For nearly two decades, global automotive manufacturers have pursued some form of “digital factory” initiatives aimed at incorporating lean practices and 3D model based integration into capital projects. In the late 1990s, under mounting competitive pressures, General Motors challenged its World Wide Facilities Group (WFG) to improve key metrics for capital projects by 25%, including schedule, cost, quality, and construction site safety. WFG realized that such significant improvements could not be achieved by merely modifying existing processes. Working closely with Ghafari, WFG focused on developing a new approach to project delivery that used 3D modeling, lean practices and a more collaborative design / construction process.

With these enhancements forming the foundation for a new method of project delivery, WFG launched a series of smaller pilot projects to prove its potential. Ghafari was engaged as architect, engineer, 3D BIM consultant and integration manager for the project series. In 2004, the first of ten projects adopting "3D enabled lean" was launched to deliver safer, higher quality results with accelerated schedules and reduced costs. Ghafari developed and deployed 3D and lean enabled workflows while maintaining a running list of lessons learned and best practices.

Achieving virtually collision-free solutions enabled major efficiency gains, including off-site fabrication and preassembly of fabricated components, increased just-in-time delivery and installation, and a build-to-the-model mandate.

The GM series demonstrates how 3D model-based data exchange enables improved flow and transparency of data between design team members and their build-side partners while dramatically reducing coordination issues.

Faster and Better Quality: up to 26% faster delivery; reduced steel mill orders from 10-12 weeks to as little as 10 days; 3D as-built models created before construction; no field rework and material mistakes; no delays for interferences

Lower Cost: up to 15% cost reduction from initial cost model; earlier value engineering decisions using full-discipline 3D schematic model; virtually no field overtime; bidirectional data exchange; time-to-market accelerated; no change orders from design / building interferences

Safer: increased off-site fabrication; reduced scrap material by up to 20%; less job site clutter; better trades coordination

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