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PSZ 19:16 (Pind. 1/07)
NOTES : * If the thesis is CONFIDENTAL or RESTRICTED, please attach with the letter from the organization with period and reasons for confidentiality or restriction.
DECLARATION OF THESIS / UNDERGRADUATE PROJECT PAPER AND COPYRIGHT
Author’s full name : Date of birth :
Title :
Academic Session :
I declare that this thesis is classified as : I acknowledged that Universiti Teknologi Malaysia reserves the right as follows :
1. The thesis is the property of Universiti Teknologi Malaysia. 2. The Library of Universiti Teknologi Malaysia has the right to make copies for the
purpose of research only. 3. The Library has the right to make copies of the thesis for academic exchange.
Certified by :
SIGNATURE SIGNATURE OF SUPERVISOR (NEW IC NO. /PASSPORT NO.) NAME OF SUPERVISOR
Date : Date :
PROF. MADYA DR. ABDUL KADIR MARSONO 41312
OPEN ACCESS I agree that my thesis to be published as online open access (full text)
RESTRICTED (Contains restricted information as specified by the organization where research was done)*
√
2007 / 2008
CONSTRUCTION: CASE STUDY
LOGISTICS FOR SEMI-PRE CAST CONCRETE
SIMULATION OF ALLOCATION ACTIVITIES OF
28-03-1979
WISAM MOHAMAD S. MASOD
CONFIDENTIAL (Contains confidential information under the Official Secret Act 1972)*
November 2007 November 2007
UNIVERSITI TEKNOLOGI MALAYSIA
Status Declaration Letter
Date: November, 2007
Librarian Perpustakaan Sultanah Zanariah UTM, Skudai Johor
Sir,
CLASSIFICATION OF THESIS AS RESTRICTED
SIMULATION OF ALLOCATION ACTIVITIES OF LOGISTICS FOR SEMI-
PRECAST CONCRETE CONSTRUCTION: CASE STUDY WISAM MOHAMAD S. MASOD
Please be informed that the above mentioned thesis entitled “SIMULATION OF ALLOCATION ACTIVITIES OF LOGISTICS FOR SEMI-PRECAST CONCRETE CONSTRUCTION: CASE STUDY” be classified as RESTRICTED for a period of three (3) years from the date of this letter. The reasons for this classification are
(i) COMMERCIALIZATION OF RESEARCH PRODUCT (ii) NEGOTIATION STAGE WITH UTSB SDN. BHD. AS BUSINESS
CONSULTANT (iii) NICHE IBS PRODUCT COMPONENTS ARE WAITING TO BE
MANUFACTURED
Thank you.
Sincerely yours,
“We hereby declare that I have read this project and in my opinion this project is
sufficient in terms of scope and quality for the award of the degree of Master of
Science (Construction Management) by taught course.”
Signature : …………………………………….
Name of Supervisor I : ASSOC. PROF. DR. ABDUL KADIR
MARSONO
Date : November 2007
Signature : ………………………………………
Name of Supervisor II : DR. MASINE MD TAP
Date : November 2007
i
SIMULATION OF ALLOCATION ACTIVITIES OF LOGISTICS FOR SEMI-
PRECAST CONCRETE CONSTRUCTION: CASE STUDY
WISAM MOHAMAD S. MASOD
A project report submitted in partial fulfillment of the
requirements for the award of the Degree of
Master of Science (Construction Management)
Faculty of Civil Engineering
Universiti Teknologi Malaysia
November 2007
ii
I declare that this thesis entitled “Simulation of Allocation Activities of Logistics for
Semi-Precast Concrete Construction: Case Study” is the result of my own research
except as cited in the references. The thesis has not been accepted for any degree and
is not currently submitted in candidature of any other degree.
Signature : ………………………………
Name : WISAM MOHAMAD S. MASOD
Date : 23 November 2007
iii
Especially to my beloved family
iv
ACKNOWLEDGEMENT
The author wishes to express his sincere appreciation to all who have helped
directly or indirectly in his Masters Project research work. The first gratitude is to
Allah for his prosperity and guidance. A big thank is to my main thesis supervisor,
Associate Professor Dr. Abdul Kadir Bin Marsono, for his passionate assistance, and
concern. With his invaluable advices and superb directions, the author has
successfully completed his Masters Project. It is indeed a true honor and privilege for
being able to work under the supervision of such a dedicated and enthusiastic
lecturer.
Special thankful is due to my co-supervisor Associate Professor Dr. Masine
Md Tap for her close guidance and assistance throughout the process of carrying out
the research work. Besides, the author would like to thank all the participants of
Taman Ehsan Jaya project for their helpful and concern. A particular grateful are due
to project manager Calvin K. C. Kok and site supervisor Nor Yazid Bin A. Manan
for their unlimited helpful, support, and assistance.
Last but not least, the author would like to express his heartfelt gratitude to
his family members and friends for their utmost support and motivation throughout
this research work. Thanks to all of them.
v
ABSTRACT
The thesis presents a 100 units multi-storey case study endeavor to simulation
logistic allocation of activity modeling. It also reviews, assess, and improve the
current construction practices in Malaysia. First, building the implementation process
diagram for a model of simulation is presented for determining a good and better
allocation of activity. Secondly, alternative models for implementation processes and
for monitor and control the logistic processes are presented with three missions of
government regulation process, site management process, and improvement of IBS
process. Finally, a real case study is presented on semi-precast concrete project, on
the time completion for each activity that needed to finish the overall project. It will
cover financial status, project management consultant, consultant and contractors,
local authority, civil engineering works, manufacturing of components, transportation
of components, assembly of components and finishing. For the case study, the data
were obtained in two stages: (i) during the construction period and (ii) during the
interview with participants. During the construction period, data were collected in
collaboration with quantity surveyor, site engineer, and site supervisor. During the
interview with participants, the interview was conducted with project manager walk-
in interviews. The importance of construction logistic in a developing country was
clarified as time-based analysis, in which the completion time of semi-precast
concrete project in the overall duration to client were calculated separately by using
Witness (2001) software, as was an optimization to activity by simulation of the
processes .
vi
ABSTRAK
Tesis ini adalah berkaitan penggunaan simulasi model aktiviti logistik
dijalankan ke atas satu kajian kes pembinaan 100 unit bangunan bertingkat bagi
tujuan semakan, penilaian dan penambahbaikan amalan pembinaan di Malaysia.
Pertama, carta proses pelaksanaan satu model simulasi dibangunkan untuk
menentukan kebaikan sesuatu aktiviti. Kedua, model alternatif untuk proses
pelaksanaan dan pemantauan serta penyeliaan proses logistik ditunjukkan untuk
proses peraturan kerajaan, proses pengurusan tapak dan proses pembaikan IBS.
Akhir sekali, kajian kes sebenar dibuat untuk projek konkrit separa pra-tuang, ke atas
masa siap bagi sesuatu aktiviti sehingga meniapkan keseluruhan projek.termasuk
status kwangan, perunding pengurusan projek, perunding dan pemborong, pihak
berkuasa tempatan, kerja-kerja kejuruteraan awam, pembuatan komponen,
pengangkutan komponen, pemasangan komponen dan kemasan. Bagi kajian kes ini,
data diperolehi dalam 2 peringkat iaitu (i) semasa jangka waktu pembinaan dan (ii)
semasa sesi temuduga. Semasa jangka waktu pembinaan, data dikumpulkan dengan
kerjasama juruukur bahan, jurutera tapak dan penyelia tapak semntara sesi temuduga
pula dijalankan bersama dengan pengurus projek di tapak pembinaan. Kepentingan
logistik pembinaan bagi negara membangun telah dikenal pasti berdasaran analisis
time based di mana masa siap projek separa pra-tuang konkrit dalam jangka masa
keseluruhan kepada pengguna dihitung berasingan menggunakan perisian (Witness
2001) untuk mengoptima aktiviti melalui proses simulasi.
vii
TABLE OF CONTENTS
CHAPTER DESCRIPTION PAGE
TITLE i
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENT iv
ABTRACT v
ABSTRAK vi
CHAPTER 1 INTRODUCTION 1 1.1 Introduction 1
1.2 Problem Statement 4
1.3 Aim and Objectives of Study 5
1.4 Scope of Study 6
1.5 Significance of Study 8
CHAPTER 2 LITERATURE REVIEW 9
6.1 Introduction 9
6.2 History of IBS Construction 10
viii
6.3 Industrialized Building System (IBS) 11
2.3.1 Introduction of IBS in Malaysia 11
2.3.2 Why IBS in Malaysia 13
2.3.3 Towards Global Competitiveness 14
2.3.4 Common Types of IBS Systems 15
2.3.5 Classification of Industrialized Building
Methods 16
2.3.6 Principles of IBS Systems 19
2.3.7 Benefits of IBS 19
6.4 Supply Chain Management 20
2.4.1 Introduction 20
2.4.2 Supply Chain Management in
Manufacturing 21
2.4.3 Supply Chain Management in
Construction 22
2.4.4 Analysis Of The Supply Chain
Management 23
2.4.5 Logistics and Supply Chains in
Construction 24
6.5 Introducing IBS 26
2.5.1 Background of IBS Construction
Logistics 26
2.5.2 Points to Logistics being poor in the
Construction Industry 27
2.5.3 Consequences of poor Logistics 28
2.5.4 Potential benefits by improving
Logistics 29
2.5.5 Preventing the Industry by Addressing
Logistics 30
6.6 The Functions of Logistics 31
6.7 Programme for Introducing Logistics 32
2.7.1 Local Authority 32
2.7.2 Financial Status 33
2.7.3 Project Management Consultant 34
ix
2.7.4 Manufacturing of Components 35
2.7.5 Transportation of Components 35
2.7.6 Civil Engineering Works 36
2.7.7 Contractors\Consultants 36
2.7.8 Assembly of Components 37
6.8 Case Study 38
6.9 Learning from other industries 39
6.10 Simulation 39
2.10.1 Definition of Simulation 39
2.10.2 Simulation Advantages 40
2.10.3 Simulation Disadvantages 44
6.11 Witness 2001 Software 45
2.11.1 Steps for Simulation Model Study in
Witness 2001 45
CHAPTER 3 METHODOLOGY 50
3.1 Introduction 50
3.2 Literature Review 52
3.3 Selecting Attributes of Logistics Process 52
3.4 Forming Systematic Workflow Processes 54
3.5 Data Collection 54
3.6 Modeling and Simulation 55
3.7 Data Analysis and Discussion 55
x
CHAPTER 4 DATA COLLECTION 56
4.1 Introduction 56
4.2 Data Collection 57
4.3 Case Study 58
4.4 Semi-Pre Cast Concrete Construction Project 59
4.4.1 Financial Status Activity 60
4.4.2 Project Management Consultant Activity 60
4.4.3 Consultants and Contractors Activity 61
4.4.4 Local Authority Activity 62
4.4.5 Civil Engineering Works Activity 62
4.4.6 Manufacturing of Components Activity 64
4.4.7 Transport of Components Activity 65
4.4.8 Assembly of Components Activity 67
4.4.9 Finishes Activity 68
4.5 Logistic Process 71
4.5.1 Simulation Framework 71
4.5.2 Alternative Processes Framework 72
4.6 Witness 2001 Software 74
4.6.1 Using Witness Software Data 75
4.6.2 Benefits of Simulation 76
CHAPTER 5 RESULTS AND DISCUSSION 77
5.1 Introduction 77
5.2 Simulation Models For the Process of the Project 78
5.2.1 Simulation Model For Government
Normal Step Process 78
5.2.2 Simulation Model For Site
Management Process 80
5.2.3 Simulation Model For An Improvement
IBS Process 81
xi
5.3 82Analyzing Period Of Activities
overnment Process Period
Analyzing Site Management Process
t
HAPTER 6 CONCLUSION AND RECOMMENDATIONS 103
s 105
REFERE
APPENDIXES
Appendix A 112
Appendix B
5.3.1 Analyzing G 83
5.3.2
Period 88
5.3.3 Analyzing Improvement IBS Projec
Process Period 94
C
6.1 Conclusion 103
6.2 Recommendation
NCES 107
112
113
xii
LIST OF TABLES
TABLE NO. TITLE PAGE
4.1 Financial status period 60
4.2 Project management consultant period 61
4.3 Consultants and contractors period 61
4.4 Local authority period 62
4.5 Civil engineering works period 63
4.6 Manufacturing of components period 64
4.7 Transportation of components period 65
4.8 Assembly of components period 67
4.9 Finishing period 69
4.10 The overall time activities period 70
5.1 Models outputs for project completion 82
5.2 Reducing financial status time at first process 83
5.3 Reducing project management consultants time at first
process 84
5.4 Reducing consultants and contractors time at first process 85
xiii
5.5 Reducing civil engineering works time at first process 86
5.6 Reducing manufacturing of components at first process 87
5.7 Reducing financial status time at second process 89
5.8 Reducing project management consultants time at second
process 89
5.9 Reducing consultants and contractors time at second
process 90
5.10 Reducing civil engineering works time at second process 91 5.11 Reducing manufacturing of components time at second
process 92
5.12 Reducing transportation of components time at second
process 93
5.13 Reducing financial status time at third process 94
5.14 Reducing project management consultants time at third
process 95
5.15 Reducing consultants and contractors time at third process 96
5.16 Reducing civil engineering works time at third process 97
5.17 Reducing manufacturing of components time at third
process 98
5.18 Reducing transportation of components time at third
process 99
5.19 Reducing assembly of components time at third process 100
xiv
LIST OF FIGURES
FIGURE NO. TITLE PAGE
1.1 Main area of the research project 5
1.2 Research flow 8
2.1 Percentage of completed projects using IBS (1998-2002) 12
2.2 Generic configuration of a supply chain in manufacturing. 21
2.3 Generic configuration of a traditional supply chain in
residential building 22
2.4 Construction logistics tasks 31
2.5 Steps in a simulation study 46
3.1 Methodology flowchart 51
3.2 Organization of logistic process for (Witness 2001)
simulation diagram. 53
3.3 Implementation (Witness 2001) diagram 54
4.1 Model for semi-pre cast concrete houses 59
4.2 Civil engineering work procedure 63
4.3 Manufacturing of components procedure 65
xv
4.4 Steps of transportation of components 66
4.5 Steps of assembly of components 68
4.6 Finishing procedure 69
4.7 Final implementation (Witness 2001) diagram 72
4.8 Serial simulations for normal working process
(Government regulation) 73
4.9 Serial simulations for site management process 73
4.10 Serial simulations for improvement IBS process 73
4.11 The start up windows interface of Witness 2001software 74
4.12 Elements used to build the models 75
5.1 Government regulations (normal working process) 79
5.2 Site management process 80
5.3 Improvement IBS project process 81
5.4 Financial status for first process 84
5.5 Project management consultants for first process 85
5.6 Consultants and contractors for first process 86
5.7 Civil engineering works for first process 87
5.8 Manufacturing of components for first process 88
5.9 Financial status for second process 89
5.10 Project management consultants for second process 90
5.11 Consultants and contractors for second process 91
xvi
5.12 Civil engineering works for second process 92
5.13 Manufacturing of components for second process 93
5.14 Transportation of components for second process 94 5.15 Financial status for third process 95
5.16 Project management consultants for third process 96
5.17 Consultants and contractors for third process 97
5.18 Civil engineering works for third process 98
5.19 Manufacturing of components for third process 99
5.20 Transportation of component for third process 100
5.21 Assemblies of components for third process 101
xvii
LIST OF APPENDIXES
APPENDIX TITLE PAGE
A Progress report of the actual project 112
B Construction draws of the actual project 113
1
CHAPTER 1
INTRODUCTION
1.1 Introduction
All organisations move materials. Manufacturers build factories that collect raw
materials from suppliers and deliver finished goods to customers; retail shops have
regular deliveries from wholesalers; a television news service collects reports from
around the world and delivers them to viewers; most of us live in towns and cities and
eat food brought in from the country; when you order a book or DVD from a website, a
courier delivers it to your door. Every time you buy, rent, lease, hire, or borrow anything
at all, someone has to make sure that all the parts are brought together and delivered to
your door. Logistics is the function that is responsible for this movement. It is
responsible for the transport and storage of materials on their journey between suppliers
and customers (Donald Waters, 2003).
Materials supply is an important element of operation of construction enterprises
and thus a factor affecting the quality of construction projects. The level of materials
costs reaches up to 70% of total construction cost estimations, therefore any actions
towards rationalization of size, structure and organization of material consumption,
delivery, and planning are important in terms of project efficiency and require proper
management.
2
Many industries attempt to integrate logistic process into logistic chains of
suppliers and customers, starting with obtaining raw material, through manufacturing,
distribution and final sale and service to the end users. Logistic processes, being crucial
for successful completion of the project but in fact auxiliary, are often entrusted external
professionals specialized in logistic services, and this tendency is also observed in
construction (Baumgartner, 1998).
In the field of construction, supply (ordering, transport and storage) and
production dominate the logistic processes (Serra, 2003). Supply and production are
often difficult to separate due not only to organisational but also technological reasons
(considering as erection of in-situ concrete structures and ready-mixed concrete
deliveries). Traditionally, contractors taking part in a project were responsible for their
individual supply chains to provide materials and services required within their scope of
works. At the present time of well-developed market for building materials and
services, centralising and outsourcing the project supply logistics is considered to be a
more efficient solution facilitating the project control.
A variety of systems and strategies of logistics are used by enterprises. The
choice of a logistic model implemented in a project should be based on careful analysis
of the supplier's market limitations, structure of material consumption, accuracy of
consumption planning and logistic cost minimisation. Also the scope and complexity of
the project and its procurement system have a considerable impact on the logistic
arrangements. The construction procurement systems evolve and "traditional" systems
such as general contracting are often replaced by project manager systems, where the
manager acting on behalf of the employer decides on designers, contractors, and
supplier's selection (Tenah, 2003). Along with procurement system development, the
constellation of decision-makers is changes. For example, the choice of materials, their
manufacturers, or even suppliers belongs no longer to the designer or the contractor,
3
but to the employer or his consultants or project managers. The latter decide also on the
logistic system on the building site.
Deciding on project logistics requires a wide knowledge of the building materials
market, financing, managing contractors' approaches to supply, and a deep under-
standing of the logistics impact on the project efficiency in terms of cost, quality, and
time. It is of great importance to be aware of logistic costs and their relationship to the
model of logistics and assumed decision variables such as batch size, place, and time of
the delivery. These depend on current market conditions such as cost of capital, material
and transport prices, storage costs and possibilities, safety and environment protection
law (Sobotka, 2000).
The study discusses a number of aspects of logistics with regard to a
construction process as an organisation and as a participant in a construction project. It
is based on the results of recent research on patterns of development of logistic
systems in Polish construction enterprises. The enclosed calculations of logistics
expenses present the impact of logistic system on costs. Two problems have been
analysed: the first consists in the method of introduce logistic process from the total
time of a project execution and in determining or estimating their best time according
to the deployment logistic model. The second problem is the choice of supply system
for all parts such as local authority, financial statue, project management consultant,
manufacturing of component, civil engineering, transportation of component,
contractor/consultant, and assembly of component. Conclusions of the analysis of the
above problems allow substantiating the integration of logistic tasks under a logistics
management unit within the project organisation structure in the form of an internal or
external logistic organisation. The responsibility of this organisation would be planning
and co-ordination of resources supply processes at each part of the project, from the
initial planning and design to execution and commissioning. The scope of
responsibility of such an organisation may be wider and include management of flows
of resources other than materials (equipment, staff and workforce, finance,
information), and not only supply but also production.
4
Actually, the applications of simulation in construction logistics and
industrialized building system are increasing rapidly. Consequently, simulation is a
unique ability to accurately predict the performance of complex processes at the IBS
projects which makes it ideally suited for systems planning. In addition, simulation is
emerging as an important developed tool to enhance the logistic process performance of
IBS. In overall, a highly processing planning and an accurate logistic of IBS construction
process are required to enrich the logistic activities of industrialized building system
component.
1.2 Problem Statement
The supply chain of Industrialized Building System at the concrete construction
involves many processes. One of the most important processes of IBS is the logistic
process, especially if we talk about the logistics management, supply chain management,
small limited availability of component, standardization for IBS construction such as
(sizing, project management, policy and regulation) and forms on logistic deployment
management. In fact, this process is considered as one of the critical effecting factors in
term of time, resource, and operation.
Strategic forum for construction (SFFC) in September 2002 highlighted that a
considerable amount of waste is incurred in the industry as a result of poor logistics. The
requirements of providing the appropriate logistic process for every project enforced
multiple efforts to cover that information flow and to enhance once again the workability
of IBS projects. It is essential to reduce time, plan the resources and the activities of the
whole processes.
5
The need to adopt an optimized model solution is essential to enhance the
optimization, reduces the time, and eliminates the complex routine involved in the
process. So there is a lot of opportunity for change. Construction has been slower than
other industries to realise the benefits that the application of good logistics can provide.
1.3 Aim and Objectives of Study
An overall goal of this study is to meet the demand for Industrialised building
construction component by ensuring a good balance between quality, economic and time
needs. As a result of the mentioned background the capabilities of precast concrete
component with construction building system for logistic process will be explained. The
study concerns three main areas, illustrated in Figure1.1, where prefabricated precast
concrete component, logistics supply chain management as a managerial tool and
simulation software (Witness2001). However, in this study project these subjects have
been put together in order to find a common denominator of the three subjects. The
research focus is to find and simulate the potential both for this building system and the
supply chain management tool in order to introduce the construction process for on
order, demand, and delivery. One way of doing this is to use the Witness2001 process in
combination with the industrialized building system.
6
Case Study on Semi-Precast
Concrete Project
Simulation Software
(Witness 2000)
Logistics Process
Figure 1.1 Main area of the research project
The industrialized building construction industry has for many years maintained
the time-tested but labour intensive traditional approach in construction and investing
little in research and development. So the new technological advances shall play a major
role in changing the competitive work environment in the construction industry.
Concurrently the demand for production and quality increases, the industrialized
construction industry must focus itself in innovation and be supportive of new
technological techniques in construction.
The objectives of this study by using simulation model (Witness 2001) are as
follows:
7
• To develop an action plan that highlights the steps that needs to be undertaken by
the different parts of the industry.
• To identify the key issues that needs to be addressed to improve logistics in the
construction industry.
• To simulate and optimize deployment model for industrialized building system
house of 100 unit houses project for certain month’s completion time.
• To determine catalogue of strategies for activity deployment of IBS house.
1.4 Scope of Study
The scope of this study is focused to selecting and forming the systematic logistic
workflow process in overall construction project process in IBS projects. The purpose of
this study is to determine whether the ways in which logistics management can provide
value for construction process better, faster, and cheaper. The study will also seek
criterion for a good logistics vision statement is that it should provide the road map for
how these two goals are to be achieved especially in reducing the overall construction
period as the follow:
• Examine the logistic process in the IBS construction projects that may play a role
in good time achieving at construction projects.
• Explore the problems that are encountered in the simulation design, production,
and erection processes in IBS system.
• To introduce the logistics model with influence of time factor on simulation.
• Analyze the deployment process among the parties involved in project
simulation.
In general, this study was done in three stages, namely:
8
• Literary study on IBS and strategic forum for construction logistics.
• Modeling and simulation for achieving a good overall IBS project period as well
as the attributes of process, time needed and Alternative models for organization
process.
• Data analysis of the results and conclusions.
Making references to relevant books, journals and other sources, as well as
conducting literature study on logistics of IBS concrete construction and its applications
were performed in the first stage of the research. The second stage involved a modeling
and simulation using the (Witness, 2001) technology. The implementation like this
technology allows the users to monitor and reduction on time and cost for IBS
construction. The third stage of the study was the analysis of the results. The final stage
ends with the writing of findings and conclusions, Figure 1.2.
Literary study on IBS project
Study in logistic process to be used Selecting attributes
of process
Forming systematic workflow processes
Data collection
Simulation & Optimisation
Data analysis by Witness 2001
Result and discussion
Write technical paper and report.
Figure 1.2 Research flow
9
1.5 Significance of Study
• Proposed simulation model in this study can be applied in the planning of IBS
projects especially the logistic process of organization work flow and the
execution at the IBS construction projects.
• Propose scheme production of catalog system for IBS such as (specification and
standardization).
• Propose alternative models for organization and to monitor and control the
process.
• Optimum work flow process in achieving a good overall IBS project period can
be calculated from the proposed model.