INTRODUCTION TO

MANUFACTURING PROCESS
PART 2 (IBS AND PRODUCTIVITY)
 INDUSTRIALISED BUILDING SYSTEM
CHARACTERISTICS

1. OPEN SYSTEM AND CLOSED SYSTEM

 Open system allow for design flexibility which all the component from
other IBS manufacturers can be used, indicating flexibility of its usage. This
system also known as OPEN BUILDING CONCEPT.
 Government building project was the first strategy to build using this
system and it has produced large volume of component
PWD, agency who has using own standardise building plans, only convert
conventional to standard IBS drawing.
 based on Government standard plans.
1. OPEN SYSTEM AND CLOSED SYSTEM (continue)
 Closed System, two categories, i) production based on client’s design and ii)
production based on pre-caster’s design.
The first category, is designed to meet a spatial requirement of the client’s with
specific architectural design for that specific project.
Second category, includes designing and producing a uniform type of building in
mass production of repetitive components.. But it will be economically only with
following circumstances:
 Sufficient demand e.g. school, so that a mass production can be obtained.
 Marketing strategy to enlighten the clients and designer the potential benefits of
the system
 The size of project must be large enough to allow distribution of production in
terms cost per component incur due to the specific design.
2. MODULAR COORDINATION (MC)

 can reduce the variability of dimension

and allow for the adaption into any layout
within the building.
Decrease the complexity of customisation.
Proven that MC improve IBS productivity.
Established the Malaysia Standard 1064
(Part 1 to Part 10) a guideline for
dimension standardisation in modular
system.
3. STANDARDISATION AND TOLERANCES
 All component need to be standardised for production.
Need prescribing tolerance at different construction stages such as manufactured
tolerance, setting out tolerance and erection tolerance, so when combined tolerances
obtained on statistical considerations within the permitted limits.
The structural design strongly influenced by installation and manufacturing tolerances
and tying action between the modules.
Production resources can be used in effective when the output is standardised.
 what is tolerance ? The connection must therefore have tolerances that allow some
degree of misalignment. The connection must have the ability to be adjusted easily
4. MASS PRODUCTION
 Investment in equipment, human resources, and facilities will be economically when produce the
component is large volume.
 Advantages, producing high level of precision because production line machine, lower costs because
automated in assembly line requires fewer workers.

5. SPECIALISATION
 Large production output and standardisation allow high degree of labour specialisation. Workers are
exposed to their repetitively work with higher productivity level.

6. PRODUCTION FACILITY
 Initial facility by setting a permanent factory, with plant, equipment, skill workers, management
resources to be acquired before commenced the production.

7. INTEGRATION
A high degree of coordination must exist between relevant parties .
 SHOP DRAWINGS

r/Fabricators
Manufacture
Showing how they
CONCEPTUAL
manufactured the
(CLIENT
components
REQUREMENT)
Early Decision -making

PRELIMINARY
PLAN
CONSTRUCTION /
WORKING
DESIGN ESTIMATE /DETAIL
DRAWINGS
ARCHITECTURAL
Limit of design process

CIVIL MECHANICAL &

&STRUCTURA ELECTRICAL IBS DESIGN STAGE
L
 IBS CLASSIFICATIONS
IBS classifications
IBS classifications

Precast Formwork Steel Block work Prefabricated Innovative

concrete framing timber framing
framing & panel
Column & Column & Wall
Beam Beam
Wall
Column &
Column & Beam
Wall
Beam Roof truss

Slab Roof truss

Wall

Slab
 PRECAST CONCRETE (PC) SYSTEM :
FRAMING SYSTEM : COLUMN AND BEAM

Precast RC column (1 tier) or two tier, and Precast RC) beam

MANUFACTURING PROCESS OF PRECAST CONCRETE FRAME
STRUCTURE

Preparation steel mould Cut, bend and tie Check reinforcement,

Cleaning and put oil inside reinforcement cages tightness before concreting
(mould supplier produce
mould and send ii to
production)

Install the reinforcement

inside the steel mould .
MANUFACTURING PROCESS OF PRECAST CONCRETE FRAME
STRUCTURE

Preparation steel mould Cut, bend and tie Check reinforcement,

Cleaning and put oil inside reinforcement cages tightness before concreting
(mould supplier produce
mould and send ii to
production)

Install the reinforcement

inside the steel mould .
MANUFACTURING PROCESS OF PRECAST CONCRETE FRAME
STRUCTURE

Finishing before
transporting for installation

Pour concrete. After harden, dismantle and

lifting to storage area

Click here https://www.youtube.com/watch?v=atJv308BHA0

PRECAST
CONCRETE (PC)
SYSTEM :
PANEL SYSTEM :
SLAB AND WALL

PRECAST HOLLOW
CORE SLAB [TOP]

PRECAST HALF SLAB

[BELOW]
PRECAST CONCRETE WALL PANEL
 MANUFACTURING PROCESS OF PRECAST CONCRETE PANEL –
Hollow core slab

Production line (bed) for Prestressed Steel before Prestressed

Hollow core slab machine
Hollow core slab
 Measure hollow core slab Pouring concrete to the bucket

MANUFACTURING PROCESS OF PRECAST CONCRETE PANEL

Click here https://www.youtube.com/watch?v=f7ZSK_tdbH8

 FORMWORK
SYSTEM

http://provenholding.com/en/what-is-ibs/formwork-system/
 PRODUCTION PROCESS OF FORMWORK SYSTEM- Zone 1 Zone 2 Zone 3
Tunnel form & Load Bearing Wall
Reinforcement for wall
Aluminium Mould
Install reinforcement for wall Install one side formwork &
transported to the
site
install conduit (M&E, Zone 1 Zone 2 Zone 3
services)
Install one side of formwork
Reinforcement for wall

Install Conduit (M&E, piping-if Install another one side of

required) formwork & pole to support
Zone 1 Zone 2 Zone 3 Reinforcement for wall
upper floor
Install another one side of formwork
Install one side formwork &
Install single pole/support floor upper slab install conduit (M&E,
services)

Rebar for upper slab

Install one side formwork &
Rebar &, services Zone 1 Zone 2 Zone 3 install conduit (M&E,
formwork
Install any services for upper slab upper slab
services)

Install another one side of

Concreting formwork & pole to support
upper floor

Install another one

Concreting Zone 2 Zone 3 side of formwork &
pole to support upper
floor
Click https://www.youtube.com/watch?v=KoEyT_RXGeE Rebar &, services
here formwork
upper slab
STEEL FRAMING SYSTEM
 MANUFACTURING PROCESS OF STEEL FRAMING

Light steel was set The details of the

using FRAMECAD product has been set
software to be out, the send it to All the products will be
tailored the Light Gauge steel assembled at the site
construction Framing Roll
schedule Machine to form
Wall Stud,/Floor
Joist and etc

Click here https://www.dahezbforming.com/mf-gauge-steel-framing-machine/

BLOCKWORK SYSTEM
MANUFACTURING PROCESS OF BLOCKWORK SYSTEM

MIXING MOUDLING CURING CUBING AND

STORING

Aggregates Pouring Move into Kiln Unstacked the

concrete to the blocks and
Water block mould placed on a
chain conveyor
Vibration and pass
Pigment/cement Takes Place through a cuber

Removing Blocks move to

blocks from cubing system
mould and stack on a
wood pallet and
Blocks wrapped in
placed on plastic
steel Pallets
Click here https://www.youtube.com/watch?v=afHS-vUnld8
MANUFACTURING PROCESS

The various process routes may be different in respect of principle, technique, quality of products
and time requirement and cost of manufacture.

The best one is to be selected based on some criteria. Achieving the goal in manufacturing requires
fulfillment of one or more of the following objectives:

1. reduction of manufacturing time (lead time, cycle time and takt time)

2. increase of productivity

3. reduction of manufacturing cost

4. increase in profit or profit rate

 COMPARISON S-CURVE PHYSICAL WORK OF CONVENTIONAL
AND IBS

Conventional physical
work IBS physical work

Lead time/Planning Shorter Period of

Planning time Period of actual time actual physical site
physical site

INTERVIEWEE CONVENTION AL VS IBS

Ibrahim Mohd Noor, “Based on S-Curve graph, it can easily see that for conventional, the graph peak
Kenchana Precast Sdn Bhd
up during the planning process but slows down when it comes to construction
period. While IBS is slow during the planning process but become very fast when
it comes to construction period”