would limituse oflargetoolsor fixturea They arenow converting toAutoCad in the Engineering Department. i Products Manufactured Modular houses with modules 12 feet or 14 feet wide and up to 54 feet long. These can be grouped in various configurations for one story or two story houses. Type of siding is an option. Vinyl is common, 'i Raw M_terial and Invento_ Materials are stored under roof in a separate building. Plant space is so limited only absolutely necessary materials are kept in the plant. No special inventory control is used. Manufacturin_ Methods Housingmodulesarebasically stick builtunderroof.A module progresses down one line tothe end,istransferred overand progresses down the otherlineand out the doorto a transporter. I saw lotsofhand measurementsusingtapesflaying out thefloor, forexample).Tresses are purchased, cabinets are purchased. The electricians job was made easier by pre-grooving thebaseplate. QualityControl QualityContxolinspector reportstothe president. They have a QC manual. They take responsibility forthe house module,but,not the foundations and sitework. Modules appearedwellcaulkedand tight. Ener_ Performance Energyfeatures arestandard insulated wallsand floors, Rf9including ceiling, baseboard heat vaporbarrier and doublepaneRf1 windows. Options areavailable R.19 fiberglass insulation inthefloor and $38 intheceiling. They offer R-13(Owens.Coming3-5/8' thick areselected basedon withan material availability andboardR-4 thickness ofcavity intowhichitisplaced. fiberglass) inthewall extra insulating overthat.The insulating values The Mod-U-Kraftrepresentative stated thathiscompany isconcernedaboutenergyand .. q i promotesenergyefficiency. The are,however,customerdriven. Standardheatingisbaseboardelectric. Ductsarenotinstalled becauseoftransportation problems.Ifa heatpump isdesired by the customerthe factory provides registers only. The heatpump isselected by the customeror localbuilderand installed by the local builder.This manufacturertriesto "localize" those componentswhich may require follow-on service. The house manufacturer removeshimselffrom thatloopcompletely. The housemanufacturer alsoremoveshimself fromtheappliance loop.He provides Scan kitchenappliances withthethoughtthatthecustomercan getservice practically anywhere the country. Mod-U-Kraft reports theyarechanginghotwatertankvendorsfromAO SmithtoMor-Flo. The hot watertanktheyprovideisan energyef_cient model August 1, 1989 TRIP REPORT i TITLE: Meadowood Industries Tour DATE: July 26, 1989 LOCATION: Lebanon, Oregon ATTENDING: G.Z. Brown, Rudy Berg, Center for Housing Innovation PURPOSE: Facilities Tour SUPPORTING DOCUMENTS: Test Data REPORT PREPARED Rudy Berg BY: We visited the "plant" (actually a farm building) of Leonard Opal, a W'fllametteValley grass seed farmer who has developed a resin-bonded ryegrass-straw building panel failed MeachawtxxL Mr. Opal has been at work on this product since about 1977. Presently his entire production apparatus consists of a hay chopper, a modified dryer-tumblerused to mix chopped straw and resin, and a pair of heated presses, the largest of which (4' x 8') is the sort of low-pressu_ (240 psi) press used to make plywood, A smaller, higher-pressure press is used for smaller test panels. Basically production consists of chopping the straw into 2" lengths, mixing it with liquid resin, spreading the mix by hand between metal "cad plates" inserted into the press, then using proper combinations of heat and pressure to solidify the mass into a solid sheet. The resin Opal uses is proprietary; he did mention that it cost $1.50/lb vs. 15 cents/lb., for the formaldehyde-based resins commonly used for wood products, and constitutes 2-3% by weight of the finished product. A press cycle (which might produce 6 or 8 sheets in one pressing) requires about 10minutes. Virtually ali stock made in this way so far has been 1/4" thick. In short, Opal's products at this point are hand made, inconsistent and expensive -- presently about $15.00 per 1/4" sheet. Still, the results are interesting. Meadowood, like the various bonded-wood products it resembles, can be made with various densities, overlays, and raw materials, lt can also be made into 3-D shapes; we saw experimental one-way pallets with molded-in ribs, and corrugated sheets of several patterns. One interesting property of Meadowood seems to be its ability to form small-radius bends and variable thicknesses with little structural effect. Another, when the raw material is rice swaw or especially rice hulls, is to use the high silicate content present in these materials to achieve considerable Rrc resistance. In this regard, Opal has had Meadowood tested (see notes attached) with promising results. It achieved a Class C fire rating; in practical terms Opal demonstrated how the product would not continue to burn in the absence of flame. It also appears,to provide R=.68 per 1/4" sheet, or R=2.7Anch. Mechanical properties are equal to or superior to particle and wafer boards. OSB, Meadowood absorbs water and swells considerably at its edges, but much less through its faces. Opal has provided samples of Meadowood to Western Insulfoam (see trip report 7/26/89) who have fabricated stressed-skin panels using his 1/4" product, and are testing the resulting units. He is also working with an engineer to develop a production system, at least partially toward the goal of mm-key manufacturing plants for Asian countries or other states such as California, whose rice growers have shown some interest in Meadowood. I + July 14, 1989 TRIP REPORT Site Visit to Western Insulfoam/R-Control Panels June 23, 1989 19041 80rh Ave. S,, Kent, WA. G.Z. Brown, Rudy Berg, Margot McDonald To study design and manufacturing of energy efficient panels in order to identify appropriate software tool development. Center for Housing Innovation; Energy Efficient Industrialized Housing Research Program Supporting Documents: R-Control Panel Building System booklet, Better Homes and Gardens article, AFM R-Control Panel Load Design Charts, R-Control Stress- Skin Loading Bearing Panels sheet and brochure. Regort prepared by: Margot McDonald, Rudy Berg Premier Building Systems is the leading manufacnn'er of insulated foam panels for building construction. They am also the largest constituents of the A.F.M. (Association of Foam Manufacturers) board. During this visit we met with Loren Haug and General Manager Mike McKinney who discussed design, marketing, and manufacturing strategies. This included a plant tour at thesame location. Company Overview An important feature of Western Insulfoam products is their use of EPS (expandc.d polystyrene) rather than urethane, another plastic foam in use by manufacturers such as Winter Panel. EPS 0dcUgCtS areexpandedwithsteam(details below)whileurethane foamsemployFreson orother ases, whlch damagetheearth sozonelayer. WesternInsulfoam manufactures awiderangeoffoamproducts fromhottubcovers toC-cotech (foambeadsbondedwithasphalt tocreate a drain "gravel" panel) tomoviesetprops.Although we v_sited theentire manufacturing plant, we focused ourdiscussions on thebuilding p.anel. We began withageneral discussion oftheR-Control panelwhichisa product ofPremier Building Systems. Manufacturing Process lathe manufacturing ofinsulated foampanels isanefficient process performed inarelatively clean ctory environment, The original foambeadsare1/40their final size whichmakesforefficient shipping, storage, andhandling.Becausethebeads(moldable polyethylene copolymer) area trolcum basedproduct, theyaresubject tolarge price fluctuations. Two suppliers usedby estern Insulfoam areBASF (Parsnippany, N.J.) andARCO (NewtownSquare, PA.). Thepreparation offoamstock fromthese beadsisa two-stage process: first thebeadsaresubject to steamheating ina hopper, rather like a commercial popcorn machine, whichpuffs themtosome p..artial degree, Thc_ aresorted forsizeandstored m large overhead sacks todry.Alltransport at tins stage Ispneumauc.Thenthedried, sorted "pre-puff" beadsareredinmeasured batches intoa large moldcquapped witha steam/vacuum manifold. Heretheyaresteamed again, butsubject m R-Control Panel Trip Retmrt/R1 1 compression as they expand, so that they cohere,,into a large block, Once expanded, the foam is subjected to a vacuum to draw off excess moisture, and ejected from the mold, This second cxpansio_mold process requires only two or three minutes, Again, this block is stored in a hot room for several days to permit moisture to escape, , ' The machinery involved in the bead, molding process, at least as performed at Western Insulfoam, is larger and more expensive than anything else we have observed in the housing industry, short of bamc lumber mill machines, It appears, too, that the amount of energy consumed in this process is rather large. There is virtually no waste. Standard foam blocks arc a nominal 3'h x 4'w x 24' long, Sections are wire cut to shape, Remnants are ground up and vacuumed to another part of the factory where they are used for other foam product such as bean bag chairs. Some products, such as R-Conn'ol panels and"dryvlt" c,oatcd foam,require 100% virgin foam.Thisistomaintain quality and conformity inbeadstzcandtexture, Also, somer_ycledfoammay havebeenusedwithfood products andmay contain residue, The R-ControlProduct The R-Control panel isconstructed ofanexterior layer ofO,S.B.(oriented strand board), oneof several thicknesses ofE,P,S, (expanded polystyrene foam)andaninterior layer ofeither O,S,B, or gypsumwallboard, ltisusedforroof, wall, andfloor systems, ltismade asfollows, The twoouter layers am run(separately) through a gluemachinewhich contains atwopm'tsolution ofISOSET (isocyanate, waterbased) glue,Theouter layer issetdown (glue sideup)ona stack wherethefoamisapplied. The stack workslike a jigsuchthat tlmfoam can be properly located on thesandwich_ outer layer, Nextathe other outer layer is covered with gluecorrect and set ontopofthe foamtoforma Panels _'e stacked inthis fashion and, whenthe numberisprepared, thepanels axepressed. Thepress makesthestructural bondoccurbetweenthe glue, outer layers, andfoam.Premier Building Systememploystwopresses --a 4 x 8 unitwhose products canbehandled totwopeople, andan8 x 28 press foroversize panels requiring lifting machinery. | Assemblyofthepanels requires useofO,S.B. splines whicharedriven betweentwopanels along theshorter dimension. Inthelonger direction, 2xplates arerunthelength ofthepaneland nailed to it. ProductQualityControl A Q.C,orquality control inspector isanin-house staff member.Thisindividual collects samples of everyrunofpanels. Three12"x 12"samples aretaken. From this a 6"square piece isextracted andsubjected totensile (suction) andpressure testing. Thesesamples areretained todemonstrate adequate strength ofthepanels toU.L.inspectors who visit theplant several times a month.The samplemustmeeta 17psiminimum topassthestress test. + How R-Control Panels are Introduced to the Market Premier Building System's designer, Gary , works with the public to develop hcuse drawings that utilize R-Control panels. In this case, the "public" is either consumers or builders sing stock plans or the consaraer who is purchasing drawings from R-Control, Premier Building ystems offers numerous stock plan options which have detail references and drawings using the panels for a nominalcost. Interestingly, these company drawings do not attempt to optin'.ze the modular panel system, Instead typical house designs, as one would find in any house plans book are sol& The majorobstacle facing this industry isthelackoffamiliarity contractors andarchitect havewith thepanelsystem. Thereisa resistance toaccept new anddifferent techniques. Inaddition, contractors finditdifficult toestimate thesavings brought aboutby substituting thepanels for - | I R-Control PanelTrip Report/Rl 2 conventional systems, Although materials cost is more for the panels over a typical roof, wall, or floor assembly, labor is potentially less, Until contractors begin acquiring experience 'withthe product, it will be difficult to attain widespread acceptance, Building Code Compliance Similar to the problems encountered with builders and designers who are not familiar with (and therefore hesitant to use) the product, most building departments are not familiar with it either, Premier Building Systems has had some success with repeat projects in Clark County, Washington, because the building official there (Duane Kerma)was on a national building code committee and reviewed the panels previously, Prermer Building Systems has taken it upon themselves to educate builders and inspectors alike in order to gain more acceptance of their product. Energy Conservation Portland General Electric (P,G,E,/Jack Waldron) has familiarized themselves with the R.Control panels and have begun their own campaign to promote their use in construction based on energy efficiency, ' Freedom Homes (Washougal, WA,) has been ma.rkzting homes which use the panels based on improved energy performance, Computer Use Premier Bull,dlng Systems used Autoead antl abandoned it. They found that it was an excessive amount of ttme to input the_customer's design in order to develop panel details. The panels themselves are standard and not subject to much change, Therefore, panel drawings need only be xeroxed and notated for the occasional irregularity. If scanning capabilities had existed and been affordable at the tin_ this company was using computers, the tool may have proven effective. Instead, the company spend many man hours learning a system which could be more effectively duplicated by hand. Western Insulfoam uses computers for wire,cutting, In this case, an optical scanner traces out the pattern to cut by following a full scale drawing of the design. The drawing may be computer generated or hand drafted. In the case of the former, it would be a natural progression to generate numerical control codes to run the machine direct from the computer rather than pasting up the image. The manufacturer of "Big Wally," the wire cutting machine with an optical scanner is Gateway Precision Systems. Future Marketing Strategies In order to remedy several sales obstacles facing their fh'm, Premier Building Systems is focusing on a three year marketing plan which includes the following: * complete residential package 0aouse drawings) * dealer networks * finished product (model after manufactured housing) * speculative housfilg (includes land) Century 21 (real estate) made a marketing proposal which included land sale data banks whom an interested buyer could locate ali available properties listed by this realtor. 'l'h_ data bank would be located in a housing park which manufacturers buy into for approximately $100,000. This way potential homeowners can select both a house and a home sitd at one location. IdeasforProductImprovements R-Control Panel Trip Report/R1 3 i_,_lmllllllh, The cox_pany has been approached by an Oregon gr.assseed farmer (Meadowood Industries, 33242 Red Bridge Road, Albany, Oregon, 97321, (503) 259-1303)to consider a composition Ryegrass board as a substitute for the O,S,B, The ryegrass board has a better R.value and is more tim resistive, One negative aspect oi'the ryegrass board is the large amount of grass it requires per board. The industry is not yet in mass production, Conclusions The major obstacle facing this insulated foam panel manufacturer is the lack of familiarity to the public and building industry, Efforts are underway to educate architects, builder, and students of building trades, as to the merits and uses of this product. In addition, no significant effort has been made to make modular designs out of a modular product thus optimizing its inherent cost efficiency, Perhapsthis is an area where our computer tool can man'y technology and design interaetiv¢ly and in the hands Ofthe consumc_r, ,i I _ -- R-Control Panel Trip ReporffR1 4 bJE/C SystemsConferenceTrlp Report June 19, 1989 t TITLE: The DesCon '89 A/E/C Systems '89 conference DATE: June 5-8, 1989 t. LOCATION: Anaheim Convention Center in Anaheim, California ATTENDING: O.Z.(Charlte) Brown, Margot McDonald, and Tomoko Seldguchi PURPOSE: Oathcr information on software in the arcldtccturc, construction, and building industriesandto gain information ontrendsof d_cL_dustryby attendingseminars SPONSOR: Center for Housing Innovation SUPPORTING DOCUMENTS: Description by Margot McDonald of the seminars that she attended. Copy of the program and exhibit gui_ which contains a l!st of exhibitors, all event which took place at the conference, and speakers at each event. An index of all documentation gathered fromtheexhibits, f TRIP REPORT PREPARATION: Tomoko Seldguchi Schedule forTomoko: ,8:30-5:00 Plant visit to Flcctwood Enterprises, Inc., Riverside California Zmsta.z 8:30-10:00 Seminar - Special Panel. System Compatibility: Translators, Interfaces and other Exchanges 10,'00-2:00 Touring ofexhibition hall 2:00-5',00 Concurrent ConferenceMacForum , aamstl.z 8:30I0:00Seminar. Special Panel.Future Directions inMlcroCADD 10:00lI:00Macintosh Spe.cial Session -The En_nccrs' andContractors' Forum Il:00-12:00 Seminar-New ToolsforSpecifiers 1:00-3:00 Touring ofexhibition hall 3:00-3:20 Seminar.The Use ofComputersinJapan Description ofschedule items: TheHcctwoodTrlpreport will bemade byMargot. Setnin.. ar-Special Panel-SystemCompatibility: Translators, Interfaces andother Exchanges. Five "p.anclist discussed sys_mscompatibility forCAD systemonPC computers. The discussion was elementary. Themostunpor'tant information obtained fromthis seminar isthefact thatthedata format ofeachCAD systemcanbedifferent andthere arenorealsolutions tothis problemdueto thecompction amongCAD vendors forthePC. Touring ofexhibition hall - Th.is was themostworthwhile portion oftheconference. Oftenthe names of exhibitors were rncnuoned in seminar session and it was extremely useful to be able to imm.,ediately talk totheexhibitors abouttheir product, Therewereover_ exhibitors. We picked uplltcrat_trc ordemonstration software, fromover40 ofthevendors. 'rhls information willbe included m ourlibrary andusedinenhancing oursoftware survey. Housing:A/FJC TripReport I Concun'_nl Conference -MacForum -Thiswas a simple overview ofthehistory, currenl state, and future of Macintosh hardware and software, The s_aker mentioned harris of software and hardwa.re vendors from which we were able to get literature tn the exhibition hall, SeminarSpecial Panel -Future Directions inMIcroCADD -Therewerethr_speakm,One speaker fromtheWhimey GroupfromTexasisaprincipal inanall computerized firmof23 employee, The software theyuseisint_rgraph on theMacintosh, The other speakers wereCRSS fromIrvine, California andLPA fromCalffomla bothofthese firms am much larger withover150 employe.es each,TheyalsousedIntergraph software onPC andVAX computers, Theemphasis of the speakers was on the use of CAD as a design tool rather than a production tool he,causeCAD systems are able to produce a database of information while drawing, So while drawing a design youam able,to creat, mat,rials lists, etc. Macintosh Special SessionThe Engineers' and Contractors' Forum -Thissession was also elementary. The interesting partoftl_Is s_ssion was thecreative useofMicrosoft Exceltodojob estimating andtracking andtheextensive useofmacrostoreach this end. Seminar.New ToolsforSpecifiersExtremely elementary session whichbrought tolight the unsophisticated state ofthespecification tools fortheindustry. Seminar - The Use of Computers in :Iapan- I was only able to attend the first one third of this seminar due my departureschedule. But I was able to obtain the script of the speaker. The speaker flashed quickly through slides of work produced by his company, BUS Inc. Insummarythis wasa veryproductive trip forgathering information andmea.,,aring the tempcrarm_ ofthearchltecttwal, enginccring, andconstruction industries' advances in domputerization, Information ofthefutu_direction ofthecomputerization oftheindustry was not "e_ophasized butthecurrent state oftheindustry was. l Housing:ME/C Trip Report 2 Seminar - Special Panel. New Tools for Specifiers- One speaker, an architect who Is alsoa committee member on AIA Master Spec, spokeon electronl¢ specifying. Products include Sweets Spec (an automated system for producing specificationsbased on a query approach); Superspeo (a checklist completed by the designer, malled In, and specifications returned); CSI- Spec text (word processor for speclftcatlon edttlna only); SpecEditor, R-Com, Eclat (ali word processors for spec.s). There is also an on-line database called Sweets Search which uses CD-Rom technology. Moremanufacturers are making product literature, formerly In hard copy only, available on disk. This may be specificationInformation, CAD drawings for a symbol library, englneertng calculations, estlmating/budget information, and design details. There Iscurrently a committee underway to evalute and set standards for specification writing and processing. AIA MasterSpeo is one committee. The speaker encouraged the exchange between manufacturers and designers for experience sharing of these new specifyingtools. 0 4 • ql Seminar- Special Panel- Artificial Intelligence and Expert Systems This panel of three speakers discussedcurrent developments in the fields of AI/ES as it pertained to their work. The speakers _'epresented: CERL - Construction Englneerlng Research Laboratory, US Army Corps of Engineers - This speaker presented a number of AI/ES projects underway at CERL includinga large government grant to study alternative energy (i.e., solar) including alternative methods of construction (i.e., modular). SOM - Skidmore, Owlngs, & Merrill- This speaker described the development and use of in-house knowledge based software. One tool already implemented is the RBC, or Rule Based Calculator. (Attached isa copy of an article by the program author.) CPSLO. California Polytechnic University at San Luis Obispo- This speaker presented a knowledge based software tool which is based on a comprehensive modeling of the design decision making process. The software is being developed on a Hewlett-Packard computer using Mountaintop software. The software should be ready for beta.testing in December. Housing:Seminars 1 Brochure and .!Jterature from AJFJC Conference Product magazine magazine magazine _ • magazine magazine AutoCAD Pegasys mechanical-HVAC Sun386i &SPARCsystem Minicad+ personal computers ' AutoCADproducts AutoCADproducts Automating the Marketing Function (paper) SuperCard SuperPaint Super3D Darkroom DREAMS . MacDraft V_ CADD,products Company Architectural & Engineering Systems Architecture Computer Graphics Review Computer Graphics World Architecture on the Macintosh Timberline Software Corp. IGC TechnologyCorp. ASG (synthesisofArchsoft& Chase Systems) Sun Microsystems Graphsoft _AQ INTERGRAPHCorp. Apollo Cash & AssociatesEngineers Silicon Beach Software Silicon Beach Software Silicon Beach Software Silicon Beach Software Innovative Data Design Inc. Innovative Data Design Inc. VoiceTechnologies Generic Software MacProject II videographics products Clads CAD Engineering So'tware Ve_-_aCAD I --i CLARISCorp. Truevision Inc. CLARISCorp. ' I_IERCALC Inc. Prime Computer Inc. Republic Training Training Center - class on MicroStation Research Centers, Inc. ASHRAE Data Disks - info retrieval system ASHRAE article Claire M. Leaman AutoCAD Autodesk S, Klein Newsletter Intertec Publishing Corp. F/X Software ARRIS products ArchiCAD Graphisoft magazine CADalyst microcomputerCAD/CAM Kramer Consulting, inc. GeographicInfo. System ARC/tNFO ARC news Environmental Systems Research Institute BuildingCode Analyst Architectronica newsletter Ultimap Corp. newsletter Macintosh ConstructionForum Copiers Xerox CAD software Drawbase computer graphics CALCCMP design sy,_terrVcamcorder NEW IMAGE IndustriesInc. Pepper GraphicsSystem Number Nine Computer Corporation CAD TrainingCentre Data Image BUG voicecommand system Comma.,'K.i Corp., Inc. Page 1 I - Brochure and Literature from AJE/C Conference QuikCAD Dimensions Presenter CAD products MlcroArchltect • FastTrax computer software CAD/Laser Cutting CAD products ProfitCAD/ProfllBID design solutions Archi-TREND AUSR3NT CAD products MAC ARCHITRON/I & II HVAC software software programs marketing specialists ARTIST (newsletter) Dimensions accounting software Swivel 3D Mo_,IShop Windows newsletter speclalreport Mac products software tnfo. MacPerspecttve Assuring Our Energy Future (brochure) weather Shield Mfg., Inc. Visual Information Development, Inc. Houston Instrument IDEAGRAPHIX Dupont HOK/CSC Computer Software Scale Models Unlimited Numontcs ConstructionData Control, Inc. CADAMINC. FUKUI Computer Graphic Computer Services GTCO Corporation Gimeor, Inc. TopDUCT i.m.a.g.e. Software Catalyst Marketing Group Control Systems Visual Information, Inc. ,.%NvtSARA PAR,N3OE'P PAFMK_CMP Pella MacWEEK AppleBuslness Turtle Creek Software Apple Computer, Inc. Knick Drafting, Inc. California Energy Commission V Page 2 = = June 22, 1989 e TRIP REPORT Flcctwood Enterprises, Housing Group Monday, 5 June 1989 ': 8:30am-5:OOpm 3200 Myers SL, Riverside, CA. 92523 _./_d. To determineoperating anddecision making structurein design and production with an emphasis on computer use and potential. G.Z. Brown, Tomoko Sekiguchi, Mm'got McDonald Centerfor Housing Innovation; Energy Efficient Industrialized Housing Resea._h Program Supportjn_ Documents: Photocopies from Fleetwood; nlustrations of production process. Report prepared by: Margot McDonald • _t _8?hyFleet'wood # Our visit toFleet'wood Enterprises, thenation's lar!gest manufacturer ofmobilehomes,was arranged forseveral reasons. First, because ofthen" production volumeandsales, Fleetwood offered amodelenvironment forstudying marketing, design, manufacturing, andother In'cresses related to the production and sales of mobile,homes. In particular, the Riverside location is the design headquarters for ali regions. Vice-President, Second, Heerwood is a stearing is al_adycommittee a participant member.We in our rese.a_h havetherefore gr_nU Jon established Nord, Heetwood's thecommon Senior objective ofresearch as::isfing industry andviceversa. I I Las_y,we wereattending theA/E/C(Architectm'e/Engine, ering/Cons_'uction) SystemsConference inAnaheim,CA.,whichisapproximately thirty milesfromFleetwood anddecided tocombine visits. Company Profile Fleetwood consists of two manufacturing divisions: mobile homes (5.0 billion sales) and recreational vehicles (R.V.) (1.0 billion sales). Although some of the processes in R.V. design and production may apply to our interests, we focused on the mobile home product line. Fleetwood produces 35,000 mob_c homes a year and distributes nationwide. There am 26 manufacnning plants ".n5 divisions. The divisions are sectioned by geographic region: Western Div., Central /)iv., Mid Atlantic Div., Southeast Die., and Florida Die. (See p. Al.) Most sales fall within a 300-400mileradius. Flectwood mobile homesarcsoldexc!.usively through dcalcrL Fleetwood 'I The Housing Group Our visit to Fleetwood's mobile home division (called "The Housing Group") was well organized by their staff, allowing us to meet with many members of top management. In the morning, we began the visit by attending a presentation of Fleetwood's organizational infrastructure and marketshare. This was delivered by Jon Nord, Senior Vice-President, EclSalsbury, Engineering Manager, Jeff Woolclridge, Design Manager, and Dick , Mechanical Engineer. In the afternoon, we toured the Rubicell manufactunng plant with Doug , Plant Manager. The plant tour was followed by a r_tum to Fleetwood headquarters where we visited the d.mfting department and met with , Drafting Supervisor. To conclude our visit, we sharezl in a round table discussion on automation and computer use with Wayne Smart, MIS Director, E,d Salsbury, and Jon Nord. The charts on pp.A2 and A3 Outlinethe organization of management and staff in the Housing Group and Production and Product F.,ngineering. ProductDevelopment TheHousingGroupconsists ofthr_mainbranches intheareaofproduct development: design, engineering, and manufacturing. BecauseFleetwood's product ismarket driven, design and marketing functions aremerged,ltisthedesigner's roletoanticipate futu_trends andrespond to specific customer preferences. Inordertoaccomplish this, theDesignManagerspendsa significant amountoftimeoutinthefield meeting withdealers. The manageralsoanends national conferences (e.g., NAHB), seminars (e.g., ColorMarketing Group), conducts orusesexisting statistical surveys, and stays current withwadepublications. The engineer's roleistomake thein-house ,designer's concept buildable andtocheckforcodecompliance withthese andother customer modifi_ orders. + Engineering together with the QC (quality control supervisor) havethe capability to review for DAPIA andIPIAcompliance. Ase.as outside their jurisdiction aresenttoRADCO, anindependent testing agency.Turnaroundtimefxombothengineering andRADCO varies but, inbothca_s, slowsdown themanufacturing process especially ffanon-standard itemisnotdiscovered until the order reaches theplant floor. Construction Documents Standard Fleetwood modelsarebuilt frompre-approved floorplans, details andschedules. These engineering documents arekeptinlarge volumesandserve .as reference material forcoordinators who oversee workingdrawings. Similarly, aQC inspector hasaccess toapproved specifications (Federal Standards forHUD-Code Homes)fordealing withnon-standard itemsintheplant. The purpose ofthese engineering documents istoestablish S.A.M.sorStandard Assembly Methodsforstandard modelswithsomevariations. Thesedocuments arevital totheplant operation because theycontain information formanufactm'ing. Product datasheets list all poss_le options within a product line. (Seep.A6.)Thissheet completed by thedesigner todescribe a modelformanufacturing. Forexample, roof, wall, and floor consu'uction, randinterior finishes are_ed on this form. Manufacturing worksfromthese product _cations orasimilar formcomplel_l bya salesperson in the dealer's showroom. This verbal description toge_ with a floorplan _. A 11) ar_ the consm_on documents used to build a mobile home. C_stomer changersto a floorplan simply notated on the plan and not redrawn. Fleetwood 2 Manufacturing Efficiency Flcctwood's manufacturing principle is to hire unskilled labor to do a discrete task in the factory. Changes in configuration arc cosily in terms of retraining laborers and interrupting the assembly line. Although labor is 15% of the cost in manufacturing a mobile home it is a critical factor. Energy Issues in Design and Marketing As with the product,Fleetwood's response to improved energy efficiency is also market driven. For example in Oregon where the Bonneville Power Administration (B.P.A.) offers an incentive to increase residential energyconservation, Fleetwood offered mobile homesthat mettheprogram's standards. The "Super Good CentsProgram," asitiscalled, usesacomputer programcalled Wattsun. TheWashington State EnergyDepartment made this computer programavailable to Fleetwood's mechanical engineer andworkedwithhim toreachcompliance. Insome cases, special construction details needtobedeveloped toaccommodate increased insulation (especially in floor androofconstruction). Otherwise, designers, engineers, andQC inspectors worktomeetIRJD'sminimumstandards for energy conservation. Forexample, tables inengineering reference volumesoutline alternatives to achieve glazing persq.ft. aswindowareas aremodified ina design. ComputerTools The NtISDirector on theHousingsidegaveusa full description ofthecomputer equipment currently inuseatFleerwood. Corporate computing needsaicmet ona DEC VAX. Fleetwood has beenusing DEC equipment foratleast 13yearsstarting withPDP 8's, upgrading toDECMates, 'andthentotheVAX. Corporate applications include payroll, accounting, sales analysis, Spreadsheets, warranty claims history andanalysis. On theR.V.side, VAXes arealsobeingused.Applications include MP& (materials resource planning) forinvoicing, anddealer activity. Flcctwood has centralized computing at its headquarters and networks with five satellite plants in California, The network usedisParadigm. The goal isstation. tonetwork to ali plantsIndiana, (50 plusVirginia, factories)andOregon. with the VAX having 4-6 terminals and 2-3 printers per companymade Besides theVAX, the employees Macintosh itnitiated hecorporate a Macintosh standard trend because by bringing ofthewideacceptance computers infromhome.The ofthis personal computer andbecause ofthenatural connectivity withtheDEC. Applications runonthis machine include Excel. Observations Many ofthe tasks, especially indesign andengineering ofthemobile home,were primecandidates forautomation. Standard drawings, specifications, schedules, codes, couldIx: electronically stored andmanipulated. To goonestepfurther, this information couldalsobeviewedelectronically on thefactory floor. Increased direct communication intheformofdatasharing may limit the non-approved custommodelbottleneck currently experienced inthefactory. The same consm_ction communication gap that exists betw_nconventional site builders and designers, isfoundbetweenmobile home manufacturers., andtheir designers. The manufactmet, whoseprimary concern isproduction efficiency, isfac,-.a:l withincorporating customdesigns intothz assembly lineframework. The designer, on theother hand,isresponding tocustomer demands whichoften stemfromtransporting conventional housing ideals toamanufactured home irrespective of the manufacturing process° One _a of improved efficiency is the cross education of design about manufacturing. In this way, manufacturing efficiencies can bedesigned into a product from its inception. - I Fleetwood 3 F]eetwooclis primed for automation. Cur_nfly, four controllersin the corporateoffice use Macintosh SEs. The Drafting Supervisor is experimenting with Claris CAD and VersaCA.D on the Mac I1. The main accounting operations are carried out on a DECNAX mini _omputer, The hardware configuration is excellent for networking (Martsto DEC). Moreover, because they are using Macintosh, they are compatible with "Energy Scheming," the energy software tool developed at the U of O. Conclusion The visit to Flcetwood was very informative about the design and manufacan'e of mobile homes. Direct n',x.etingswith engineers and managers gave a more realistic view of how we might contribute to the process. The visit also scrve.dto bring the public sector up to date on our more recent research goals. The interchange was invaluable. o Flcctwocxl . 4 I 9 June 1989 TRIP REPORT TITLE: Automated Builder Magazine DATE: June 2, 1989 LOCATION: Carpintcria,CA. ATTENDING: MargotMcDonald PURPOSE: To discuss existing compu_r use in the industry and computer survey SPONSOR: Center for Housing Innovation; Energy Efficient Industrialized Housing Research Program SUPPORTINGDOCUMENTS: mmmmmm mp • w iilmmamemm mm mmlm, IDQIDwlmm lR• tDui_ Advertisement, acdcle. IDIO • Hm_ea,_el_ wm • _mm _mgguuo ,mmo awe, s • _ me oa e,am _ mD,mio,mmNmBaHmm_mmcmm, One aspect of establishing baseline data for _e computer.softw.aretools _ 'revolves su_eyin_g a r_presentative number of manufac..m_ housing nrms to o_termme type ano aegr_ ox au_omauon. As the indusu'y's leading tr_clepublication, Au_or_.ed B_lder Ma&azine was con .mcmt for background information on the state of automation m the industry, for initial leads m nanowing the field of firms to survey, and to assist with the review of survey content. To collect this information, I arrangeda visit with Don Carlson, president of Automated Builder Ma&azir_ , (Carpinteria,CA.) and member of the EEIH Steering Commim_. ', I • 'First, Don provided valuable ifformadon r_gardin$ tlmsmtcofautomation Within themanufacttm_ housing indus_y. Automation starred with the engineering of _'ussplates where compumn were used to do complex engineering calculations. For this reason trusses wcr_ always engineered by a truss plate companywho ownedits own software whichw.as. usually ..develop_ in-house. The software was eventually made available totruss companies directly atlittle orno charge sothat ._¢7 couldengineer andmanufacture their own trusses. Formany.years, this was zheonlynoteworthy aspects typeOfcomputerization tothemanufactured hous_ industry. Sincethen, other of the building component mdusu'y has become automated w_ththe arrival of computer control _tap for truss assembly (variations on multihead presses, roUer_,and plains connecting plates to truss members). Some truss tolocate attachment points fortruss plates on members laid out with amanufacrm'_rs framing jig.am usinglasers Another recent comput_riz._ dcvelopracnt intheindustry isthecomputer controlled saw.For manufacturers who havearepetitive cutproc_uretheinvesmacnt hasprovencosteffective although theinitial costoftheequipment remains high. Om_ suchcompanyisSpeedcut (Corvallis, OR,).Another, Auto-Omni, hasa modelcosting approximately $125, .000. A manufactured I m housing companyusin_ this technology isShelter Systems Group(I-lamesport, NJ.). As Often withany machining task, setup rene usually farexceeds time spent inproducing thedesi,w.d result. housedesigns arearrived atbydcsignc.rs withno knowledge ofthis manufacturing principle, and tbcrefor_ theprocess istoonon-rel_fi_ive toeffect anysavmgs. Inthesecondm-v.a ofnarrowing thefield tobesurveyed, Don Carlson identified softwarepackagea used in manufacrur_ housingindustry and_ that heknewusedcomputers either intlmpast or present. These include: 1) 2) On-line Data(Richardson, TX.) The Plan (Ted Dasher & Assoc., Birm/ngham, AL.); wall/roof/floor component producer 3) A_C_ (Florida) 4) 5) Mim_o (Saco, Maine); computeroperated wall system Auto-Omni; computer operatedsaw Automated Builder Magazine ' .............................. I ".. ........ .... ,' ". .... • ' ' .' .' _," " " ""," T '." ,'-" __ / ICG (Integrated Compu_r Graphics, Atlanta, GA,); complete CAD design/drawing/estimating/.., system 7) N,V. Ryan; manufacturer using ICG on multiple terminals with in house program add-ons 8) Alpine Eng'incering Products ,, 9) GangNadl I0) Hydro-air 1I) Clarity Corp, 12) Teclok 13) B-Max Don recommended that we contact these companies formoreinformation on product _d application. Inthear_aofmarketing, Don knew ofonefu'rn thatusedthecomputer asad_monstrauon tool; that is, Nanticoke (Delaware/contacts: JohnMervme,pres,, orOreggMervine). He was unsurt asto their success andthought that theyhaddropped thetoolaltogether. 6) Q theareaofforeign technology, Don knew ofa.numberofsuccessful 3apane_, f'ums whichhehas isited fivetotenyears ago.Theseinclude: Sekism.Timc (steel panel construcuon using robotics for welding), Masawa Masanoto. Don described thewood technology usedinJapanwhichisa.wood panel, tongue andgroovelattice. Mostofthefinns nan_.cl abovear_knowntodosome workwithcomputers. Hisrecommendation fora survey across theentire manufacRa'cd housing field wastolookatthetopI00. firms andsurvey a portion of that list knowing that the .207.80rule applies (by surveying 20% of the industry we can discover what 80%of the industry is doing). The August issue of Automated Builder hadli to.p lt_ ho.n_. producers list. A.Iso, themagazine publishes a directory ofmanufacturers (_thfull staustics) whlchisupdated yearly. Finally, intheareaofsurvey content, itbecamecP.mr that duetotheappa.,_nt low, level ofautoma, tion intheindustry we should focusonautomation potential andunderstanding in-place n_m_actunng p/o_esses. We will also b¢ able to determine computer hardware trends; that is, what eqmpn_nt is currently being used for other in-house manufacturing functions such as accounting, marketing, inventory control, etc. Automated BuilderMagazine 2 July 12, 1989 TRIP REPORT TITLE: Blazer Industries Plant Tour DATE: June 1, 1989 LOCATION: Silverton, Oregon ATTENDING: Barry McGirm and Rudy Berg, Research Assistants Center for Housing Innovation PURPOSE: Plant Tour SUPPORTING DOCUMENTS: None On June 1, 1989, Barry McGinn and Rudy Bergof the Center for Housing Innovation tomv.d the manufacturing plant of Blazer Industries near $il,¢erton, Oregon. They were guided by Chuck Hill. ' w Blazer produces custom, chiefly modular buildings, though at times they have shipped panelized buildings. Many of their products such as construction offices alld temporary school buildings are mounted on wheeled chassis, yet all are built to UBC rather than HUD standards. Blazer builds entirely toorder. Theyhavenoinventory ofstandard models,Buildings ofseveral thousand square feet, two-story bu!.Idings, andshipments asfarasAlabamaandAlaskaaresomeofBlazcr's accomplishments. Thefirmoffers engineering, design anddrafting, lumbergrading, certified welding, andtruss design andconstruction services asweil. On a 12-acre site, Blazer has,about 42,000 square feet ofproduction, storage andoffice space. The plant is rather modest, with some of the funkiness and disorder that accompanies unplanned growth. The newest and largest building houses the framing operations. The "production lira" is rather non-Bear. Virtually the only industrialized tooling here consists of a pneumatic wall framing table, overhead cranes, andpneumatic staplers. Wallsub-assembLies suchasdoorandwindowframes am produced inanadjacent building, asam rooftrusses, Thoseinevidence during ourvisit wereabout14footspan, inbowstring andflat varieties. Otherroofstructures arediscussed below, Floor decks are framed stick-fas!ti.onon the building floor, except that one rim joist is temporarily screwed to a steel angle mounted m the concrete. This holds one rim jo_st fixed and straight while framing is completed and squared. Blazer uses laminated veneer lumber as rim joists because of its strength, and because it is available in lengths to 66 feet. The floor is usually insulated with Fiberglas batts and covered beneath with reinforced plasuc film. If the deck is to be chassis-mounted, lt is hoisted aboard and fastened to the chassis rails with lag screws and clips. Walls are framed, squared and sheathed or paneled (interior) on the framing table. LVL is us_ here for single, full.length top and bottom plates. A hoist lifts walls to the deck, where they my. installe_ Many ofthese units aredouble wide,andsome suchasschool buildings comprise single clear-span roomsaslarge as28'x 32'.To accomplish this span, laminated veneer beamsam again used. Theseinthe interim stages actasheaders nearly nonexistent marriage walls. When thebuilding halves aremated, a doubled ridge balong eamresults --for 32foot spansat40 psfsnow loadthese are24"deep.Special braces areinstalled toprevent rotation oftheridge beams.T-bar ceilings wereusedineverybuilding we saw. i Blazer indusmes Plant Tour/Ri 1 Therewas onenotable exception, however,Blazer hasdeveloped a modularpublic bathroom for California rest stops, Thisunit employsa hiproof, andanexposed-beam ceiling withroof decking. The roofframc splits at the ridge, and when fully assembled looks quite urtlike any "industrialized" roof we have seen. Since these units arc installed on slabs, _ey are built without floors, and hoisted and anchored using a clever, proprietary system of wall-base anchor plates and long lift rods. The rods are threaded into the anchor plates (which am in mm .sc'._.. wed to the bottom plates of the walls) and extend up through the wall and roof, ending in lifting eyes. After a modularisset, its rodsareunscrewed andpulled upthrough theroof.The roofispatched, andthe anchorplates arefield.welded tomatc.hlng plates castinto theslab, Hilldeclared that Blazer's operation was toosmall andvaried tomake effective useofthe , computer. He was also skeptical of the likelihood (or valuet) of uniform building codes, and third party inspection. Altogether he and Blazer seemed like good examples of the small, innovauve, independent.minded firms comprising the majority of U.S. builders. Blazer Industries Plant Tour/Rl 2 June 23, 1989 TRIP REPORT TITLE: Ryland Modular Homes DATE: April 27,1989 LOCATION: New Windsor, Maryland ATTENDIING: Rudy Berg, Research Assistant, Center for Housing Innovation PURPOSE: Manufacturing Plant Tour SUPPORTING DOCUMENTS: Roof d_tall photos, inspection sh_ts Ryland Modular Hor_s consists of thee plants in Maryland andVirginia. The new Windsor facility, covering 100,000 sq, ft,, produces several models of SFD homes and townhouses. The_ are produced on t_/o parallel production lines (models are mixed) which split into four lines at the finish stages. Maung halves arekept abreast of each other and check-fitt_ before they arc shipped. A ty?_cal hornc is built m about 7 work days, then loaded onto trailersand shipped to a site prepared I_ythe dealer s er_w. About 90% of the units travel less than 100 miles. Production tools and techniques at this plant seem fairly typical of industrialized housing: pneumatic framing tables and nail/staple guns and overhead cr_es, forexample, with tasks such as door hanging and truss bmlding performed adiacent to the malr.production line. Several production ideas were new to this observer, however. These are pictured in photos A, B, I sheathing. Thismaterial, fgable orfaces, provides (R=2, asIrecall) smallinsulating andC attached. PhotoA duetoits showsthe endofa I/2some house unitsheathed in"Thcrmo-Ply" value, butits chief virtue inproduction isits small thickness--about I/8"--pormitting lapped instead ofbutted joints, andfaster sheathing mstallation asa result. Thisphotoalsoshowstheroofing "mezzanine" fromwhichshingles areinstalled. Insomemodelswithsteep roofpitches, travel helght limits require folding roofs. PhotoB showsthehingeline ofsucha roof, andPhotoC showsthefolding kneewall(here temporarily erect) whichholds thetrusses in their final position. PhotosB andC alsoshowa ceiling, whichformsthebaseoftheroofassembly. Drywallsheets arelaid facedown on a smoothtable, thentrusses areassembled onthemand"glued" inplace with foamsealant PhotoB. The result isareliably flat ceiling, andnooverhead railing, Quality iscamfuUymonitored intheplant, astheattached inspection formssulggest. The "subcontractor" issimply theproducuon workerresponsible fora givenoperauon; thetermis carried overfromanearlier system oforganization. Third-party inspectors alsoexaminevirtually everyRylandModularHome atsomestage before it leaves theplant. My impression was oneofconsistent quality inthese products, eventhough they werefairly modesthomes. Ryland's standard energy performance isestablished byR-13wallinsulation, R-30ceiling insulation, andR-19insulation atthefloor pcrimcmr. Theyoffer a '°Sul_r-E" packagewhichadds 5/8"Atlas EnergyShield Insulation overthestuds, boosts ceiling insulation toR-38,andinsulams the enti_ floor to R- 19. i Ryland Modular Home Tour July 6, 1989 TRIP REPORT TITLE: Ryland Construction Systems (Panelizad) Manufacturing Plmat DATE: April 27, 1989 LOCATION: Columbia, Maryland ATTENDING: Rudy Berg, Research Assistant, Center for Housing Innovation PURPOSE: Manufacturing Plant Tour SUPPORTING DOCUMENTS: Wall/Deck Fabricator Lists Many aspects of this plant's work have ah_ady be_n described in the March 1989 Industrialtz_ HousingResearch Project trip report memo fromLarryMaxwellofFSEC, Iwill addsomefurther details and observations. The Columbia plant, about 50,000 square feet, is presently operating at 150% design capacity, producing roughly 3,000 units per year. As the earlier report noted, computer use is limitr.d. An HP 3000isusedforadministrative andsecretarial functions andtogenerate fabricator lists those attachex:L .'the tour guide, Ken Pierce, stated that the plant was just beginning to involve Autocad in its operations. Work at this plant is high-volume, as the 3000 unit figure would indicate, Lumber is purchased direct frommills andconsumedattherate ofth.re.e orfourcarloads pcrweek.Pierce announced dmt thecrewon oneframing table hadproduced "amileofwalls" inoneshift rr, c_ntly, The work tended to appear frenzied and low-tech, but it certainly provided employment for many who would probably not otherwise find jobs in the building trades. Another social sidelight is that ofpmvidlng entry (in to this case, home ownership) to the otherwise Ryland has pmgr',tms help its to employees buy R_,land homes, again unqualified. with the likely consequence One kind of potential in the industrialization of housing, th_n, might be self-housing for the poor. Rylandseemstoberecognizing this, ortohavediscovered itinadvertently, As ourworkfocuses onindustrialization (i.e., automation) we mightrecall thesocial differences betweentheU,S,andits Japanese andScandinavian mentors, What level ofindustrialization is appropriate here?How canwe helpsolve onesetofproblems, andnotaggravate another? _ RylandConstruction Systems I June 22, 1989 CONFERENCE REPORT TITLE: "Modular Housing: The Trend for the 90's" DATE: April 25-26, 1989 LOCATION: Penn State University ATTENDING: Rudy Berg, Research Assistant, Center for Housing Innovation SPONSORS: Industrialize_ Housing Manufacturer's Association (IHMA); Penn State Housing Research Centei" SUPPORTING DOCUMENTS: mM_m m q.,._ .Ru Program .m mm_ m m. I.,., e mm m ..m.m w mm...,,. _ lo N,.-',wg _. i,, _ ,,,.. _,,,mu w _ _. i,_ u m,,,m,_., m m. m. N _,,,,,. i,.-.. _ u .m,.. ,.,,q.... ,-.,,,,....I, m._. m. m.,,.--,., w _- This was a first-time event put together by Jack Wi_enbrock, Professor of Civil Engineering at Penn State, and James Shields, IHMA Executive Director, About 150 attencle, d. maybe 40% manufacturers, 40% builders, and the remainder people from finance, government, architecture, and academics. Willenbrock exhorted the manufacttum_ to trade infommtion (the "science" model) rather than sell. To varying degrees they complied. t The mid-Atlantic states areaboutsevenyears intoabuilding boom. Pennsylvania isthechief modular producer (40manufacturers) andexporter:, two..tltirds ofits output goestoother stains, lt looksquite prosperous. "State of the Art Modular Housing," Steven Winter: Opened with statistics .. claims modular was 6% (vs, 3% _ of U,S. starts-- the _industry segment that grew in 1988. In NE represented 12-15%, almost nonexistent on West Coast. Modulars have doubled capacity insevenyears, expancl_ upscale. 87modularplants betweenMaineandVirginia. SFD bigger, metacustom, moream,enilaes, Thusmetacomplexdmign/fabrication, more computerization -.ma bes :al "boutique" operations/crows. °'Prefab", notadirty' wordto consumers anymore. _fa s_will _peakat 55% of starts, Affordabflitv = ZOrlin2;Iots of resistance to hlgher densities, In constant dollars, housing constmcti0n costs have fallen _5 years straight. Multi-f,a_y holds promise for growth and innovation; recent progresswith steep and folding roofs. Winter showed a slide of an ultra-low-cost condo (built) designed to F,_ for $30K. Sees need for 900-1100 S,F, modular int"tilfor $50K. Manufacturers need flexibility - medical, schools, jails are new markets. Deluxe Homes (PA) makes nailable steel-frame modulars, sells to NYC (codethemlikes "noncombustible" ideal) Questions/Answers, Energy Savings? Manufacturers only make what sells; modulars are tighter coinddentallv, thus energy efficient. Steel? Material costs much more variable than wood. PennState ModularConference I i Forclgn competition7 No imports of foreign prefabricated _, but Iota of _, Thus, a threat to the U,S, economy, not housing industry., Mitsubishi and others eyeing industrialized housing industry, could dominate and likely will, Japanese already own U,S, companies and real estate; "they re crazy not to buy us,' ' "The Assembly Process," John Mervlne, Nantieoke Homes, Very impressive, Started raising chickens, convened chicken house to modular factory, Now, #6 in Automated Builder's top 100 Manufactured Home Dealers, $65 million in sales in 1988; top modular manufacturer, While retardatah'e in some ways (still builds walls on the floor ctecksl), his was the only house shown with energy performance beyond code as Standard construction, Adds 1"foam over 2x4 studs (Delaware), Air tests houses, _ energy performance. Yet when asked about vapor barrier .. (facetiously) "What's that7" I,di'osyncraticand shrewd` Day care foremployees, highly regarded, Has 12 draftspersons, 1 architect onpayroll. Builds five houses a day, Showed 7,000 Elllott Fabri, Chelsea Homes: Also felt "no problem" omitting vapor barrier, Ducting a problem: builds 6-module home costing $500 k, "Delivery and installation," Bob Killkelley, New England Homes: Many problems of season, weather, laws--needmoreuniform laws.Foundations arecurrent problem--shell needs tolerance + I/4". Introduced topic ofwhentogetpaid: common practice ss_ setting modules, atwhichpoint theyturnrate real estate andcan't berepossessed. Builders upset withthis C.O.D, idea, unlike other majormaterial deliver/pay arrangements. Site arrangements responsibility of builder-dealer. Tricky points of"builder" as"broker" or"delivery system." SteveStahly, RylandHomes: Unlike many builders, Rylandusesbottomless 2ndfloor modular--removable braces instead, Many arrangements inusere:setting, inspection, delivery, FOB. Some useroll-on (rail) installation; saves crane costs, takes longer, onestory only.Ryland J_t I I has10yearwarranty to builder. "Finishing," SharonJensen, HarborLightHomes: Detailed post-set work--seaming carpet, drywall/mm onmarriage line, utilsues. Turnkey builder can"educate" abuyer. Advantages of Indust,riallzed/Modular Housing, ,t Steven Kerr, Westchester Modular Homes: Advsce to builders: "Don'tbecome a dealer." (Suggests industry needs builder-- at ]east as zmageor "front man"-- as "factory authorized builder.") Sells G-module, on 2.story unit 7/12 ,.roof requires 2-3 weeks to finish. Saves about for $89k builder's foundation, 8%overstick.built. Mosthouses produced inplant in6-7days.Trashon site, i_sposal a ]tt,Z deal, especially on LongIsland, Another virtue ofmodular. ,! "The National Regulatory Atnlosphere," Bob Wible, Executive Director, National Conference ofStates on Building Codes.Another impressive speaker. Mentioned "Street ofDreams"inOregonlast year, whereJapanese showedaprefabricated house(7). Ten percent ofhousing cost(andrising) isduetoregulation. Fourmajorforces atworkregarding housing: I. Economicdevelopment --costtied tohousing, development sometimes restricted by housing lack(GM movedSaturn plant toTennessee fromIndiana, forexample). 2. Homelessness --1 I/2to3 I/2million, 50% arefamilies, 32% haveworking parents, DC haswelfare hotels wherehomeless havelived sixyeats. 3. Shift ofresponsibility fromWashington tostates --state governments now de.al with l majorissues, HUD hasrecommendations butno 4. U.S.economic competitiveness -.. in1992whenEuropeconsolidates, canhavefast technology transfer, we nccdtoscreen forcosts ofchanging U.S.co¢_s. I w PennState ModularConference 2 "Future Trends: Innovative Applications and Automation in Modular ttousing," Dan Desmond, Deputy Director, PA E_+ergy Office: Newly industrialized countries add to energy/resource problems, waste disposal costs now at $100-150/ton in East, sees molded paper replacing many plastic parts (roof vents, etc.), some stick builders (including in Eugene) building hypo-allergenic houses, heat recovery and waste processing at home, hydrogen fuel likely, sees 20 year development time for modular industry. Heat distribution systems lose at 40% of heat+ mostly through infiltration in returns. Penn Stat_ Modular Conference 3 June 2I, 1988 INDUSTRIALIZED HOUSING PLANT VISIT I I Title: Advanced Building Systems (ABS) plant visit report Date: April 19, 1989 Location: Bennington, Vern_nt Attending: Barry McGinn Purpose: To view an industrialized housing plant. Sponsor: Energy Efficient Industrialized Housing Research Program Supporting Documents: Computeri2edFabrication Plans; House Plans i On Apri3 19,1989, a representative of the Center for Housing Innovation at the University of Oregon visited manager, the Kurt offices O. and Dahlin, plant the of Advanced 40,000 sq.Building ft. plant manufactures Systems in Bcnnington, large panelVermont. condominium Under its new residences. A.B.S. has recently developeA a new line of detached single family homes and a marketing strategy (attractive brochure and dealer network) to sell the product. Both of the house one two one designs intheAmcricanseries aresteep roofed bungalows is stories andtheother is story. The twoScandinavian series hou3es areyourbasic Swedishcottage. Bothofthese series were designed in-house orbyABS'sparent company, Faluhus AB,Sweden. The third series areuppezend two designs putsystem, out by Schoz Master Builders are Inc.--a 'Victorian' and a 'Colonial'. Through its well story developed CAD perspective customers encouraged to customize their house package within set parameters. Examples of this include adding on rooms and porches and changing window sizes and wall insulation. J ABS's.CAD system c,_nsists of a Sun 360 workstation running a ICG ('Integrated Computer Graphics) Aries CAD system using a HIlL Unix CAD operating system. The computer hK a 16 MB memory and uses a 724 hard disk drive. They have plans of expanding to four workstations in the near future. The CAD system interfaces with a Hewlett Packard 9000/300 which is pro_ to run their menu driven construction library. , - IE The procedure is to first run the various construction menus to select stud size and spacing, window ty_, insulation, etc., on the H.P. Then modify the catalogue house design as requi.,v.don the Sun which will fezd the design information to the H.P. via a DFA7Translator (mathematical co-_). The H.P. will generate four lists to instruct the shop personnel in manufacture. The last is the piece ABS Plant Visit 1 Q list (plate cutting List)for use at the automatic cross-cut saw in cutting the various plate lengths (Appendix-1). The second is the plate list used at the framing jig for assembling the wall frames _,Append.ix-2).The third is the buck list which is a subcomponent framing schedule e.g., door frames, partitions (Appendix-3). The fouyth is a pool list which lists all the items which are shipped Outas part of the package and serves as a £malcheck of all the pieces. The plant is based on Swedish Factory Crafted House factory layouts as designed by such fm'ns as Nordisk Kar_o. The plates and subcomponent framing assemblies _ pr_cut on the automatic cross-cut saw. This Swedish saw has five different cutting length settings which operate stops on the ouffeed table. The stock is driven forward by roller action and when it contacts the selected stop a circular saw blade swings up from below the cutting table to make the cut. The lumber is then set on to the framing jig; the studs between teeth that swing up from below the jig bed while the plates are pressed between end stops. An integral nailing gun slides along the entire length of the jig and automatically stops at each 2 x 6 stud to insert three nails. The wall frame is then slid on to the next station where an 8 mm Swedish vapor barrier is rolled off a suspended relier and is manually stapled in place. The next stationis the squaring jig where the flame is _gned with hydraulic jacks _d interior fun'ing strips applied over the vapor barrier to accommodate the 1 1[2"of interior fiber glass insula,on. Temporary sheathing is applied at the next station to prevent the furring strips from getting caught at the next station - the panel turning jig. This jig effects a 90 degree change in production process direction. The insulation is then manually set in piace. The insulation is stored adja_-nt to this space in a storage area above the office area. Following this, the wall panels are turned an additional 90 degrees on a system of ball bearing type conveyor tables and sent back the direction they came to complete a U-shaped plant layout. At the four remaining stations the exterior sheathing, subcomponent elements, siding, and exterior trim are applied. / Tl_e.compietexi panels are then set up against the storage area wall in their respective housing packages to await transport to the site. A house pac_ge usually comprises two separate truck loads; wall panels loaded vertically for easy unloading at the site by a crane and another truckload with everything else. Temporary furring Strips at the edges of the panels prevent damage during transport The panels axe shipped open faced but have flexible plastic electrical conduit in place as well as predrilled plates and studs for plumbing. The panels leave complete with lag bolts at the comers for quick assembly on site, The walls are R-25 and the roof is R-38. A Swedish double bulb rubber gasket seals the bottom plate to the floor deck and the windows are lined with rubber gaskets to e_xinate any infiltration. The second story floors are manufactu_ as 8' by up to 32' trussed floor cassettes. The plant purchases the pre-manufactured roof trusses from an outside source and does its own erection witha fairly heavyrented crane. Theplant iscurrently operating atreduced capacity, alternately manufacturing anderecting two-story condominium units insets offourinnero'-by North Adams,Massachusetts. The crane isrented inonedayblocks fortheerection oftwounits ata time. ThisSwedishsubsidiary plant hastargeted middle incomehouseproduction, whilemanyother east coast ind.stri_zed housing plants haveorareinthepr_.css ofdropping their middle incomehouse packages andgearing upforhigher endproduction. KurtDahlin is_onfident hecancompetitively supply energy efficient factory crafted homestoaneager market anditwill beintcresUng tofollow his progress inthis venture. 2 ABS Plant Visit m , ; CONTACTS AdvancedBuilding Systems Kun O, Dahlin Manager Advanced Building Systems Christopher T. Stitcher Engineerialg Manager (CAD Specialist) Morse Industrial Park Route 67A P,O. Box 140 Bennington, Vermont 05201 Tel: 802-447-3511 Fax: 802-447-3510 Swedish Executive Homes Lenart F. Lekborg President (ABS sales agent) 20 Popes Lane, Danvers, MA 01923 Tel: 617-598-1818 Fax: 508-777-7410 4 1 - _ i ABS PlantVisit 3 June 21, 1989 INDUSTRIALIZED HOUSING PLANT VISIT Title: Key-LocHomes (Division ofHodgsonHousesInc.) Plant Visit Date: April 17, 1989 Location: Suncook, New Hampshire Attending: BarryMcGinn Purpose: To visit anindustrialized housing plant. Sponsor: Energy Efficient Industrialize,d Housing ResearchProgram ' On April 17,1989, a representative oftheCenter forHousingInnovation attheUniversity of Oregonvisited theoffices andplant ofKey-LeeHomes inSuncook, New Hampshire. The plant manufactures modularhousing froma catalogue offorty basic plans, ranging fromtwo-story colonials, gambrels, andcapestoranch-style bungalows. Inresponse toa $300,000 marketing study: thefirmisre_e_ting their housing production toward theupper-middle income, group.Theyam just completing aprototype modelon thepremises which willbecomethebasis fora new line offully customized luxury homesandtheywillpresumably phaseouttheir economymodels.The prototype isalarge two-storied gabled home withatwostory bayelement rising upcentrally inthemar,abalcony/fi'ont porchclement andthree front attic roof dormers. The interiors arecharacterized bya central stair, ninefoot ceilings, a master bathroom with ajacuzzi undera large window,andtubontheinside wallwithanadjoining toile_anity anteroom andamaster bedroomwitha drysauna. s The firmisintheprocess ofdeveloping a twofold marketing approach: I)markeling tothetopend builder, 2)marketing on ammilbasis byscattered sales lots andsuppling buyers' namestobuilders. Themodules theybuild am a totally closed-in unit withfully finished interiors complemwith electrical andplumbing stubbed offintothecrawlspace orbasement. Theexterior siding isapplied on site after theunits havebeensetonthefoundation andconnected together. Thefloor decks, whicharethefirst stage ofconstruction, am built espe.cially strong toreduce the risk ofdamaging interior drywall finishes duetosettlement. The 2 x I0floor joists aresuppormdon a ledger board a,ttached totheinside ofthedouble 2 x 12joist header andareend-nailed through tlm hca_r.The 5/8'floor sheathing isthenglued, resin stapled, andcaulked fora level surface. The deckisthenlifted offthejigbytheoverhead crane, setontolowrolling dollies, andpushedoverm tbcnextstation toreceive thewallandpartition _. Key-Loc Plant V'utit 1 w I The frames, complete with sub-assembly frames made in a neighboring building, are assembled and nailed on A-frame jigs and lifted on to the wa_tingfloor deck by the overhead crane, The interior wall boarding is then applied and the electrical and plumbing roughed in, The electrical boxes and other wall penetratior,s are caulked from the inside to eliminate any infiltration, The unit is tl't_:,6 p_!hed over to the next station to receive the trussed wall assemblies which are built directly adj_,_,_i_tI'tae ceiling wallboard is layed out on a perfectly flat bed and the half trusses are then positio/_ed:afi¢lau,tachedwith a foam adhesive, This allows for flat finish ceilings- no spraytcx stipLingne.ededl An electrical tray (built in-house) is installed in the ceiling and the COpl:_"r wiring installed, Also at this station the insulation is instal.ledand the exterior plywood sheathing is installed. The joints in the sheathing arc caulked and sanded smooth. Each modular unit is Lifteddown on to the highway transport dollies wlEciaare of particularlyheavy six axle construction so as to not damage the finished drywall. Two long columns of units mc formed down a longer building at right angles to the sheathing station. The three coats of drywall mud are applied and sanded at all joints with the drying helped along by portable gas heatcr/blow_ units placed in various rooms. Lesser establishments, as you know, simply run plastic moldings around the inside edges to hide the ugly joints. The column runs alongside a second story shingle storage area which is convenient for the roofing operation. The 2x6 walls provi_ an insulation value of R-19 and the roof is R-38. All materials are stored in covered open sheds or in enclosed warehouse ar_as. The finn does have a CAD system used primarilyforgenerating production drawings and cutting lists, but expects to use it more as a sales/design tool as they get into the fully customized upl_r mad modular house. The plant appears to be utilizing the plant facility to produce a higher quality product than is possible with a conventional stick built hort_ and they fcel confident they can compete m the upper end market. OI I I i f ! I v | Kcy-LocPlant Visit 2 Z5 January198g Annual geeting National Association or Home Builders January 19 - 22, 1989 Atlanta, Georgia , "[his meeting wu structured arounda _ exposition withseminars and educational sessions running slmulcanaeously. Approximately _,O001people registered asattendees, therewere another go0orsocorporate exhibitors ranling insizerroma oneortwo personbooths toseveral thousand square feel . ' " There were IgT scheduled gOminute seminar'sor presenations.Eachhada themethat ,wa_formallydiscussedby a panel andmoderatorconcludingwith questionandanswer format. Thesevaried in size from about50 to350.I attendedsix of thesesessions:An Overview of ConsumerPreferencesand Emerging DesignIdea in New Homes.,Affordable Housin_ ][ey Factorsin Housing'sFuture; MakingStaall LotsWork / Smaller Smarter,More Affordable Housing; Archit(;cture Into the 21st Century and Foreiln Competitors in the Single Family Market. Of these the l[ey Factors in , Houslng'sFuture ( William Apgar on demographics, Jim Schuyleron politic, David Seiderson economiesand Lew Wise on technology)andForeign Competitorsin rh-.SingleF.amilyMarket (David Engel from HUD, Michael Joroff from MIT, Bob Irwm with the UI[ trade councilandTerry Mc Hammera developerfrom Washingtonworkingunder foreignownershipmoderatorDeaneEvansfrom StevenWinter Assoc,)were the mo_tsubstantive and provocative. Most of these sessions were taped and areavailable from a firminMaryland I have an order formand catalog. During the Key Factorsin Housing'sFuture sessionNAHB releasedtheir official long range planning report 'Framework for the Future: 1989- 1991' (one supposesthattwo years constituteslongrang vlanningin the housinl| industry). This.report examines Demoiraph]es, _|omtc_.TechnololD,, Pol!tws and Soc.ialTrends for their influenceon housing. I managedto get one o_me few copiesavailable, More ca_ be obtainedfromNAHB. Oneof the _elists .w.u .JoanMeCIoskey,Ezecut|ve Building Editor of Beter Homesand distributedcopiesof her presentation'How ChangingFamily LifesWlesAffect HousingNow. andinthe Future'. The formerdocumentin particular can contributesignificantlyto our report andI urge everyoneto reid it. There wer,_a numberof componentbuildersin attendance,l introduced myself to Lew W_sewho is president of the NVRyans new'building sy_tm company. They seemto be goingafter eomponenls and systems building in a bill way. H_ wu agreeable to sending us a video and follow up JI. _urrv=pun_'n_l. ,, O I also met the marketingdirector of Shelter Systems, Janet Hoff,m_ who will sendus a copyof a video'The Great AmericanBuild-Of,f"that visually comparesthe constructionof a s(_ebuilt with a componentbuilt one, They havejust purchaz, ed a plantin Sacramento, Anotherfirm Pre-l:'abSystemsusesa tru_ basedproductionframinl system theyare marketingon ,akindof franchisebasis, I met David Saunders('Mr, Pre-F'ab')who 'claimsthey candothe whole processfrom desiiptto productionon computersover the phone. , l ] alsometTedCheneyof CheneyBuildingSystems,a stressedskinpanel producerwho hasbuilt publichousingin the Chicagolrea. He promises documentation of a multi-familyprojectusinghis system. , FSECseemsto havesignedup DonCarlsoneditorof AutomatedBuilder for the SteeringCommittee. Cardinalis on the vergeof Chapter11bankruptcy. Severalof'the Universitiesin the NAHB/NRC housingresearchnetwork presentedwork in progress(ITniversityof Minnesota;ColoradoState;TexasA & M and Penn State specifically). Texas h_ a report just published m "Factor'sContributingto Sucessin the Factory Built HousingIndustry', Penn Statewill sponsora symposium on 'ModularHousinl: The Trend tor the _'s' on April 25 and26. Minnesotawas curiousif we were interestedin signing up. The Ioneestline in the expositionwas to get into Nest 89a modularhouseby Berku_ The GE'plastichouseandNAHB's SmartHousecameacrossasovermarketed air. The electronicsindustryhu a CBUSsystemthat will competedirectly with SmartHouse_d usez simplerzpplizzzcebased(asopposedto house based) technolow. I Thepresenceof architectsandthe AIA was unique andinteresting. Severalof the designorientedseminarswere organized,chaired,andpresentedby nationalhousingdesignfirms. Over 40 architectural anddesignfirms had booths-- ali were very conspicuous.Mostsoldplan boob, hadproefolioa availableanda$ressivelymarketedtheir services. The AIA sponsoreda bestof housingdesignsessionthatwas_ well attendedandslickly produced.They alsosponsoredseparatesite plan andbuilding designreview workshopsthat were very popular, lt lookedlike _ new consultinganddesigncommisioas were forgedin the proceJL Smallhouseson small lotswasa very visible Issueandtopicof discussi_. The , emphois being placedon smarterover smallerfor a vllue consciousbuyer. .M._yof thedesi_ strategiespromoted- simplerform_,addedvolumethrou_ ht_er plates and steeper roofs; better site-buildinl[ fit; inclusion and _re_J design of' adjacent outdoor spaces; better light; planning for expansion, multiple use oFspace and so on ali seem to be improving the design of developer housin| in thoseareasdominatedby this houseform. I Wide/ shallow (zipper) andZ-lotsare in tor their curb appealandbelier lightopportunities. Muchdeba_m centeredon the approp_atedimensionzl • # o better than the more common?0 x 50 deep versiem. 61¢q_ ,..-.,el. . Housinghasbecomemoreof a commodityin the heartsandmindsof more PneOple than ] hadever imagined. Hou.,,es were consistentlycalled'product': tertor designershavebecome'interior merchandisers'andlandscape architects'exterior merchandisers'. Wet paving,like slightly moistor oiledskinin cosmeticandperf'umeadsis very much'dertgeuer' in residentialarchitectural photographsthesedays, Entry portalsandgateshavegainednew importto 'beginthe owners experience'as soonas possibleon thesite. ,.. Bathroomsandkitchenswill continueto get bitter with doublesinksetc. while overall housesizedecreasesastwo incomef_tlles needto cookandget ready tor work at the sametime. Banquettesare becomingpopularnext to foodprep areu. The affordablehousingdrive of NAHB is first andforemostan attackon codes andre_lations. They havea checklistwith which to grill your localbuilding officials andpromiseto Plyoutexpertsto testify on behalf of'buildersseeking relaxationor substitutions. _/ext to thematuringbaby boomersthe nazi largestgroupis over 75 who will seekgoodquality expensivehousingwith opportunityfor adaptiveremodelu they becomelessmobile. Housebuyers haveacquiredmore IPamilyand homeorientedlifestyles. Duplexesare back in vitalized Pore. Next year is predictedto see 1.38million starts(-7_,). About1 million of'those will be SF. In the future 1.5million will be seento be a very goodyear. Weyerhaeuserpredicts1.3falling to 1.03the year al'_r, MedianhousesizehasdiminishedProm1911sf In 1987to 1808sl' in 19_. Read my lips "nonew squarefeet" 1\112 hourcommutesare roll,seento be acceptableu af'oorclablelandneeds pushhousingdevelopmenteven farther out into rural andsmallto,vn areas surroundinglarger cities. .Tapanwill havemorehousingstarts in the nextfew years (about _1.7 million) than the US. In 1983the US hada $40_million surplus in buildingproductstrade. In 1989 that hasbecomea $6 bilion deficit exclusiveof HVAC, paint andelectrical products. The USspendslessper capita _ RandD than any otherIndustrializednation and within the US the building industry spends less than per $sa_es than any other. Increasedliability exposureIs perceivedto be a barrier to Innovation. Nati_al politics is expecte(J to see an significant Interest in first time homebuyers. Possibly though a remodel of FHA policies. lP The real Japanese threat to the building industry is seen to be at least i0 years away. Japanese companies are now buying real est,'_tein secondary markets-50,000 acres in Rivers/de CA, Mont_nta, and so on, Even though Japan buys less than other countries it is their |end•hey to use these investments to leverage their way Intothis and other markets from those positions that causes concern. Once in piace the products and services to sell wall rollow auto,hatedoffice systems to their tenants;buildingproductsto their developers andsoon. F In the UK I_d com are 50%or the costof'housingwb_lethey are aboutZ5'/, here. Foreign companieswill not comehere seekingtosell whole buildingsytems but wall inste_ rind marketnicheswhere no USproducLsare availableand there are rew competitiors. The perceptionthat the US marketts andindustryis toodiverse,disat_regated and dominatedby fiezible, low capital businesses is changingrapidly. As • consequencelt will becomelessinsulated_ainst unilateral interventions. There were a numberor productswith somelocalinterest. Gyp-creW s lightweightgypsumlevellingmixturethatsetsup in 90 minutescan I_ivewood floorsa fire rating andacousticattenuation.A numberof prefabricatedstair t_ | I suppliers. MatsushiLa is marketinl_a soundinsulatingandfire retJrdw_tplank flooring. Lacolumberhasturned T-Ill intolap plywoodsiding, STO is marketinga ran_ or ezterior insulation_d finishsystem for hi,rise and renovationapplications, Werzalit is marketinghigh-densitymouldedwood trims andfinisheswith acrylic andmelaminesurfaces(milled unwood). Notesby ][ellett. EE1-H Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89.14a ] ', DateofReport: 12/01/89 Piace Visited: multi family housing subdivision inIngebo, Sweden (about 20kilometers south ofLinkoping) DatesofVisit: 09/07/89 Attending: J.Finrow Propose of Visit: View subdivision using SFC housing units Visit Report: While subdivisions are somewhat unusual in Sweden, they are not unprecedented. This project is located in a small town in a na'al setting and in,eluded close to 100 housing units mainly in the form of duplex, triplex and quadplex arrangements of townhouse types, The manufactta_r of these housing units was not demrminext,but it was possi,ble to view housing uni'ts at various stages of assembly, The most interesting aspect of this visit was seeing the foundation systems which were made of prefabricatedconcrete elent_nts. There was no site casting of concrete for any of the foundations for these housing units, Trenches were cut into the ground and leveled, with precast foundation elements set into them. The sy.s, tem represcntexlessentially a precast grade beam system with inte_te beams as ne_.,d to support panel points in the center of the house. Houses wer_ very simple,, probably in the area of 70 to 80 square meters. P_s of the project were completed and occupied, and parts were still just begmmng. Occupants in part of the p.rojectwere beginning to put up fencing and other elements of personalization. Supporting Documentation: Slide documentation. ifp EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89.1$a ] 0 [ Date of Report: 10K)1/89 Place Visited: Bromma District of Stockholm Dates of Visit: 09/10/89 Attending: J, Finrow Purposeof Visit: To photographa post WW IIprefabricatedhousing development Visit Report: Swedishprefabricated housing building mchnology hasbeenused since the1900's. Therear_many subareas ofStockholm whore small commumties havebe, cnbuilt inthe1930's andafter WW II using prefabricated wood housing building systems. Mostofthe majorSFC housing companies gottheir start during these times. TheBrornma district issuchanarea. ltcomprises several acres of land with gently curved roads lined by small woodentwostory houses that are brightly painted. Since the original development of the site, occupant have planted trees and othe landscape elements and changed the character of of their houses, neighborhood now is .m,d highly have changed the colors their housesThe as well as have addedto sought after asa piace tolive because oftheve, rynicequality that ispresent themasaresult ofthe_cale andnature ofthese small houses, Inacertain sense, these conJ, _mnities illustrate thepotential ofdeveloping energy efficient industrialized housing andwhat a\ communityofhouses could bellke in40years. Supporting Documentation: Extensive slide documentation ofthis community. EEI]-I Cenler for Housing Innovation University of Oregon TRIP REPORT FORM [,tfS89-14b ] i Date of Report: 10/01/89 Place Visited: Hostevetet 1, Stoc_olm, Sweden Dates of Visit: 09/09/89 Attending: J, Firu'ow Purpose of Visit: To photograph an energy efficient atriumhousing project Visit Report: Buildin_ in 1986, this 4 story apartmentblock utilizes a glasse,d over amum space in thecenterof the project and innovative heat pump technology to deve!op new ideas in urbanenergy efficient housing, Theinterior atrium space tsfully glazed (asdifferent formthe Bodbetjanten project which has a roofed atrium), with a smallwinter playground in the center space, Hay,ing the atrium provides some energy efficiency by providing passive "greenhouse"type heating that, atcertain nn_softheyear, reduces thetemperature differential betweenunit and"outside" (courtyard) space, The atrium isalso usedasanelement intheheatpump system whichutilizes quite deep earth boreholes foraheating source. Appa._nfiy problems havebeen encountered inthecontrols f_ thehea_ngsystem, andtheproject is inovolved inlongtermmomtoring bytheSwedishCouncil forBuilding Research. Supporting Documentation: Slides andbookdocumentation i EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [JP389.14¢] Date of Report: i0/01/89 Place Visited: Kejsaren 20, Stockholm, Sweden Dates of Visit: 09/09/89 Attending: J. Fh'n'ow Purpose of Visit: To photographan urban energy efficient housing project Visit Report: The Kejsarenprojectis an urban inFtilp_ject locatedin the Southernpartof Stockholm in an urban redevelopmont , ar_a, The siteoforthe projectis vse_ constrainedand the building isjust a piec_ falarger street ofsmilar buildings. The building is6 stories highandiscappedwitha large active solar collecuon array that provides hotwaterthat isuflllz_ through a heatpump system tohea!theapariment units inthebuilding. Heatfromthesolar collections isstored inathermal storage areainthebasement ofthebuilding andthenhotwaterispiped totheapartments andiscirculated through theholes inthecore floor slabs providing bothaheated floor andcieling ineachunit. Eachbuilding hasa balcony andbecause ofthedghmessofthesite, an interior artiumis not possible to provide for dfis project.The building fits into the urban context quite well, Suppor'|£ngE_x:umcntation: sli_s and some book documentation i EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89.14d ] Date of Report: 10/01/89 Place Visited: Sjukskoterskan 5 housing project Dates of Visit: 09/09/89 Attending: J. Fim'ow Purpose of Visit: To photograph a Swedish energy efficient apartment complex Visit Report: This project was designed to take advantage of a small scale project based district heating plant. Built in 1985 as a three story project with a single loaded corridor, the project_ is pleasent, but not particularly architecmmUy innovative. The heating plant, while apparently quite efficient, shows little on viewing. Suppor_g none Documentation: EEIH Center for ttousing Innovation University of Oregon TRIP REPORT FORM [jfS89- 14e] _. I ] l el ! DateofReport: 10/01/89 Piace Visited: Konsolen I,energy efficient housing project DatesofVisit: 09/09/89 Attending: J. Finrow Purpose ofVisit: To photograph anenergy efficient multi-family housing project Visit Report: Whilenotbeing particularly visually interesting, theKonsolen project pioneers someveryinmrtsting energy efficient ideas. The maininnovation isaprecast concmmexterior wallthat pmvid_ thermal massstorage andtheoppornmity forpreheating ventilation air into the housing uniLThe exterior wallpanels facing south havecavities (ducts) inthewall whichpro_decirculation for ventilation air overalongdistances inthewall(togainheat) before accessing thehousing unit. Inaddition, thepro.iect makesuseof innovative heatpump technology andacentral heating plant to improveenergyefficiency in heating interiorair to the housing units. The project is very conservative in it's appearance and offers little of in_cst except for the innovativeuse of the exterior mass wall panel. SupportingDocumentation: a fewslides somebook documentation. EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jl'SS9-14f ] Date of Report: 10/01/89 Piace Visited: Skogsalmen 2 housing development, Stockholm Dates of Visit: 09/09/89 At'tending: J. Fim'ow Purpose of Visit: To photograph an L"movativeenergy efficient industrialized multi-family housing project Visit Report: Thisproject isoneofthemoreinteresting ofthenew energy efficient experimental houses supported by the Swedish Council for Building Research. The project is formed of two and 4 story homing blocks organized around interior courtyards of comment activities such as day care, communal gardens, etc. The most striking fcatm_ ofthis project arethelarge glaze.zl sunspaces that areusedonthe south side ofthebuilding tobuffer the exterior wallofthebuilding fromthedirect outside _" md thusproviding somere<luction inheating _. The sunspaces areveryeffective andalsoprovide anaddedroomfortheaparmacnts andareextensively utilize.xl byresidents fora variety of activities. Inaddition, there isalsoa central heating plant that provides hotwater totheapartments anda heatexchange system forpreheating outside ventilation air. Heatfromthesunspaces areblownthrough thecoreslabs toheatup thefloor andcielings oftheapartment units. Theproject isquire\ interesting andstemstobesuccessful. Supporting Documentation" Extensive slides andsomebookdocumentation. EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89.14a ] Date of Report: 10/01/89 Piace Visited: Housing project at Bodbetjanten Dates of Visit: 09/09/89 Attending: J, Finrow Purpose of Visit: To photograph an innovative urban energy efficient housing project in Sweden Visit Report: The Bodbctjanten project is one of the experimental housing projects supported by the Swextish Council for Building Research located in a southern suburb of Stockholm. the project is nn apartment block occupied in 1985 which makes use of several innovative energy ideas. The most significant idea in this project is the use of an atrium space for solar gain and for advanced ,_at pum.p technology usedtoprovidespaceheating fortheapartments m me building complex.Inaddition, theproblemutilizes mixed 1, Stockholm, Sweden building. To that thenort}-, am placed offices whichgenerate heatform use activities are meant balance the heating needs of the the workers and their _mchincs which is passed to the apartments which need heat to keep them at comfortable heating levels. Tlm exchangeofheat isaccomplished throught _ atrium and fromheatexchange technology usedinextrat:ling heataCrrvmSPe the offices andputting intotheapartments. Thisproject ispartofa longtermmonitoring research project whichisexaminingthe success oftheproject intermsofitsinnovative components. Supporting Documentation: I Slides and book documentation. EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89-13b ] Date of Report: 10/0 1/89 Piace Visited: Housing project (unknown) in south Linkoping, Sweden Dates of Visit: 09/07/89 A_nding: J. Finrow Purpose of Visit: To photograph a new housing project under construction that combined a significant area of SFC housing with more conventional multi-family site built housing. Visit Report: This project was undereonstruetion when visited with completion scheduled for October. The project consisted of one area of multi-family housing and one area of single family detached housing. The second area was composed of small panelized SFC houses. These houses were located across a major road from the multi-family part of lhc project. Most of the houses were occupied. While a very nice project, there was nothing particularly remarkable about it. The multi family housing area \ utilized an interesting combination of 6 story *_.nd2 and thtr, story \ housing types together than created a reasonable scale. Nicely defined and developed commons spaces were mad_ and there was some use of "so.rlspal_s". Supporting Documentation: Slides EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [,jfS89.13c ] Date of' Report: 10/01/89 PiaceVisited: Larnbohovhousingarea,westofLinkoping, Sweden Dates of' Visit: 09/07/89 Attending: J. Fiarow PurposeofVisit: To photograph an experimental housingproject supported by theSwedishCouncilforBuilding Research Visit Report: The Lambohov project islocated inanew developmentareawhichis southwest oftheTechnical SchoolinLinkoping.Therearesevc,_l different kinds of housing projects in the general development ata. The energy project that was visited includes several row house\ buildings all oriented south with active solar collectors for roofs. Them am about70 dwelling units intheexperimen_area.h addition toactive solar hotwatercollection systems, thisgroupofhousingalso utilizes heatpump technology andthermalmassenergystorage j fenced garden areastothe.;outh. The longrowsofhousing seem abit systems. Housingunits typically have northsideentry access with monotonousandrigid withtheblacksolar panelstothesouthcreating a heavyanddarkappearance, espc_aily incontrast toa l_oject closeby J thatismuch lighter andmore character. Converstations witha few residents pointed outthatcheerful thepeople who lived hem seemedtolike theplaceandfelt thattheywereimportant aspartofa national building experiment. The active solar panelswerepositively regardedandpeople felt that, whiletheir roofs"lid notlooklikeotherhouses, theydidnot feelthatthepanelsdetracted fromtheir houses.Therewas acertain spirit ofadventure thatpeopleexpressed living inthisprojectResidents mentionedthattherewerenotproblemswiththesolarpanels, butone resident mentionedthattheir panelhadleakedintothehouseanddid destroy some furniture, butthatitwasquicklyrepaired anddidnotleak again. Supporting Documentation: Slides EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89- 12ai ] Date of Report: 10/(31/89 Piace Visited: Myresjofonster AB (a window plant owned by Myresjohus) Mr. Thomas Jamland., Box 153, S 574 01 Veflanda, Sweden Dates of Visit: 09/06/89 Attending: J. Fim'ow + Minnesota group lead by Paul Kando Purpose of Visit: To visit a state of the artautomatedwindow plant Visit Report: This plant is extremely highly automated and vertically integrated company that supplies window units to the Myresjohus company and also on the open market including export. This company is the third largest window producer in Sweden. They employ 325 le and produce about 300 million SKIt in windows each yem-. ix prttluction is allocated as foUows: 30%to contractors for spe,ria1 windows, 25%to the home improvement market, 41% to the SFC industry (with Myresjohus being only9%) and about 4%for export. They currentlycannot keep upwith their orders and have a 16week backlog of unfilled orders. First we toured the older part of the plant where windows areproduced in a less automated fashion. This plant was still well organized, but afmra visit to the main plant, it clear that this facility was not particularly automated. The main plant was w_Uorganized with extensive use of automated milling machinery that was computer controlled. Ali casing materials and millwork was formed by automated machines. They have dcvelol_ a particularly innovative automatic painting facility that was able to seal, paint and dry a high volume of casing materials in a few hours, window frames and casings were put togetherin a hand operated jig and glass installed in a rather labor intensive setting, hardware was the last to beinstalled. On the plant site was also a plant that took glass and made insulamd window units. These triple glazed windows were use in the fianms that were manufac_ in the other plant facility a few metersaway. This facility was quite important as tt provided the glass for the frames. In addition to the vacum bed for creating the chambers between layer of glass, there was a special section formaking gas filled and coated glass units for special orderneeds. Supporting Documentation: slides and a standard window catalog EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jtS89-12b] | Date of Report: 10K}1/89 Place Visited: Myresjohus AB, Ms. Catharina Ekwall, S 574 85 Vetlanda, Sweden Dates of Visit: 09/06/89 Attending: J.Fim'ow+ Minnesota groupleadbyPaulKando Purpose of Visit: to view the state of the art in SFC technology Visit Report: The Myresjohus plant is the most automated factory in Sweden. In addition tothehouseplant, thefactory alsohasa complete sawmill whichproduces wood forboththeplant andforsale toother companies. Thisplant produces 1,800 houses peryearwith150export houses. The plant employes 210people andhas40 sales offices inSweden.The value oftheproduction oftheplant is600million SEK peryear. 20% ofthewood useinthehouse, factory comesfromthesawmill with80% being purchased frommarket sources. 40% ofthefactory production is intheformofmult-family housing units. Thisplant isthemost highly automated ofall oftheplantsvisited. Theywerealso inthe an additional production line that would to increase producticrafrom process of making a significamtaddition the basic plant in order the to Kid plant. The sawmill was fully automated with computer control for most of the cutting and sorting activity of the plant. After cutting, the wood was dryed in large kiln dryersthat were also located on the plant site. Them was a considerable stockpile of basic wood on the plant site. The house factorywas impressive becauseof the highly automated natureof the plant. The most innovative partof theplant was the fully automatedfloor production facility andthe automated insulation insertion machine which istheonlysuchmachineinSweden(oranyother piace). Workingwith Nordisk Karto(anequipment manufacturer andfastening system supplier) andaninsulation company, Myresjohus hasdeveloped a way ofautomating insulation installation intowallandfloor paneLs. The insulation arrives infully cut batts that are drotrtx_ into thewall cavities asthewallpasses theinsulation station. Normally this process isdonebyhandandhasbeentheonepart oftheproduction process that hasbeenleast industrialized. Bugswerebeingworkedoutofthesystem during ourvisit. Theplant engineer discussed theissue ofproductivity. Thiswasa veryimpressive plant operation. Supporting Documentarlon: Myresjohus promotional brochures only, cameras werenotallowed in theplant itself. @l I EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jrs89-12c ] Date,of Report: 10/01/89 Placc Visited: 4 plex aparm_nt under assembly in Vctlanda Dams of Visit: 09/06/89 Attcnding: J. Finrow + Minnesota group lead to the site by Ms. Ekwall Purpose of Visit: to view a multifamily housing unit under assembly Visit Report: This Myresjohus multi family unit was a 4 unit flat house with twounitsup and two unitsdown. thehousehad theexterior w_,1,1s inplaceandtheroofwasjustfinished. The building hadjustbeen enclosed and much work remained on the interior. The main floor was slab on grad_. The second level floor was fortmd of precast concrete slabs.Allinterior partitions wcn_to be site built andthe ext_ri_finishes wereto be completedinbrick. The panelscome tothestmforthisproject unfmishezl on bothsides.The designof thisproject was uninspired and lackezl intor, st. The sizeofthetwo bedroomunitsappearedto be quitesmall.The extantofindustrialization intheproject seemedverylimited withonlythewallpanelsand roof trusses factory produced. Supporting Documentation. slides el' theproject. EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89-11b ] Date of Report: 12/1/89 Piace Visited: GuIlringshus AB, S 590 81 Gullringen,Sweden contacts Mr. Heinz Will and Mr. Mats Borsjo Dates of Visit: 09/05/89 Attending: J. Finrow + Minnesota group lead by Paul Kando Purpose of Visit: to visit and document SFC plant Visit Report: OuUringshus is one of the largest manufacturen of SFC housing in Sweden. The plant we visited produces about 1,200 houses per year with 30% of their producuonin multi-family houses. 400 units are site assemble by their own crews ratherthan by local erectors, They currently have a 20 week waitingperiod beforedelivery. 15%of theirproduction isexported, mainly to Germany. They have a total of 60 sales offices in Sweden. Their average house is about 720,000 SEK excluding the land. The plant managermentioned the currentboomin $FC housing production and discussed the tax issues involve in the current production run. The plant is highly auto.n_,tedwith very efficient panellines, especially the floor panels which had little human operatorneeds. The plant was very large and allowed for each line to product thatwarehouse were stacked andcoordinated fordelivery. We also visitedpanels a supply where cabinets, appliances and other support items were being stockpiled for delivery with houses. Cabinet parts were completely prefabricated and sent with the house parts for final assembly. Suppliers were encouraged to provide "just in time" items forthe houses and the warehouse was not very full. We were able to view a house being placed onto a truck which was an interesting experience. The stacking of house pans into the truck is very ordered, with the parts needed first stacked 1astso that taking partsof the truck was organized and coordinated to assembly rtw,ds. lt was also mentiomxl that there were problems associated with site _ sembly that would probably mean that eventually all site assembly wouldbe done by the company. Supporting Documentation: slides of the production process including truckloading and company brochures. I i ., EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jPS89.11a ] Date of Report: 10/1/89 Place Visited: Hultsfreds-Hus Ab, Box 501 S 577 00 Hultsfrod, Sweden Mr. Tore Falkenhaug and Ms. Ragnhild Ekselius Dates of Visit: 09/06/89 Attending: :I.Finrow + Minnesota Group lead by Paul Kando Purpose of Visit: To view an SFC plant Visit Report: Hultsf'reds plant was interesling because it had a sawmill attachedto the plant and also they ulilized a small panel concept in addition to a new large panel facility. The total production of this company is about 2,500 houses per year with the factory we visited producing about 1,000 houses. About 10%of their production is for export and the rest for the domestic markeL Theproduction line in this factory was more industrialized than that of Boro Hus. The use a CAD system in the plant to supportthe internalneeds of the factory (they do not use it in a sales environmen.j. They produce 1.2 million small panels pcr year. The cost of a typical house from their plant is about 6,000 to 7,000 $EK (Swedish Kronor $1= 6.4 $EK) per sq. meterand about 5,000 to 6,000 SEK for multi family housing units. The averageran_geof house sizes are betw_n 110 to 120 square meters, they anticipatein the futm'eto be building largerhome, in the rangeof 130 to 140 square meters. Most buyers arepeople who already have a home and want to "buyup" to a larger and better qualtiy house. They have some problemsin atlr_ting workers to their factories. They use a lot of foreign workers, at the moment they have mainly Icelandic workers, lt was also mentioned that new regulations will present certain problems for them in the need improve the quality of their product because of more stringent warrentec issues. They will likely becor_ involved more directly in the assembly of the houses in the future. Supporting Documentation: slides of the plant operationandcompany sales brochures. EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89-11c ] Date of Re4x_: 10/01/89 PlaceVisited: in The Gullringen home of Mr. Heinz , Will, plant engineer for Gullringshus Dates of Visit: 09/05/89 Attending: J. Fim'ow + Minnesota group lead by Paul Kando Purpose of Visit: to view a Gullringshus Visit Report: Mx.Will invited us to visit his house to see what a GuUringshus looks like. His house was built about 5 years ago and was a one story house built over a full basement. The main living floor had two bedrooms and all of thepublic spaces of the house. The basement had two bedrooms, a kind of family room, a sauna and workshop room. The house had brickexterior claddingand tile roof. The interiorfinish is mainly wallpaper over gypsum board with a very fine wood ceiling. The overallfeeling of the house is qtutepleascnt with reasonable light l l door toMr.Will _vhich ,#as ust ralso ecently completed. Whilethis house arld high quality finish. We jwere able tovisit another house next I wall boardmaterials hadgave a joint thatthe while different home wall panel baton, much same feeling.than a U. S. mobile was alsonice, itdidnotfeel quite thesameasMr.Will's house.There was astronger sense that this-house was amanufactured house. The Supporting Documentation: none except direct experience. I EE1H Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89.10a] Date ot!Report: 10/01/89 PlaceVisi_ Buttock, AB / Verkstadsgatan7 / S 571 00 Nassjo, Sweden Dates OfVisit: 09/134/89, Anencting: J. Finrow + Minnesota group guided by Paul Kando PurpoSleof Visit! To document an equipmentmanufacuring plant for SFC technology Visit Report: This plant produces much machinery forSFC plants in Sweden. They currentlyareworkingto develop new machinesthaiwill improve the productivityof SFC plants,especially relatedto the r,ailing of sheathingto floor and wall panels. The plantis highly sophisficauut producing from stockjust about all of the partsto complete a SFC factory including valves. The plantcurrentlyhas a backlog of orders for p_3ductionof various machines forplantlocated in Smaland. We saw severalof _is plants new machinesbeing installedin factorieson out visits to SFC plants in the areas. The factory also offers complete planning and design services for new factoriesincluding fully computerizedplantdesign capability. The factorywas recently urchased by a groupof investorsbut the plantmanager,Mr.Roll urman,remains the main personin the firm. In additionto the productionof plant equipment, this plant has a very sophisticated electronics sub assembly areawhere all of the wiring for the productionmacl_ery is completed. SupportingDocumentation: slide documentation of the plant and some brochm-ematerialsprovided by Buttock. ¢ EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89-10b] Date of Report: 10/01/89 PlaceVisited: Bore AB (plant for Boro Hus) in Landsbro,Sweden the contact personwas Mr. Elon Gustavsson S 570 12 Landsbro Dates of Visit: 093)4/89 Attending: J. Fim'ow + Minnesota group lead by Paul Kando Purpose of Visit: to visit an SFC plant of Borohus the largest of the various SFC companies in Sweden Visit Report: The Boro Hus plant was at full production when visited. The manager arranged a general meeting to discuss the plant and the Bom Hus perational concept then lead a tour of the plant. The manager said that materials for the SFC plant were also purchased on the open marketin orderto get the best price for the product. The plant was quite automated, but was not the most automated plant visited. They wen: also in the process of installing a new panel line using equipment supplied by parts Burme,k. One of the more interesting of the plant was the small component productionline when: bay windows and gable end wails were manufactured. These items were essentially hand made, butin a factory setting. This factory the "trusstud"elements that appearsto be quite importantto theutilized thermalperformanceof the SFC house. The sub area when: these studs are manufacturedwas quite interesting, but was studparticularly plates whileautomated. a rolling press the threeelements together. The not Twoformed operatorsset the cords and lay in the factory was well organized and quite clean. Workerswen: working hard, but not particularly stressed. The general sense of the factory was positive, good lighting and not overly loud. Hus showing house sold bymarketingliteratureform the company. Supporting Documentation: Boro slide documentation of thetypes factory plus EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89-10c ] Date of Report: 10/01/89 PlaceVisited: Myresjohus underassembly nearVetlanda Dates of Visit: 09/04/89 Attending: J. Fim'ow and Mary Vogel of the Minnesota group Purpose of Visit: to view an SFC house under construction Visit Report: Apparently it was not possible to actually v_sita house that was being assembled, but we did manage to find a house that was almost completed and to view it. The house had all of the panels in piace and the roof on but the panels were not completely sealed and it was possible tosee the panels and how they were attached. Roofs seem to be site built based on wood trusses that are set and stripped on the Sitewith 6Jeaset on the roof. This particular house had a completely lrref_ncated in the roof which was an interesting sub assembly item that can be added to any Myresjohus house. In this house the exterior was clad with board on board solid wood siding that was stained. The interior had yet to be finished i.na coventional gypsum board fashion, probably with wall paper. There was also a completely site built fir_lace unit. The foundation also looked to be pmeast concrete elements rather than poured in piace foundations. Our visit occured in the evening and no workers were on the site to discuss the project with. w'm, SuFporting Documentation: slides ! EEIH Center for Housing Innovation University of Oregon " i TRIP REPORT FORM UfS89-11c ] Date of Report: 10/01/89 Plate Visited: in GuUringen The home of Mr. Heinz Will, plant engineer for Gullringshus Dates of Visit: 09/05/89 Attending: J. Finrow + Minnesota group lead by Paul Kando Purpose of Visit: to view a Gullringshus Visit Report: Mr. Will invited us to visit his house to see what a Gullringshus looks like. His house was built about 5 years ago and was a one story house built ovm"a full basement. The mair, living floor had two bedrooms and ali of thepublic spaces of the house. The basemetrt had two bedrooms, a kind of family room, a sauna and workshop room. The house had brick exterior cladding and tile roof. The interior finish is mainly wallpaper over gypsum board with a very f'me wood ceiling. The ovmzll feeling of the house is quite pleasent with reasonable light da_ high to Mr. Will ft.,fish. which was completed. Whilehouse this house and quality We just wererecently also able to visit another next was also nice, it did not feel quite the same as Mx. Will's house. There was a stronger sense that this house was a m_ufacmmd house. The wall had gave a joint th_,tthe while different homeboard wall materials panel batten, much same feeling.than a U. S. mobile Supporting Documentation: J di none except direct experience. EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM UfS89-10a] Date of Report: 10/01/89 Piace Visited: Buttock, AB / Verkstadsgatan 7 / S 571 00 Nassjo, Sweden Dates of Visit: 09/04189 Attending: J. Fin.row + Minnesota group guided by Paul Kando Purpose of Visit: To documcnt an equipment manufacturing plant for SFC technology Visit Report: This plant produces much machinery for SFC plants in Swe,den. They currently atc working to develop new machines that will improve the productivity of SFC plants, especially related to the nailing of sheathing to floor and waLlpanels. The plant is highly sophisticated producing from stock just about ali of the pans to complete a SFC factory including valves. Thc plant currently has a backlog of cn'ders for production of various machines for plant located in Smaland. We saw several of this plants new machines being installed in factories on out visits m SFC plants in the areas. The factory also offers complete planning and design services for new factories including fully computerized plant design capability. The factory was recently purchased bya groupofinvestors buttheplant manager, Mr.Roll Burman, remains thc main lg'rson in the firm. In addition to the production of plant equipment, this plant has a vcry sophisticated electronics subassembly areawhereall ofthcwiring forthe production machincry iscompleted. Supporting Documentation: sLide documentation oftheplant andsomebrochure materials provided byBurmck. # EEIH Center for Housing Innovation University of Oregon + TRIP REPORT FORM Date of Retxm: 9/18/89 Piace Visited' Architectural Museum and Bookstore, Copenhagen, Denmark Date of Visit: 8/26/89 (jfS89-3a) Attending: J. Fin.row Purpose of Visit: Locate literaua'e related to energy efficient industrialized housing design Visit Report: I found and purchasedseveral items that relate to the EEIH project which are Iisted below. Supporting Documentation: IndustrializedHousing in Denmarl(;Kjeldsen, Marius, Danish Building Center Bookshop, 12E Skolegade, DK-2500 Valby, Denmark, 1988, ISBN 87-503-71762 , Danish Social Housing Corporations. Vol _; Salicath, Ncils; Danish Ministry of Housing and Building, International Relations Division, Slotsholmsgadc I 12,J216 Kober_havnK, Denmark, ISBN 87-87744570. Arkitekuare i Danmark:Byg _: Bo 88 Odense; no author given; Fremtidens I Boligbyggeri pa Blandstcdgard. Danish Architecture,1879 - 1979; no authorgiven; ArkitcktensForlag. Tag Over Hoveder,Nygaard,Erik; Arkitektens Forlag, 1984; ISBN 877407-064-9. Laengeboligcn;Orum-Nielsen, Join; KunstakademietsForlag,Arkitektskolcn og Arketektens Forlag, 1988, ISBN 87-87136-01-5. (note: all books arepersonal copies of J. Fim'ow) I EEIH Center for Housing Innovation University of 0 regon TRIP REPORT FORM [jt'S89-3b ] Date of Report: 9/18/89 Piace Visited: Hosby Hus n/s DK-7130 Juelsmincle, Denmark DatesofVisit: 8/26/89 Attending: J. Finrow Purpose of Visit: To view the manufacturing process of a Danish wooden factory crafted home manufacturer. Visit Report: Visit was not eomplete,d do to the schedule of the company, I I was unable to visit. They would agree to have me visit at another time that would be more convienent to them. Supporting Documentation: none EEIH Center for Housing Innovation nlverslty of Oregon TRIP REPORT I I i el I FORM [jfS89- 4a ] Data of Report: 9/18/89 Piace Visitad: Roslev Hus 2 Frisenborgvej DK-7800 Skive, Denmark Dates of Visit: 8/27/89 Attending: J. Finrow Purpose of Visit: to observe the manufacturing process of a Danish wooden factory housing manufactu_r. Visit Report: Could not contact the plan, my phone calls were never answer_ I la_'r found out that this company has gone out of busniess be,cause of a recent contact that will be mentioned lamr, Supporting Documentation: none EEI]-I Center for Housing Innovation Universiiy of Oregon TRIP ,,_EPORT FORM [ jfS89.5a ] Date of Report: 9/18/89 Place VisitS: Ebbeltofl re,creational housing community northandeast ofAarhus, Dcnmaxk Dates of Visit: 8/28/89 Attending: J. Finrow Purpose of Visit: to view and photograph an industrially manufacatred recreational communityproject. Visit Report: I visited the project and took many photol_aphs. I talked with a salespersonabouttheproject, ltisa unqme andinteresting housing schemebecausetheyintent tosell mostofthehousingtobuisnesses who would usetheproject asa recreational facility fortheir employees. A veryinteresting project withanicesenseofplace.Locationisa bit isolated and it did not seem very occupied. Supporting Documentation: Sales brochures and descriptive information that will bc placed in ourlibrary ofliterature. Ihavemany personal slides oftheproject. , EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [ jfS89- 5b ] DateofReport: ,9/18/89 Place Visited: xxxxxxxxx, AarhuS, Denmark Dates of Visit: 8/28/89 Attending: J. Finrow Purpose ofVisit: toviewandphotograph examples ofcontemporary Danish industrializ._l housing. Visit Report: Thisproject was alowrise concrete housing system whichwas_vclop_ asn'zxlcrate incomeattached housing. The project wasnicely designed and adaptedto the land of the site. The project shared a district heating system andthesiting wasdonetominimize windaccess toinner courtyard spaces -a goodenergy siting strategy. Supporting Documentation: personal slides oftheproject Qi I EEm Center:for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89- 5c ] Date of Report: 9/I 8/89 Place Visit_t: ?,Aarhus, Denmark Aarhus Arldtektgruppc, architect Dates of Visit: 8/28/89 ,'.,tending: J. Finmw Purpose of Visit: to photograph and document energy efficient industrialized housing Report of Visit: A very nice project built in concrete smallpanel system with wood and brick facing. One of the buildings uses an interior .]gj_., nhouse corridor which provides sn ener_ efficient space between buildings that is highly used by residents. This space is probably about 20 feet wide with connections to community spaces including a day care centro'. The space was full of children some on small wheel carts using the space. See sketch below: Supporting Documentation:personalslidesof thisprojectIncludingthegreenhouse space. EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89- 5d ] I i Date of Report: 9/17/89 Piace Visited: Energy efficient Co-Housing project, Fredrica, Denmark architect and specific name of project unknown Dates ofVisit: 8/28/89 Attending: J. Fiarow Purpose of Visit: to photograph anddocument a projectusing a large intm'ior greenhouse toreduce energy usage. Visit Report: This housing project was very interesting because it was a good example of,,_e valueairlock of a ".g_.__nhouse" d_sign concept outsid_ that seeks tocreate a thermal between the conventional ofabuilding wallandtheinside. Thereweretwobuildings inthis project eachofwhichwas composedofseveral groups ofapartments that shared a common interior greenhouse space (see sketch). The interior greenhou_s werefull ofactiwty andlife andalso appeared to have an air distribution system for recycling greenhouse air. I SupportingDocumentation:Manyslidesweretakenwhichdooumentthisproject.Later questioning of arohltectsInCopenhagen did notturnupany additional information aboutthisproject. t a ,I I EEH-I Center for Housing Innovation University of Oregon TRIP REPORT FORM [ jfS89 - 6a ] DateofReport: 9/I8/89 Place Visited: Byg andBo housing exhibition site, Odense, Denmark large housing;project involving many different architects anddevelopers Dates ofVisit: 8/29/89 Atlending: J.Firtrow Purpose ofVisit' To documentandstudy the"state oftheart" incontemporary Danish multi-family housmg,.several projects of which employ mr_ovadveenergy and mdusmalized building strategies V'sit Report: This exhibit was opened in 1988 and is currently occupied. The exhibit was developed by the city of Odense (the third largest in Denmark) to celebrate the 1,000 th anniversaryof Odense. The project includes about 600 housing units in 19major buildings with over 1,500 occupants. Built on the site of an old manorhouse, the projectwas designed to create experientialdiversity by using a number ofimportant Danisharchitects. Two projects ofthis grouputilized the "greenhouse'' streetidea in a bat different form than seen elsewhere in Denmark. In one case, there was a major cubic interiorcourtyard and m another case the greenhouse was a kind of enclosed street that formed thewinter circulation patternwithin thecomplex. Several projects made use of attached "sunrooms" on balconies which provide and unheated extens,on of the hying space in the better parts of the year. See diagrams below: t Supporting Documentation:Many slides weretaken andabookofonlylimited technical merit wereacquir_todocument theproject. ' EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89- 6b ] , " I " I ! Date of Report: 9/18/89 Piace VisitS: Tinggardenhousing project, Koge, Denmark architect: Vandkunstenarchitects Dates of Visit: 8/29/89 Attending: J. Fira'ow Purpose of Visit: Study andDocument ContemporaryDanishenergy efficient housing Visit Report: This project is comprised of two different parts, Tinggarden 1 and Tingga_en 2, both designed by thorsame architecturaloffice. The Va'stproject is designed as clusterhousing with open garden areas betw_n building wings. There ¢_realso extensive common facilities which are shared. Energy '..tolerationsinclude district heating. The second project was bull! later and is more "urban"in the sense that public spacesaresomet,_,hattighterand morefinished with a greatersense of enclosure. Tl_.ematerialsare also quite differentand the cha,.,cter of the project is a bit "harder". This project also u_ district l_..ating,,Both projects are built with industrializedconcrete panel constraction systems. Supporting Documentation: Extensive slides weretaken andbothphases ofthis project are represented inthebookspurchased atthearchitectural museum.A EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [ jfS89 - 6c ] DateofReport: 9/18/89 Place Visited: HolmebaekHousingproject, Herfloge, Denmark Aarhus ArkitektGruppe Dates of Visit: 8/29/89 Attending: J. Finrow Purpose of Visit: To photograph and document the firstmajor industrialized wood panel housing project inDenmark. 'Visit Report: Thisproject pioneered theuseofprefabricated woodeninfill panels inconcrete shell construction. Floors andparty walls weremadein poured inpiace concrete. Interior walls and exterior walls we,re factory produced wood panels that werecladon:site withfinished material onbothsides ofthewall.Inaddition, prefabricated elements suchasbalconies, sunrooms, living roomextensions, etcwereeither factory made andaddedorsite built togivevariety thethese buildings. This composite construction strategyhas been extensively utilized in Denmarksince this project and has significantly changed the way such housing is designed. See diagrambelow: i t J The projectalso utilizes a district heatingplant and extensive garden plots. Supporting Documentation: extensive slide documentation wasdoneandthis project isrepresented intheliterature purchased fromat thearchitectural museum. @ ;i • .! EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [ jfS89- 6d ] Date of Report: 9/18/89 Piace Visited: Sun, Wind and Light Co-Housing project, K,_ge,Denmark Dates of Visit: 8/29/89 Attending: _IL W , I I _ J. Finrow Purpose of Visit: Documentation andstudy of a significantenergyefficient housing project Visit Report: This projecthas pionecr_ a considerable numberof energy efficient design issues while at the same time based on a coramunal housing design stral_gS,. The project makes extensivc use of active solar panels forhot water heating. Many of the housing units also havesouth sidegreenhouse spaces whicham usedasnon-heated extensions of interior spaceaswell asfor domestic agricultu.,¢. The project also gains some power from a commercial power generation windmill that is located 1 km from the housing project site. The project is designed arounda series of garden courtyards in parts of two It_four units. The project is painted bright and light colors and generally projects a cheerful feeling. As in most of the Danish housing projects, there is a district heating plant in the project. This is a very interesting andinspiring projectenergy that demonstrates that it is possible tocombine manydifferent efficient strategies into oneproject ina goodway. Supporting IX)cumentation: extensive photo documentation was carried out and the project is represented in the Co-Housing book. 01 ! , , EEm Center for Housing Innovation University of Oregon i i TRIP REPORT FORM [ jfS89 - 6e ] Date of Report: 9/18/89 Place Visited: Tastrup Hoj development areawest of Copehnagen a large "new town" with many differentproject areas Dates of Visit: , 8/29/89 ArtencLing: J. Fim'ow Purpose of Visit: Examine and document the development of the newest of the Danish housing developments. Visit Report: Tastrup is located just west of Albertslund, the land mark housing project in the Copenhagen region of the 1960's. Tastrup is intended to be a major "center" with a large population. The area ah-'cadyhas many large but not very interesting housing projects and the new project is an attempt to create the physcial definition of a town. The project uses the latest thinking in urban design derivativeof the theoretical ideas of the Krierbrothers. Energy issues are not very 'anportant in the project center whichcombines c_ office and housing space together along narrow and well defined streets which feel like a city. The surroundinghousing projects that arc pH of the broaderTasu'upcommunity aresomewhat less rigid, and take _','_tage of such energy efficient features as sun spaces, central heating plants and superinsulation. One of tile projects in this development was built by the Yesperson& Son company that I visited on Thursday. This project was very nicely designed being organized around a well defined interiorcourtyardspaces. This project area is still underconstructionand will be interesting to visit in about two years as more of the town will be visable. It is unfortunate that energy considerations are not a signficant issue in the Tastruparea as it is the "leading edge" of currenthousing design thinking in Denmark. Supporting Documentation: Slides articles from the Danish architectural magazine arc available. EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89-9a] Date of Report: 10K)1/89 Pla_ Visim:l: North of Copenhagen Dates of Visit: 09/2/89 Attending: .l. Finmw Purposeof Visit: Photographa retro i_thousing project Visit Report: This project is the best designed of all of the current group of 1950's & ,60'S concrete housing projects that have been retrofitted in the last three years. The original project was a large project of 3 to 5 story concrete slabbuildings organized aroundinterior courtyards. The project had apparentlydeterioratedvery badly and was in need of substantialrehabilitation. In additionto this work needed, the project was to be retrofitted in order to improve energy performance. In addition toimproving the energy performance,the designers of the projectsought to improve the generalquality and characterof bener envixonment. trusses were installed ,vith metal roofing the piace at the sameRoof time therefore, making a moresuppc_ive and ' to provide better weathering andtobeableto install roof insulation. Many existing balconies wererebuilt tofully enclose themwithglass I creating "sun spaces" living that would and providean additional spaceimproveenergy forthe housingperformance units. Existing concrete pant._s wv,e insulated andresided withconcrete boardwhich in the wall.bener Windows replace with glazedenergy uniu. performance The provided scale atwere the same time as triple improving landscape.,was also redesigned as were the open spaces to provide beuer quality generalenvironment. The project is very successful in an:h- I | itecturaA termsand also gives improved energy performance asweil. SupportingDocumentation: Main documentation through slides, this projecthas be.enPublished in the Danish architecturaljma'nal. EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89.9b] D_.teof Report: 10/01/89 Plate Visited: Damgardsarealet project area in Albertslund Dates of Visit: 09/02/89 Attending: J. Finrow Purpose of Visit: study and photograph a project under construction using Danish composite construction technology Visit Report: The Damgardsarealet project area comprises three project - phases 1, 2 and 3 each of which was designed by a different architect. Phase three designed by Vandkunsten, was under construction and it was possible to see the technology that was being used. Phase 1 was designed by Martin Rubow and was occupied. Phase 2 was just finished and probably was 1/2 occupied. Both of these projects were built using the composite system and were finished in wood or concrete board siding. Phase three was about 2/3rds f'mished and it was possible to see buildings that were just being framed andsome that were almost finished. Concrete slabs were poured for the ground floor, then pre,cast intermediate walls (party and bearing walls) were set in place and then precast floor slabs set irt place. This process was repeatedfor floors two and three. Then inftU wood frame panels were installed. These wall panels were only partiallyfinished and windows are addedand finished interior and exteriorsurfaces. Wall panels were full insulatedand had sheathing attached. Roofs were framed on the ground using preformed wood trusses madthe whole roof assembly was then lifted by crane to its finished position and thenroofing tile was installed. Exposed concrete aroundthe panels were insulated with loose insulation before exteriorsiding was installed. In additionto the prefabricatedconcreteand wood frame elements, kitchen cabinets and exterior and interiorstairs areprefabricatedfor the project and installed on site. The site was highly organized with the largemoving crane atits center. Materialswere efficiently stackedandorganized. The wood panels for this projectwere simply bid, with the suppliera Finnish f'u'mcalled Makrotaloat RatamestarkinK.1 l, 00520 Helsinki, Finland. Panels were manufactur_ in Finlandand then shipped to the site for installation. SupportingDocumentation: Extensive slides takenof all threeprojects, some additional documentation suppliedby Vandkunsten. qP EEIH Center for Housing Innovation University of Oregon ,, TRIP REPORT FORM [jfS89-9c] Damof Report: 10/01/89 Piace Visited: Sibelius-Parkcn housing project in West Copenhagen Dates ofVisit: 09/02/89 Attending: J. Firtrow Purpose of Visit: Visit housing project that makes extensive use of "sun spaces" Visit Report: Sibelius-Parken is a well known project in Denmark because it was designed following the principles of "Defensible Space", the seminar theory work by Oscar Newman concerning housing public safety concerns. In addition to this design idea, $ibelius-Parken is also known because it has pioneered the use of balcony "sun terraces" as an energy efficiency stramgy. The sun spaces are all oriented south and providc a rather large semi-enclosed space for each housing unit. Sun terracesarefully glazed and extend over most of the exterior wall of the housing unit. These spaces allow residents space "buffcrifig" totreduce he:_tlost inyear winter. The project is sona', an additional space ousemuch ofthe andalso provides comprised of a large open central courtyard with housing units surrounding. Circulatio" n isaround the perimeter oftheproject. The sunterraces provide a quite nicespace that hasbeenc_tensivcly personalized byhousing occupants who usethese spaces forgardening, cloths drying, sitting andother household activities. Theenergy benefit ofthesunterrace spaceisinsomedispute, butthese spaces certainly doprovide anaddedspatial dimension totheoccupants of thehousing units. Supporting Documentation: Extensive slide &x:unacntation. ¢ I I ! EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jPS89.9d ] Date of Report: 10/01/89 Piace Visited: urban mixed use building (including housing) Etagehus, Alekstevej 168-9, Copenhagen, Demm_ Dates of Visit: 09/02/89 Attending' J, Finrow Purpose of Visit: Photograph an urban industrialized housing project Visit Report: : This project is very interesting as an example of a new kind of Danish industrialized construction technology that does not make useof anypouredconcrete, Thewholesystem isprefabricated with theuseofbolted connections between component parts all ofwhich areprefabricated. The wholebuilding isakindof"kit ofparts" system that formsa simple building system. The lowerfloor isa foodstore (supermarket) andtheupperthre. floors an=housing. A system ofprefabricated concrete andsteel elements formthe floor framing systzm withmetal andgypsuminffll panels with metalsiding, all building systems comefrom theexterior ofthe wallwhichallows tenants tomovetheinterior partitionsofthe project. Greenhouse typesunspaces areutilized alongthe circulation floors atthe2hdfloor level andatthetopfloor level. units am twostories highusingavariation ofthe"skip stop" ,elevator arrangement. A large interior courtyard isformedwhich isforchildren toplayandsomelimited parking withservice access forsupplying thefoodstore. Thisisa veryniceproject with high quality and long lasting exteriormaterials. Has be.cnpublished in the Danish architectan'aljournal. Supporting Documentation: Exterior slide docun_ntation. , EE]H Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89.ga ] Date of Report: 11/15/89 Place Visited: Architectur_ office of Martin Rubow/Hul._, Thurc Neigh and Rubow / Herm_gade 24, 2200 Copenhagen, Denmark Damsof Visit: 9/1/89 Attending: J. Finrow Purpose of Visit: Discuss energy efficient industrialized housing production in Denmark and the work of Martin Rubow. Visit Report: htr. Rubowis a well known and extremely active architectin Denmark who does work that is both energy efficient and very well desi_od. We discussed currentdevelopments in housing construcuontechnology and he showed many buildingdetails from projects currently underwayin his office. He discussed the development of composite construction systems using both concrete and wcr_ panels systems. Most of his most recent projects were done in ., housing systems andhementioned that onelarge companyrecently this way,We talked about thestatus ofDanish woodenfactory cra.ft_ wentbankrupt (Roslev Hus)after having comple!ed a part ofone plannh_g areaina project wherehehadoneaproject inAlbcrtslund l , " I q (Damgardsarealet phase two). We also discussed developments in retrofitting 1960's concrete elements housing projects in the subt_. s around Copenhagen andtheproblems amd costs associated withthis. He suggested that twoareas bevisited whichwouldgivea goodideaofhow this kindofworkwasprogressing, He pointed outtheimportance of thinking about thearchitcctm'al developments ofthese projects aswell asthetechnical issues insolving theenergy problems, He alsomentioned that themwasanother Woodenhousesystem manufacturer inDenmark called TreUeborg,which is locatedin the Copenhagen area, Supporting Documentation: Project brochures from Martin Rubow'soffice, ' EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89-8b ] Dat_ofReport: 10/01/89 Plm::e Visited: Architectural Office ofVandkunsten inCopenhagen, Tegnestuen Vandkunsten, Bro_,mandsstraccle 6,1407Copchnagen K, Denmark DatesofVisit', 09/1:89 Attending: J,Finrow Purpose ofVisit: Discussion ofindustrialized construction technology inDenmark Visit Report Vandkunsten is one of the best archite_n.al office in Denmark. They have beeninvolved inthedesign of_veralCo-housing projects aswellas many other "conventional" housing projects. Then" workhasbeenwidely published bothm EuropeandintheUSA. The discussion wasmainly with Seffen Kragh, anassociate inthefirm.Mr.Kraghdiscussed andshowed several housing projocts, We talked mainly about a new project currently underconstruction ina development areainAlbertsltmd called Damgan:_amalet, phase3.Theproject demonstrates thenew Danishsystem ofcomposite construction utilizing traditional precast concrete slabs andparty w.,alls withexterior walls ofprefabricated wood panels, Mr,Kraghdiscussed thedevelopment ofthis construction system and the fact that it is both moreenergy efficient and lower in cost than the traditionalconcretepanel systems. Wood panels arealso much Hghterand easierto wo,_ with than concretepanels, He suggested thata visit be made to the site m orderto really view how the construction system isput together. He showed mc aroundthe office and then introduced me to Jens Am_ the,main panner in ).hefirm. I brieflytalked with Mx. Arn.f-red about his work with co-housing clients. We talked about the JystrupSawmill Co-housing project and he discussed working withthat paru,cular group. He alsotalkedabout thestate of industrialized housing m Denmarkandthedevelopment ofthewood panel andconcrete composite construction systems whichhehas, tosomeextent pioneered. We also talked abouttheexterior cladding materials which makeextensive useof"concrete board". We looked atafewdrawings and details concerning how theboardisattached toframewalls, Supporting Documentation: Photographs oftheDamgardsarealet site andabrochure that theygivem prospecuve clients about theworkofthefirm. EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89-8c ] ¢ { Date,of Report: 1OK)1/89 Place Visited: Norgards plantage (Norgards orchard) in Hesselbo, Denmark (northwest of Copenhagen) Dates of Visit: 09/1/89 Attending: J, Finrow Purpose of Visit: To visit energy efficient industrialized Danish housing Visit Report: Norgards orchardis a Largeproject of over 200 housing units locatezl inanorchard inwhichthe hour,lng project hasbee. n built. The project was designed by Vandkusten architects, The project utilizes Danish composite indusmalize,d construction (wood panels and concrete slabs). The project is simple and clearly organized in an L looking into a large open space that is the orchard. Connected row houses create an edge next to the orchard and 1,ookout into the open space of the orchard. small onestory row housing units runperpendicular tothe edgebuilding andcreate alternative small gardens andwalkwaysbetween building. energy aspects project The efficent of'.he include active solar,passive solar andadistrict heati?jg pLant. Gardensandplanting xsquite extensive, withco.mmunity andpnvate gardens formosthousing units. Sun spar.,s arcalsoincluded insomehousing units. Supporting Documentation: Slides andprinted materialsfromVandkunsten brochm'e materials. 'l ) t 01 ! EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [ jfS89.8d] Date, ofReport: 10/01/89 Place Visited: Fuglsangparkcn, Farum(north westofCopenhagen) DatesofVisit: 09/I/89 Attending: J,Finrow Purpose ofVisit'. Photograph contemporary industrializ_ housing project that utilizes Danishcomposite construction technology. Visit P,_;x_ Fuglsangparken isoneofthemajorprojects designed byVandkunsmn architects using thewoodpanel andconc'rete construction system andalso using energy efficient designpractices. The projectis located near Copenhagen in an areaof many other new housing projects. A very im_t pan of this projectwas the design of the site to take _vanmgc existing landscape ('includinga smallcreek that goes dm)ugh the site). The project is composed of several hrge open courts that are oriented south facing a larger open space along the creek which is the majorcommon area of the site. A public school is located at the centerof theprojects andeachofthecourty_, dsam connected bya pathsystem to the school complex. The project utilizes a districtheatingplant to supply energy for the housing units. Them am also some greenhouses and sun spaces that am utilized forenergy efficiency. Theuseofwood Infill panels provides addedthermal performance. Thedesignquality ofthe place isexceptionally lively considerable visual andspatial riches created inthecomplex. . Supporting Documentation' Extensive slides wcr_taken andsomedocun'_ntation intheVandkusten f'u'm brochure. °'I + EEm Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89-7h ] DateofReport: 10/15/89 Place Visited: Graese Bakkeby, lowrise family row housing project Dates of Visit: O _ + 8/31/89 Attending: J, Fin.row Purposeof Visit: View recenthousing producedby Modulbetonconcrete housing system Visit Report', Hostforthetour was Somn Bech,project managerforA,Jes_r_n andSonsa development andconstruction companythat is51% owner of Modulbeton concrete factory, The projectwas located about5 kilometers for the concrete factory, The project was a number.of row house buildings, each of which hadbetween 3 and 7 housing units, Thebuildings weretwostory units withgarages andprivale fenced back yards, Exterior finish material was brick, Serialofthebuildings made useofaglasse_d insunporcharea all ofwhichfa_.,ed south, _ccupants haddonequite a lot ofpersonalization mclumr_,g extenmve gardening and interior development of the units, the projectis fully occupied. Bech discussed the process of housing development that his firmusesforthese project, partially developed through a groupot u_ers andpartially soldinthe private housin.g market. The e.nergy. performance ofthese bltildings isqui_, goooaccording toMr,t_ecn re!_tive toother projects asadditional insulation wasusedandthe houses The use wofconcrete eresited totake asaprimary maximum building advantage s.ystem ofpassive contributes solar tothe,̀ gain.+ utilization ofsolar heating, Mr,Bechwasme project managerontn_ project, I l 1 Supporting Documentation: slides weretaken aswellasbrochures produced byJespersen intheir marketh_g activity for the project. , EEIH Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89-7a ] Date of Report: 10/15/89 Piace Visited: Visited Modull_ton, Concrete eletmnt factory Kommarkcsvej 20 /DK-2605 Brondby /Denmark Datesof Visit: 8/31/89 Attending: J, Fim'ow Purpose ofVisit: Viewtheplant manufacturing process inamodem concret_ panel plant, Visit Report: Plant visit was hosted by Jimmy Wtrved, a Director of the plant and Peter Toksvig, Chief production engineer, The tourbeganwitha discussion oftheproduction process andtheelements andsystems that thefactory manufactures, Photographs ofpr_vmusprojects were shownanddiscussed. Construction drawings werealsoreviewed inorder togeta sense ofthesystem theyutilized, Current plant production is directed toward producing commerr.:ial wallsystems andfloor andparty wallelements forhousing, Theycurrently wereworking onelements forhousing inSweden,We discusse_l changing concrete plant technology inlight ofener_efficiency. Theyshoweddetailed ofwallpanels with integral insulauon. After thediscusslon, we wentonaplant tour, Tlm fastareavisited wasthefinishing andshipping mca forcompleted wall panc, ls,Nextwe viewed, ,acasting bedforwallpanels andthen the vertical casting shed. In this facdity, wall panels are cast in the vertical position which produces roompanels inless space thaninthe flat casting area. Also vertically cast pane!s are cured in steam heated pressurechambers which speeds up the cunng process. We also visited a floor slab casting facility whereslabs overI00meters longwerecastandthencutinto sections forshipping. Thelast stopwas theconcrete mixing plant which wasfully computerized andqui_impressive in&llvering the kindofconcrete toanypart of'the plant viaoverhead pumpingtubes, • i Supporting Documentation: The interior oftheplant wasextensively photographed (slides). 'lm t; EEm Center for Housing Innovation University of Oregon TRIP REPORT FORM [jfS89.7c] , i l Date of Report: 10/15/89 Piace Visited: TorstorpNorreby, east of Albcrtslundin the Copenhagenregion Dates of Visit: 8/31/89 Attending: J.Finrow Purpose ofVisit: Viewenergy efficient concrete lowrise housing construction project produced by A, Jesperscnusing Modulbetonconcrete elements Visit Report: Soren Bech was the host for this tourto one of the newest housinga areu in the Copenhagen region. Thisproject was in an area that was visited previously. This project was underconstruction and it was possible to seethe concreteelementsbeingassembled.TheprojectIs comprisedof numberousrow house type buildings of 1 and 2 floors. Exteriorfinished cladding was brick and stucco. Houses had private gardensand parking areas. The organization of this project was highly regularizedand the housing took more of the form of urban courtyardhousing than row housiJig. Inte,rior courtyardswere highly defined and planting was planned but not yet executed for this piace. A few duplex housing units were alsoincluded in the iFneral areaof this projec_ The construcuion process involved the pounng of slabs on grade with appmte'iate perimeter slab insulation and then the prefabricated wall andsecond floor slabs wen: set in place and grouted. Roofs were formed of prefabricated wood trusses with concretetile roofing. Insulation and then a layer of panels were exposed. Sorcn Bech is the projectmanagerfor this project brickwas installed over the exteriorwalls, none of theconcrete which is being sold on the private housing market. A typical 2 bedroom housing units sells for neat $125,000. Support:ingDocumentation: Extensive slides were taken of this project. EEIH Center for Housing Innovation University of Oregon TRIP REPORTFORM [ jfS89-7d] Dam:ofReport: 10/1'5/89 Place Visited: ErikSkoven, Assistant Directorof Studies, the Dannish International Studies ProgramoftheUniversity ofCopenhagen; Copenhagen, Denmark. Dates ofV'_::::t: 8/31/89 Attending: J.Fin_w Purpose ofVisit: To discuss possible architects, projects andother possible contacts related toencrgy efficient industrialized housing inDemmrk Visit Relx_: ErikSkovenisveryfamiliar withcurrent housing developments inDenmark a.swellasthearchitects who are active in Otisfield. He suggested and called severalpeople who were subsequently visited. He also recommendeda numberof possible projects which were also visited. He discussed importantissues in this areaincluding the differencesbetween Swedenand Denmarkin regardto the development of energy efficiency in housing design. He pointed out the differences in climate and cultural attitude and buildingtraditions ('lessuse of wood and single family housing in Denmark). His view was that Danishenergy efficient housing was generallymore "ecologically" oriented than was that in Sweden. He suggested discussions with MartinRubow and Jens/.m_r_ (Tegnestuen Vandk_Isten) as the best people to visit. We discussed research contacts aralhe suggested contactingErwin Petersen andIvar Moltke at the Teknologisk Institut in Copenhagenfor currentinformatiou. SupportingDocumentation: Writtennotes DATE September 22, 1989 TRIP REPORT TITLE: Kyoto University DATE: August 15, 1989 10 a.m. LOCATION: Kyoto, Japan ATTENDING: G.Z. Brown Kazuo Tatsumi, Professor of Architecture, Kyoto Univerlity Tetsukazu Akiyar_:a,Instructor of Architecture, Kyoto Univ. PURPOSE: To review ongoing research , SUPPORTING DOCUMENTS: Reviewed the state of industrialized housing in Japan from Tatsumi's perspective. Explained the EnergyEfficient IndustrializedHousing programand our desire w learnfrom Japan'sexperience in industrialization. Reviewed Tatsumi's publicationwhich covers housing issues in Japan, including industrial housing. Industrialized housing is defined in terms of the degree to which firms integrate the roles of designer, developer, contractor, crafisperson, and seUer. Fully integrated firms are called industrialized and comprise 15% of Japan'shousing marketof 500,000 units annually. (Sekisui House, Ltd., the largest producer, manufactures 30,000 units annually.) Defining the industry by level of firm integration may have some advantages of the common U.S. I practice do.finingindustrializingby thetechnical. type of construction system---modu!ar,panel, etc., ff the importantofissues are, business rather than which pinpoint buyersfactor preferences other consumer goods (clothes. furniture) which are them Marketing is a major in homefor sales with some firms using techniques like questionnaires used to determine what model house they will prefer. Tatsumi Japan's lack of concern forair energy conservation stems from their traditionalspeculated very low that energy use in their houses (no conditioning and charcoal heaters). traditional emphasis on designing the house for summer rather than winter has made insulation an unimportant consideration. There are currently government subsidies for using insulation although the levels are much lower than in the U.$. We visited a manufacturer's housing park that had models from each of the major manufaeturen. The set-up was not very different from builders in the U.S, building models ali on the same although the promotional literaturewas more extensive. Publications attached. 550/TripReport/C1 KyotoUniversity ! I DATE September 22, 1989 TRIP REPORT TITLE: Waseda University, Tokyo, Japan D-'..TE: August 16, 1989 LOCATION: Tokyo, Japan ATTENDING: G.Z. Brc, wn Nobuo Hozumi,Professor ofArchitecture and Dean,International Studies, Waseda Univ. Shun Watanabe,Asst., DepartmentofArchitecture ComputerAidedDesil_n, Waseda Univ. Ken-ichi IGmura,Professor ofArchitecture, Waseda Univ. PURPOSE: To review ongoing research SUPPORTING DOCUMENTS: Reviewed the researchworkbeing conducted by Kimuracovered in the papers'andongoing research in the environmentalcomfort chamberand solardehumidification. The environmental comfort chamber (being used to test automobile heating andcooling systems when I visited) research is directed at determining comfort under conditions typical of passive systems, i.e., asymetrical radiantfields and difference between airtemperatureandMRT. The dehumidification project involved testing to determinevalues needed to develop computer simulationsthatcould predict ratesof dehumidification for various parts of Japan. Professor Wa_'_abe is developing an AI-CAD system and demonstrated a prototype. The system as it currently stands will design a room based on a simple rectangledrawnby the user. The system produces the walls, windows and structuralsystem. The usercan query the programabout any element in the system (wall, door, window, etc.) and receive a description. Walls c,r.other elements can be added or subtracted. The program runson the Apple Macintosh, is pro_ in Small Talk and displays multiple windows. The system would work well for industrialized systems that have a limited universe of parts. Japanese currentlypay about$.20 kwhrfor electricity. Many'new houses use heatpumps for heating and cooling. Currentcodes restrict energy use to about 3-5 kilo calories/sq, meterof floor area, Iu', oC. which amounts to 5 cm's of insulation. 449/TripRepon/R 1 Waseda Urdversitv w, 1 I DATE September 2 I, 1989 TRIP REPORT TITLE: Misawa Homes Co. Ltd. DATE: August 28, 1989 LOCATION: Takaido.Higashi Suginami-Ku, Tokyo, Japan ATTENDING: G.Z. Brown Hideaki Sagawa, Director/General Manager, Tech Der. D|v. Yoshiya Kato, Managing Director Tomohiko Nonuzo, Techmcal Manager Isamu Suga, Manager, General Adm., Design Associates Hiroaki Ishizawa, Asst. Mgr., Architectural Engineering Div. PURPOSE: To review housing products and marketing and manufacturing strategies. SUPPORTING DOCUMENTS: • O I | | Product literature According to the 10 minute film (we have a video copy) Misawa'sprimaryconcerns arc a suitable place to raise your children,fire protectionand earthquakeprotection. They express their concern forthe customer's interest by offering extensive aid in planningthe home aud its furnishings, manufactures two building systems - a stress pane! builton a wood grid infilled with batt utilizing expert staff, interior show rooms andskin numerous brochures of images. Misawa insulation andgluedskins applied tobothsides andanautoclaved lightweightconcrete (ceramic) panel. The major marketthrustwas using "technology to develop the 21st century house." There are 17 manufacturingplants in Japan,two of which make ceramicpanels (see ceramicgrid. plantTvisit relX_). The ceramic panels are madeofsilica andlimestone witha steel reinforcing he steel isputina moldfilled withceramic andthenautoclaved. The panels areassembled into modulesandcompletely finished inside andout, shipped tothesite anderected usinga crane. One ofthemodelsmentioned wasforthree generations onanurbansite. Theymention(yJ home automation as importantbut a latervisit lo a model revealed it to be a cenu'al on-off switchingunit for lights, locks, etc., with little capability f_ programming times, partialoperation, or temperature ranges. Misawaisapparently supporting research inCanadaon woodproducts. Theyhave several project locations around theworldincluding theU.S:Misawabuilds 40,000 units annually ofwhich26,000 aresingle family. Of the26,000, about10% areceramic. Attheconclusion ofthefilmwe visited their environmental test chamberwhichisl.ar/_e enoughto -accommodate anentire house. Thetesting includes hotandcoldtemperatures, radiauon gain, rain, andwind.Theyhadjust completed atest oftheceramic system undercoldconditions whenI visited. We had2a general discussion oftheir interest inenergy intheir products. Currently their average of (160m )home consumes 7,500,000 kcal/yr.?? forheating, 1,000,000 kcal/yr, forcooling, and 4,500,000 kcal/yr, forwaterheating (seeattached graph). Theyintend tocutthis figure by I/3in thenext5-6years. Theyseethis reduction astechnically possible butdifficult toachieve atan acceptable cost. Theydo varytheconstruction of their home with climate zone.The healing fu_ aregas,oil, orheatpump.Their strategy forreducing energy useisthree fold:I)Improved envelope performance through increased insulation andbetter windows.Airtighmess iscurrently good due to the industrialized process. Windows are an issue for them because of the Japanese Misawa Homes Co. 444/R1 1 preference for large openings. They are currently investigating a bead wall system which sounds similar to that developed by Steve Bear in the U.S. 2) More efficient heating and cooling systems which use the floor construction systems. They said they were going to use the mass of the floor system as an off peak cooling strategy. I doubt it but something may have been lost in the translation. They do recognize dehumidification as a significant comfort problem and seemed interested in F8EL DESRED system. 3) UtiLizing solar and ground water heating systems. Misawa has made three mtempts at computerizing their sales, design and manufacturing operations. In 1974 they developed a CAD system on an IBM and Hitachi based on their free design (not one of their preplanned models) panel system. The system worked well but was very difficult to update as codes and specifications changed and fell into disuse. Their next attempt was based on the Japm't/ARC(?) CAD system and was for internal use to turn out drawings and specifications for their preplanned houses. It was unclear whether this system is still in use. The third system which is currently in use and undergoing further development is based on a CAD system developed at M.isawa. In its current form it operates on a PC with a hard drive (nobody knew how big it was). The sales person develops the plan on paper with the customer using sample plans and photographs. Once the design has been developed it is input, using a tablet and stylus, by the sales person (only one or two people are knowledgeable per office I suspect). The CAD system has a data base of Misawa products, therefore when a wall is created the computer knows the specs for the panels involved. The drawing sequence is 1) exterior walls, 2) interior walls, 3) openings, 4) built-in furnishings like kitchen cabinets and bathroom fixtures. The exterior walls are created just by cLicking on the module (910 mm & 455 mm width) grid on the screen, using the stylus orthe tablet 0ike a mouse) at each wall beginning andending point. After that, interior rooms are created by clicking on the diagonal comers of the room and then the room type is sel_, __._from the tablet menu. Given a plan, the software will calculate the panel size (3'x6' or 8'x12 sizes) after the roof pitches and gable locations have been selected in roofplan. Once the drawing is complete Theuser then selectss the finishes from three groups, using either the laser disk system or photographs or sample or a mix of these techniques. The system will check to see ff floor panels have been mistakenly used for wall panels, etc. Interior room sizes and corridor widths are checked visually by the operator. The computer will print material lists and develop the cost estimates for the customer. The dealer (privately owned) then marls invoices to Misawa. The system has been in use four years. This system is being upgraded to the ZIP system which will transmit information directly from a 16 bit ternfinal at the dealer to a 32 bit terminal at the factory. The implication was that once the data was in the factory terminal it could be used directly in machine conu'ol. The system is being developed internally with consultants. The ZIP system is expected to be operational in one year. Misawa used a laser disk system at its main dealerships to assist customers in selecting finishes and materials. They went to the laser disk after a hard connection to a main frame computer lmaved to be too slow. The main menu is 1) exterior, 2) interior, 3) products, 4) image video about Misawa life sytles. There are submenus under each main menu item. For example, interior is divided into living room, Japanese room, children's room, kitchen, etc. Within each of these room catagories there are images of interior spaces. The general system was developed by the Ministry of Construction with support from all manufacturers (8 disks). Misawa then went on and prepm_l two proprietary disks for its own use. The customers preferences are remembered and can be played back for f'mal selection. If the dealer wants complete specifications on any product, a compute,'/fax combination queries the main frame at Misawa which returns the specs via fax to the dealer. The system has been in use for four years. Because it is expensive only the major de,alert have the system, lt wasn't clear how effective Misawa thought it was as a sales tool. Product literature forallhomes isavailabM. Misawa Homes Co. 444/RI 2 2. SOFTWARE BIBLIOGRAPHY 2, SOFTWARE BIBLIOGRAPHY Docu m¢latPreparation Spec.Writer: Pinkenon-Galewsky, 550 Fannin, Suite 100, Beaumont, TX 77701 Data Manioulation AEC Infor/nation Manager: AEC Management Systems, Inc,, 20524 Amethyst Lane, Germantown,MD 20874 Excel: Microsoft Corp., 16011 NE 36rh Way, Box 97017, Redmond,CA 98073 MacProject II: Clarls Corp,,5201 PatrickHenryDrive, P.O, Box 58168, Santa Clara,CA 95052 MicroPlanner: Micro PlanningInternational,235 Montgomery St., Sre. 840, San Fransisco, _, 941O4 More II: Symantec Corp., 10201 Torte Ave., Cupertino, CA 95014 SuperCard: Silicon Beach Software,Inc., P.O, Box 261430, San Diego, CA 92126 Reference Data Masterspec AIA. A/S/C Edition: EPPS/Architectonix, 1950 Stemmons Fwy, Ste, 5001, Infomart, Dallas, TX 75207 Masterformat Outline Specification: Yeoman Technical Software, R.FD#3, 629 Voluntown Rd., Jewctt City, CT 06351 Residential Construction Symbols Library: Engineered Software,P.O. Box 18344, Greensboro, NC 27419 SPECTEXT: CSI DataServices, 400OserAve., Hauppauge, NY 11788 Graphics Tool_ • _ i | - Archibus/gM: .lung/Brannen Research and Development Corp., 177 Milk St., Boston, MA ArchICAD: Graphisoft, _)0 Oyster Point Blvd., Suite 520, So. San Fransisco, CA 94080 Archi-Trend: Fukui Computer,Inc., Yokohama Office, Hodogaya-ku Kamadai 48-1, 5-403, Yokohama240JAPAN Arris: Sigma Design, Inc., 6251 S. Greenwood Plaza Bled., Englewood" CO. 80111 AutoCAD: Autodesk, Inc., 2320 MarinshipWay, SausaIito, CA 94965 BorgCAD: (address notavailable) CADAVANCE: Cadgraph Systems, Inc., 2727152ndAve.NE,Building 6A,Redmond,WA 98052 ClarisCAD: Claris Corp., 5201 Patrick Henry Drive, P.O, Box 58168, Santa Clara, CA 95052 Draw: HOK/CSC, 1831 Chesmut St., Suite 601, St. Louis, MO 63103 Dreams: Innovative Data Designs, Inc., 2280 Bates Ave., Ste. A, Concord, CA 94520 FDM: Facilities Design andManagement: CADD ShareCorp., 180 Techwood Drive, Atlanta, GA 30313 Generic CAD: Generic Software,Inc., 11911 N. Creek Pkwy. S., BotheR, WA 98011 MacArchitrion; Gimeor, Inc., 1815 H, St., Washington, D.C. 20006 MacDraft: Innovative Data Designs, Inc., 2280 Bates Ave., Ste. A, Concord, CA 94520 MacPerspective: Knick Drafting, Inc., 1275 S. Patrick Dr., Ste. P; Satellite Beach, FL 32937 MegaCAD.D Design Board: MegaCADD, 65 Marion St., Suite 301, Seattle, WA 98104 MGMStatton CAD: Micro CAD/CAM Systems, Inc., 5900 Sepulveda Blvd. #340, Van Nuys, CA 91411 MicroArchitect: IDEA Gmphix, 2452 Branch Ava., Altanta, GA 30305 Modelshop- Paracomp, Inc., 123 Townsend St., Ste. 310, San Fransisco, CA 94107 MountainTop: Accugraph Corp., 5822 Cromo Drive, El Paso, "IX 79912 Pe_a:s.y.s.:IGC Technology Corp., 305 Lennon Lane, Walnut Creek, CA 94598 romz t.me: Robi Graphiks, Ltd., 122 E. Olin Ave., Madison, WI 53713 QuiekCAD: Weathershield Manufacturing, Inc., P.O. Box 309, Medford" WI 54451 SuperPaint: Silicon Beach Software, Inc., P.O. Box 261430, San Diego, CA 92126 39 Reporl/Vol. t 2 Disk 2,1 / Super3D: Silicon Beach Software, Inc,, P,O, Box 261430, San Diego, CA 92126 Swivel 3D: Paracomp, Inc,, 123 Townsend St,, Ste, 310, San Fransisco, CA 94107 The Plan: Ted Dasher & Assoc,, 4117 Second Ave, S,, Bi.rmingham, AL 35222 Trahus CAD: Borgs_om Enterprises, Ltd,, P,O, Box 731,810 W, Broadway, Vancouver, B,C, V52 4C9 Ve_aCAD', VersaCAD Corp,, 2124 Main St,, Huntington Beach, CA 92648 Vislonael: Advanced Graphics Systems, 5150 E, Pacific Coast Highway, Suite 219, Long Beach, CA 90804 Analysts Tools ANSi'S: Swanson Analysis Systems, Inc., Johnson Rd., P.O. Box 65, Houston, PA 15342-0065 A-Systems Contractor DI, Bldworx, AIAdraw: B,A.T., 777 River Ave., Eugene, OR 97404 Beam Analysis: Heizer General Corp., 1941 Oak Park Blvd., Ste. 30, Pleasant Hill, CA 94523 Building Code Analyst: Architectronica, P.O. Box 787,300 The Village #109, Redondo Beach, CA 90277 CADLight 1: EnergyWorks, Inc., Wiley Professional Software, John Wiley & Sons, 605 Third Avenue, N.Y., NY 10158 CALPAS 3 & 4: Berkeley Solar Group, P,O. Box 3289, Berkeley, CA 94703 Controlite 1.0: Lighting Systems Research, Building 90-3111, Lawrence Berkeley Laboratory, Berkeley, CA 94720 Dalite: National Institute of Standards and Technology, Building 226, Room A-313, Gaithersburg, MD 20899 Daylit: Graduate School of Architecture and Urban Planning, 405 Hilgaxd Ave., Los Angeles, CA 90024 Deneb Construction Accounting & Estimating System: Deneb, 201 Riverside Drive, Suite 2C, Dayton, OH 45405 DOE 2.1D: Simulation Research Group, Building 90-3147, Lawrence Berkeley Laboratory, Berkeley, CA 94720 Duc!!ink: Software Systems Network, Carrier Corp,, P.O. Box 4808, Syracuse, NY 13221 Eng3neering Software Company: Engineering Software Co., Search Plaza Suite 760, 10670 North Central Expressway, Dallas, TX 75231 Enerealc: Engineering Software, 3432 Via Oporto, Suite 207, Newport Beach, CA 92663 Heatioss: Yeoman Technical Software, 41 Wedgewood Drive, Jewett City, CT 06351 Homebuilder: Ttmberline Software Corp., 9405 SW Gemini, Beaverton, OR 97005 Idle: Facet, Ltd., Marlborough House, Upper Marlborough Rd., St. Alban, Hens., ALI 3UT, UK LARSA: Innovative Analysis Corp., 330 W. 42nd St., N.Y., NY 10036 Lumen II/III: Lighting Technologies, 3060 Walnut Street, Suite 209, Boulder, CO 80301 MacNaii 2.2: Turtle Creek Construction, 651 Halsey Valley Rd., Spencer, NY 14883 Microlite: Department of Architecture, Graduate School of E_esign,Harvard University, 48 Quincy Street, Cambridge, MA 02138 Plan-Trae, Open.trac, Plan-Trac.cm: Computerline, Inc., P.O. Box 308, 52 School Street, Pembrooke, MA 02359 Profit Builder, Profit Manager, Profit Bid Estimating, Basic Builder: Consmaction Data Control Inc., 3675 C.restwoodParkway, Ste. 4430,Atlanta, GA 30136 Quicklite 1: Windows and Daylighting Group, Building 90-3111, Lawrence Berkeley Laboratory,Berkeley, CA 94720 Slmplespan, Backspan: Arch Software, 1642 Pullan Ave., Cincinnati, OH 45223 S_SD:Small Systems Design, 2540 FrontierAve., Suite 104, Boulder, CO 80301 Sticks and Bricks: Industry Specific Software, Inc., P.O. Box 25249, Gr_nville, South Carolina 29616 Superiite: College of Arehit_tur_ end EnviromnentalDesign, ArizonaState University, Tempe, AZ 85287 UWL-i-g-ht:9DepartmentwA 8105 of Architecture, Gould Hall, JO-20, University of Washington, Seattle, '89Repon/Vol.2 Diak 2-2 Wattsun: Washington State Energy Office, 809 Legion Way SE, FA-11, Olympia, WA 98504-1211 Manufacturtn_ Anvil 5000pc:-Manufacturing and Consulting Services, Inc,, 6 Hughes, Irvine, CA 92718-1895 Auto.Omni: Engineering Services Company, P,O. Box 696, Rochester, MN 55905 BorgCAD: (address not available) CADAM: CADAM Inc,, 1935 N. Buena Vista St., Burbank, CA 91504 Gang.Nail Sys!ems: Gang-Nail, Inc,, P.O, Box 59-2037 AMF, Miami, FL 33159-2037 ICT: Informauon Control Technologies, Inc,, 1901 N. Beauregard St., Suite 104, Alexandria, VA 22311 MGM Station CAD/CAM: Micro CAD/CAM Systems, Inc., 5900 Sepulveda Blvd., #340, Van Nuys, CA 91411 Shortcut: HeurtisticsInternational,32 River Road,CosCob, CT 06807 Source,Layout: Clary Corp., 1801S. GreatSouthwestPkwy, GrandPrarie,TX 75051 The Plan: Ted Dasher& Assoc.,4117SecondAve. S.,Birmingham,AL 35222 TrusStar, TrusStar2, Trakstar: On-LineData,Inc,, P.O,Box 2750, Richardson,TX 75080 Trus-Calc: Alpine Engineered Products, (address not available) Integrated Systems CAIJAM: CADAM Inc., 1935 N. Buena Vista St., Burbank, CA 91504 ICG: Integrated Computer Graphics, Inc., One Buckhead Plaza, Suite 800, 3060 Peachtree Road, NW, Atlanta, GA 30305 Smart CAM 4.0/Anvil: Personal Workstations Inc., 1201 Western Ave., Suite 204, Seattle, WA 98101 , Other Sv.qtems BUG Voice Command System: Command Corp., Inc., 6045 Atlantic Blvd., Norcross, I '89Report/VGl. 2 Disk 2-3 3. COST COMPARISON OF SWEDISH & U.S. HOUSING 3, Cost analysis of affordablllty of $FC house In Sweden compared to site built U, S, housing, J, Finrow The comparison presented here is of comparative affordabiltty of housing within the context of each country, This analysis dots notspeculate on what the cost might be of SFC housing if producedin the U,S, A detailed analysis of that subject has been carried out by Paul Kando in a publication entitled When the Best Cost Less, published by the Swedish Trade Council, Chicago, Myresjo Hus is one of the largest SFC housing companies in Sweden, Houses are marketed by this company in the same way as other companies through sales offices in the major cities of Sweden, In addition, Mymsjo Hus usually has one or two houses in each region that prospective customers can visit (demonstration houses), These houses will be used for a few months then sold. The following 4 cost information comes from a visit to one of these houses in Vetlanda, Sweden, The sale price of SFC houses do not usually include the price of the lot. The house for which this financial inf_mation is presented is not necessarily the "average" SFC house, but a "typical" SFC house, Comparative date taken for thetided "average" U, Economies, S, house is taken from statisticspresented in various issues of the publication Housing a publica_on of NAHB. [ I The SFC demonstration house price totaled excluding land costs was 884,000 SEK (Sww.lish Ka'onor). In addition to the cost of the house, a 12% value added tax is represented in this price, hl the tax b forthis the houseis Given removed, cost 777,920 SEX. theexchange rate atthe llme ofthe _'bit (6,416 SEK perU,S,dollars) thecostis$121,247 andthetaxofabout$16,000. The size ofthehouse was 117,4 square meters or a little over 1,250 square feet making the cost of the house about $97 pea" square foot. The average U,S, site built house was valued at $117,555 (without land prices or sales taxes include.d) forl,995 square feet of area or about $59 per squarefoot. The difference in price per square foot is $38 per square foot, Land prices in Sweden and the U.S, are comparable as a percentage ofcontruction costs, beingbetween10% to15% ofthecostofthehouse.Ofcom'mthis varies withlocation, highly desire.able housing sites inthemajorurbancenters ofbothcountzies are extremely expensive andwouldclearly exceed these figures. Inaddition tothecostofthehousing unit andlandcosts, financing costs area significant factor in overall housing affordability. Loans in Sweden tendtobeata higher interest rate andforlonger periods oftimethanconventional U.S.housing practice. Conventional home mortgages inSwedenat thedme ofthevisit were11.5%interest for 40 years whileintheU.S.interest rates atthat time about10.25%for20year '89Report_ot2 Ditk ( 3- I fixed rate mortgages, In order to enhance affordabillty, the Swedish government "buys down" lhc interest rates onhome loans inthefirst 5 years oftheloan,InthecaseoftheMyr_sjo Hus demonstration housetheinterest rate inthefirst yearwas5% whichthenraises tothefull market rate of 11.5%attheendofthe5 ycaxbuydownperiod, Thisr_presents a significant subsidization ofhousing costs, The initial downpayment forthedemonstration housewasListed as64,000 SEK orjust a bitunder $I0,000 whichisabout7,2%,Inaddition, thepurchasel paysthelot costwhichinthis casewas 72,169 SEK or$I1,250 (averyinexpensive site) whichmakesatotal cashpaymentneededtoquality fortheloanofalittle over$21,000 whichis15,4%ofthecostofthehouseandlottogether, Deducting these costs fromthetotal costs ofthehouseandlotleaves abalance tobcfinanced of820,000 SEK or $127,825. ltisinteresting tonotethat theVAT isalsofinanced intheca_ ofthis housepurchase case. Inthefirst year,payments wouldbeabout47,448 SEK whichis$7,396 pcryearor$616pcrmonth, Inorder tomake a comparctiv¢ analysis withU. S.housing, tl_costpcrI00gl.ft. pcrmonthforthe SFC house@ 5% interest is$51.30 pcrsq,ft. pcrmonth,IftheSFC housewas notsubsidized by the government andtimfull 11.5 % interest ram charged, the cost pcrI00gl,ft. forthe SFC housewould bealmost twice this rateor$97per100sq,ft, pcrmonth.The average site built houseintheU, S. usingthesamepercentage ofdownpayment and inmmstramsineffect attlmdam oftheSFC comparator house(10.5%@ 20yrs) wouldcostabout$59 oronlyabout60% ofthecostoftheSFC house at full interest rate maturity. Whilestimulating home buying byoffering thebuydown,eachSFC housesold represents a substantial public subsidy. The full costofhousing attheprevailing interest ramwouldbe$1,245 pcr monthora total yearly costof$14,936 oracosttothegovernment of$7,540 pcryearforeachhousein the first year.It is interesting to note that the VAT pays almost 50%of the firstyear subsidy. In addition, as in the U, S,, interest paid on home mortgages is fully tax deductable, so that the remaining $7,396 that the purchaser pays is completely written off their taxes, which at the currenttax rates in Sweden, is a significant tax opportunity. Over the course of the 5 years of subsidy, the total interest subsidy paidforthis particular SFC houseisalittle over$22,000 inaddition tothetaxdc&ration. An additional issue inhousing economics arcencrgycosts, According toKandoenergy costs forSFC housing can be as lit'deas $200 pcr year (Kando, 1989, p. 45). If we also take his data for the "worst case" comparative energy costs (Houston) for an average U. S. house of $792 pcr year, we see a substantial difference in energy costs of $592 pcr year. SFC house energy costs pcr year in Sweden is only 25%of that for a U. S, house. This is impressive energy savings, but when factored into tlm overall cost of ho_ing it 119Repon/Vol 2 Disk 3- 2 represents a very small percentage of total monthly housing costs, Even for the "bought down" SFC house, the energy costs per month ($16) represent only 2,6% of the total monthly mortgage payment. For the U, S, house, energy costs ar_ more expensive ($66) but still represent only 5,6% of the total mortgage payment, The addedsavings, whenviewedinrelation tothetotal costofhousing, isnotan espccially significant factor inincreasing theaffordabiilty ofSFC housing, Inspite ofthis massive subsidization, theSFC houseinSwedenisstill almost twice asexpensive asits U.S.counterpart, Inaddition tc) exm'nining thecosts ofSFC housing we havetoalso studytherelative pumhaslng powerofpotential housing consumers inSwedenandintheU.$.According tothe November4,1989issue oftheBritish publication tiffed TheEconomicst (page123)thepurchasing poweroftheaverage Swedeisonlyabout 75% ofthat oftheaverage American. Whilehaving among thehighest standard ofliving intheworld, Swe&n isstill notquite uptothepurchasing powerlevel of means prcscnz.d theU. S.according tostatistics inTheEcoqomist. This that theaverage Swedehas 75% less purchasing powerwithwkichtobuya housethat isalmost twices asexpensive asthe average houseintheU.S, Giventhis conomic analysis, itthe islikely that SFC housing inSwedenis p urchased bypeople withmuch ehigher incomes than average Swede.Those who cannot abeing fford tobuyanSFC house, arcmostlikely topuchase multi-family housing whichcosts much less thanSFC housing. Whiletl_ costofSFC housing isquite expensive, themiscurrently a boom inSFC housing production. This boom canbcpartly explained interms ofthetaxing system andthedegree ofgovvmmcntsubsidization oftheSFC industry, According totheGullringshus plant manager, theVAT onhousing islikely tobe • doubled inthenextyearorso,whichmeansthat consumers arcplacing orders now tobewellaheadof thepossible increase intaxon housing inthenextyearorso,Giventhis example, this wouldaddan additional $16,000 tothecostofthehouse, Housingsubsidies may alsobecutbackinlight ofgeneral changes intheattitude oftheSwedish government tosubsidization. Ifbothofthese factors happen, thenthecostofthis SFC housewouldincrease to$150,370 ora f'manced amountof$128,416form increase ofover8%. Without interest subsidization coupled withthein_ taxwouldmaketlm costper100sq,ft. pcrmonthforanSFC houseofalmost $107orabouttwice asexpensive asit currently isinthefirst yearofthemortgage. Suchasubstantial increase inthe cost ofhousing would probably havea veryserious effect on SFC housing production. The sameplant managercited above responded toa question about this issue by saying that whilehehasnohouses "inthesun:king warehouse" this year, nextyearheislikley tohaveawarehouse full ofhoums. . '89ReponfVol 2 Disk 3-3 BASIC SFC HOUSE COST INFORMATION Total House cost 884,000 SEK $137,802 Value Added Tax (12%) 106,800 SEK $16,536 Housecost 777,920 SEK $121,265 72,169SEK $II,250 'Z Typical LotCost Housesize 117.4SCl, mea'rs 1,263sq.ft. Required downpayment 64,000SEK $9,977 Total CLientpayments 136,169 SEK $21,227 Percentage client payment 15.4% 15.4% withlandcost 7,241SEK/sq. meter $105persq.ft. without landcost 6,626SEK/sq.meter $96 persq.ft. Cost per unit measure BASIC AVERAGE U.S.HOUSING COST INFORMATION Total House cost $138,300 Lot cost(15%) $20,745 •Averagehousesize 1,995SCl. ft. Housecost Down pa.yment $I17,555 15.4% $18,103 Costper umr measure withlandcost ' without landcost '89l_on/'Vol 2D_k $69persq.ft. $59persq.ft. 3-4 4. CONTACTS V -. i INDUSTRY CONTACTS C,O_,=A_Y STAFF production panelized modular HUD code component NAHB Annual Meeting Atlanta,GA Ryland Homes NortheastDivision (pan) , Columbia,MD Acorn Structures (pan) Acton,MA MOD-U-KRAF Homes, Inc. (rood) RockyMount,VA I O L DATE Written Phone Interview Visit RK V 1/19/89 PF, LM, BS, JR, CK, MG V 2/2/89 SC, PF, BS V 312/89 JR, BS, AE V 3/2/89 Titan Manufacturing Company (pan) LM, JR V 3/2/89 Kissimn_ee, L Ryan HomesF(pan) PlantCity,FL SC, JR, LM, BS, TB V 3/24/89 Fieetwood Enterprises, Inc. (HUD) HainesCity, FL Llndal Cedar Homes (comp) Dave Reed Sacramento,CA Key-Lot Homes (rood) Suncook,NH Acorn Structures (pan) Concord,MA Advanced Buiding Systems (pan) Bennington,VT Gode Industries (pan) ChuckGode Eugene,OR Cardinal Homes (rood) Williesburg,VA Nationwide Homes (rood) Martinsville,VA SC, JR, BS, LM, TB V 3125/89 GZB, JR, RK I 6/../89 BM V 4/17/89 BM V 4/18/89 BM V 4/19189 GZB,JF,.RK BM,RB I 4/20189 JR, BS, AE V 4/31/89 JR, BS, AE V- 5/1/89 '89 ReportP/ol2 Disk -- CONTACT , 4-l , National Building Systems (pan) Collinsville,VA American Standard Building Systems (pan) Martinsville,VA Automated Builder magazine Don Carlson,Editor Carpinteria,CA DesCon '89 A/E/C Systems Conference Anaheim, CA Fleetwood Enterprises Housing Group (HUD) Riverside,CA Good Neighbor Care Centers (mocl) Daniel Dealer Springfield,OR Western Insulfoam (comp) Kent, WA Modular Housing Symposium Penn State Ryland Modular Homes (rood) New Windsor,MD Ryland Building Systems (pan) Columbia,MD Ryan Homes (pan) Thurmont,MD New Era Modular Home & Design Center (rood) John Schuman Westport,MA Blazer Industries (rood) Silverton, OR Bohemia Lumber (comp) Goshen,OR Blazer Industries (rood) Chuck Hill Silverton,OR JR, BS, AE V 5/1/89 JR, BS, AE V 5/1/89 M_I V 5/2/89 GZB,MM, TS V 5/5189 GZB, MM,TS V 5/5/89 RB V 5/16/89 GZB,MM, RB V 5/23/89 RB V 5/25/89 RB V 5/27189 RB V 5/27/8.° RB V 5/28/89 RB P 5/30189 RB,BM V 6/1/89 GZB,JF,DC RK, BM,RB GZB, JF, RK V I American Transpacific Housing (pan) Dr. Matthew Gruber Salem, OR Meadowood Industries (comp) Leonard Opal Albany, OR Profile BUilding Systems (comp) Chris Scott La Jolla,CA Street of Dreams Home Show Portland,OR AFM Corporation (pan) MichaelW. Tobin,Exec. Dir. J I I I Excelsior,MN InsuI-Tray, Inc, (comp) EdwardW. Story,Pres. Redmond,WA Rick Henson, builder (pan) Rick Henson, Eugene,OR Benchmark Homes, Inc. (rood) GeorgeKirby, Pres. Brookville,OH Ali American Homes, Inc. (mod) Mike --Decatur,IN Unibilt Industries, Inc. (rood) GZB, RK,BM, RB I 6/15/89 GZB,RB V 7/17/89 RB W, P 7/25/89 RB V 8/15/89 RB I, W 8/17189 _ W, P 8/22/89 RB I 8/23189 LM,SC V 9113189 LM V 9/13189 LM,SC V 9/14/89 LM,SC V 9/15/89 GZB, RB W, P 9119189 RB P 9/21/89 RB W, P 10114/89 = e_,=, =Nn= Vandalia, OH Pease Company, Inc. (comp) / e,lN,,mm,m Hamilton, OH Mansion Industries, Inc. (pan) RobertB. Glassco,Pres. Industry,CA Barrier Systems (comp) Bill Brod,Sales Manager Canastota,NY Electropane (comp) Joseph Pastore, Pres. Capitola,CA 39 Repor_ol 2_ 4-3 2 Palm Harbor Homes (HUD) ' SC V 10/17/89 JF V 8/26/89 JF V 8/26189 JF P 8/27189 JF V 8/28/89 JF V 8/28/89 JF V 8/29/89 JF V JF V 8/29/89 JF V 8/29/89 JF V 8/29/89 V 8/15/89 C-.-.-.-.-.-.-.-._B V 8/16/89 GZB V 8/28/89 GZB I 6/17/89 GZB I 8/17/89 GZB V 8/17/89 Plant City, FL DENMARK Architectural Museum and Bookstore Copenhagen Hosby Hus a/s Juelsminde Roslev Hue Skive Ebbeltoft Recreational Housing Community Aarhus Energy Efficient.Co-Housing Project Fredrica Byg and Bo Housing Exhibition Site Odense Tlnggarden Housing Project Koge Holmebaek Housing Project Herfloge Sun, Wind and Light Co-Housing Project Koge Tastrup HoJDevelopment Area West of Copenhagen ' 8/29/89 AL_LUt Kyoto University Kyoto Waseda University Tokyo Misawa Homes Co. Ltd (pan) Tokyo Federation of Home Contractors Tokyo Issiki Architects Tokyo Building Center of Japan " Tokyo GZB , Mitsui Home GZB V 8/18/89 GZB V 8/29/89 GZB V 8131189 GZB V 911189 _ V 9/4/89 GZB V 9/7/89 (com) Tokyo Sekisui Helm (rood) Tokyo Meiji University Tokyo ,: Sekisui House Tokyo ' Sekisui House (pan) Oskaba Building Research Center Tsukuba City I I I 5. LIBRARY 5. LIBRARY M, Fincher Library support for the Energy Efficient Industrialized Housing research program is provided by a hag-time librarian from the University of Oregon Architecture and Allied Arts Library, She is responsible for collection evaluation, selection of materials, online database searching, reference assistance, processing of materials being accessed directly into the Energy Efficient Industrialized Housing collection, and management of all materials housed in theE.EIHProject Room. The Acquisitions and Catalog Departments of the University of Oregon Library provide _g, cataloging, and processing services for EEIH materials which am being cataloged for the Architecture and Allied ArtsLibrary. Items acquired for the EEI]-IcolI_tion include 13 serial titles, 150 journal articles, and 255 books, government documents, and technical reports in such areas as building components, energy codes, 1 I energy-efficient design and construction, housing, indoor air quality, n_chanical sysmms, and U.S. and foreign construction technology. Out-of-print titles have be.cnborrowed through the inter-li0rary loan system, as hay,: articles from journals not owned by the University c,fOregon Library, Photographic slides documenting industrialized housing production andsimsarcbeing cataloged andstored underarchivaLly approved conditions. Them isalso a collection ofproduct limratum and samples. i . Irfformation on all materials in the EElH collection is enmnxl into a Hypcrcard rcfcccncc management system used with a Macintosh SE computer. Separate stacks have been cav.atedfor:.1) slides; 2) product samples; 3) relevant ritlcs fzom the UO librarycollection acquired prior to the EEIH project, and 4) print materials acquired and purchased with El/IH funds. '89Rcport/Vol 2 Disk 5- 1 6. INDUSTRIALIZED HOUSING MANUFACTURING SYSTEMS ANALYSIS -- Fleetwood University of Central Florida Department of Industrial Engineering and Management Systems INDUSTRI_IJ_ HOUSING MANUFA_G SY_I'EMS ANALYSIS I for a I FLEETWOOD MOBILE HOME MANUFACTZ.rRERS Haines City, Florida I Final Repon Florida Solar Energy Center Cape Canaveral, Florida September 20, 1989 1 e t TABI.,F.S OF CONTENTS Page EXECUTIVE SUMMARY ...................................................... i INTRODUCTION .......................................................................................... 1 CHAFrER i 1. Factory Overview .................................................................... 4 2, WarehouseAnalysis .................................................. 15 3, TrussFabrication .................................................... 21 4, ChassisAssembly.................................................... 33 5, FloorAsscrnbly ..................................................... 43 6, F._crior WallAssembly............................................... ...... 57 7, Intcrior WallAssembly......................................................... 69 8. Interior/Exterior Wall Installation ...................................... 81 9, Roof Assembly 10. Roof Installation ............................. ..102 11. Exlcrior Finishing ................................................... 114 12. Interior Finishing .................................................... I_ 13. Inspection ............................................... 137 14. OthcrPotential Improvements.......................................... 139 90 t APPENDICES .. . .oo• ..••o,. e, 0, • • . • • oi o _, Jo •. • ................................................................................................143 A. Equipments List B. Manufacturers List J EX_CLTFIV_ S_Y INTRODUCTION This report is the first of a series which ultimately will prey/de a scenario depicting how energy efficient, affordable housing will b¢ designed, fabricated, and erected in the 21st century, This studywas conductedin order to gather baselinedata for the deve)opmentof a generic industry manufacturing model. This model will serve to develop a comprehensive industry manufacturing strategy that will anticipate future problems and bottlenecks, and define methods, procedures,and technologiesmost suitable for their resolution. Included in these strategieswill be guidelinesdictating if, when, and under I= what conditions various type of computerization, automation, and robotization will be candidates for implementation. This report provides a description and documentatiori of current processes and facilities used by a "typic.ai"industrialized housing manufacturers. Such manufacturers can be categorized as panelizers, modular, or mobi]e home bui]ders. The latter category embodies processes common to all. Hence, the Haines City, Florida facility of Flectwood Industries was selected as representative, of industrialized housing manufacturers from a process and facilities point of view. ,, FAC'I'ORY OVERVIEW Fleetwood produces single and double wide mobile homes at the Haines City facility. These homes are typically complete with wiring, plumbing and ali interior ,t finishing items installed. Double wide homes are built as two separatemodules, whereat singlesare just one module. These modulestypically range in size accordingto the ii follo_ng specifications: l)Length: 32 ft. - 60 ft. 2) Width: 24 ft.. 28 ft. (double wide) 12 ft.. 14 ft. (single) 3) Area: 752 sq. ft.- 1500 sq. ft. Each moduleisproducedentirely within thefactory environment througha number of cutting, fabrication, and assemblyprocesses performedatvarious workstations, Each workstation isdescribed in detail in subsequent chapters°A generaloverviewof the factory is presented at this point. The factory is approximately 60,000 square feet not including office space with 65 percent of that being production space and the rest storage and transport space. understand and how they are interrelated to one another, a brief the plant's operations overview is provided. The fabrication of the chassis is the first operation. To The finished chassis is then moved to the first station of the main production line where the floor system is assembled. The floor assembly is moved to the next station where interior and exterior walls, bath and kitchen counters are installed. The wall systems have been i brought from the assembly workstations workstation. The walls are manufactured located on either at these stations. side of the installation The house assembly is moved to the next workstation where the roof system is installed` The roof system has been produced at the roof assembly workstation adjacent to the installation station. The trusts have been fabricated at a workstation located outside of the main plant and then transported to the assembly station. Once the roof has been fastened to the home the decking and covering is attached and the assembly is moved to the next workstation where iii aliexterior finishing such as the installing of siding, sofflts, doors,windows,cfc,are performed, These materials were supplied from a storage area located outside of the plant. The assembly is next moved to the interior finishing workstation where appliances, interior trim and finishing, lighting, etc. are installed. The appliances are transpormd, to theassemblyfrom a storage arealocated adjacent to thefinishing workstation,Afterr ,,' completion ofthemoduleassembly, a final testand insl:>Cction isperformed.A detailed operations/activity chart, factory layout, and processflowchartare included withthisas wellassubsequent chapters. WAREHOUSE ANALYSIS FlcctwoodPlantatHainesCitycurrently has two warehouseslocated nexttothe main production building. The main warehousecontains most of the different panels, e i g suchaswallpanels, floorand roofdecks,and c_iling boards.Othermaterials storedin thiswarehouseare thestudsusedformakingtrusses, floorand wallsframes.Most of these materials, before taken to the production line, must first go to a cutting station. For this reason they are transported on pallets using a forklift. The secondary warehouse contains all other materials that can be moved directly into the production line, such as finished trusses, doors, insulation material, screws, bolts, and carpets. Such materials are also transported to the production line using forklift trucks. In addition, there arc some outside storage areas for other materials such as uncut beams, wheels, bath tubs, windows, glass doors, and kitchen appliances. There are four forklift trucks operating around the facility. Each truck has specific service areas, such as floor/top assembly area, sheet metal, plumbing, and cabinets area. ! 1 iv Purchase orders are placed on a weekly, biweekly or monthly basis, depending on Most of their suppliers are located in the _omral Florida the usage of the material. .. -. area. Orders can take from one to three days for delivery. TRUSS FABRICATION WORKSTATION I J The trussassemblyareaislocatedoutsideofthe main plant.Trussproduction supplies theHainesCityplantaswellas otherfacilities inLakclandand PlantCity, both located alsoinFlorida. Raw materials (2 ft. x 6 ft. studs) arestoredina warehouseon pallets. They are moved tothefirst cutting workstation usinga forklift truckand placedincans. At this cutting station studsare reducedto 2 ft.x 2 ft.pieces.Piecesarethenmoved to both angularand smallcutworkstations. Cut studsare thenmoved totheassemblystation, wherepiecesofdifferent sizes and shapesare storedon top ofthe workingarea.Piecesam laidout and assembled . usingstandard jigs, fixtures and a truss machine. Good pieces areselected forassembly and defective piecesare sentback tothesmallcutoffstation. The following operations areperformedattheassemblystation: o Piace bottom plates. o Layout truss configuration on top of the plates in fixtures. o Place clips on top of truss members. o Insert assembly into press. o Activate press machine for final fabrication. o Remove finished u'uss and piace it in a cart. V There are two truss assembly stations operating are stored in the secondary warehouse. , , Forklifts. Time to assemble one truss is 1 minute. man this station. Raw Between operations, Finished trusses Finished trusses can be shipped to other plants or move to the roof assembly workstation. Seven workers simultaneously. material is stored material is brought to the station and moved on roller carts. on Finished products are placed on pallets and eventually moved to the secondary warehouse' Visual inspection detects defective studs which are sent to be cut into smaller pieces. The report contains suggestions for improving layout, labor utilization, process, and materials handling. CHASSIS ASSEMBLY WORKSTATION Raw materials such as beams, wheel axles and wheels, are stocked outside the plant. Beams art: placed on a chain driven conveyor, and then on a roller conveyor that transports [ them into the cutting station. and the residu_ Here beams are cut to length using an arm saw, part is welded to the next beam on the conveyor. Cut beams are moved to the Chassis Frame Assembly workstation There the chassis frame is assembled by arc-welding. an overhead in the assembly area. rail for moving purposes using a hoist. Welding machines are set up on The chassis frame is then moved to the final assembly area where the wheel axles and the hitch assembly are welded to the chassis support frame. Wheels are then am_chcd to the axles. The finished chassis is then taken out of the plant to the paint workstation a _ ! >LIIU.II----*' l,Y_l(_],Oi-. using A '-'-Vm_.-'" lU>t l _>iSh_i-,tpaint--'-" l_'-appncu"-"_0 tnt"-¢;ua:):,1>-' ..... '....u_mg" ..... au _,_.L,' ......... u>m._'- vi paint system. The chassis is then moved to a drying area. the front of the production to produce one chassis is 45 minutes. line. Time Six workers man this station. After drying, it is brought to Raw material is brought to the station on Forklifts, a conveyor brings the beams to the cutting and welding area from where subassemblies i are moved by crane. No apparent A tractor transports formal inspection procedures the finished chassis to the next workstation. take place at this station. The report contains suggestion for improving the layout, labor usage, process, and material handling. FLOOR ASSEMBLY WORKSTATION The chassis is brought from drying area to the beginning of the production J The chassis is placed on a raft system, which is driven by a chain-pulled cutting station is located behind the assembly area and plumbing conveyor. materials line. The are brought from an adjacent workstation. The following operations o are performed at this workstation: Cover chassis with plastic tarp. house. site. o Apply insulation (R-7 fiberglass). o Start electrical o Assemble and plumbing conduits work. floor frame using pneumatic nailers. to the floor assembly workstation which is located o of the This is done to prevent dust from getting into the house at construction brought This serves as the bottom Plywood decking is from a cutting station, behind the workstation. Electrical conduits are attached to the frame with tie wraps. vii o The Screw flame to Chassis. chassis is then pushed to the deck assembly area where the following operations are performed: ,o o Finish electrical wiring and plumbing conduits. Apply glue to frame. workstation i Floor A glue hose is attached to the top of this where it can be moved through the work area. o Lay sections of decking onto glue-coated opening pneumatic nailers. operations then frame and assemble Normal deck panel size is 4'x 8'. take place at the next workstation where using the following tasks are performed: o Cut holes for toilets, electrical, and plumbing conduits. PVC connections are assembled in a workstation located to the right of the floor openings workstation. o Reinspection, additional nails are used where needed and screws for floor support. l The following operations "" are performed at the next work area: o Seal seams between boards (mud filler). o Sand floor deck. o Remove dust. o Piace a foam padding onto deck for carpeting. o Install carpet or vinyl. o Cut off any excess carpet or vinyl. o Cover carpet with plastic. It takes 45 minutes to prepare one floor. viii A total of nine workers are active in this workstation. Material handling includes a tractor for the chassis, a chain driven floor conveyor system for the floor assembly, and a small conveyor system to transport studs. Inspection for leaks in plumbing conducts and missing nails in the floor deck is performed. The report contains suggestions for improving the layout, process, labor utilization and material handling EXTERIOR WAIL Wall paneling procedures. ASSEMBLY WORKSTATION and framing studs are cut to size in an area located behind the framing tables. The following operations are performed at this workstation: o Assemble wall frame, no jigs/f'_tures are used. o Install insulation (R-11 fiberglass). o Apply glue to frame. o Attach inside wall panel to frame using pneumatic o Cut holes for windows and doors, electrical outlets and light switches. o Move finished exterior wall to temporary o Move exterior wall to production nailers. staging rack. line with an overhead hoist. Time to complete an exterior wall assembly is 50 minutes. Five workers are employed at this workstation. station via Forklifts. cranes. Completed No formal inspection Raw materials are brought to the walls are taken to the installation a_'ea using overhead procedures appear to exist at this station. The report contains suggestions for improving the process, labor usage, and ix materials handling. It also contains a more detailed description of the workstation for one for frame studs and one for paneling, are plumbing assembly. _OR WALL ASSE2VIBLY WORKSTATION Two additional cutting stations, located behind and adjacent respectively, to the assembly tables. The frame assembly ,:onsists of the following operations: i o Assemble wall frame with pneumatic o Holes are drilled for electrical wiring. o Install electrical wiring. nailers. Finished frames are then placed in staging racks where they wait to be moved to the wall panel installation table adjacent to the framing table. The following operations are performed: o Apply glue to frame. o Install gypsum paneling. Adjustments are manually performed with tapes. o Cut holes for electrical boxes, and openings for doors. Finished interior walls are then manually transported it is taken to the production line with the hoist. It takes 8 minutes to produce Five workers are employed station is manual. transported to another staging rack before Raw materials an interior wall. at this workstation. are brought to the assembly area by overhead Ali material by Forklift handling within the and the finished wall is crane. ;i J I i X The report contains recommendations and materials handling. INrERIORN_.,XrE._OR WALL INSTAI.,LATION hoist. A weather connecting walls forming a corner, a support while they are being nailed/screwed support and nailed When clamp is used to hold the walls together into exterior walls, wall studs. to the floor deck. after which the clamp is removed. together, wires are installed cables to exterior using an strip is first installed between the wall and the floor deck. The wall is held up until it is screwed The electrical AREA walls are moved from both wall assembly workstations Interior/Exterior overhead to improve layout, labor utilization, process, Kitchen cabinets a metal plate are also is used to installed at this workstation. lt takes 45 minutes to install the walls. There are a total of eight workers at this station. brought by an overhead Inspection is performed The report hoist system. Ali other Interior and exterior walls are materials are moved manually. to assure that walls are securely fastened. contains recommendations to improve labor utilization, process, and materials handling. ROOF ASSEMBLY WORKSTATION Panels are brought to this workstation They are stored in the workstation from the warehouse using forklift trucks. and manually placed on a mobile pallet. Panels are stacked on this mobile pallet which traverses the length of the table. The ceiling of the roof system consists of 4'x12' sheetrock panels (gypsum boards) which are laid out face down on the work'table adjacent to one another. _ _ = i Seams between panels xJ are taped and trusses are set onto ceiling panels. A front perimeter end of the truss. frame is laid along the edge of the ceiling and nailed to the The l_rame is made of 1'x 2' boards and is attached pneumatics.,. A similar operation is used for the rear perimeter frame which is laid along back edge of the ceiling and nailed to the large end of the trusses. made on a worktable Polystyrene i to the truss with These frames are adjacent to the assembly deck. foam is sprayed in to connect trusses to paneling. The foam is very strong and provides a level ceiling surface. 2'x 4' studs are installed for support to the roof truss. Ventilation ducts are also installed at this workstation. From this workstation, the roof is lifted with a 4-ton hoist system and transported to the adjacent finishing workstation. The following operations I are performed at this station: o Seams between wallboards are taped. o Wallboards o Holes are cut for vents, lighting, etc. are finished with a drywall mud which is applied twice. A pneumatic jig saw is used for this purpose. The roof is then transported finish is sprayed onto the ceiling. are installed at this workstation. to the popcorn spray workstation where the popcorn A popcorn mixer is located outside the plant. Vents After the roof is finished it is moved to the production line using a hoist. There are a total of eight wo_'kers in this station. brought to the station with Forklifts. • I - I Assembled hoist through the rest of the operations. Trusses and ceiling panels are roof panels are transported by overhead + The report contains recommendations to improve the labor utilization and the process. ROOF INSTAI/.ATION The assembled AREA roof truss is transported and lowered onto the shell. perimeter by a chain hoist to the production Before it is secured, for insulation purposes, a weather strip is laid around material is applied The roof deck is laid and fastened to truss assembly. of randomly oriented compressed are stored in containers located overhead by using a high pressure on the roof. Measurements blower. The paneling used for the roof wood panicle board. These panels mounted on a track which extends throughout the work area. Decking is attached using pneumatic nailers. them together. A metal the roof system to the exterior walls, A dry rock wool insulation deck is composed the The roof is then fastened to the upper wall studs, Additional studs are screwed to the roof borders where fascia is later installed. plate is then used to reinforce line Metal clips are used to hold are made using a ruler to mark where cuts are to be made These cuts are made by a powered hand saw. Then fascia is installed. r After installing the roof deck, a layer of black sealant is applied over the edges I of the roof. A waterproof and alignments a knife. cover made of tar paper is rolled over the roof. Adjustments are performed The waterproof manually. Excess material around the edges is cut with cover is then stapled to the roof top. Shingles are then placed on top of this cover and stapled. Time to install one roof is 45 minutes. Eleven workers are employed + at this station. line using the hoist system and lowered The roof truss is brought to the onto the walls. Roof decking is stored in ,li X'III J above the station and is manually brought down and placed onto the roof. compartments Shingles, tar paper, fascia are also stored Inspection The is performed report above and are manually retrieved for use. to ensure that the roof is properly assembled. contains recommendations to improve the process and materials handling. EXTERIOR FINISHING Outside installation i is installed of Extruded Polystyrene wall frame. board. insulation AREA on exterior walls and sidings. Insulation The exterior siding is attached This includes the boards which are stapled to the exterior and stapled to the exterior wall insulation Sidings are hand cut to fit smaller spaces, such as between windows and doors. Window and door frames are installed in exterior walls. used to provide additional insulation. A weather strip is also Windows and doors are then installed in a clam shell fashion. Once siding, windows, and doors are installed, the exterior electrical wiring is connected, such as lights, switches, and electrical boxes. A plastic cover is used to protect the open side of the trailer. lt takes 45 minutes todo are employed at this station. the exterior finishing on one assembly. All materials are moved manually. Twelve workers One inspector is used to assure quality. The report contains recommendations INTERIOR INSTAI2.ATION/FINISIIING to improve the material handling system. AREA J¢ installations consist of the following operations: Interior o Bathroom and kitchen counters installation. - xiv o Living room cabinets. o Bedroom closets. Gypsum boards (also called dry wall panels) are cut to size for interior wall panels, then moved to the production line where they are stapled to the wall frame. Electrical wiring is installed inside the house which includes electrical switches. Sealing of walls and cabinets is performed before the house is cleaned and moved to the inspection area. A crown mold is installed to cover edges or seams between walls and roof. curtains/mini-blinds may be installed in this workstation. Also Kitchen appliances and interior lightings are also installed. There j_ a final inspection, usually visual, performed by a supervisor of the finished operations. etc. Inspection may include electrical testing for switches, connections, lighting, lt takes 45 minutes to do the interior installation and finishing. Nineteen employees are employed at this workstation. places.manually with the assistance of hand cans. Material handling takes At this station, a final inspection is performed to ensure that components are securely assembled and installed, and house is checked for any missing or out of specification elements. Electrical testing is performed to ensure that all lighting, plumbing, and appliances are working properly. OTHER POTEN'IIAL IlVlPROVEME,NT OPPORTUNITIES This section elaborates on suggestions to centralize cutting, reduce inventory, improve the material handling systems, and to provide more inspection. 1 INTRODUCTION This report provides a comprehensive a "typical" Industrialized review of the processes that take piace with housing manufacturer, lt is the first of a series which ultimately will provide a scenario depicting how energy efficient, affordable housing will be designed, fabricated, and erected The scenario in the 21st century. will assume effectiveness are directly related, there I will be an industry affordability that industry from one where a high percentage by a small number housing pressures This "shake out" will restructure cost- increase, the housing of the market share is held by a large number to one where that same share of the market will be held of competitors, r'his i:henomenon, already experienced industries such as food, will see the efficient, well capitalized, I manufacturer lt also assumes that, as competitive "shake out". of relatively small competitors and firms acquire or simply drive the others out of the business. be room for the regional, specially oriented manufacturer. As successful companies grow, they will experience and marketing by other oriented Of course, there will always increasing pressure on their manufacturing facilities. These pressures will arise out of the need to increase production rates as well as out of the increasing need to enhance quality while being able to satisfy a great range of customer demands. these pressures, companies will have to develop comprehensive To successfully overcome the challenges which will anticipate future problems and bottlenecks, and technologies most suitable to their resolution. manufacturing posed by strategies and define the methods, procedures, Included in these strategies will be. guidelines dictating if, when, and under what conditions various types of computerization, automation, and robotization will be candidates for implementation. 2 This report documents a "typical" industrialized housing manufacturer for the purpose of providing base line data that can be used to develop a generic simulation model, Such a model will be the basis for detecting and classifying manufacturing bottlenecks and evaluating potential resolutions. will constitute the foundation for determining The combined results of these studies a manufacturing strategy for the industrialized housing industry, Fleetwood Homes Industries, the nation's largest manufacturer of mobile homes, has a plant in Haines City, Florida, which is within reasonable access from the University of Central Florida. This company is represented on the advisory board of this research project and has been supportive in this research. Their headquarters office in Riverdale, California collaborated closely with another phase of this project conducted by the University of Oregon. These factors contributed to the selection of the Fleetwood Haines City, Florida plant as the "typical" manufacturer. However, the primary reason for the selection was that the processes that take piace in the manufacture of mobile homes have a great deal in common with processes that take piace' in both modular and panelized manufacturers. For example, the processes involved in the manufacture of wall systems at Fleetwood include the cutting of ali raw materials to be used in the system, building of wall framing, and attaching the wall board to the framing. A similar process would be observed ff a panelized or modular plant were being investigated. Fleetwood's roof system consists of the cutting of ali roofing materials, building roof trusses and attaching them to ceiling material, spraying a finish on the ceiling, and installing roof decking, Mod!_lar manufacturers build each component of the roof system precisely in the same iJ 3 manner. Fleetwood produces complete floor systems as weil, This process includes the cutting of all raw materials to be used, assembling the steel chassis and floor framing, and installing the floor decking. Again the processes involved in the manufacture of' this ,_ystem are similar to those employed by other manufacturers. The mobile home that Fleetwood manufactures of modular and panelized housing types, within the factory environment. almost identical can be viewed as a combination All of the structural components The process to the way in which panelized of prefabrication builders are assembled of the components produce them, Fleet'wood connects the three systems as well as ali finishing components I just as modular manufacturers is In addition, in the factory do. In spite of the above, certain differences must be acknowledged. Fleet'wood does not generally mud and cure the interior walls of their units, a process which appears to create bottlenecks in certain modular home builders processes. I in Fleet'wood's units manufactured climates of the de,cp south. Manufacturers in their designs and processes transportation. The impact in Haines City, Florida The low roof pitches used ideal for hot and humid producing higher pitched roofs must include manners in which to hinge and fold the roof during of these, as well as some other differences between various segments of the industrialized housing industry will be more fully evaluated the gencraliza,tion phase of the study where the findings at Flcetwood industry process model. the during are welded into an 4 ( FACI'ORY produces Fleetwood facilit_ These homes OVERVIEW single and double wide mobile homes are typically complete finishing items installed. at the Haines City with wiring, plumbing and all interior Double wide homes are built as two separate modules (units), whereas single wide are just one module, These modules typically range in size according to the following specifications: 1) Length: 32 ft. - 60 ft. 2) Width: 24 ft. - 28 ft. (double wide) 12 ft. - 14 ft. (single) 3) Area: 752 sq. ft.- 1500 _q. ft. Each module is produced entirely within the factory environment through a number of cutting, fabrication, and assembly processes performed at various workstations. Each workstation ¢ is descn'bed typica!ly made in batches. in detail in subsequent , widthwise orientation. -= _ The daily production lt should be noted that this number can vary depending Modulcs are transported _ The batch types are determined orders for that day. The production line typically contains an average of twelve modules _ any one time. about ten, Production runs are That is, one day they will produce only double wide homes; another day only single wide homes will be produced by the specific production chapters. t;:'oughput averages on the module size. from station tc station lengthwise rather than the conventional The line is powered u_ Lira lavLuiy i_ V_sei3_d by a chain driven floor conveyor. a_ u,_ Fu,,, A general Q 5 60,000 square feet not includir:g office space with 65 The factory is approximately percent of that being production understand the plant's operations overview is pi'ovided- space and the rest storage and transport and how they are interrelated The fabrication to one another, of the chassis is the first operation. chassis is then moved to the first station of the main production system is assembled. exterior [ cabinets are installed. The finished line where the floor at the roof assembly workstation trusses have been fabricated side of the installation The house assembly is where the roof system is installed. moved to the next workstation at a workstation to the assembly station. decking and covering is attached adjacent The roof system has to the installation station. The located outside of the main plant and then Once the roof has been fastened to the home the and the assembly is moved to the next workstation all exterior finishing such as the installing performed. These materials plant. a brief The wall systems have been brought from the assembly workstations located on either workstation. The walls are manufactured at these stations. transported To The floor assembly is moved to the next station where interior and walls, bath and kitchen been produced space. where of siding, soffits, doors, windows, etc. are were supplied from a storage area located outside of the The assembly is next moved to the interior finishing workstation where appliances, I interior trim and finishing, lighting, e_c. are installed. the assembly from a storage area located adjacent completion operation of the module assembly, The appliances are transported to the finishing workstation. a final test and inspection flow is summarized in the operations/activities m _ After is performed. The chart at the end of this chapter. Specifically, this chart shows the sequence of processes, the relationship - to between them as one flows into the next, and ultimately how the flow through the plant is structured. A factory layout is also provided iri this chapter to give an overall picture of the factory as 6 it is laid out. workstations This layout also provides line are subassembly workstations. line. be the used in the manufacture described is summarized All of the blocks on either side of the main The addition, the blocks outside of the plant represent storage locations for inventory stock to the appropriate about the location of the various For example, in the center of the plant and running from within the plant. top to bottom is the main production brought information These warehouses of the homes. workstations contain all of the materials to As they are needed, these materials are for use. The production process in the p, ocess flow chart at the end of the chapter. previously This chart is briefly discussed ir_ the next several paragraphs. A process flow chart is a device used to examine the flow of operations a workstation or factory as well as the flow of items into and out of the stations. within This flow chart is a useful tool for identifying problems with a layout resulting from inefficient material flow. A process flow chart can also provide an overall picture of what is actually raking place within the particular facility. The process flow chart can also serve as a layout so as to optimize the sequence of operations as starting ground for restructuring well as the flow of incoming and outg_iag materials or assemblies. be superimposed The flow chart should onto the layout so that the exact location of each operation and storage area is correct for the analysis. Each symbol has a specific meaning. represent operations, arrows represent inspection operation, and a D represents follows the direction of the arrows. _'aW _+--_4e:1© first operation _ le th_ tr_ncnnt'tlng to be performed Triangles represent storage locations. transportation processes, a delay in a process. a square Circles signifies an The flow of materials For example, $3 signifies the storage area for chassis nf thp..¢_, rnaterial.¢ tr_ z at the chassis workstation, staging area $10. 08 is the 09 the second and so forth. Fr=_ I 7 of the finished assembly out of the workstation, T8 signifies the transporting follows for all of the processes in this flow Chart. first transport 02 and se on. Another example is TO which is the The chassis is being brought to the main production line to in the layout. begin the first assembly operation operation This logic O1. T1 is the transport to the assembly to the second A complete listing defining all of the symbols is contained is this chapter. It is hoped that this factory overview will provide enough background to allow the reader to work through this document with a good understanding of the material contained within the subsequent chapters which describe Fleetwood's manufacturing operations in detail. lh'oduetioa Ram Aaab_ This analysis is !ntend-.d to verify the rest_lts obtained criteria for verification important factors must be considered on total production i downtime, is that the required capacity lew production include transport home (module) rates are satisfied. in this analysis: 1) the production discarding Three rates are based that may arise such as equipment problems orders, employee times between stations. because daily production in the time studies. The abscenteism, 3) operation etc. 2) that operation times times are based on one half of the they are made as two separate halves and connected on-site. The analysis is based on the following specifications: 1- Home size: 2- Production 3- Shift: 60'X rate: 8hrs.- 4- Cycle time: 12' (double wide) 20 modules/day 2(10min.) breaks - 460 mm. based on the longest operation The productior_ rate analysis for each workstation time in the workstation is demonstrated with the time charts. z i o l - 8 SECONDARY STORAGE AREA MAIN STORAGE AR.F_ FABRICATION i i IToP_OWF_ _S ' FLOOR PANEL ASSEMBLY 'I .... ,,_, i ..,.°.,.°, ........ m_Dwatt, ASS_LY EXTF_OR I HZ_Tm_S II I INTERIOR FINISHING _CAL _NO COUNTER TOP FABRICATION AREA EXTERIOR SIDE "mt._.h_" WALL WALL ' ASSSMBLY ASSEMBLY CHILING _RE FINAL INSPECTION CEILING FINISHING ROOF FRAMING ASSEMBLY SIDING CU22_NG AR.F_ ,,,,, APPLIANCES INSTALLATION APPUANCES STORAGE ,,, _ __ ,, ,,, WINDOW/ _oR STORAGE AREA ............ WINDOW/DOOR STORAGE TOOL ROOM ,,, _LL,_] " _._,=m -- l CHASSIS ASSEMBLY ROOF FRAMING INSTA_TION EXTERIOR FINISHING CABINET FABRICATION AREA _' ' w^'ma PLUMBING WALLS INSTAI/_TION WALL ,, ..... wHF2.iS INTERIOR WALL ASSEMBLY PA_._ mxrr_G ST^'nON , STOR_G_ .......... OUTSIDESTORAGE _^c _ues { { m_ot_,s TRUSS °,,,...,...,.....,,. ....... S'rF.m. CHASSIS PAINT ARF.A .,..,.....,,,......°,... i ,.° .-. 9 i MAJOR , , ,j' ' OPERATIONS/ACTIVrFIES ;/ '/' ,1 ": Floor Assembly "1..... Interior Wall Assembly Cabinets / Counters Work Area Chassis Assembly ] J Int./Ext. Exterior Installation Walls Assembly Wall Panel Truss I Fabrication 1 Framing Installation I ------- ........ ] Exterior -- Framing Assembly Window / Door / Siding Storage Area Finishing 1 ' Interior ( Finishing Electrical & Finishing Work 1 lner_r.t_ - Shipping - i / Appliances Supply f 11 PLANT PROCF_i_ FLOW DF_,SCRIFFION i l I $1: Storage for all raw building materials. $2: Storage for trusses, toilets, sinks, mirrors, carpeting,etc. $3: Steel beam stock for chassis assembly. $4: Stock for showers, HVAC materials, chassis components. $5: Kitchen appliance $6: Window and door stock. $7: Finished product $8: Staging of assembled $9" Staging of cabinets and counters. Sl0: Staging of chassis beam stock. SI1: Staging of bath items such as toilets, sinks, etc. S12: Staging of finished exterior walls. $13: Staging of roof components. stock. storage. interior walls. 9_mr.mo O0: Truss fabrication workstation. O1: Floor frame assembly. 02: Floor 03: Installation deck assembly. of carpet, vinyl, showers and toilets. r i I k 12 04: Installation of interior/exterior walls, kitchen/bath counters electrical wiring, 05: Roof installation, roof deck installation, shingles, fascia. 06: Exterior finishing, siding, windows, doors, etc. 07: Interior finishing, lighting, trim, mirrors, etc. 08: Chassis beams are cut to size. 09: Chassis frame is welded and assembled. O10: Final assemblies Ol1: Paint station for chassis. O12: Plumbing cutting and assembly. O13: Cutting for interior wall studs. O14: Interior wall frame assembly. O15: Cutting for interior wallboard. O16: Final interior wall assembly. O17: Exterior wall end panel assembly. O18: Kitchen and bathroom O19: Cutting for exterior 020: Exterior wall assembly. O21: Exterior 022: Mixing station for ceiling drywall mud and finish texture. 023: Roof truss assembly station. 024: Ceiling finishing station. 025: Ceilir,g spray station. of hitch and axles. cabinet/counter fabrication. wall paneling and studs. wall ass¢:mbly. and cabinets and 13 Transportation i I J _ TO: Chassis is transported TI: Unit is transported to floor deck assembly. T2: Unit is transported to carpet and vinyl station, T3: Unit is transp0ned to wall installation. T4: Unit is transported to roof installation. TS: Unit is transported to exterior finishing. T6: Unit is transported to interior finishing. TT: Raw beam stock is transported TS: Finished chassis is transported TI0: Finish,:d inte_rior walls are transported T9: T11: Interior wall materials stock are transported interior wall station. cutting stations. Cabinet and counter is transportedto to assembly TI2: Finished cabinets and counters are transported T13' Sinks, toilets, and other plumbing items are transported T14: Bath and plumbing items are transponed T15: Showers are transported T16: Exterior wall materials are transported to exterior wall cutting station. T17: Cut studs and paneling are transported to assembly tables. T18: Finished exterior walls are transported T19: Finished trusses are transported T20: Drywall finishing materials are transported T21: Finished roof truss is transported T22: Windows and doors are transported to production line. to chain conveyor. to paint statio_. to staging and then to installation. to installation. to assembly station. to installation. to installation. to the to installation. oof assembly workstation. to the ceiling finishing station. to roof installation. to exterior finishing. 14 T23: Appliances are transported to interior finishing, T24: Finished home is transported to final inspection. T25: Finished home is transported to storage area. T26: Finished trusses are transported to temporary _ storage. Pelays DI: Finished chassis must wait until drying is complete. D2: Interior wall frames wait until previous wall assembly is completed assembly. D3: Roof assembly waits for finishing station to be vacated. Ins._ctiQn 11: Finalinspection isperformedon entireunit. J before panel 15 WAREHOUSE ANALYSIS Fleetwood's facility in Haines City currently has two warehouses main production building. The main warehouse drywall materials, floor and roof decking. 2 x 2's for truss fabrication, located next to the contains most of the lumber, Other materials stored in this warehouse floor joists and walls studs for framing. materials, before being taken to the production are Most of these line, must first go to a cutting station. For this reason they are palletized and transported The s¢:condary warehouse such as by forklift (Figures I and 2). contains all other materials that can be moved directly into the production iine, such as finished trusses, insulation material, screws, bolts, mirrors, and carpeting. I Such materials are also transported to the production line using forklift trucks. In addition, there are some outside storage areas for other materials such as uncut beams, ',_des, bath tubs, windows, glass doors, and kitchen appliances. Figure's. 3 through 7 show some of the outside storage areas for these materials which are transported production to the line using forklift trucks. There are four forklift trucks operating at the facility. Each truck has designated service areas, such as floor deck assembly, sheet metal, plumbing, and cabinets storage. Purchase orders are placed on a weekly, biweekly or monthly basis, depending the usage of the material. For example, plumbing and drywall orders are placed every week, while low usage materials ordered area. on on a monthly basis. such as medicine cabinets and kitchen appliances Most of their suppliers are are located in the central Florida Orders can take from one to three days for delivery. 16 Figure I, Forklift operating a_ the Main Warehouse, 17 Figure 3, Windows stored outside, + I Figure 4. Glass doors stood out,de. 18 ]9 ,... E E J o.- _ < _ N ='_ -_ ._ ,,, ' ' ii I ii i 2O iiii t --- o _ ° sm t t t m m m 21 TRUSS FABRICATION WORKSTATION Process Deserip'tion The truss assembly area is located outside of the main plant. supplies the Haines City plant as well as other facilities in kakeland Truss production and Plant City, both also located in Florida. Raw materials are l,:oved (Figure 8). (2 ft. x 6 ft. studs) are stored in the warehouse to the first cutting workstation using a forklift truck and At this cutting station chords and webbing are reduced on pallets. placed They in carts to 2'x 2'. pieces (Figure 9). Pieces are then moved _.oboth angular (Figure 10) and small cut workstations (Figure 11). Good pieces are selected for assembly and defective pieces are sent back to a small cut off station. Cut pieces are then moved to the assembly station, where pieces of different and shapes are stored on top of the working area (Figure 12). Truss configuration out and assembled is laid using standard jigs, fixtures and a truss machine. The following operations O sizes are performed aT the assembly station: o Piace bottom plates. o Layout truss configuration o Piace plates on top of truss members. o Insert assembly o Activate pres:_ machine for plate pressing. o Remove finished truss and piace it on a mobile dolly (Figure 13). on top of the plates in fixtures. into press. 22 m 41II - & t 24 There are two truss assembly stations operating are stored in the secondary warehouse. simultaneously. Finished trusses Finished trusses can be shipped to other plants or moved to the roof assembly workstation. Labor Utilization A total of six workers are employed at this workstation. each truss press while the other two perform cutting operations. is needed for materials Two workers operate at An additional person handling within the work cell and to storage. Mat#ria_ Hanmiag O operation to operation with roller cans. After bytruss has beer built, is it ' transported Truss from lumber is brought from warehouse to workstation forklift. Ali stock is then palletized warehouse and temporarily stored. Pallets are then transported to the secondary again using forklifts. Impeetioa There is visual inspection for defective pieces at the assembly station. Defective parts are sent to the second cutting station, where webbing can be reduced to smaller sizes. EquipmentDescription o Cutting: 1 table saw 1 angular cut table saw 1 radial arm saw. o Assembly: 2 automatic truss presses. o Jigs/Fix'tures: 2 jig set ups, o Materials Handling: 1 forklift and 2 roller carts. Recommendations _r It is recommended 1. that the following suggestions be investigated: Layout: o Exchange the finished truss stock with the truss cord stock area. o Expand workstation size to allow for more efficient flow of materials. o Relocate workstation reduce transport balance near the roof assembly area to potentially time that exists with current location. between trusses Production used and trusses sent to other Fleetwood plants should be considered. 2. Labor: o Labor utilization should be examined. be performed This operation might possibly with a smaller crew if adequate materials handling and are utilized. cutting equipment _ b_ o Truss machines production 3. exist that rates than current are capable of substantially higher machines. Process: o Reasonably production o efficient. Truss presses are adequate for required volume. Cutting systems exist that are capable of straight and angular cuts on one machine, thus eliminating the need for two saws. An example f 26 of such systems is shown in Figure 14. o Multi-head cutters are available that are capable of cutting multiple studs simultaneously. ': This production increase makes the possibility of using one man for cutting a feasible alternative. other available cutting equipment Figure 14 see Appendix A. For a list of 27 4. Materials Handling: o Replace roller carts with automatic conveyors such as the one shown in Figure 15 in order to eliminate the need for manual transporting of components o within the work-cell. Reduce loading and unloading efforts. available that can perform automatic Automatic stacking finished trusses, thus reducing labor time. truss stackers are and pallet/zing An example of such truss stackers is shown in Figure 16. For list of available equipment Appendix A. TRUSS STACKER of CONVEYOR see 28 29 TRUSS FABRICATION FLOW CHART Raw Material Storage r Reduce 2 x 6 to 2 x 2 Studs , ,,,_ Truss Assembly Press Tru_ Plates Finished Tn_ Storage - : Cut Studs into Smaller Lengths / 1 3O 31 Truss Fabrication: $20: Initial staging of 2x6 lumber waiting to be cut. $21: Specific converted 2x2 pieces are waiting in process to be sent through an angular cutting process. Then they are sent to $22 & $23 staging areas. r $22: Other converted 2x2 pieces not needing angular cuts are staged at this point before assembly. $23: Same as $22 for other assembly station. $24: Finished trusses are placed on pallets and staged. $25: Same as $24. O28: 2X6 truss members are converted 029: Angular O30: Web members O31: Metal plates and truss members to 2X2's with a table saw. cuts are made to small truss members as required. are cut to size at this station. are set up in standardized press for final assembly. O32: Same operation as O31. T21: Wood stock is brought in from main warehouse. T22: Finished trusses are transported T23: Same as T22_ to storage. ' jigs and sent into a 32 TIME CHART FOR TRUSS FABRICATION Operation # No. of Ope_ rators Reduce lumber (2x6) to (2x2) 1 Cut lumber (2x2) into smaller pieces 1 Assemble Truss (2 Workstation): - Set metal plates and studs in jigs/fLx'tures - Operate press machine - Move truss to storage can 4 __o.___ 30 sec Mo_e Finished Trusses to Warehouse __0duction Rate Analysi_ Requirement:300 trusses/shift @ 30/unit Cycle Time: I min./truss/machine Production Rate: (1 truss/min, x 460 min./shift x 2 machines) o! m I - 920 trusses/shift 33 CHASSIS ASSEMBLY WORKSTATION Process Dc_ription Raw materials are stocked outside the plant, such as beams, wheel axles and wheels. Beams are placed on a chain driven conveyor, and then on a roller conveyor that ,,vii] move them into the cutting station (Figure 17). }Iere beams are cut to length using an arm saw, and the residual part is welded to the next in-coming beam. Cut beams are moved to the Chassis Frame Assembly workstation (Figure 18) where the chassis frame is assembled set up on an overhead rail (Figure by arc-welding. 19) for moving purposes using a hoist Welding machines are in the assembly area. The chassis frame is tbr_n moved to the final assembly area where the wheel axles and the hitch assembly attached me welded to the chassis support frame. Wheels are then to the axles. The finished chassis is then taken out of the plant to the paint workstation using a small tractor (Figures 20 and 21). A black rust resistant paint is applied to the chassis using an electrostatic paint system. The chassis is then moved to a drying area. drying, it is brought to the front of the production After line (Floor assembly workstation). 35 c_ _o _w c_ 36 Labor Utfliza_on Three welders operate at the chassis frame assembly station, one of which is also responsible for cutting beams to size. area. There is one person responsible for iransporting Ma_riaB in charge of the paint I work in the final assembly workstation. Another person the chassis to the paint area, and to the production is line. Handling Beam stock is transported lt is then Two other assemblers by forklift to a chain conveyor outside of the building. manually (2 workers) placed on a roller conveyor and brought into the building for cutting and arc welding. The beams are then crane transported the chassis to be welded and assembled. and moves it to final assembly. A tractor An overhead to the next area for crane hoist then lifts the frame is used for transporting the finishecl chassis i to the next station. I Inspection No inspection is performed at this workstation. [ y Equipment Description o Cutting: 1 band sav_ 0 Assembly: 6 arc welding machines o Jigs/Fixtures: o Materials Handling: 1 chain driven conveyor, 1 roller conveyor, 4 ton overhead hoist, 1 tractor, and a forklift and pneumatic screwdrivers none ] 37 Reeommen_tions It is recommended 1. that the following suggestions be investigated: Layout: o Relocate chassis workstation near the painting area. This will result in reducing material handling effort as well as creating floor space for other operations. production o An alternative area to the chassis p_inting station. Cross train all chassis crew members for both p_inting and assembly operations constitute o in order to avoid overexposure hazardous Crews would operate operating to paint chemicals which environments. on rotating shifts. Pr, Jcess: o 4. is to set this station up in piace of the warehouse Labor: o 3. chassis may then be moved to the line as needed. that is adjacent 2. The assembled Process is relatively efficient for this operation. Material Handling: none. 38 39 CHASSIS ASSEMBLY FLOW CHART Raw Material Storage 1 Cut Beams 1 + ChassisFrame Assembly 1 ' Wheel Axle / Hitch Assembly i ,, Rust Re, istant Pam'L 1 I Dr,ang 1 Move to Floor Assembly ' ' 4O 41 $2: Storage area for beam stock to be used for truss assembly. $10: In-process staging conveyor where beams wait until ready for production. $11: Storage area for axles and hitch assemblies, 08: Beam cutting operation. 09: Cut oeams are welded together. O10: Chassis frame is assembled. Ol1: Final assembly is performed O12: Electrostatic TI: Beams are transported "I"2: Overhead including axle and hitch assemblies. painting of chassis. crane to staging area. system transports welded beams to assembly area. After the frame is assembled, crane lowers it down onto axles and the hitch is then installed. T3: Chassis is tractor-pulled to the paint station. 42 CHART FOR CHASSIS ASS_LMBLY Operation No. of _Operators Total Ti_c Frame Assembly: 3 - Cut beam to size - Weld small, piece to next in-coming beam. - Move beam to frame assembly area for welding Assemble • chassis frame - l_ove chassis to next workstation 45 min Assemble Axle Wheels/Hitch 20 min 2 Move Chassis to Paint Area Paint Chassis i I 5 min 1 20 rain , Move Chassis to Drying Area 5 min Move Chassis to Production Line 5 min * Note: Estimated mar,imum cycle time for chassis completion is 45 minute. Production R_,_t..__ Requirement: 10 chassis/shift Cycle Time: 45 min./chassis Production Rate: (1 chassis/45 min. x 460 min./shift) = 10.2 chassis/shift . 43 FI.L)OR ASSEMBLY WORKSTATION ProecB I_m-iption Chassis is brought from paint area to the beginning of the production line. The chassis is placed on a dolly system, which is driven by a chain-pulled conveyor (Figure 22). The cutting station is located behind the assen,bly area and plumbing materials are brought from an adjacent workstation (Figures 23 and 24). The following operations are performed at this workstation: o Piace scrim cloth over chassis. This protects insulation and seals bottom of the house. o Lay down insulation (R-7 fiberglass). o Layout underfloor electrical wiring and plumbing piping (Figures 25 and 26). o Assemble floor framing using pneumatic nailers (Figure 27). Plywood decking is brought to the floor assembly workstation from a cutting station, which is located behind the workstation. See layout. o Electrical wiring and plumbing piping' are attached at the frame with tie wraps. o Screw frame to Chassis (Figure 28). The chassis is then pushed to the deck assembly area (Figure 29) where the following operations are performed: o Finish underfloor electrical wiring and plumbingpiping. o Apply glue to frame (Figure 30). A glue hose is attached to the top of this workstation where it can be moved through the work area. 44 o Lay sections of decking onto glue-coated pneumatic nailers (Figure 31). Floor opening cutting operations frame and attach using Normal deck panel size is 4'x 8'. then take place at the next workstation where the following tasks are performed: o Cut holes connections for toiler.s, electrical conduits, are assembled in a workstation and plumbing. PVC located to the right of the floor openings workstation. o Reinspection, additional nails and screws are used where needed for floor support. The follow_x_goperations o are performed Seal seams between at the next work area: decking panels (wood filler). f o Sand floor deck. o Remove dust o Place a foam padding onto deck for carpeting. o Install carpet or vinyl. o Cut off any excess carpet or vinyl. o Cover carpet with plastic (Figure 32). ,_ 4S F In 47 O 48 Labor Utilization In the floor frame assembly workstation is also responsfble for cutting floor joists. assembly area. Four additional workers there are three assemblers, one of which Two additional assemblers operate in the deck are utilized in the other two floor assembly areas. Materials Handling Chassis is brought onto production cans , connected transported assembled line by a tractor and placed on mobile pallet to a chain driven floor conveyor system. from warehouse by forklift to in process storage. on the top of the chassis. Floor frame materials are Joists are manually put The finishe¢l floor flame is transported onto smallstation conveyor on which are notched cut to decking length. decking by the chain they conveyor system. and Floor to the Thebrought frame is is to then the workstation manually. After holes are cut for toilets and showers, toilet fixtures are hand carried to production line. Showers are also brought in manually and installed. The floor assembly is moved secondary warehouse to the next workstation. Carpe_ by forklift to be installed. and vinyl is brought in from ¢ I.m_ctioa Inspection is performed at this station to check for leaks in the plumbing piping as well as for any missed nailing in the floor deck. 49 F.,qu/pmcnt I_scriprion o Cutting: 1 radial arm saw 1 circular hand saw 1 notching saw 1 jig saw o Assembly: pneumatic nailers and screwdrivers ] glue gun I electric floor sander o Jigs/Fixtures: o Materials none. Handling: Chain driven floor conveyor system I tractor Rr,commendations It is recommended 1. that the following suggestions be investigated: Layouu o The inst2,11ation carpet in the plant. This could the risk of damage to the materiai. 2.. Process: o Floor deck installation produces substantial amounts of scrap. extra scrap could be eliminated by precision cutting. This Computerized cutting systems are available to increase cutting speed and accuracy such as the one shown in Figure 33. o Eliminate reinspection panel staplers. for missed nailing by the use of automatic Appendix A shows some available equipment for this 50 purpose. 3, Labor: o Manpower can possibly be reduced two for decking, one for sanding/floor plumbing. Decking to six workers; two for framing, openings and one for installing tables such as one shown in Figure 34 are available. 4. Materials Handling: o Install an overhead storage & retrieval system for bringing toilets and showers to the production '1 i line. 51 Figure33 The Senco/Carlson Decking Table, Senco Products and Carlson S)_terns_ Lidesigned to handle lar_er and hea%-iermaterials, The table clamps, squares and fastens lumber from 2x3 to 2x12 for floor or deck modules up to 16'x16'. The tool carriage is equipped with Senco SN4 pneumatic nailers ancl features full s_fety controls and in adjustable fastener part, m. Retractable Joist iocators on 16" and 24" centers can handle most designs. Hardened steel plate-clamp posts provide vertical nnd horizontal clamping to ensure square, tight.fitting floor moduJes. Fixed posts are used for 2r,.3to 2x6 construc. tJon; extended posts are used forJotst material up to 2x12. Twin center supports speed the loading of heavy .joists and the deck removal s3_tem includes air powered lift :,ud manual rolioff, Figure 34 0 FLOOR PANEL ASSEMBLY FLOW CHART ScrimCloth on Chassis 1 __ Insulation ",u Electrical/ Plumbing ....Underfloor I _ Cut Floor Joist .... Frame Assembly Floor Decking Installation 1 Cut Openings for Plumbing/Electrical : . _ Toilet/Shower Installation 54 1 Z o 0 0 I 0 55 Floor As_mb_ Sl9: 'r'emporary staging of floor frame stock. O0: Floor frame is assembled. O1: Floor deck is attached. O2: Openings for toilets, showers, and plumbing are made and toilets and showers are installed, O3: Carpet and vinyl installation. 04: Interior/exterior walls, and kitchen cabinets and counters are installed. T4: Finished chassis is brought onto production line. T5: Floor framing stock is transported from main warehouse. T9: Previously defined. T12: Previously defined. T13: Previously defined. 56 C_IART FOR FLOOR ASSEMBLY Frame Assembly: - Place scrim cloth on top of chassis . Piace insulation - Piace underfloor electrical wiring/plumbing piping - Cut joists to size . Assemble frame - Move unit to next work area 3 45 min Assemble Deck Floor: . Apply glue to frame - Attach floor decking . Seal gaps between boards - Move unit to next work area 2 30 min I Floor Openings 2 20 min i - Sand Installation: floor deck Carpet/Vinyl . - Remove dust and apply protection coating - Install foam padding/carpet or vinyl - Cover carpet with plastic - Move unit to next work area 2 15 min ' Production Rate Analysis Requirement:10 floor units/shift @ 2 floors/home Cycle Time: 45 min./floor Production Rate: (1 floor/45 rain. x 460 min./shift) ,- 10.2 assemblies/shift 57 E,XTEI_OR WALL ASSEMBLY WORKSTATION Proceu Description Wall paneling and framing studs are cut to size in an area located behind the framing tables. The following operations are performed at this workstation: o Assemble wall frame, no jigs/ftxtures are used (Figure 35). o Install insulation (R-11 fiberglass). o Apply glue to frame (Figure 36). o Attach inside wall panel to frame using pneumatic staplers. o Cut holes for windows and doors, electrical outlets and light switches (Figure 37). o Move finished exterior wall to temporary staging rack (Figure 38). o Move exterior wall to production line with an overhead hoist (Figures 39 and 40). o A small working station for plumbing is located next to this workstation. Labor UU'lim_on This workstation has two work tables, with crews of two at each table. There is also a small work table for end walls, in which there is only one worker. A similar work table is located next to the interior wall assembly area. workers. Panels are cut by the same ,58 v 60 Materi Haadting Wall board, stud framing, and other building materials from the maia warehouse with forklifts. Materials are brought are placed to this station on pallets in temporary storage areas until needed. After cutting is performed materials are manually transported to assembly After are temporary worktables. staging area. completion, They are then taken walls manually to installation placed in another using the overhead crane hoist system. Inspection No inspection Q Equipment is performed al this station. Description o Cutting: 1 table saw and 1 radial arm saw. o Assembly: pneumatic nail guns . J and hammers, drywall knives, 2 .,. worktables. o Jigs/Fixtures: none except for small templates used to cut openings for electrical boxes and light switches. o Materials Handling: 2 forklifts, 1 overhead crane hoist, and 1 staging rack. Recommendations lt is recommended 1. O that the following suggestions Layout: None. be investigated. 61 O 2. Process: o Employ the use of jigs and fixtures for framing. o Utilize automatic framers that can improve the speed, accuracy, and quality of the process. o Use polyurethane lt is believed that foam can produce a stronger, level assembly, panel. Additionally o as well as increase the longevity of the wall it reduces the need for glue and nails. A major consideration to current is shown in Figure 41. foam for wall panel assembly rather than pneumatic nailers for fastening, more An example would be the cost of the foam as compared methods. A PMHI CREW assembles a 2x6 _atl panel _4th a Diamond Quad Framer by Trlad_lerrlck Machine Co., equipped with Paslode nailing _uns. PHMI a_o builds 2x4 exterior wall_ Window and door openings are framed at the head oi the line (note units standing ota end) and tub-com. penent4 (Jacks, tees, corners) are built at ii work_tallon to the left, (not sho_la). Figure 41 62 3. Labor: o Work is currently Additionally, performed with crews of two at each table. there are two others building end panels bringing the total to six. o Eliminate second framing and assembly crew. lt is believed that this would not effect meeting production requirements storage buffer exists for finished panels. because a sizeable Manpower is then reduced required by the workers. to four. o 4. Remove cutting operations. Materials Handling: o Reduce Automatic 42), the amount of handling time stacking and palletizing equipment, and vertical rollers (see Figure 43) exist that could perform these otx_rations efficiently. I ., I conveyors (see Figure 63 o Plumbing stock, sinks, and toilets are transported into this workstation. Toilets are placed on elevated storage racks and wait to be sent for installation. temporary from secondary warehouse Plumbing and PVC materials are placed in storage until pipes and conduits have been cut and are ready for assembly which could be done on a work table like that shown in Figure 44. Plumbing items are manually transported to production for installation. 64 I = ii I 65 EXTERIOR WALL ASSEMBLY FLOW CHART Cut Frame Framing Stud Assembly J Insulation f Cut Gypsum Wall Pantl _ 1 J Interior Wall _ Installation Panel ) / .l Cut holes for Window / Door 1 Move to Staging Racks I L Main Assembly Line for Installation Move to l 67 Exterior Wall/Plumbing Assembly:, S13: Plumbing and PVC stock are temporarily staged, S14: Toilets and bathroom sinks are staged, $15: Framing studs are temporarily stored, S16: Drywall is temporarily stored, S17: In.process storage for assembled exterior walls, O0: Plumbing lines are cut to size, O00: Plumbing items assembled, O18: Drywall is cut to size. O19: Framing studs are cut to length. 020: Drywall to frame assembly is performed including installing insulation. O21: Same as 020, "I'9: Plumbing and PVC materials are brought from secondary warehouse. T10: Framing stock is transported from main warehouse. Tll: Panel stock is transported from main warehouse, T12: Exterior walls, toilets and sinks, and plumbing are transported to production line. 68 TIME CHART FOR EXTER/OR WAI_ ASSEMBLY Side wall Assembly: . Cut studs to size . Assemble framing - Apply glue to framing 4 25 rain - Cut dry wall to size - Attach dry wall . Cut holes for window/door - Move finished wall to staging racks I End wall Assembly: Same side as wall 2 25 rain assembly Move Exterior Wall to Production Line I Produc_on Rate Analy_s Requirement:30 walls/shift @ 6 walls/unit Cycle Time: 50 min./wall/erew Production Rate: (1 wallj50 min, x 460 min./shifl x 4 crews) = 36.8 walls/shift , 69 IN2_R.IOR WAIL ASSEMBLY WO_ATION Process I:_scripfion Two cutting stations, one for stud framing studs and one for paneling, are located behind and adjacent respectively, to the assembly tables (Figures 45 and 46), The frame assembly consists of the following operations: o Assemble wall framing with pneumatic o Holes are drilled for electrical wiring. o Install electrical wiring, nailers (Figure 47), Finished frames are then placed in temporary storage where they wait to be moved to the gypsum drywall installation operations table adjacent to the framing table, The following are performed: o Apply glue to frame (Figure 48), o Install gypsum drywall. Adjustments are manually performed with tapes. o Cut holes for electrical boxes, and openings for doors. Finished interior wall is then manually transported 49 and 50) before it is taken to the production to another staging rack (Figures line with the hoist. 71 72 Labor UU2imtion Total manpower utilized in both working areas is five. by the same workers that assemble the frames. Studs for framing are cut In a similar fashion the people that attach wall paneling will have to cut the panels at a station located next to the worktable and manually place them for attachment, Materials Handling Wallboard, flaming studs, and other building materials from the main warehouse with forklifts and temporarily hand carried to cut stations. table. After cutting js performed Once the frame is completed, are brought to this station stored on pallets. materials are moved to framing it is placed in temporary assembly table for wall board attachment. Stock is then staging, then put on an Drywall sheets have also been hand carried to assembly table. After completion, walls are hand carried to another tempora:_y staging area, from there they are taken to main assembly line for installatien using an overhead I i crane hoist system. ¢ No inspection 1 Eqmpmcm is performed at this station. Dcstwiption o Cutting: 1 table saw 1 radial arm saw 2 worktables -_ -- - I W q 73 o Jigs/Fixtures: none o Materials 2 forklifts Handling: 1 overhead crane hoist Re_mmcndatiom It is recommended 1. that the following suggestions be investigated: Layout: o Remove all cutting operations only. Additionally, and dedicate this station to assembly more floor space is created. See section on general recommendations. 2. Labor: o With presentsystemthereare approximately sixworkersinvolved. Thisnumber couldbc reducedtofiveby employingsame method u_ thatused forexterior walls, 3. Process: o Employ the use ofjigsor f_ures for framing. o Utilize automaticframersthatcan improvethe speed,accuracy, and quality of the process(Figure41). o Use polyurethane foam forwallpanelasscmblyrather thanpneumatic nailers forfastening, ltisbelieved thatfoam can producea stronger, more levelassembly,as wellas increase the longevity of the wall panel.Additionally, itreducesthe need forglucand nails. o Performentire operation on one tableand have two tables operating atonc time.Maim considerations arcifproduction requirements can V be maintained and the cost of the foam as compared to current 74 methods. o Utilize layout tables with jigs that can effectively reduce the need for skilled framers. o Utilize other equipment Figure 51), component that are available such as framing tables (see nailers (see Figure 52), and framing machines, and automatic panel staplers for assembly (see Figure 53). This equipment can ensure consistency, additional equipment 4. increase and production improve quality. rates, reduce See labor, and Appendix A for listings. Materials Handling: o Reduce the amount of handling time required by the workers. is equipment available to accomplish this task. and palletizing equipment Automatic There stacking such as the one shown in Figure 54 and conveyors exist that perform these operations efficiently and allow the workers to spend more time in productive operations. See Appendix A for additional { V t listings of equipment. 75 TrLad's New Heart Duty Framing Table with Slud Stltcber Bridge is custom.built from 12' to 80' to tit your needs. Adjusts from 3'-6" to I0.'3" for clIiTerent wall heights. Cast iron stud locating flippers 16" and 2.t"O.C. C_ntlnuous Kluaring lip full length of the mole. llea,r'y duty steel rollers _dth roller bearings used to convey s_alisofT.Simple push bulton controls opernle table und roller eonlrolsystem.Tape frock for LayingIn _tndow and door. openings, C._.4 Sub Component Nailer is desqined,_tb Trend's quiet qunUty. The C_.4 can nccommodate ever)lhlng from a 2x4 to a 2xl_. Tools can be mounled in the overhead position or on their sides. A _lip. a_y squaring slop nnd c|amping capabilities from both the sldu and overhead stroJGbten out normally culled lumber, One man operution and _tlh dual clamp bullons and dual fire bullons, the machine ts rmfr. _11 build corners, hcaderr,, leeS,ek etc. Automatic Lumber Stacker I.EF_ liO.Aiem: Ik,clwii ,_,, _ lumNr iswlw, _ imals uP m SO_ m,tm_ m.mum_ Panel SWple_r bY Triad helps you control today's construction costs by building qusdJtT,SClUSrew_s _tth fewer people, l_e assured of accur-te nsU and staple placement to codes. Latest s_te-of.the.art I.au_r Pointer for incUc_lJ_qlsl.apis _nd mali locations, Idon; with programmable controUers that control the functions of one bridlle- Space fin toois i used to fasten top and bottom plate. One man i oper_Uon with a simple conLrol box make for high producUon. lm. 76 I _ I 77 INTERIOR WALL ASSEMBLY Cut Framing Studs J LI. FLOW CHART Frame Assembly 1 Cut Holes for Electrical Wires , t Install Electrical Wir_ I a ....... Move to Staging Racks ! •, Move to Wall AssemblyArea I Cut Wall Panel Wall Panel Installation I Cut out for Electrical Outlets 1 ! Move to 2hd. StagingRacks Move to Main Assembly Line t,.,,. T.... 1,..,;,-.., 7_ 79 Intcrior Wall Assemb_ SO: Raw wood stock is temporarily stored before being cut for use, $8: Drywall sheets are temporarily stored before being cut for use, $9: In-process storage for assembled O13: Framing studs are cut to length, O14: Studs are framed and electrical boxes are mounted. interior walls. ' O15: Drywall is cut to size. O16: Drywall to frame assembly is performed. O17: Exterior end wall assembly. T6: Raw framing studs are transported T7: Drywall sheets transported T8: Interior wall assemblies are transported to production line. T12: Exterior wall assemblies are transported to production line. D2: Delay due to imbalance in production rate between frame assembly. to workstation to workstation from main warehouse, from main warehouse, assembly and wall 8O 7:M:E CHART FOR INTERIOR WAI_ ASSEMBLY Ope_ ratio No.of_Opc'rato Frame Assembly: 3 - Cut studs to size - Assemble framing - Dr'ill holes for electrical wiring - Install electrical wiring - Move frame wall to staging racks, then to next workstation Attach Dry Wall to Framing: - Cut dry wall to size - Apply glue to framing - Install dry wall - Cut holes for electrical switches and boxes 8 min 2 7 rain - Move finished wall to stag/ng racks Move Interior Production Wall to Production Line Rate A_ Requirement:55 walls/shift @ 6 walls/unit Cycle Time: 8 min./wall Production Rate: (1 wall/8 rain. x 460 min./shift) = 57.5 walls/shift 81 INTER.IORJEXTER.IORWALL INSTALLATION AREA Interior/F_erior walls are moved from both wall assembly workstations using an overhead hoist (Figure 55), A caulking strip is first installed between the wall and the floor deck. The wall is held up until it is screwed and nailed to the floor deck by overhead crane (Figures 56 through 58), While connecting walls to the floor, a pneumatic clamp is used to pull wall assembly down while they are being nailed/screwed together (Figures 59 and 60), after which the clamp is removed, Exterior electrical wiring is installed (Figures 61 and 62), a metal plate is used to protect wiring in exterior wall studs from nails (Figure 63), Kitchen cabinets are also installed at this workstation, Labor Utflimticm There are four workers installing both interior and exterior walls, two installing the kitchen cabinets and two performing electrical wiring. Materia_HaadUag Interior and exterior walls are brought onto the line using overhead hoist system and lowered onto floor deck and installed. Cabinets, counters, and other items are hand carried and then installed. 83 8_ 85 t , ii 4 Figure 61, Electrical wiring lnstallatio_ Figure 63, r Ftgure 62. Metal plate used for wiring support, Electrical wiring installati(_n. 86 Inspection Inspection Equipment consists of manual checking to insure that walls are securely fastened. Dcscrip_on o Cutting: electric hand saws o Assembly: wall clamps and supports pneumatic I nailers and screw guns o Jigs/Fixtures: none o Materials Handling: 2 overhead crane hoists and ? Reconunendatiom It is recommended 1. 2. I that the following suggestions be investigated. Layout:None. Labor. o Manpower l possibly could be reduced to six: two for setting walls; two for installing bathrooms and kitchen cabinets; and two for electrical wiring, one inside and one outside. Required production rate must be considered. 3. Process: o Automatic fastening systems and self feeding screwdrivers (Figure 64) are available equipment ._. to reduce installation time. An example is shown in Figure 64. For additional equipment see Appendix A. of such listings 87 4. Materials o Handling: Utilize overhead storage & retrieval systems to transport cabinets and counters to the production line. , . Figure 64 88 INTERIOR / EXTERIOR FLOW WALL CHART Interior Wall Installation Exterior Wall Installation i i 1 Electrical Wires Installation [ Kitchen Cabinets Installation INSTALLATION 89 CHART FOR WAI/_ _OR/INTERIOR Operation INSTALLATION No. of Operators Total Time Exterior walls installation: - Move exterior wall from assembly area - Install wall (screw to floor deck) 2 45 min Interior walls installation: - Move interior wall from assembly area. - Install wall (screw to floor deck) 2 30 min Electrical wiring installation 2 30 min Kitchen cabinets installation 2 20 min operations are is 45 minutes. * Note: Interior and exterior wall installation simultaneously. Approximate time for combined operations performed pr0ducti0ra Rate Ana!ysjt Requirement:l/module @ 2/home Cycle Time: 45 min./installment Production Rate" (1 installment/45 rain. x 460 min./shift) - 10.2 installments/shift 9O ROOF FRAME ASSEMBLY WORKSTATION _oceu Description Ceiling drywall is brought trucks. to this workstation It is stored at the workstation Panels are stacked overhead. from the warehouse using forklift 4 and manually placed on a mobile pallet. on this mobile pallet which traverses the length of the table The ceiling of the roof system consists of 4'x12' gypsum board panels which are laid out face down on the worktable adjacent tO one another. Seams between panels are taped and trusses are set onto ceiling panels (Figure 65). A front perimeter frame is laid along the edge of the ceiling and nailed to the end of the truss (Figure 66). The frame is made of l'x 2' boards and is attached to the truss using pneumatics nail guns. A similar operation is used for the rear perimeter flame which is laid along back edge of the ceiling and nailed to the large end of the trusses. These frames are made on a worktable I Polyurethane foam is sprayed adjacent to the assembly deck. along the edge of truss bottom cord to cor,,nect trusses to paneling (Figures 67 and 68). The foam is instantly setting and with sufficient strength to preclude additional fasteners, and provides a 14vel ceiling surface. are installed for roof truss bracing. From this workstation, The following operations o HVAC ducts are also installed at this workstation. roof is lifted with a 4-ton hoist system and transported adjacent finishing workstation o (Figures Wallboard layers. to the 69 and 70). are performed Seams between wallboard 0 2'x 4' studs at this statioTa: are taped are finished with a dry,vail mud which is applied in two z t 91 o Cut holes for HVAC registers, lighting, etc. (Figure 71). A pneumatic jig saw is used for this purpose. The roof is then transported to the ceiling texture workstation finish is sprayed onto the ceiling (Figure 72). where the textured A mixer is located outside the building (Figure 73). HVAC registers are installed at this workstation (Figure 74). After the roof assembly is finished it is moved to the production line using a hoist (Figure 75). Labor Utilization Eight workers; one is responsible for bringing raw materials into the assembly area; four men work in assembly; and three at the finishing and pop corn areas. _,'_t_iltllT,!il_l_l]lllr'I_ " ,r, r,i....... In .... Jn..... '1'1 92 _3 94 ! t ! 95 MaterialsHandling Trusses and ceiling panels are brought to assembly station by forklifts. is staged outside the station. worktable. Truss stock Panels are stacked on a mobile pallet mounted Trusses are manually brought in and placed on panels. are cut and again manually brought to assembly table. over the Other frame materials After roof truss is assembled, an overhead hoist lifts it and transports it to the finishing station where it remains suspended during operation. Crane system then moves to the next station for spraying. After this, the roof truss/ceiling assembly is moved to the main assembly line for installation of walls. Impe_on No inspection is performed at this station. Equ/pmentI m'/ptton o Cutting: I radial arm saw I jig saw o Assembly: pneumatic nailers 2 airless sprayers I worktable o Jigs/Fixtures: o Materials none Handling: 1 overhead crane hoist 1 mobile pallet I scaffolding on top 96 Recommendations lt is recommended I, Layout: 2. Labor: o that the following suggestions be investigated. None. A balance primarily problem exists between to a lack of manpower bottleneck I and finishing for finishing creating during high production perform the finishing operations, assembly due a potential runs. Th,ough one person can he cannot keep pace with assembly. Also, too much time is used up walking back and forth for tool changes, hand washing, etc. The assembly station has a crew of four. It is recommended o that one worker be shifted to finishing in order to reduce the imbalance. 3. Process: o The assembly of the rooftruss system is good. o The insulation as well as the roof decking could be installed at this workstation, primarily because men can work more efficiently on the ground than at a height on a slanted roof. Additionally, risk of injury is reduced. handling One drawback and floor space problem. stored on the second level. 4. Materials is that this might create Handling: None. Currently a material these materials are 97 iiii i . ' ' . ,,',',,' _ I ii i ii I I I , i ....... _ - _ IIIIII ,-- - ,, " Z _ : i , ,.N 0 = IIIII Z: _ _ - --'±-'" . _. © _ a u'_ II I < 5_D © © + 98 + ROOF ASSEMBLY FLOW CHART Roof Truss Assembly ,1 C_fling Finishing t Pop Corn Spray 1+. Move to Main Assembly Line for Installation ' 99 100 Roof Frame Assembly:. S18: Trusses are temporarily 022: Finishing mud and ceiling texture materials 023: 1 x 12 board stock is cut to size for roof truss end framing. 024: Boards are glued together in layers of three in preparation 025: Truss assembly is performed. 026: Ceiling is taped and finished. 027: Ceiling is sprayed with popcorn coating. T14: Ceiling panels are brought from main warehouse. T15: Trusses and other framing materials are brought from storage. T16: Finished roof assembly is transported D3: Delay between assembly and finishing. staged before being used. are mixed. to production line. for assembly. 101 TIME CHART FOR ROOF FRAME ASSEMBLY Ol_ration No. of Operat0rs Bring Dry Wall Panels and Finished Trusses from Warehouse 1 Roof Assembly: - Layout dry wall - Assemble perimeter framing - Set trusses on dry wall 4 Total Time 30 min - Install Spray foam HVAC ducts - Move roof assembly to next workstation Roof Finishing: - Tape seams between I 1 30 rain 2 10 rain boards -- Apply drywall mud Cut holes for registers - Move roof to next workstation Spray "Popcorn" Texture Move Finishcd Roof Assembly to Production Line Production Rate Analysis Rcquirement:10/shift @ 1/module Cycle Time: 40 min./roof Production Rate: (1 roof/40 rain. x 460 min./shift) - 11.5 roofs/shift 102 ROOF INSTAIJ..ATION The roof truss assembly is transported lowered onto the shell (Figures 76). the top of the wall frame around by a chain hoist to the production the perimeter for insulation purposes (Figure 77 and to the exterior wall framing (Figures 79 and 80). framing is screwed 1o the roof borders where fascia is later installed (Figure 81). A metal strap is then attached 82). An overview of the finished roof installed is shown in Figure 83. to tie the roof system to the exterior walls (Figure Rock wool insulation material is applied by using a high pressure 84 and 85). The roof decking is laid and fastened to truss assembly. for the roof decking supposed is oriented on a overhead mounted Decking is attached Measurements line and Before it is secured, a caulking strip is applied to 78). The roof assembly is then fastened Additional AREA strand board. The decking blower (Figures The paneling used is stored in containers track which extends across the work area (Figure 86). using pneumatic nailers. Metal clips are utilized between panels. are made using a tape to mark where cuts are to be made on the decking. These cuts are made by a powered hand saw (Figure 87). Then the fascia is installed (Figure 88). After installing the roof decking, a layer of black asphaltic sealant is applied at all edges of the roof decking (Figure 89). A waterproofing over the roof (Figure 90). Adjustments and alignments are performed material around the edges is cut with a knife. roof decking. Shingles are then placed cover of roofing paper is rolled manually. Excess The roofing paper is then stapled to the _ on top of this cover and stapled (Figure 91). ,, 103 104 105 lp _r .... ,_n I06 107 Labor Utfliza'don Total described man power utilized in this working area is 11, duties of workers are in the time chart for roof installation. Materi Hdling Roof truss assembly is brought to the line using the hoist system and lowered onto the walls. Roof decking is stored in overhead pallets and manually placed onto the roof assembly. Shingles, roof paper, and fascia are also stored above and manually retrieved for use. A Inspection Inspection is performed to ensure that the roof is properly assembled. t Equipment Descril:n/on o Cutting: o 2 electric hand saws Assembly: 1 air compressed blower and pneumatic I guns o Jigs/Fixtures: o Materials none Handling: 1 overhead hoist crane I scaffolding 2 overhead containers v , nail and screw 108 Recommendations 1. Layout: None. 2. Labor: None, 3. Process: o Investigate the possibility of eliminating the roof dc,"_,,_g installation from this station_ o Only roof attachment to the walls, fascia installation, paper and shingles need to be installed at this point. lead to a reduction o Automatic used. 4. Materials o This could also in manpower. framing nailers exist that are faster than pneumatics Installation equipment waterproofing time could be decreased. now For a listing of available see Appendix A. / Handling: Automatic storage and handling equipments are available such as materials handling bridges (see Figure 92 that can be used for placing roof panels rather than performing the risk of injury and hazardous • I_igl,ll'_ , 92 it manually. This could reduce operations. New M.ler/_l ll.ndlLn| Brtdgt Is ¢tmtem. buUl Lo nt ?'o_ needs. H_.7 dul 7 steel con. struct_n wtlh _m'bb)e speed 1/2 ILP. drh't for 0.150 l_M frm'el speed. Tlu'et n_ to _ dc_n_ for forkl_'L Auto rtturn Id_r mat_rl,ml IJ laid out. DesJl[ned-,_d buLIt tOlic¢otzuzjoClale )'our malel_itL _u[U¥ edIpt. abb to ea_tLBg Triad Li_ex. 109 IlO ROOF INSTALLATION FLOW CHART Roof Installation I Apply Roof Insulation l Roof Decking Installation I Fascia Installation __ ___ Roofing Paper Installation ShingJes Installation ..... ' 111 112 Roof Imtsllsdon-' $27: Roof deck.ing, tar paper, shingles stock, 05: Roof installation (_ct up), 06: Roof insulation application. O7: Roof decking installation. O8: Fascia installation. 09: Tar paper installation. O10: Shingles installation. 3"21: Finished roof is transported T22: ._sembly T23: Roof decking is transported T24: Assembly is moved to next workstation to the roof installation area. is moved to next workstation (Roof insulation/top/fascia). from overhead container to installation area. (Tar paper installation/shingles). 3"?.5: Tar paper and shingles are moved to installation area. 113 TIME CHART FOR ROOF INSTAIX_TION O__ration No. of Operators Install Finished Roof Assembly 3 50 rain Blow-in Insulation 1 25 rain Install Roof Decking and Fascia 2 45 rain Install Roofing Paper 2 15 rain Install Shingles 2 50 rain Inspection 1 Move Unit to Next Workstation Move Unit to Next Workstation Roof Installation Production An_lysi_ Requirement: 10 roof/shift @ 1 roof/unit Cycle Time:Rate: 50 min./installment Production (1 installment/50 rain. x 460 min./shift) = 9.2 installments/shift * • Production rate is less than requirements. More detail time study is needed in this area, first bottleneck may occur at this point (Finished roof frame installation). 114 EXTERIOR Proccu FINISHING A.RE,A Descr/prion Outside insulation is installed on exterior installation of Extruded Polyurethane wall frame (Figure 93). Insulation walls and sidings. This includes the boards which are stapled to the exterior The exterior siding is attached and stapled to the exterior wall insulation board (Figures 94 and 95). Sidings are hand cut to fit smaller spaces, such as between windows and doors. Window and door frames are installed in exterior walls (Figures 96 through 99). A weather strip is also used to provide infiltration barrier. Windows and doors are then installed in a clam shell fashion. Once siding, windows, and doors are installed, the exterior electrical wiring is connected, such as lights, switches, and electrical boxes. A plastic cover is used to protect the open side of the trailer (Figure 100). Labor Utilization There are four workers installing the insulation panels and the siding (one for ends and two for sides). one person For the window and door installations there are five operators. is respons_le for installing workers installing the outside lighting. the plastic cover. There Also are two additional llb 3 117 ill m_ b 119 Materials Handling Windows and doors are brought from a small storage area to a temporary near this workstation. and installed. staging When needed for installation, they are manually brought to station Vinyl siding and soffits are inhouse stored, then brought to a small cut station for odd size pieces. These materials are then taken to the production line to be installed. Inspection No inspection is performed at this station. I F_xtuipment Dcscr/ption / o Cutting: 1 radial arm saw o Assembly: pneumatic nail and screw guns i o o Jigs/Fixtures: none Materials Handling: none Reeommen_tio_ lt is recommended that the following suggestions be investigated. 1. Layout: None. Z Labor: None. 3. Process: None. 4. Materials o Handling: Utilize storage carts to transport materials to the production the storage cart shown in Figure 101. such as 120 o Transport carts could be used for storing and transporting and doors to the production in Figure 102. line. An example of such carts is shown This would reduce unnecessary time for retrieving materials. I I I I Frame Storage Can Profile Transfer C4ui ,,' Figure 101 windows Figure 102 121 EXTERIOR FINISHING InsulationPanel _ ,,, V"Installation ,, 1 i F;,amc I i Installation .- _I I Outside ug_ting Installation l ' 1 kns_on t _.__._ FLOW CHART Siding Installation , ,., Window/ Door Installation 122 CHART FOR EXTER/OR FINISHING TIME Atta :h Panel Insulation 1 10 min Install Siding: - End - Side 1 2 50 min 60 min Install Windows/Doors 5 25 min Install Outside Lighting 2 20 min Attach Plastic Cover 1 10 min * Note: Some of this operation may not be finished in one workstation, for example siding installation will be completed in two workstation. Estimated longest time in one work station is 45 minutes. Production Rate Analysis Requirement: 10/shift @ 1/module Cycle Time: 45 min./assembly Production Rate: (l assembly/45 min. x 460 min./shift) = 10.2 assemblies/shift 123 INTERIOR [NSTAI/._TIONNINISHING AREA Process I_scziption Interior installations consist of the following operations: o Bathroom and kitchen counters installation (Figures 103 through 113). o Living room cabinets (Figures o Bedroom Dry wall boards production 114 and 115). closets. are cut to size for interior wall panels, line where they are stapled to the wall frame (Figure then moved to the 116). Electrical wiring is installed inside the house which includes electrical switches and boxes. Scaling of walls and cabinets is performed to the inspection between I area. A molding strip is installed to cover exposed edges or seams walls and roof (Figure 117). workstation (Figures , installed. before the house is cleaned and moved 118 and 119). Also curtains/mini-blinds Kitchen appliances There is a final inspection, usually visual, performed operations. Inspection may be installed in this and interior lighting is also by a supervisor of the finished may include electrical testing for switches, connections, lighting, etc. (Figure 120). Labor UU2imtion Operations finishing. and duties of workers are described in the time chart for interior ' 124 125 126 O 127 128 0 0 129 130 O °,.. ,D ..=, =d 131 = l 132 Materials Handling Other cabinets .hre manually brought to the line for installation from an in-process storage area. Trim for windows, doors, baseboard, area to be installed. etc. is brought from an outside storage Curtains, blinds, etc. are manually brought from an in-house storage area to workstation. Finally, appliances are transponed to the line using hand carts. J Impectitm No inspection is performed Equipment at this station. Description o Cutting: 1 radial arm saw o Assembly: Basic hand tools pneumatic nailers screw guns o Jigs/Fixtures: o Materials none Handling: manual from an in-house storage area 133 INTERIOR INSTALLATION/FINISHING FLOW CHART Bath/ Kitchen Counters Installation I CutWall Panel I WallPanel Installation Conncc'xions Outlets / I.... Electrical Wire 1, I Cletmtng t I 1 Inspection ........ Kitchen Appliances / fagoting Installation l .... ,i, "I Elccuical Testing 1 Fmlfl Impc_ion 135 Finishing and Fired Impeetion: I.ntcrior/Ea'_rior i I I $7: Window and door stock. $8: Kitchen appliance $26: Exterior siding and soffits are stocked. Ol1: Roof top is assembled O12: Exterior siding, windows, doors, and aluminum soffits are installed. O13: Interior O14: Appliances I1: Final testing and inspection are conducted. T16: Siding is brought in for installation.• TI?: Window and door stock is transported T18: Kitchen appliances T19: Finished stock. and finished, trim, lighting, and other accessories are installed. are installed. are transported house is transported from storage to production to production out of production line. line. and into temporary storage. 136 (, TIME CHART FOR INTERIOR FINISHING Counters Installation 3 40 min Closet/Cabinets Installati'on 3 45 min Wall Panel Installation 2 30 min Wiring Connections 2 35 min Cleaning 2 20 min Kitchen Appliances/Lighting Installation 4 30 min Electrical Testing/ Inspection 3 ° Note: Most of these operations are performed simultaneously, estimated total time for Interior Finishing is 45 minutes. Rroduction Rate A,naly_js Requirement: 10/shift @ 1/module Cycle Time: 45 min./assembly Production Rate: (1 assembly/45 min. x 460 min./shift) = 10.2 assemblies/shift 137 i WORKSTATION SUMMARY FOR INSPECTION Matcrial_ Handling No handling involved other than managing test equipment After inspection is completed, house is transported which is done manually. out and placed in finished storage (Figures 121 and 122). Inspection i A final inspection is performed to ensure that components are securely assembled and installed, and house is checked for any missing or out of' specification Electrical testing is performed elements. to ensure that all lighting, plumbing, and appliances working properly. I Equipment I_ripfion Inspection is visual, and testing is done with electrical diagnostic equipment. are 138 Figure ]20, Inspection marks for electrical testing, 1 ]39 OTHF2_ PO_ OPPOR_ IMPRO_F The following recommendations should be investigated. Centralize Cutting o Centralize cutting for all structural components as well as gypsum board and plywood paneling. Every workstation has its own cutting , section. Assemblers often have to perform their own cutting which slows down production time. The area created by the removal of chassis assembly could be utilized for this operation. The crew would consist of 3 to 4 workers suoplied from those taken off other o processes that are over supplied. The use of computerized sawing machinery capable of precision cutting at substantially higher cut rates could prove beneficial when considering production volume. Figure 123 shows an example of automated computer-controlled cutting systems. See Appendix A for additional listings of available cutting machinery. AUTO OMNI ...... The Ultimate Component Saw! • • The Industry'sOnly AutomatedComputer-ControlledCuttingSystem • Cuttinglistsaredownloade_fromyourtn.housecom. purerdirectlyto the saw'scontrolconsoleand stored until you are readyto producethe component • The desired componentappears on the IBM PC screenat your command Fig are • 15 to 20 seconclslater you Are cutting luml:_r ... withoutrunninglast pieces • InOustr7leaderslike Truswal,On.Line Data, Bemax andHyOro.Aircannowprovidesoflwareto download directlyto the Auto Omni 140 Reduce Inventory o Warehouse always contains substantial amounts of stock. The holding costs could be substantial for both materials Inventory control procedures and finished products. such as materials requirements planning, could be adopted to help optimize desired inventories. o o Developing a structured system will aid in improved scheduling. If excess inventory does exist as suspected. Schedule and purchase materials only to fill customer change can only be considered after determining planning and orders. This what the, stock turnover rate is. Improve Material Handling System o Overhead cranes work very well for transport of heavy materials such as building components, of manual but there is still a large amount handling of heavy items, which increases likelihood of injury. o The use of small conveyors_ vertical roller cans, automatic conveyors, pallet tables, and automatic 124 for Appendix example) should A has additional be lumber stackers considered for listing of available both lifts and (see Figure production. materials handling equipment. MAK-STACKER stacks lumber on the off-feed side of compon_.nt 141 Provide More Im1_on o Very little inspection is performed products. other than inspection of finished More stringent criteria of selection should be used for raw material acceptance. Inspection of cuts, joints, pre_esses can lead to a higher degree of quality for the overall product. Jigs and F_s o Currently the use of these tools is scarce. Only for truss fabrication are they employed extensively. For assemblies such as interior/exterior wall frames and floor frames, workers lay them out i from memory and by sheer repetition this operation. have gotten very proficient at It is doubtful that jig_ and f'_tures could substantially improve the process over the current methods used. o This is true as long as skilled workers are performing the operations, but when new people must be trained the operation is slowed considerably, making jigs a more attractive alternative. Additionally, the quality of the product would be improved. o Adopting the use of jigs and effectively eliminate operations fixtures (see Figur_ the need for skilled workers to perform these and thus reduce labor costs. It is believed that these tools can offset the loss of production time caused by the use of less skilled people. . /" ii F_ 125) would . i , • 125 STEELTABLE JIGGINGHARDWARE WOODTOP JIGGINGHARDWARE • 142 o They could also be used in cutting operations now used for measuring. which would save time Additionally, more consistent and precise cuts would be made improving quality. o Layout tables with jigs are commercially available. for listings of available o Only consideration See Appendix A equipment. would be the trade off between labor savings and the cost of building the jigs. o Another alternative configurations that would be to develop templates are used. making jigs and fmures, for the various This would be less expensive as well as ease handling efforts. than 143 I APPENDIX A I Listings of Available F_._uipmcnt / LIST OF POTENTIAL EQU]PMENT I. Clary Multi-Purpose 2. AutoOmni 3. Whirlwind Cut-OFF 4. Linear and Miter Notching Saws (Sampson 5. Cut-o ff Saws (Sampson 6. Speed Shop 'A' turntable 7. Timber Mill 6-20C muti-hcad 8. Timber Mill 5-20 High volume cutting system (Speed Cut Inc.) 9. TC-8 Turntable 10, Mobile Speed Builder mobile cutting station (Speed Cut Inc.) 11. Mobile Framer 12. Mobile Little Framer 13. Ma"/'ek Easy-Set component Component Cutter (Clary Corp.) cutting system (Engineering Programmable Services Co,) Saw machine (Whirlwind Inc.) Corp.) Corp.) cutting system (Speed Cut Inc.) W cutting system (Speed Cut Inc,) cutting system (Speed Cut Inc.) (Speed Cut Inc,) (Speed Cut Inc.) saw machinery (Gang Nail Systems Inc.) II ' $peed-C:}}t,Turn[able Cutting SystemTC$.8 The Turntable Cutting System Model TC$-8, Speed Cut Inc., features a 22' carbide.tipped blade with an 8_'depth of cut designed especially for the log home builder. Easy angle selection and depth ofcut capacity allow the builder to quickly and accurately cut gable end components, large open beam ceiling framing timbers or other members. Support components have been specially modified to handle heavier log and timber frame members. 146 _MiTek EASY'SET TM Compgnent Saw i i i i i i ii i the most advanced safer), and guarding systems available in the industry, with both cable and push button shut-offs, air brakes, expanded guarding and manual backups. EASY.SET will be sold through Gang-Nail Systems Inc., Miami FL, (John Hurder, 288-4264 or circle No. 98; and Hydro-Air Engineering (800) Inc., St. Louis, MO, (Ken KAasing, (800) 325-8075 i 147 A new line of competitive truss machines has been introduced _yCommercial Machinery Fabricators Inc., including this gantry r_lus roller press with 15 hp drive performance. Also in the line , _.re layout tables with wood or steel tops, jigs, liftouts, conveyors. and truss stackers. ] 48 MAK-STACKER stacks lumber on the off-feed side of comoone, nt cutters replacing off-bearers. ,: -' nc • .. 149 urnkey Production ResponsibiJJty for ac.hie,,'_',g productiongoals Technology is sharedbe. tween theproduct manufacturer andthemachinerysuppler.Both of thesepartiesmustbefamiliar withthe productandtheequipmeritandjoinUyworktogether to developa "plantlayout"that ' utitizes avaJ]ab]e floor spaceand manpower so as to ma._drr_ze t efficientmaterial flow, ltachieve isthen production volumeand theresponsibilityot thesupplier I andequipment asweilasthe necessarytr_ andstart'up as. sistance to themanufacturer, Theendresultis a "turnkey" m:'mulacturing pro_arn that' takes into account bothcurrent i andfuturerequirements. Programs_ CUTTING • SingleCut.OffSaws • Double Cut.OffSaws • Double Miter/No[chlng Saws • Aulomatic Feedand Cut,Off Saws FABRICATION • Hydraulic PunchPr_ " EndMills • Copy Route.rs * Tool& DieWork " DnUUnJ_ " Measuring Gaug_ ' M ,_fiproc_smg , * SawBlades ,, , .... ASSEMBLY • Vinyl Welders • ComerCrimpers .. •• Weld Ai._mbly Tables Cleaning Machinery • HandTools i HANDLING , *Tables • Carts ENT , •* Racks Roller= "TransferUni_ • TestUniL_ ,MENT . , ,MENT , , 150 t G i i I rrusWal Systems' "C" Clamp Truss Assembler _ i The Gantry "C" Clamp truss as;embler, TrusWal Systems Corp., (not )ietured) allows simultaneous assembIy }f several different truss styles v_ithout free consuming set-ups. The machine is :asiIy ex-panded as production grows by Ldding additional fixtures or complete _ as required. The assembler can also _e eonf]gured for or later converted to nagnetic h61d.do_s. i iiii i 151 [ Roof or Floor Trusses Anytime with the Jager MINI-8 I 1[ • Conven]enr,_: The MINI-S simply stands on lhc floor wi_h no rails or _racks, nor are special foundations [ required. Thismeans the MINI.S can be moved and installed wJlhout ] special site preparation, • Versatility. The solid sleel fable accommodales magnelic or bolt-on jig ] hardware which makes set up easy and fast for special trusses such as gable ends, gh'ders, hip cottages and l jacks. • Prod_ctiv]_-: Ifshortrunsofunusual _rasses slows )'our production, the MINI.S will _lJm your production foremanintoa p_'oduclion genius. • Ens)'to Opernte:No special skilB required. Train.ing is miaimal. Simple hydraulic hand controls and rider platform for operator to stand on minimizes operalor fatigue. • Floor :I'russe_: without adjustments _he hIINI-8 can be converted into building 4x2 floor tn._ses. dager Industries Inc. [ • a__ _ Ianufacturlng Division _,,_v ,_uLLu._u_u o.)v., <.algarT, Aiberta, Canada T2V 2X4 Telephone (403) 259-0773 Telex 03-824666 ,. The $enco/Carlson Deck.ing Table, Sen__ets-aad Carlson Systems, is desizned to handle largerand heaviermaterials.Th_ tablecIa_ ,_,squares and fastenslumber from 2x3 to 2xl2 forflooror deck modules up to l6_×16,.JThe tool_ carriaoeisequipped vdth genco SN4 pneumatic nailersand featur_.$..full s.afety controlsand an adjustable fastenerpattern.RetractablejoistIocatorson 16" and 24" centers can handle most d_esi_ns. Hardened steelplate.clamppostsprovidevertical and horizontalclamping to ensure square,tight-fitting floormodules. Fixedpostsare used for2x3 to 2xG construc. ti'on; ex'_tended posts are used for joist material up to 2x12, T_Jn center supports speed the loading of hea_ 3' joists anc_ the deck removal system includes air powered lift and manual ro]loft. Deck ]enghts of over 16' are available in 1' increments up to any prec. tical size. II i Heavy-Duty 24" Dia. ROLLER PRESS ,,, Only $15,250! , ,. , ',', ,,., i ' .. " Also--Full Set of Axles and 16 Bogie Wheels for Any Gantry Unit on!FS1,250 (A $1,600 Value). _ . : J ' J ..... Commercial Machinery offers the component industry a complete linet ' ' of machine !ools and equipment a prices consldered to be the MOST COMPETITIVE IN THE BUSINESS! Check Us Out For: : • Gantry Plus RollerPresseswith 15 h.p. DrivePerformance I • • • • Layout Tables With Wood or Steel Tops--PlusJigs Liftouts& Conveyors TrussStackers No 'Extras' To Buy--Ali Equipment CompletewithAir & ElectricLines& Hardware e CALL TODAY--Ask for Ed Joseph Commercial Machinery. Fabricators, Inc. 3530dosetteLane, Lansing,Ml 48906 Phone: 517-37,+.6845 !11 _,,,,,_,,_ ......._l .., .. • . ' You Need MUSCLE ONLY TRIAD HAS IT. _ A TRIAD ! II CAN GIVE YOU... THE HEAVY DUTY "__.,_ __/'_ __ WALL PANEL MACHINERY " 0 We have the fo//ow/ng machinery avai/ab/e: • • • • Framing Tables Squaring Tables Sheathing Tables Handle Bar Routers ® • • • • Sub-Component Machine3 • Panel Lift (PL 1000) • Wind Brace Saws YOUR MACHINE IS TAILOR-MADE MaterTal Handling Material Bridges Router Bridges Stud Stitchers Carts • Screw Bridges • Complete Wall Builders • Complete Floor Builders FOR YOUR SPECIFIC PLANT _ J P.O. Box 130 CALL TODAY 68810 PH' (308)384-1780 ,_,da, NE Merr_ck Machine Co. _ FAX: (308) 384-1657 155 _tting, ,, , ........... Cut-Off Saws Belowisa representation ofcommonly usedsawsfor various angular cu_ applications. ........ 156 BOB THOMPSON checks over compuler controls and wiz. ing pane_ for Cardinal's new floor extruder machine which turns out a 12'X24' framed and shealhed deck in seven minutes. Improves Quality, PADDLE WHEEL mechanism drops cross joists into posi. lion To be fed between perimeser joisls at the head end of unis. Nose push bu_lonconlrols for one.manoperation. Saves Nails & Adhesive: . ", .. Cardinal's New Floor Deck Extruder Cuts Time 88 % A NEW AUTO.kt-XTED FLOOR DECK extruder machine al Cardinal ],_dus_ries, Reynold_burg, OH, has slashed 12'X24' deck assembly time frum 60 to only seven man-minutes, an88_ improvement, DeSil_ed md developed for Cardin_'s Broad Street plant, the machiae m-lptoves cluaIi_y by eliminating the Fosmbfli_y of missed nails, saves aboaI $3 per deck on nail coals and applies exact]y the fig.ht amount of c:mmruction adhesive with no waste, Bob Thompson, corporate manager of" m_ufac_uring en_neering for Cardm_l, explains tha_ lhc machine, e_neered and fabricated ata cost of z.p_oxima'tely5500,000, is one of m_ firs: major accomplishments of Ca_ina.I's new cos reduction team headed by Ron Guyer, vice president manufacturing, and various Cardinal engineers. The machine, is approximal,ly 26' wide. md 70' }ong. In operation it feeds in sm_e ot double rim joists, handles the framing na.fling, aulomatic_y applies adhesive on the top edges oi ',he cross and lon._udinal members, lib'ts and poshions B'Xl2' sheets oi" waferboard decking, then precisely, naris the decking to the cross and perimeter joists, Builds Floor in 7 Minutes "This machine wfl.l fabricate our s_andzrd 12'X24' floor deck for our modular units in about seven mm. utes,"says Bob. "ThaT.compare: lo our previous method of two men using pneumatic na_ers to assemble a FOL'R NAILS are fed through subes and hydraulically dJ'_e_ through double perimelet joisss inlo cross joists, No_r P_ckinB mechanisms which hold joists m squared positk_a. II .... floor deck in a jig which required 60 man minutes." Bob explains that _he machine uses custom made nails, about 5¼" long. The bulk naris are fed by a hopper tray (which cyr.Jes up md down), through four plastic tubes into the driving mechanism. Similar to the old Morgan nailing machine, _he four nails are hydraulJcakiy pushed through lhc perimeler joists inlo each cross member. Whi_e missed nails ate extremely tare, if one should be missed, the computer control immediately advises ;he operalor with a signal so a correction can be made. "Even thou_ we areusingcustom. made nails," says Bob, "we figure we are saving about S3 on nzLls per deck SENSORS detecs positions of all joist edltesandeon_ruc. lion adhesive bead is applied _o top edges of al]members acdeck move¢thrnu_b the m_,chine. ' II II|II II 157 i ............... 158 MODEL FN FRAME NAILER |. I. ,1' . . .,:._q_"_°." :'// nr The Triad Frame Nailer is a rugged machine designed to provide fast, efficient, reliable assembly. The machine eliminates mis.alignment of parts and use of dangerous hand tools. Ali air systems have adjustable air cushions where needed to protect the equipment and the product. Mufflered exhaust ports reduce noise and add to general safety. Guaranteed consistancy of prod,uct even with mixed runs. Machine adapts quickly to produce todays framestyles from clad frames to sun roofs. Ali components are precision machined for Ior, ger life, reliablea¢cu-racy and the finest quality available. Solid steel tool bar provides a rigid straight line with each tool holder individually mounted on adjustable castings. The machine requires only periodic lubrication and adjustments;a'slstated in the maintenance manual. Oil cups and grease fittings are located for easy a¢cessibilit_,." "--,. .... ":.:...-. -..._._... _,_ U L,_',t-_-___"_ r'- IVI I;;) L. T I_1/'_1 L lP...I"j 159 NINDOWS 3RICK NOLD i_,, DOORS _ BLIND STOP 160 TRIAD'S P = - A LLET TA BLE Practical, versatile and rugged, yet priced to make modest runs as pro- flt,bl_ as full line production, The Triad Pallet Table is designed for low volume "in house" production as well as multiple, unit high speed, high votume:. commercial production. Comes wlth quick disconnect.,alr outlet for pneumatic .nailer or stapler. Deluxe model is equipped with ASME air storage t_,nk, manifold, air regulator and safety valve. The Triad PallOurTable makes quality pallets in far less time than other methr_ds. IP' := " 161 At Shelter Systems In New Jersey: From 100 To I80 Set-ups Per Shft From 3,000 To 5,000 Cut P/eces Per Shft uto=Omni Truly the Ultimate Component Saw! Auto-Cmni Component Cutter above is similar to the machine instai'_edat the Shelter Systems New Jersey plant. Saw's performance at SSG has led to an order for eight more ... believed to be the first S1 million equipment order in the component industry. Check YourAdvantages: • • • • Only Fully Automated Cutter Only Computer-Controlled Set-Ups Computer Screen At Sawyer's Elbow Shows The Part, Keeps The Count Robotically Controlled Arms Position Blades To 1/1000th Of An Inch • Set-Ups In 10 To 20 Seconds • Why not join the growing list of industry leaders who have the Auto-Cmni-- Shelter Systems; Villaume; Midwest Manufacturing; AII-Fab; Load-Star', Thu'rndale Roof Systems; Kent Truss; and others. CALL TODAY Engineering Services P.O. Box 696 Rochester, MN 55903 Company (507) 286-9209 or (507)288-4741 II .... "............... 162 30 Tons Of Lumber At Your Sawyer's Fingertips WITI-][][?q 30 SECONDS! ,,o ,. , ...,, ,4 * "_.' ."i: ' .':_',-'.' Pic.tm'edaboveisthe 50' modelof theEXPEDITER lumberhandling system, ltbrings aselection oflumber lengths fight tothesa_.,er inastittle as30seconds from its mostremotebay.ltfrees up theforklift towork moretimeintheplant ortheyardonother duties, \Vhat's moreimportant, theE,'_EDITER can increase thecomponent sa_Vs productivity byasmuchas 25%. Thereaxethree models Iochoose from: 30', _' and 50'diameter. TheEX 50modelhasseven baysandwill holdlumberupto2# long. TheF_.X 40modelalso has - Call .'.':',.d,#. ' ' DIT A seven bays _d willhold lumber up to 14' long, The EX 30hassevenbaysandholdslumberfora 12'websaw. Withthehydraulically poweredrollers there isno track toclogsostickers orcldps can't jamthemachine, No slab isnecessm'y since theExpediter canbeinstalled onanysurface. The EXPEDITER ksthemostadvancedmaterial handling system ofits 'kind available. Learnhowyour plant cangettheMOST outof),our componentsaw, Call ustodayand fredoutwhy we cd.littheEXPEDITER,A videotape isavailable, L • i TOLL-FREE...... " ',;." I II i| i' i _'l ,! _,, II -i, -_ i li HORIZON hfanulaClurv.r rat Jhw E_l_eailer 877 .=.[J,=__ _ _ iiii. ii " SIal i _l i ii i1__ 'qF ] 70] DowellRoad,Grant$ Pass,Oregon97527 (503) 479-5264 i I I , -- _ I Ilmll .......... __l 163 i , Automatic Lumber Stacker LEF'_,Mid.AtlanticMachine'snewautomatic lumberstacker,whichstacksupto 50pieces per minute from your ¢omponen_saw, reducingmanpowerneedsandeliminating a heavysawdustexposurejob, t Automatic Floor TrussStacker Mld-Atla'ntl¢ Machine's new floortrussstacker,whichstacks one or two high upto 40' long, in _e¢45 seconds. _antic is the expert's choice for plant _zion. The new automatic floor truss stacker a_mnatic lumber _cker join our other proven Dr-sa_g, high-produ_on equipment: 'ha_ssmaker Automated roller gantry roof -_m with 18" or 24" diameter gantry heads, .u_Floor Tmssmaker RolJer gantry fl_r .system :unng na_ a 24" d_ameter depth set-up. embedment roll and Roof Truss Stacker Automatic handling trusses up to 80' in, length. _s help increase your producuvity and reduce ' macrpowsr requirements, 0 Mid-Atlantic Machine Company, Inc. AUTOMATION SPECIALISTS P.O.BOX 585 EDENTON, NC 27932 919-482,2178 164 OURFINESTEFFORT... THECLARYMASTER f HIIv_.plUDi Tubull Steel _O#llITI_0tIO#I t Newlrlolllo_ Mir.hlned _llntd Hllld k_,ch_n/m / H,lei_#.du_# Mllldll _onvlyil t 11" Slid Oullirlg CIplbltlt# t NII Dillln Elly,lll.,rild Li_tth Tpr.lll l CIJ1_li_ |oMl_m Cholll In One Pill ! OU_I Vlbmllnl ttiiull tyitlm (Full Pin_) The Master handles 4" x 2" through 2"x 12" materials as standard. Don't miss seeing the new Clary Master in action... ORDEROUR NEW VIDEO TODAY. For complete Information contact: I __l___/_V __ _'_L.'_4% _ ----,,_,_,_ --CLAI::IY CC:IP:II=C:I::IATIQN .... _,,,-_--: Re!!__b!!!tvIn Act!on = _;;_;-.A;__=_ First Name in American Made Component Cutters 1801 South Great Southwest Parkway • Grand Prairie, Texas 75051 800-527-6621 or 214-660-3940 t lowonld Cimlpl Wit FineTurll _Jjutimlnt _65 Transfer and 3_rage Carts i :rarneStorageCart . 0 '_", , Insulatec_ GlassGlazingUnit , -_ Profile Trau'_sfer C_ tVoolPileCart 166 , • _ • o o o 168 Triad's New Hea_7 Duty Framing Table _-ith Stud Stilchcr Bridge is custom.built from I2' to 80' to fit your needs. Adjusts from 3'-6" to I0.'3" for different _'all heights. Cast iron stud locating flippers 16" and 24" O.C. Con. tinuous squaring 1lp full length of the L'_bIe. I]_eaD_duty steel rollers with roller bearings used to convey _'alls off'. Simple push button controls operate tabIe and rolIcr conlrol sys. ' _em. Tape _rack for laying in window and door openings. Table rails accommodate SItld : Stitcher. ....... $ 169 1 New _faterial Handling Bridge is custombuilt to fit your needs. Hea_T duty steel construction with variable speed I/2 I]7.P. DC drive for 0.60 FPM travel speed. Three main support beams 4' long equally spaced 3" high to allow clearance for forklift. Auto return after material is laid out. Designed and built lo accommodate your materinl _:_;_,, _,Jnnf. able to existing Triad lines. I Panel Stapler by Triad helps you control today's construction costs by building quality, square walls vdth fewer people. Be assured of accurate nail and staple placement lo codes. Latest stade-of.the.art Laser Pointer for indicating staple and nail locations, aIong vdth programmable conirollers lhat control lhe l'unclions of one bridge. Space titre tools used to fasten top and bottom plate. One man operation with a simple control box make for high production. 170 171 1 q 172 APPENDIX B I.ht of P_xlu/pmcnt Manufactumn 173 LIST OF MA.NL_ACIXJRER$ th'oducts Company ADVANCED AUTOMATION Enterprise Corp. Towers, 1 Corporate Drive, SUite 404 Shelton, CT 06484 (203) 925-0332 Industrial Engineering/Manufacturing Consultants ALPHA & OMEGA INTEGRATED CONTROL SYSTEMS, INC. 3244 Washington Rd. Suite 240 McMurray, PA 15317 (412) 941-3205 (Steve Latterrnan) Layout Equipment & Systemization ASSEMBLY AUTOMATION 1858-T Business Center Dr. Duane, CA 91010 (818) 303-2777 Automatic Screw Feeding and Driving Systems AUTOMATIC SALES, INC. P.O. Box 411 Col., MO. 65205 INC. Truss & Wall Panel Trailers I 1-(800)333-8758 , BLAN-KNOX EQUIPMENT P.O. Box 11450-T Pittsburgh, PA 15238 1-(800) _3-2000 Material Handling Lifting Equipment BUCK'S MACHINERY, Star Route 63 Box 95 Guntersville, AL 35976 (205) 582-2133 Machine Tools Lathes Mills Saws, etc. INC. CLARY CORP. 1801 S. Great S.W. Pkwy. Franklin Park, IL 60131-2176 O SYSTEMS 1-(800) 527-6621 Componet Cutter 174 CONS'FRUCTION AUTOMATION EQUIPMENT CO. 727 Deep Valley Dr. Palos Verdes, CA 90274 Cutting Machinery Material Handling Equipment Assembly Tools CYBERMATION, INC. 5457 Aerospace Rd. Roanoke, VA 24014 (703) 982-2641 Mobile Robot Systems Material Handling Tool Changes Inventory Retrieval etc. DUO FAST CORP. 3702 River Rd. Franklin Park, IL 60131-2176 1-800-752-5207 Self-Feeding Screwdrivers GANG-NAIL SYSTEMS, INC. P.O. Box 59-2037 AMF Miami, FL 33159-2037 1-800-752-5207 Truss Machines GENERAL AUTOMATION 8585.T Commerce Ave. San Diego, CA 92121 (619) 578-3033 . Assembly Machines, Parts Handlings Inspection Systems, Pnuematic Tools CO. Non-Automated HERCULES MANUFACrU_NG P.O. Box 263269 Escondido, CA HIAB GRAVES & LOODERS, 34 Blevins Dr., Suite 10 New Castle, DE 19720 (302) 328-5100 Pick & Place Lifting Equipment INC. Cranes & Loading Equipment JOGER INDUSTRIES, INC. 8710 Horton Rd. S.W. Calgary, Alberto, CANADA T2V 2X4 (403) 9_54-0773 Roof & Floor Truss Machinery JOHN W. PORTER, INC. 23 N. Bluff Rd. Chesapeake City, MD 21915 (310) 885-5233 Automated Construction Machinery; Trusses, Panels Doors, Windows, etc. 175 KAL-TECH CORP, 35-T James Way Eatontown, NJ 07724 (201) 389-_00 Custom Automated KALTENBACH, INC. 6775 Inwood Dr. P.O. Box 1629 Columbus, IN 47202 (812) 342-4471 Cutting Equipment KANT-SAG (UNITED STEEL 703 Rodgers Dr, Montgomery, bAN 56069 1.800-KANT-SAG PRODUCTS MARK V TOOL CORP. 36 Race St. Bristol, CT 06010 (203) 582-7437 MERRICK MACHINE P.O. Box 130 Alda, NB 68810 (308) 384-1780 CO.) Equipment Truss Hangers Jigs, Fixtures Tools, CNC, etc. CO. . Sub Assembly Nailers, Pallet Tables, Automated Machinery, etc. P.O. Box 411 METRIGUARD Pullman, WA 99163 (509) 332-7526 Equipment Production Line Test METRIX INDUSTRIES P.O. Box 886 691 St. Paul St. (Dept. 501) Rochester, NY 14603 (716) 232..4530 Inventory Systems Tooling Inspection Systems MUNCK AUTOMATION TECH., INQ P.O. Box 6677 Newport News, VA 23606 (804) 838-6010 Auto/Manual Storage & Retrieval Systems, Load/Unload Machines 176 NASA MACHINE TOOLS 8-T Industrial Rd. Pequannock, NJ 07440 (201) 633-5200, Ext. 9 CNC Tools CAD/CAM Systems OMNI LIFT, INC. 332 W. 1700 South, Dept. 86, Salt Lake City, UT 84115 (801) 486-3776 Material Handling: Conveyors Loaders/Unloaders Etc.. OMNI PLASTICS OF CANADA 22 Weneil Dr. Freelton, Ontario CANADA LOR 1KO 1-800-344-7788 Plastics, Molding Port Fabrication OMNITOOL, INC. 3502 48th Ave. N. Minneapolis, MN 55429 (612) 535-4240 High Precision Machine Parts Tools & Dies ,15MNI-TRON TOOLING P,O. Drawer 4402 Euchart, IN 46514 (219) 262-2083 & ENGINEERING . Conveyor Systems OMNITEK COMPUTER Bay 3, 2115oT 27rh Ave. N.E. Calgary, Alberta CANADA T2E 7E4 (403) 291-2988 SYSTEMS Data Acquisition & Control Systems O'NEILL MANUFACTURING Dept. TR, P.O. Box 949 Rome, GA 30161 (404) 295-1414 , CO. ONSRUD CUTTER MANUFACTURING 800-T Liberty Dr. La'bertyville, IL 60048 (312) 362-1560 ORANGE TOOL CO. 1733-T Monrowia, Unit "L" Corm Mesa, CA 92627 (7a4)548-7616 Lumber CO. & Millwork Cutting Equipment Tool Design, Jig, Fixtures, Dies, ere 177 ORANGEVILLE MANUFACTURING 507 blain St. Box 2150 Orangeville, PA 17859 (717) 683-5113 PANEL PROCESSING 2600-TS Emerald Ave. CO. Automated Warehouse Factory Equipment OF ILLINOIS, INC. Hardboard, Particleboard, etc. Chicago, IL 60616-_98 (312) 842-0330 [ PENDU, INC. R.D. 1, Box AB.425 New Holland, PA 17557 (717) 354-4348 Cutting Equipment, Auto-Stackers, etc. PENTALIFT EQUIPMENT CORP, 1552 Hertel Ave. Suite 901-T Buffalo, NW 14216 Elevating Docks Lift Tables Gang Saws, (519) 763-3625 POSTALUCK P,O, Box 24 Windsor, VI" CORP. QSOURCE ENGINEERING, 228 Byers Rd. Miamisburg, OH 45342 1.800-356-9039 5933-A Peachtree Industrial ROBOPAC Norcross, GA 30092 (404) 448-1120 Joint Trimmers Miters ,, iNC. Industrial Engineering/Manufactufin_ Consultants Blvd. ROYAL INDUSTRIAL STORAGE Atkins Center P,O. Box 28,_-T Spartanburg, SC 29304.2844 (803) 574-5931 Mobile Wrapper Pallet SYSTEMS SAFETY SPEED CUT MANUFACTURING 13462 N. Hwy. 65 Anoka, MN 55304 (612) 755-1600 Ext. 12 Sideloaders for Pallets, Materials Fixtures, etc. CO. Panel Saws, VenicalB--Iorizontal Routers panel 178 SAILRAIL ENTERPRISES, INC. 1935-D Dilk Industrial Blvd, Marietta, GA 30067 (404) 952-8377 Conveyor Systems Storage & Retrieval Systems Stacker Machines SAMPSON AUTOMATION 140 Commerce Dr, Hanppauge, NY 11788 (516) 231-1900 Extrusion, Cutting, Fabrication Machinery, Assembly Machines, Material Handling Equipment, etc. SHU'I_LELIFT, 49 E. Yew St. CO., INC. INC. Mobile Straddle Hoist Sturgeon Bay, WI 54235 (.414) 743-8650 SPEED CUT, INC. P.O. Box 1125 Corvallis, OR 97339 (.503) 928-1281 Mobile Frames Mobile Cutters STANDARD TOOL & MANUFACTURING 740 Schuyler Ave. Lyndhurst, NJ 07071 (201) 939-5500 STERLING TOOL & MANUFACTURING No. 60 W22700 Silverspring Dr. Dept. TR Sussex, WI 53089 (414) 246-6246 SUBNER INDUSTRIAL PRODUCTS P.O. Drawer A Highway 411 South/Subner Dr. Rome, GA 30162-1234 (404) 235-8046 TYLER MACHINERY 654 S. Detroit St. Warsaw, IN 46580 (219) 267-3530 VERSATRON CORP. 103 Plaza St. Healdsburg, CA 95448 (707) 433-8244 CO., INC. CO. CO. CO. Automation Assembly Equipment, Production Systems, FMS, etc. Machinery Transfer Jigs, Fixtures, Dies Drilling Equipment Cutting Equipment Factory Automation Systems 179 VESTIL MANUFACTURING P,O, Box 507.A Angola, IN 46703 1-800-348=0868 WHITNEY SYSTEMS 53 Park.burst St, Chelmsford,' MA 01824 (508) 937=7444 CO, Lifting Equipment Factory Automated Equipment I