Cyber-physical system based productivity improvement concept of construction 4.0

Bài viết giới thiệu khái niệm về Xây dựng 4.0, trong đó nâng cao Hệ Thống Thực Ảo, bằng cách đưa ra bối cảnh cách mạng, lịch sử cải tiến năng suất trong ngành xây dựng Nhật Bản.

Cyber-physical system based productivity improvement concept of construction 4.0 Khái niệm cải tiến suất xây dựng 4.0 dựa hệ thống thực ảo Hande Ünlü(¹), Norihiko Goto(²) Tóm tắt Đã từ lâu, tốc độ thực việc cải tiến suất công nghệ liên quan ngành xây dựng bị chậm so với ngành công nghiệp khác Tuy nhiên, suy giảm số lượng cơng nhân có tay nghề thay đổi động lực thị trường Nhật bản, số giải pháp khác vào trọng tâm trình chuyển đổi sản phẩm Trong báo này, giới thiệu khái niệm Xây dựng 4.0, nâng cao Hệ Thống Thực Ảo, cách đưa bối cảnh cách mạng, lịch sử cải tiến suất ngành xây dựng Nhật Bản Từ khóa: Hệ thống Thực - Ảo, Xây dựng 4.0, số hóa, cải tiến suất Abstract Implementation speed of productivity improvement associated technologies in construction industry has always remained behind other industries for long time However, due to decreasing number of skilled workers and changing market dynamics in Japan several different solutions have come into focus of process and product transformation In this paper, we introduce our concept of Construction 4.0 that is proposed to raise upon Cyber-Physical Systems, by giving its revolution background, a history of productivity improvement in Japanese construction industry Keywords: Cyber-Physical Systems, Construction 4.0, digitization, productivity improvement Introduction Industry 4.0 or the fourth industrial revolution is the current trend of automation and data exchange in manufacturing technologies with an aim to establish Smart Production The key technologies of Industry 4.0 have a strong focus on digitization and integration of vertical and horizontal value chains, digitization of product and service offerings, digital business models and customer/user access [1] However, it hasn’t been a smooth process to adapt these technologies into the works at construction industry easily The main challenges of construction industry could be listed as 1- its complexity: high number of components to be designed and implemented in parallel 2- increased uncertainties and different patterns at each project, 3- the rigid culture of construction which doesn’t allow fast changes compared to other industries such as automotive, 4- fragmented supply chain: high number of work packages done by many different subcontractors and 5- short-term thinking: dominant way of thinking that is project-based, to be achieved under limited time and resources [2] Technology development, implementation of new construction methods and its adaptation into the site works require interdisciplinary comprehensive planning of product and process transformation Often, the transformation is a big challenge for large design and construction companies to implement new methods [3] However, due to the reasons which are focused in this paper, construction industry is heading towards Construction 4.0 and competition is becoming more contentious towards digitization of projects from planning to design, construction and facility management stages A Concept for Construction 4.0 Inspired by Industry 4.0’s key technologies on digitization of production and coordination by ICT, there have been several concepts introduced for defining Construction 4.0 by Japanese organizations [4] and other international institutes Associatively, Takenaka Corporation visualizes Construction 4.0 as a fusion of disruptive and incremental type of product and process transformation that results in productivity improvement [Figure 1] Despite the speed of revolution in manufacturing industry, construction has always been more conventional and almost 20 years behind to adapt cutting edge technologies (1) Ph.D.,Engineer,Takenaka Corporation Email: unlu.hande@takenaka.co.jp (2) M.Sc.,Engineer,Takenaka Corporation Email: goto.norihiko@takenaka.co.jp Figure Takenaka’s Vision of Construction 4.0 S¬ 28 - 2017 101 KHOA HC & CôNG NGHê Figure CPS Platform Concept for Construction 4.0 Figure ASTM Project, 1979 into practice However, today, design and construction tools have been significantly improved such as use of BIM, CNC/3D printing technologies, VR (Virtual Reality)/AR (Augmented Reality) systems and so on As foreseen within the frame of Takenaka’s vision of Construction 4.0, construction industry will reach the age of digital fabrication soon in the near future [5] This is an inevitable evolution in construction for productivity improvement at countries such as Japan which has a struggle with decreasing number of skilled workers and correspondingly increasing amount of investment in automation and robotics applications to overcome the labor problem [6] In Japan a CPS platform has already been being promoted by the government since 2015 under the project named “I-Construction” (ICT-Integrated Construction) By introducing standards and regulations about ICT-Integrated construction besides taking advantages of such technologies as drones and auto-heavy machines, the ministry aims to 102 increase productivity of trade workers by 50% Such initiation at government level boosts the industry towards the age of digitization rapidly Due to the fact, we have examined the inevitable necessity of productivity improvement and possibilities that digitization may offer to us We have developed a concept of CyberPhysical System (CPS) for Construction 4.0 as introduced in Figure Our concept of a CPS platform provides transformations that is built upon 1- Digitalized design & engineering, 2- Digitized Procurement & Management, 3Digitized Logistic & Production System, 4- Smart Building Operation & Maintenance, 5- Smart Facility Management system and 6- Using Lifecycle Data for Design & Engineering Productivity improvement in Japan in the age of Construction 2.0 and 3.0 In the 1970s, in Japan, productivity improvement has been studied and implemented by utilizing construction T„P CHŠ KHOA HC KIƯN TRC - XY DẳNG skilled workers were still engaged in big numbers 3- During 1970s a large burden was placed on the amount of required detailed hand drawings for the prefabrication process at factories However, by the use of composite solutions (combination of prefabricated elements with conventional in-situ production) large amount of time and cost could be saved both from design and construction phases Figure Detection system network During the age of Construction 3.0 including the large amount of today’s current projects, in Japan, composite construction solutions became a key for productivity improvement By this way, the market demand on design variety could be constructed in a more flexible way compared to modularization method By the use of CAD and later BIM tools, today, complicated architectural structures could be analyzed to select the most efficient construction methods through different scenarios digitally We utilize BIM to optimize the production process by analyzing different scenarios and increase the efficiency of entire project Table presents the brief transition history of efficient methods from 1970s until today CPS based productivity improvement in the age of Construction 4.0 Figure System output on a drawing file automation through modularization [7] We call this period the era of Construction 2.0 Modularized buildings such as Takenaka’s ASTM project (mass housing project of 3,381 dwelling units; completion: 1979), had been achieved by significant transformations in the way of production, design, logistics and assembly [Figure 3] Briefly, the housing modules of: precast (PCa) concrete external walls with fitted windows, PCa floor slabs and prefabricated kitchens and bathrooms including its mechanical and electrical installations had been built at factories and delivered just in-time Such modules were rapidly assembled and pluggedinto the steel structural frame onsite This method was a unique approach implemented in Japan which had successfully saved time, cost and resources in the 1970s However, since then the use of modularization method which is recently a trend across the world (such as prefabricated skyscrapers) has become less popular in Japan With the beginning of 1980s Japan has already moved forward into Construction 3.0 The main reasons that triggered the 3rd revolution in Japan are 1- In the 1980s rapid growths in Japanese economy lowered the need of mass housing while creating a market demand change into “quality rather than quantity” Due to the fact, diversity in design became more important 2- Labor costs had decreased whilst highly On the other hand, at our most recent projects putting our concept of Construction 4.0 [Figure 1] in the core, we have been researching and testing incrementally the adaptation of CPS based productivity improvement through digitization Below are two applications that we’ve developed for the adaptation of PIM (Process Info Modelling) which is a vital component of Digitized Procurement & Management [Figure 2] in CPS based productivity improvement: Machinery and labor position detecting system: At construction sites it’s a time consuming process to find location of machineries (sometimes there are hundreds of aerial work platforms (AWP) on site) and analyze the efficiency of workers by their work locations In order to improve our onsite productivity, we have developed an information gathering system that uses wireless transmitter technology of iBeacon Figure Image of the cloud-based management S¬ 28 - 2017 103 KHOA HC & CôNG NGHê Table The triggering challenges and outputs of each construction revolution Our system is the first indoor position detection technology that uses iBeacon at a construction site As shown in Figure 4, fixed and mobile iBeacons transmit location information of machineries and workers to the Site Management Server via data receivers on site Output data indicates their location by symbols on project’s actual drawing layout [Figure 5] By utilizing this real-time detection system, we save time on searching of machineries and workers We have also developed a photo shooting application for iPad that takes photos of on-going works on site and uploads to server together with its location information By this application we save more than 30% of man-hour spent for documenting on-going works for the site management Utilizing the above mentioned methods, we have improved the efficiency of our site management tasks by saving 72 hours of work time in months Cloud-based remote monitoring system utilizing IoT: Due to increasing number of on-site machineries, management of real-time operating status and maintenance has become a more time consuming process Aiming to improve the efficiency of operation and maintenance works, we have developed a remote cloud-based machinery monitoring system by the use of IoT technology [Figure 6] This system can detect a risk of machinery failure in real-time which could Tài liệu tham khảo PwC, Industry 4.0: Building the digital enterprise, Global Industry 4.0 Survey – Industry key findings, 2016 T D Oesterreich, F Teuteberg, Understanding the Implications of Digitization and Automation in the Context of Industry 4.0: A triangulation approach and elements of a research agenda for the construction industry, Computers in Industry, Vol.83, 2016 be monitored remotely via cloud system at the office or on site In addition, this system enables a central management of data between the machinery and manufacturers In the future, we are aiming to utilize the big data that has been collected by this system for integrated construction automation Above mentioned applications are only two examples of a future CPS that integrates digitization at every phase of projects for productivity improvement Concluding Remarks At our concept of Construction 4.0, projects are being based on digitized platforms and automation applications from planning to construction and facility management activities Modularization method which provided improved productivity in the era of Construction 2.0 was evolved into composite solutions during the era of Construction 3.0 driven by changing market dynamics As observed during earlier construction revolutions, Construction 4.0 will bring product and process transformation too Given today’s technological advancements, we believe that the future of construction industry will reach productivity improvement by benefiting from digitized platforms in the form of Cyber-PhysicalSystems as introduced in this paper./ General Competitiveness Forum of Japan (COCN), Smart Construction System Using IoT and CPS (in Japanese), Industry Competitiveness Discussion Proceeding, 2015 M Kohler, F Gramazio, The Robotic Touch: How Robots Change Architecture, Park Books, 2014 MLIT, i-Construction (in Japanese), http://www.mlit.go.jp/tec/ tec_tk_000028.html, latest access on 14 July 2017 C Christensen, Innovator’s Dilemma: When New Technologies Cause Great Firms to Fail, Harvard Business Review Press, Reprint edition January 5, 2016 104 TP CH KHOA HC KIƯN TRC - XY DẳNG ... necessity of productivity improvement and possibilities that digitization may offer to us We have developed a concept of CyberPhysical System (CPS) for Construction 4.0 as introduced in Figure Our concept. .. efficiency of entire project Table presents the brief transition history of efficient methods from 1970s until today CPS based productivity improvement in the age of Construction 4.0 Figure System. .. recent projects putting our concept of Construction 4.0 [Figure 1] in the core, we have been researching and testing incrementally the adaptation of CPS based productivity improvement through digitization