DESC:SYSTEM FOR INTEGRATING VARIOUS PROCESSES OF PRECAST CONSTRUCTIONS AND METHOD THEREOF

Field of the invention

The present invention relates to system and method to integrate various processes of precast constructions as well as resources involved in pre-engineered pre-cast construction to enable effective management of both.

Background of the invention

Pre-Casting means physical construction of a building already constructed on paper by Pre-Engineering methods by making use of Auto CAD, Microsoft Excel, Hand drafting, Verbal Communication, Pre-Customization-standard module, Pre-Customization-standard module and the like. The conventional pre-cast methods suffer various drawbacks related to logistics, production, detailing, planning and tracking, operational deficiencies (cast-in situ construction). The conventional pre-cast methods also face problems such as wasted employee productivity, lack of real-time end to end visibility.

These methods are labor intensive due to all activities on-site, all on-site logistics and thus results in quality variation, material wastage, material handling and more duration. Furthermore, errors causes at any step of the process require changes to made in type of work, PC element type, production drawings, IDs, construction/installation/transportation sequence, dimensions of elements, architectural specifications (importantly, layout). The employees if subjected to environment with inefficient and disjointed processes diverge from their core duties.

Additional drawbacks of the conventional pre-cast processes are as listed below:
• multiple overlapping databases results in considerable amount of time taken to source, extract and analyze data from various processes.
• no reports showing performance across various departments and consequently no integrated view of company's operations.
• countless hours wasted trying to tie unrelated, error-prone, and out of date information together.
• delay in making critical decisions, based on inaccurate information, or hasty and risky decisions off of gut instinct.
• less control and monitoring on progress of production / overall project process
• process of tracking progress heavily dependent on manual input
• difficulties in managing changes
• data gathering was a tough task
• reporting does not show online / current status.

Thus, Pre-engineering takes a fixed period, depending on the scale and nature of project, which if insufficiently tackled with traditional art, will reduce the advantages which can be leveraged by precast technology.

Accordingly, there exists a need to provide a pre-cast process that overcomes the above mentioned drawbacks of the prior art.

Objects of the invention

An object of the present invention is to integrate all business processes applications around a single codebase/database for improved process efficiency across an organization, improved visibility and accelerated growth.

Another object of the present invention is to yield tremendous cost savings and improved business productivity.

Summary of the invention

The present invention provides a system and method to integrate various processes of precast constructions for effective management of Pre-engineered Pre-cast construction. The system for integrating various processes of precast constructions comprises of four modules configured on a processor- a first module configured for modeling of precast structures by offering customization in Building Information Modeling (BIM) system for design and drawing management, a second module configured for precast logistics application by generating a trip plan about resources and materials utilized at a manufacturing plant site and at an onsite location for effective utilization and management of available resources and materials therein, a third module configured for Pre-cast Project Planning and Tracking and a fourth module configured for SAP - Costing, Purchase, Financial Reporting and Budget Tracking.

The first module is adapted for providing 3D view of all elements giving visibility to ground level supervisors along with providing automatic SAP input database file, resolve clashes in levels, fittings and connections, allows concrete modeling, connection details and reinforcement detailing, references for all entities such as detailer, planner, production and installation departments, automatic extraction of drawings and data from latest references, and creation of Custom components for precast element connection.

The second module is adapted for providing Self-Planning and committing of activities on day in advance and timely status updates on the availability of required machinery and resources. The second module provides precast logistics application by generating a trip plan about resources and materials utilized at a manufacturing plant site and at an onsite location for effective utilization and management of available resources and materials therein. The trip plan includes details such as vehicle, vehicle capacity, current location, material (element type), material volume, start time, loading time, delivery time, and unloading time and like.

The third module is adapted for providing Centralized database of Project wise Precast Elements, Element Lifecycle, Erection and Production Planning, Post Production Element Tracking, Erection Interdependency of elements, Element tracking details, Projection of project end date and Graphical reports for management reporting. Specifically, the Post Production Element Tracking is performed using barcoding.

The fourth module is adapted for providing full-fledged customized material accounting processes as per Business Process Requirement, customized in house applications in SAP environment, Integration of production cycle with Modeling System TEKLA and the third module, Material Master Maintenance Module, Budget tracking, and Plant and Machinery Performance Tracking system.

Further, the system and the method employs a detailing tracking system of GFC deliverables and involves structuring of folders on a server that is on lines of ISO, and as per standards of Design Consultancy Firms.

Brief description of the drawings
The objectives and advantages of the present invention will become apparent from the following description read in accordance with the accompanying drawings wherein,
Figure 1 illustrates integration of processes and resources involved in pre-cast engineering using a pre-cast process, in accordance with the present invention;

Figure 2 illustrates a comparison of the conventional process and the pre-cast process of figure 1 at various stages of pre-cast engineering;

Figure 3 shows a schematic drawing illustrating integration of operational technologies and programming modules, in accordance with the present invention;

Figure 4 shows various moulds and parts produced using the pre-cast process, in accordance with the present invention;

Figure 5 illustrates role of an in-house structural design team in the pre-cast process, in accordance with the present invention;

Figure 6 illustrates optimization of trailer trips planned per day, in accordance with the present invention;

Figure 7 shows QR code marking on an element, in accordance with the present invention;

Figure 8 shows automated MIS reports generated daily, weekly and monthly, in accordance with the present invention;

Figure 9 illustrates costing and budget tracking achieved due to the integration of the various tacking programming modules, in accordance with the present invention;

Figure 10 illustrates details of Cost Tracking Head IDs, in accordance with the present invention;

Figure 11 illustrates an interface, in accordance with the present invention; and

Figure 12 illustrates a report screen, in accordance with the present invention.

Detailed description of the invention

The foregoing objects of the invention are accomplished and the problems and shortcomings associated with the prior art techniques and approaches are overcome by the present invention as described below in the preferred embodiment.

The present invention provides a system for integrating various processes of precast constructions and method thereof. Particularly, the present invention provides a precast de-prism process. The precast de-prism process is developed to integrate various processes as well as resources involved in Pre-engineered Pre-cast construction by advancements in operational technology and programming modules to enable effective management of both processes as well as resources.

The present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures.

Referring to now to figures 1 to 12, a system and a method for integrating various processes of precast constructions is illustrated in accordance with the present invention. The system and the method comprise upgradation and customization of operational technology as well as various programming modules.
The upgradation and customization of operational technology offers advantages such as quick erection time, reduced need for plant on site, easier management of construction sites, better overall construction quality, and ideal fit for simple and complex structures. The element cycle of a pre-stressed beam is illustrated herein below in accordance with the present invention:

The system and the method further comprises customization in Building Information Modeling (BIM) system using a first module (software 1):
This allows to build the entire project successfully first in the first module, and then extract data and drawings therefrom. The BIM implementation achieves integration with planning software to directly extract data from drawings for estimation and planning purposes as well as deals with critical areas with respect to precast components through automatic components, to minimize errors. The first module offers following advantages:
• Provides 3D view of all elements giving visibility to ground level supervisors as well as provides automatic SAP input database file.
• Clashes in levels, fittings, connections and the like will be alarmed and re-solved in the first module itself
• Changes (if any) are done in the model of the Building itself by the designer such that the changes are reflected automatically on all relational objects thus eliminating situation of "forgetting to revise shop drawings"
• Allows Concrete Modeling, connection details, reinforcement detailing
• Provides single and latest reference for all entities such as detailer, planner, production and installation departments
• Allows automatic extraction of drawings and data from the latest reference (erection layouts and production drawings)

Further enhancements were made to the first module to enable suitability in modeling of precast structures with intricate details of all components and to extract flawless database for input in planning tool and subsequently SAP by identifying and filling the below listed gaps:
• Custom components for precast element connection: Create components for element connections according to user requirement
• Auto connection of elements (macros): Once a particular connection component (may be by the system or custom) is applied in auto-connection setting, system should directly generate connections at all similar locations in the structure
• Shape ID of elements
• Cast group of elements
• Dependencies of elements
• Corbel reinforcement as a separate component with the all types of reinforcement bars as included in configuration file
• Column shoe as a connection component between column to column or column to footing connection (ref. configuration file)
• To handle the situation where the corbel is connected to ledge and reinforcement is continuous through corbel to ledge
• To get single corbel for column across the periphery instead of separate corbel for each beam at the junction where multiple beams are connecting to the column.
• Giving corbel at column- beam junction where beams are inclined to the column.
• To take care of stretching of elements created with custom geometry? (stretching along the angle may change thickness)
• To take care of reinforcement in custom created elements, if geometry is modified (stretching along the angle may change thickness)
• Strand pattern and strand diameters: user defined Pre-stressed beans.
• Changes in ledge level of beam at particular location
• Sleeves in ledges for connection
• Strand pattern and strand diameters : user defined
• Strand pattern for each type of hollow core slab
• Column to footing connection component: e.g. ball and socket arrangement, Column shoe to footing connection
• Various types of connection components for walls as given separately in configuration file
• Shuttering length: Element wise and pallet wise required shuttering length
• Shuttering Area: floor wise for Cast-In-Situ work
• Phase/ floor-wise Area statement
• Core dimensions and no. of cores
• Coupler as a component for reinforcement
• Sleeves in column corbels for connection
The system and the method uses a standardized design and detailing tracking system of GFC deliverables and involves structuring of folders on a server which is on lines of ISO, and as per standards of Design Consultancy Firms. The BIM system incorporates design and drawings management by allowing maintenance of a record of the statuses of each drawings which is updated along with any comments such as news about any points getting closed, any new points for hold-up and the like by respective team members in the central database/ 3D model itself. The report/report file is capable of being extracted in Excel format or any suitable form known in the art. The report is capable of being opened daily by concerned production departments for checking the statuses of their concerned drawings thereby preventing the need for them to come in person to detailing engineer and get the same things explained. Thus, the design and drawings management saves troubles of communicating the same thing again and again to everyone, and also, to make open points if any for follow-ups and closure clearly visible and prioritized.

The system and the method further comprises using a second module (software 2) for Precast Logistics Application:
The objectives are to optimize trailer trips planned per day and to utilize the number of resources engaged in the activity effectively.

Concept and Working:
The system provides a trip plan about resources and materials utilized at a manufacturing plant site as well as at an onsite location. The trip plan (refer figure 6) includes details like vehicle (e.g. trailer), vehicle capacity, current location, material (element type), material volume, start time, loading time, delivery time, unloading time and the like. Based on these details, no. of trips that would be arranged within their plant site and onsite locations is decided. Using master data files as input, the optimizer module generates an Optimized Trip Plan on a daily basis.
Depending upon the consolidated requisition list from the various sites, the user will run the program daily at a fixed decided time. The system will check the available trailers at the plant to perform the validations that the height, weight of the elements does not exceed a maximum limit of the trailer specification. On completion of the validations, it will make all the permutations and combinations, and suggest the best possible solution to optimize the trailer capacity. The user has the option of changing the requisition data and re-submitting the program, to generate the best possible solution for the modified requisition list.

The second module offers following advantages:
• Self-Planning and committing of activities on day in advance
• Viewing openly, who has booked which machinery and when and for what work
• Viewing openly, which machinery is available when, so as to book it for you work

The system and the method further comprises using a third module (software 3: Protrak) for Pre-cast Project Planning and Tracking:
In an embodiment, the third module is driven by barcode and android based cloud technology and has following features:
• Centralized database of Project wise Precast Elements
• Element Lifecycle (Product drawing to Erection)
• Erection Planning considering resource constraints, element erection interdependencies, availability of erection machinery, erection machinery speed, working time
• Production Planning based on mould sizes and availability, mould sharing across multiple projects, element erection interdependencies, mould downtimes accommodation, element type wise standard cycle times as well as crashed cycle times, working days (annual holidays, weekly-offs, overtimes
• Role Based Access control for respective operations team
• Production Activity confirmation using Android based Mobiles
• Post Production Element Tracking carried out using Barcoding
• Project based visibility of Planned Vs Actuals
• Monitoring project delays and controlling through corrective actions
• Reports
• Basic Project Information
• Geometry of all precast elements in the project
• Erection Interdependency of elements
• Production batch details, Access details for operation team
• Element tracking details
• Benefits of a Lifecycle approach adopted in this application
• Standard process flow for element and transparency in progress of element.
• Tracking of element at each state i.e. production, Quality, Transportation and erection.
• Accountability at each element level, Reduced communication gap.
• Planned date for each state of element enabling state wise scheduling

The third module offers following advantages:
• Tracking of element at each stage.
• Process flow of element.
• Traceability of delay
• Schedule for all (QA/QC, Production, Stockyard, etc.)
• Projection of project end date.
• Graphical reports for management reporting

The system and the method further comprises using a fourth module (software 4: SAP) for SAP - Costing, Purchase, Financial Reporting and Budget Tracking:

The fourth module includes following features
• Successful In-house SAP implementation of FI, CO, SD, MM and PP which are standard modules of SAP as shown in figure 9.
• Full-fledged customized material accounting processes from PR>quotation>PO>GRN to Bill passing as per Business Process Requirement
• Apart from the Standard SAP modules as mentioned above, includes customized in house applications in SAP environment to satisfy the higher management’s requirements more accurately, making the business process run as per our exact needs, which were unavailable in the original out of the box SAP product
• Integration of production cycle with Modeling System TEKLA and Planning and Tracking application third module (PROTRAK) by means of the below mentioned reports:
SAP REPORT: A report from Tekla to planning department to create Project database in PROTRAK.
SAP REPORT 1: A report containing data for entire project. Planner will generate the file from PROTRAK Excel plugin.
SAP REPORT 2:- A file input to create BOM in SAP (only URID’s produced and Promotions related to Moment to Stockyard on previous day). Planner to Export files from PROTRAK WEB interface. This report is validated for Bill of Materials (BOM) of Reinforcement Cage and Element. This integration has eliminated manual data entries at various levels to SAP.

• Material Master Maintenance Module
Material Code creation/construction through Protrak Report -2
Material reservation in SAP storage location-wise
Batch data processing
All above steps have single Validation
• Budget Tracking
In-house development that involves tracking of expenses associated with either PROJECT or PLANT/FACTORY (Main Cost Centers). The project budget is tracked against following costing-heads (CH) using tightly integrated SAP transactions data such as material, consumables, machinery, labour, staff, overheads and T&T.

All expenses to be accumulated against various heads called Cost Tracking Heads which are denoted by Cost Tracking Head IDs (CTHIDs) (refer figure 10) produced by enhancing the features as per specific requirements by in-house customization of standard SAP modules.

• Plant and Machinery Performance Tracking system
Although SAP has provided a standard PM module, we have customized and developed our own module for the sake of our business process optimization as per our custom logic.

• Project Cost Center concept used at following stages to help in budget tracking:
On consumption of materials
Cash Voucher Creation
All types of financial expenses-Book
On Purchase Requisition (PR) Creation
RMC production order (other than elements)

Advantages of the invention
• The present invention makes the tracking and change management simpler to track and manage.
• The present invention results in time optimization, cost reduction and simplification in execution – production, transportation, installation processes.
• The present invention results in extracting maximum advantages of precasting and the execution techniques implemented results in simplification of process, maximum repetitiveness in work-methodology, and minimum requirement of manual decision-making at execution stage.
• The present invention provides a single reference working platform for all team players.
• The present invention provides clear identification of departments and personnel manning different roles and responsibilities at the onset and in execution phase of the precast project, and mapping their roles in the modules.
• The present invention provides a channel of communication protocol amongst the personnel identified by software processes.
The foregoing objects of the invention are accomplished and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present invention described in the present embodiment. Detailed descriptions of the preferred embodiment are provided herein; however, it is to be understood that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure, or matter. The embodiments of the invention as described above and the methods disclosed herein will suggest further modifications and alterations to those skilled in the art. Such further modifications and alterations may be made without departing from the spirit and scope of the invention.
,CLAIMS:We Claim:

1. A system for integrating various processes of precast constructions, the system comprising of:
• a first module configured on a processor for modeling of precast structures by offering customization in Building Information Modeling (BIM) system for design and drawing management, the first module adapted for providing 3D view of all elements giving visibility to ground level supervisors along with providing automatic SAP input database file, resolve clashes in levels, fittings and connections, allows concrete modeling, connection details and reinforcement detailing, references for all entities such as detailer, planner, production and installation departments, automatic extraction of drawings and data from latest references, and creation of Custom components for precast element connection;
• a second module configured on the processor for precast logistics application by generating a trip plan about resources and materials utilized at a manufacturing plant site and at an onsite location for effective utilization and management of available resources and materials therein, the second module adapted for providing Self-Planning and committing of activities on day in advance and timely status updates on the availability of required machinery and resources;
• a third module configured on the processor for Pre-cast Project Planning and Tracking, the third module adapted for providing Centralized database of Project wise Precast Elements, Element Lifecycle, Erection and Production Planning, Post Production Element Tracking, Erection Interdependency of elements, Element tracking details, Projection of project end date and Graphical reports for management reporting; and
• a fourth module configured on the processor for SAP - Costing, Purchase, Financial Reporting and Budget Tracking, the fourth module adapted for providing full-fledged customized material accounting processes as per Business Process Requirement, customized in house applications in SAP environment, Integration of production cycle with Modeling System TEKLA and the third module, Material Master Maintenance Module, Budget tracking, and Plant and Machinery Performance Tracking system.

2. The system as claimed in claim 1, wherein the system employs a detailing tracking system of GFC deliverables and involves structuring of folders on a server that is on lines of ISO, and as per standards of Design Consultancy Firms.

3. The system as claimed in claim 1, wherein the second module generates the trip plan including details such as vehicle, vehicle capacity, current location, material (element type), material volume, start time, loading time, delivery time, unloading time and like.

4. The system as claimed in claim 1, wherein the third module performs Post Production Element Tracking using barcoding.

Dated this 7th of January, 2017
Prafulla Wange
(Agent for Applicant)