Industrial Modularization: How to Optimize; How to Maximize R&D

The modularization business case process should be applied at the earliest opportunity. Project teams should consider the modular approach the “default” approach in order to allow the advancement of modularization in the industry. (RS283-1, p. 11)

Identified over 100 differences for planning modularization projects.  These different planning scenarios were organized into the appropriate implementation phase with over half applicable to the design phase.  Four topics where identified pertaining to the plan differences (RS283-1, p. 14 ):

1. Planning and cost estimating
2. Modularization scoping, layout, and plot plan
3. Basic design standards, models, and deliverables
4. Detailed design deliverables

The team identified 21 high-impact CSFs and found that owner responsibilities for CSF achievement during the Assessment and Selection phases are especially significant. The industry appears to be having difficulty achieving CSFs that pertain to the following: (RS283-1, p. 16)

• Owner’s planning resources and processes
• Timely design freeze
• Early completion recognition
• Cost savings recognition
• Contractor leadership
• Investment in studies
• Vendor involvement
• Owner delay avoidance

The benefits of combining modularization with design standardization can exceed the additive sum; therefore, these benefits deserve special consideration. The research team discerned two basic approaches: standard modules and the modular standardized plant. The business case for the modular standardized plant should recognize 10 forms of economic advantages and three forms of economic disadvantages or tradeoffs. An eight-step process has been documented for the implementation of the standardization strategy. A documented case study provides further insight into strategy implementation, benefits, and lessons learned. (RS283-1, p. 24)

Industry-wide barriers continue to challenge broad-based achievement of high levels of modularization. The team identified 10 maximization enablers and proposes them as counter-measures to these challenges, and to accelerate modularization across the industry. In some cases, concerted, broad-based industry efforts will be needed for full advancement of modularization. (RS283-1, p. 28)