The production models of the past simply do not support today’s fast-paced, competitive, high-expectation, low-fault tolerance construction environment. Committed to developing a new model for our production process, we studied production systems used in other highly competitive industries – such as aviation and technology systems. We also asked Owners and Architects across the United States for their perspectives on ways to improve the way MEP projects are produced.

We developed a project management system very different from that traditionally employed by MEP consultants. Our new system was adapted from Boeing Aircraft’s very successful Lean Enterprise model. Lean Enterprise has three principal elements:

Just-In-Time

JIT means that you get what you need, when you need it. We schedule all critical activities and assign milestone dates to each. With scheduled milestones, our client and the other team members know exactly what information we need and when we need it. This system optimizes information flow and minimizes wasted time for the entire team.

In cooperation with our exclusive technology partner, Harrell, Saltrick & Hopper Technologies, LLC, we developed a collaborative, secure website for use on all Harrell, Saltrick & Hopper, PC projects. During design phase, this system allows us to post images of all project drawing files weekly. We also provide an action item list, a weekly updated schedule, meeting minutes, and all other relevant information on the website, which we make available to all design team members. During construction, all logs are posted and updated daily. These logs include Submittals, Requests for Information, Requests for Change, Bulletin Drawings, etc. Scanned images of each submittal transmittal, RFI, RFC, and bulletin drawing are also on the website. We also include scanned images of all field reports. This unique tool allows all design team members immediate access to all critical project information.

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Resources, Techniques, and Principles

RTP simply means having the right people assigned to the project and using them in an efficient manner. Harrell, Saltrick & Hopper, PC maintains a significantly higher Professional Engineer to Technical Support Staff ratio than most firms. Approximately 40 percent of our technical staff are Professional Engineers, with an average experience level exceeding 15 years. Our engineers have extensive experience with the NC State Construction Office, NC Division of Facility Services, SC DHEC, the University of North Carolina System and the Community College System, Charlotte-Mecklenburg Schools, and most other public agencies in North Carolina and South Carolina. We complement our engineers with a specialized administrative support staff to keep our engineers focused on engineering.

An experienced Professional Engineer conducts a programming study for each Harrell, Saltrick & Hopper, PC project prior to the start of design, regardless of size. This scope definition document is developed in cooperation with, and approved by the Owner and Architect prior to the preparation of any design documents. The interactive scope definition process includes meetings with the Owner and Architect to evaluate alternatives for all engineering systems. This approach significantly reduces the number of engineering-related changes during the design process and allows us to establish a much better construction budget.

Mid-way through the design process, and after all equipment has been selected, we produce a materials submittal for review and approval by the Architect and Owner. All visible equipment such as lighting fixtures, wiring devices, plumbing fixtures, HVAC diffusers, etc. is included.
 

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Error-Free Design

EFD, or first-time quality, is an absolute goal for every Harrell, Saltrick & Hopper, PC project. It is the result of the successful combination of JIT and RTP with one other critical element - automation. We have found that most MEP design errors occur, not in basic systems decisions, but in the routine, repetitive tasks related to system layout. Working closely with our subsidiary, Harrell, Saltrick & Hopper Technologies, LLC and several manufacturers, we have developed systems which automate much of these repetitive processes. The result is up to a 30 percent reduction in the time required to layout MEP systems, with a dramatic reduction in designer errors.

Unfortunately, significant reductions in design errors do not always result in significant reductions in construction errors and delays. However, proactive construction administration does significantly reduce these construction problems. Harrell, Saltrick & Hopper, PC believes in comprehensive construction administration services. If an Architect or Owner retains our services for Construction Administration, we do not limit either our field visits or our CA involvement. We spend as much time as is required to ensure that the project is constructed in compliance with the contract documents. As an added measure of assurance, we offer full project commissioning services for projects designed by us and for those projects designed by others. We are an active member of the Building Commissioning Association.

EFD is an essential element of our entire process. For example, the coordination of ceiling-mounted equipment with the ceiling grid, equipment mounted above ceilings, and electrical/mechanical equipment are typically troublesome in most projects. Harrell, Saltrick & Hopper, PC, as a matter of basic practice, produces more building sections to coordinate equipment locations. We routinely require the contractor to produce coordination drawings prior to duct fabrication to ensure that actual duct routing is coordinated with the equipment of other trades. Our lighting and systems layout drawings include locations of diffusers and other ceiling mounted equipment to ensure better coordination of this equipment. We have developed an automated equipment connection process to ensure better coordination of electrical connections to mechanical and other equipment.

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