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Experiences from Japan for industrialized housing production

Mag. Dr. Gerhard Schuster

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Starting Position

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Factors

&

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Factors

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Factors

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Solutions

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Solution 1: Lego Principle

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Solution 2: Spaceframe p Principle

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Basis of Variations

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Individualisations Facades

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Furniture and Fixtures

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Interior Work Individualized

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In Various Qualities and Prices

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Portacabin

Single Family Houses

Scenarios

Gaps between buildings Town House (Row house)

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Building and Construction g Industry Global Numbers

2003: 3.300 billions turnover 2,8% growth 2002 2003 Growthrate (2004 2007): 4,6% (China, Indien) US as largest global market (900 billions ) p g Japan second largest market

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European Dimensions
Annual turnover: 910 Mrd. Construction sector = biggest european industry cluster, ~ 10% of european gross national product 25% of european industry outputs 28,5% of european employees connected to this sector European profit margins : 2% (Japan : 7%)

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Competitors from Japan?

Toyota Homes
Japanese production: 5.000 Units/a (Single-family houses) Global Gl b l market l d i robotics-applications k t leader in b ti li ti No european engagement so far Spacefame-technology

S ki i H Sekisui Housing: i
Japanese production: 56.000 Units/a (Single- & multi-family houses) Largest home builder in Japan, 7,78 billion net sales, gross profit ratio: 20,3% (2003) Lego-system

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Production Method Toyota Homes

Average prices on local japanese markets Various quality levels: enable customizing to customers needs and financing possibilities Longevity guaranteed (10-80 years) Retail-market becomes possible in p Japan because of high quality housing products.

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Sales Strategy ATOLIS gy Park

7.200m 7 200m2 target group: family desiring living in comfort Buying power of target groups is of minor importance 12,1% 12 1% annual growth-rate 3 297 sold units/a growth rate, 3.297

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Toyota Homes: Sales y Approach

financing? Yes Yes Selection of building-type

Property ?

no

Searching Services by Toyota Real Estate

no

TFC (Toyota Finance Corp.) finances (100% inhouse)

Visitation of production (transparent plant) of own house

Customization and purchase of individualized house

Presentation of production benefits trust in brand Toyota

Production, transport, assembly continuous improvement process, market-analysis and customer-surveys lead to new designs and products

housing

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Production

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Production

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Production

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Production

Wiring harness

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Production Space Frames

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Production Space Frames

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Production Space Frames

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Production

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Customizing at Toyota

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Customizing at Toyota

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Customizing at Toyota

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Customizing at Toyota

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Customizing at Toyota

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Toyota Homes: Results

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Post-Industrialized Production at Sekisui House

...SIMS 2 for adults

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Nara - Plant

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Sekisui House Frame Productions

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Facades-Sandwich Facades Sandwich Panels

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Facades

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Sandwich Panels

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Sandwich Panels

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Sandwich Panels

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Sekisui Systems y

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Sekisui House

1. Planning The R&D division collects the latest information on dwellings and lifestyles, cooperating with specialists both inside and outside of the company. company The division s network includes among division's includes, others, universities, planners from the outside, and homemakers. 2. Development and Designing The R&D division uses the information it collects & to research just what can be considered a "truly comfortable house". The results of the research are then applied to housing specifications. specifications

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Sekisui House

3. 3 HAPPS: Heim Automated Part Pick-up System About 300,000 components are required to manufacture a freely planned house. Systems using AI conduct integrated information control from the ordering of parts through production, inventory, and shipping. HAPPS is the automated part pickup system, which steadily provides components t t hi h t dil id t to the production lines. It leads to high productivity, high quality, and considerable precision. 4. Delivery of Components Components are allocated for each house and supplied to the production line line.

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Sekisui House

5. Ceiling and Floor Panels Automated nailing machines fix plasterboards to ceiling joists. joists 6. Assembly Frames are assembled into a box-shaped structure by fully automatic spot-welding machines and rust-proofing is done at the welded p g points. The precision of assembled units is 2mm.

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Sekisui House

7. Attaching Exterior Wall Panels Exterior wall panels are attached to a boxshaped structure with special riveting machine and gaps between panels are filled with gaskets. 8. Attaching Partition Walls and Fittings Partition walls and fittings are attached according to each customer's plan. p

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Sekisui House

9. Installation of Facilities Most facilities, such as kitchens, baths, and stairs are installed at the factory. We can reduce waste factory and dust at the site by installing these in advance. 10. Inspection At the end of each process step, a specialist p p p conducts strict quality control inspections of over 250 items such as gaps between walls and squeaking of floors or stairs.

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Sekisui House

11. Protection Units that pass quality control checks are packed in unit-covers protective sheets and waterproof unit covers, sheets, caps. 12. Shipment Units are loaded onto special trucks by large forklifts and shipped out in accordance with the pp customer's delivery date.

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Sekisui House

13. Installation of Units Cranes are used to install units onto solid reinforced concrete bases. reinforced-concrete bases 14. Roofing Roofs are also manufactured at the factory and delivered to the site to be installed simultaneously with the units. Completed in a y p day, interiors are prevented from being exposed to rain or wind.

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Sekisui House

15. Interior Finish-Work Interior components are also shipped from the factory and interior finish-work is totally carried finish work out under a roof, thereby preventing exposure to rain. 16. Measurement of Performance (Formaldehyde) We sample the air of the completed house to p p measure the density of formaldehyde (Kitagawamethod Detector). You can see by the low values just how thoroughly we have eliminated formaldehyde.

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Sekisui House

17. Hand-over The average period of work at a site is 40 days from installation to hand-over - one-third the time hand over one third of conventional construction methods.

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Sustain Consulting g for the Construction Sector

Consulting Services - Business areas:
Industrialized Housing Production [market analysis, system valuations, valuations optimization of production processes and value chains] Expert monitoring of change processes in companies [change agents] T l f effective leadership [ Tools for ff ti l d hi [www.mindi d management.eu] DI Dr Matthias Rant Senior Adviser partner Dr. Adviser, Mag. Dr. Gerhard Schuster manager, partner gerhard.schuster@sustain.co.at gerhard schuster@sustain co at