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Build Your Own Prefabrication Shop

Build Your Own Prefabrication ShopBruce Phillips

Electrical Prefab Systems, LLC

This session is eligible for 1 contact hour

For these hours to appear on your certificate, you must:– Have your badge scanned at the door

– Attend 90% of this presentation– Fill out the online evaluation for this session

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Topics Covered1. Facilities2. Staffing3. Engineering4. Tools & Equipment5. Production6. Other Considerations

Facilities• Production Space• Utilities• Storage

– Raw Materials§ Production Material, e.g. Steel Boxes/Rings, Devices,

Brackets, Fittings, Misc. Hardware, etc.§ Packaging, e.g. Boxes, Pallets, etc.

– Work-in-Progress– Complete/Packaged Product

• Material Handling Equipment• Delivery to Job-Site (truck)

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Staffing (Required Personnel)• Prefabrication Manager

– Production Manager– Liaison with Field & Internal Personnel– Scheduling– Process Development & Control

• Engineering/Layout• CAD Operator(s)• Production Labor• Other Support Functions

– Purchasing– Accounting/HR– Warehouse/Delivery Driver– Facilities Maintenance & Repair

Engineering• Development of Design Process (Most Critical!)

– Nomenclature System/Designations– Design/Layout Scheme– Software Development

§ Required to Convert Engineered Nomenclature into a Consistent and Standardized Work-Product

– Labeling: Connecting Drawings to Fabricated Product

• Development of Production Process– Division of Labor

§ Skilled versus Unskilled Labor§ Supervision§ Quality Control

– Work-Flow– Production Methods

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Tools & Equipment• Shop Computer(s)• Industrial Label Printers• Storage Racks/Shelves• Assembly Benches• Jigs & Fixtures• Hand Tools• Wire/Cable Stripping Machines• Power/Pneumatic Tools

– Battery Drills– Pneumatic Screwdrivers (Compressor)

• Testing Equipment• Packaging Equipment/Supplies• Material Handling Equipment, e.g. Pallet

Jack/Fork Truck, etc.

Production• Material Flow

– Supply of Components to Shop Floor§ Determining What is Needed and When§ Ensuring Production Labor is Never Idle

• Process Flow – Level of Sophisticationa) Assembly of all Components by One Worker?b) Assembly Line: Assigning Repetitive Tasks

• Means & Methods• Developing a Flow-Chart - What Must Happen 1st, 2nd, etc.• Planning for Final Assembly

• Training to Ensure Quality Control & Consistency

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Other Considerations• Heavy-Duty Packaging for Transport • Carton Identification, e.g. Job Name, Floor/Unit Number• Training of Field Personnel

– Proper Installation of Materials (brackets, back supports, etc.)– Understanding of System Methodology & Identification– Reporting Design/Production Problems to Design Engineer– Encourage Positive Feedback for Product Improvement

• Support & Leadership from Corporate Management• UL Listing Requirement?

– Required by Authority Having Jurisdiction (Electrical Inspector)– Required by Project Specifications

• Increased Inventory Levels (and associated storage requirements)• Accounting Issues, e.g. Job Costing, Assignment of Costs, Honest & Transparent Understanding of

Added Overhead Costs.• Impact of Re-Assigning Valuable Personnel to Prefab Initiative from Other Critical Operations.

Questions?

For More InformationVisit us in Booth 517