Manufacturing

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Innovation

Totally Modular are at the leading edge of innovation and digital design. We are working closely with many of the leading innovation organizations within the UK. We have also been awarded 3 UKRI Innovate UK grants, following our outstanding submissions to the Transforming UK Construction Competition.

Each of our projects encompasses an innovative, digital spine throughout the process to drive quality assurance and provide a transparent audit trial by integrating Building Information Modelling (BIM) technology. The BIM model acts as the birth certificate of the homes, from design all the way through to delivery, and then supports the client or homeowner by acting as the equivalent to a MOT and service book.

Innovative Manufacturing

Our manufacturing process operates from our 40,000 sqft factory in the West Midlands, where our facilities are purpose built to enable us to build precision engineered housing solutions on a production line. At present we have capacity to manufacture 40,000 sqm a year.

The improved quality from the precision engineered manufacturing process naturally lowers the failure rate of the assets, thereby improving predictability and reducing quantum of asset maintenance costs.

Accuracy is heightened through our delivery, as typically traditional construction suffers the stresses of ever changing weather conditions, scheduling problems or document management on site. Offsite construction controls this process with each trade located inside the factory, where key-stage inspection points are documented within the manufacturing procedures, which are monitored by proactive quality control inspectors positioned within the production environment which can’t be overlooked due to vast scrutiny at each workstation.

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Benefits of
Modular Manufacture

01.

DfMA
Methodology

Using Totally Modular’s innovative Design for Manufacture and Assembly (DfMA) methodology we are leading a step-change in the increased productivity of the construction process, tangible quality improvements and the associated reduction in true costs.

DfMA is a catalyst for creativity/innovation, it is an approach to design that focuses on ease of manufacture and efficiency of assembly. The programme savings that DfMA enables is an important driver. This streamlined/efficient methodology allows for repeatability of end products.

02.

Building
Information Modeling

Each project encompasses an innovative, digital spine throughout the process to drive quality assurance and provide a transparent audit trial. Two key digital approaches utilised are BIM and BOM (Bill of Materials).  The use of BIM allows for; better collaboration, improved coordination, scheduling and increased productivity.

BIM makes it possible to detail the materials, cost model and maintenance modelling for every house type and allows for better collaboration between parties. There are benefits that BIM can bring to both off-site and traditional construction, with its ability to provide a visualisation of the proposed design allowing project managers to iron out any potential issues before work commences.

 

The BIM model acts as an overarching skeleton of the houses, as it provides a transparent audit trail from design all the way through to delivery. For example, if a door needs to be replaced, the BIM model shows the door manufacturer, product code and product details.

The integration of an advanced digital BOM benefits estimation, supply chain coordination, systems installation, the final construction and manufacturing process. The advantages of this lead to inventory efficiencies, lean manufacturing practises and less wastage.

03.

Modern Method
of Construction

According to the Governments MMC Framework, Totally Modular fall under ‘Category 1’ – Pre Manufacturing (3D primary structural systems).

A systemised approach based on volumetric construction involving the production of three-dimensional units in controlled factory conditions prior to final installation. Volumetric units can be brought to final site in a variety of forms ranging from a basic structure only, to one with all internal and external finishes and services installed, all ready for installation.

 

Volumetric modular building is a construction method where accommodation is created using predetermined, self-supporting volumes or modules, manufactured offsite, in factories, under controlled conditions. The volumetric modular technique avoids many of the limiting factors and challenges faced by traditional construction methods in favour of a manufacturing and engineering orientated approach.

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