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Design for Manufacturability in Offsite Modular | McAvoy

McAvoy colleagues onsite look at the layout of modules designed using DfMA princples on a tablet.

Design for Manufacturability in Offsite Modular

Design for Manufacturability – how to define DFMA?

To fully harness the benefits of offsite construction, it is crucial to adopt Design for Manufacture and Assembly (DfMA) principles. DfMA refers to a set of guidelines that reduce the number of components, ensure clarity, simplify fabrication and assembly, build tolerance into every component and structure, and reduce the need for adjustments. With a focus on using less to do more, DfMA projects are efficient to design, manufacture and then quicker to install. This lean process saves time in the factory and then on site, which also means there is more certainty of programme and cost certainty too. If you need a new classroom or modular ward, it can be on site more quickly, meeting pre-agreed dates and budgets.

The DfMA operates on five key principles:

Principles of DfMA

  1. Reduce the number of components – fewer parts simplify the manufacturing and assembly process
  2. Ensure clarity – designs should be easy to interpret and execute
  3. Simplify fabrication and assembly – components must be designed for ease of production and installation
  4. Incorporate tolerances – building flexibility into designs minimises errors
  5. Minimise adjustments – standardised designs reduce the need for onsite modifications.

Applying these principles enables a streamlined and efficient manufacturing process, from design to assembly. The prefabricated nature of modular construction naturally reduces the number of components, simplifies construction and uses designs that are repeatable and suitable for many applications.

Optimising Design for Manufacturability

A key aspect of design for manufacturability in offsite construction is ensuring that design dimensions align with modular specifications. Using a grid-based format tailored for offsite manufacturing helps designers achieve the best possible layout. While traditional designs can be adapted for modular construction, this often requires costly redesigns and may limit the advantages of prefabrication, so it is best to design with DfMA from the outset.

Applying DfMA principles involves balancing bespoke designs with standardised components like wall build-ups, windows and door locations. This standardisation does not restrict creative vision but instead enables smarter design choices that achieve the same outcomes with fewer variations.

Benefits of DfMA in standardisation:

  • Simplified wall build-ups and material choices enhance efficiency
  • Standardised design for manufacturability layouts optimise production
  • Less room for error and waste, reducing the time required for the factory to produce and assemble

The application of DfMA spans various sectors, including healthcare, education, commercial buildings, pharmaceutical, and single-living accommodations. As offsite manufacturing continues to grow, understanding and embracing DfMA principles will be key to achieving optimised designs, reducing costs, and improving overall project efficiency.

DfMA construction and BIM

Additionally, design for manufacturability benefits from the use of BIM (Building Information Modelling) and detailed digital models within the design process. Not only to support the creation of the models, but also to improve the detail and accuracy of the model information. This is then used for creating precise manufacturing drawings, assisting with planning the manufacture, along with analysis of the module and subassembly weights and associated installations. Also, with extremely accurate models, a greater level of planning can take place for installations. For example, DfMA designs using BIM can easily ensure that the building’s mechanical, electrical and plumbing services are well planned before the construction begins, avoiding any costly clashes that could interfere with the structure such as overlaps in the ceiling voids.

McAvoy unlocks the benefits of DfMA by enabling a streamlined and efficient manufacturing process, from design to assembly. For more about our projects and to see what solutions might work for you, visit: https://www.mcavoygroup.com/projects/

McAvoy is a leading precision manufacturer of modular buildings in the UK and Ireland, offering permanent and temporary buildings across educational, healthcare, commercial and other sectors. If your organisation is in need of temporary classrooms, a modular office, modular healthcare buildings or similar, get in touch to find out how we can help, today.