2024 Hacking for Homebuilding

Problem Statement:
The homebuilding industry is highly dependent on accurate forecasting of material needs and labor availability. However, these forecasts can often be inaccurate, leading to cost overruns and project delays. How can we leverage machine learning and AI to improve the accuracy of these forecasts and optimize resource allocation?

Things to Think About:

1. Data Collection: What types of data (e.g., past projects, weather conditions, market trends) would be useful for making these forecasts, and how can we collect this data?

2. Machine Learning Models: What types of machine learning models would be most effective for this type of forecasting? Consider models for time series forecasting, regression, classification, etc.

3. Integration with Existing Systems: How can we integrate these predictive models with existing project management and resource allocation systems?

4. Continuous Learning: How can we ensure that our models continue to learn and improve over time as they are exposed to more data?

5. Interpretability: How can we make the outputs of these models understandable and actionable for project managers and other decision-makers?

Problem Statement: 

Quality control is a critical aspect of homebuilding, but traditional methods can be time-consuming and error-prone. Can we use machine learning and AI to automate quality control processes and detect potential issues earlier?

Things to Think About:

1. Image Recognition: Can we use image recognition algorithms to automatically inspect photos or videos of the construction process and identify potential issues?

2. Sensor Data: Can we use sensor data from the construction site (e.g., temperature, humidity, vibration) to detect potential problems?

3. Training Data: How can we collect and label the necessary training data for these machine learning models?

4. Integration with Existing Processes: How can we integrate these automated quality control systems with existing processes and workflows?

5. Alerting and Reporting: How can we design effective alerting and reporting systems to ensure that potential issues are addressed promptly?

Problem Statement: The transportation of deckboards via railcars presents significant challenges due to inadequate strapping that fails to keep the boards stationary during extended travel periods. This issue results in boards slipping on top of one another within bundles and even shifting between different bundles. The consequences of this problem are twofold: first, the removal of a bundle often leads to damaged or broken products due to the instability caused by the slipping boards; second, the pressure from the straps within the railcar causes the deck boards to form a shingled arrangement, further exacerbating the slipping issue.

Additionally, the presence of loose cables within the railcar environment has been identified as a contributing factor to the problem. These loose cables have led to the displacement of protective corner caps, intended to shield the product from damage caused by cable rubbing. Furthermore, the insufficiently secured bundle covers and strapping allow for movement of both covers and the deck material during transit, resulting in varying types of damage to the shipped products.

Things to Think About:

1. Supply Chain Efficiency: The slipping and shifting of deckboards not only lead to product damage but also disrupt the efficiency of the supply chain, causing delays and potentially increasing operational costs.

2. Product Quality: Ensuring the integrity of the shipped deckboards is crucial to maintain product quality and customer satisfaction. Consistently damaged or broken products can harm the company's reputation.

3. Transport Safety: The instability of deckboards within railcars poses safety risks not only to the shipped products but also to the railcar operators and those involved in loading and unloading.

4. Damage Assessment: Developing a comprehensive system for assessing and documenting the extent of damage incurred during transit is essential for accurately addressing liability and improving future shipping methods.

5. Strapping Technology: Exploring advanced strapping techniques, materials, and technologies can play a pivotal role in mitigating the issues related to slipping and shifting of deckboards.

6. Corner Cap Design: Reevaluating the design of corner caps to ensure they remain securely in place even in the presence of cable movement can enhance protection during transit.

7. Bundle Cover Solutions: Implementing more robust and secure covers for bundles can prevent unwanted movement of both covers and deckboards.

8. Railcar Configuration: Investigating railcar modifications or configurations that promote stability and prevent shingling could significantly reduce the slipping issue.

9. Quality Control at Loading: Implementing stringent quality control measures during the loading process can identify improperly secured bundles before transit, reducing the occurrence of product damage.

10. Collaboration with Railcar Providers: Engaging with railcar providers to address the design and structural aspects of railcars could lead to joint solutions that benefit both parties.

11. Documentation and Training: Providing clear guidelines and training for loading personnel on proper securing techniques can minimize the risk of product movement during transit.

12. Damage Compensation: Developing a clear process for handling claims and compensation related to damaged products is essential to maintain positive relationships with customers and distributors. 

Comments from the business: 

• Product Integrity is Paramount: As a company dedicated to delivering high-quality building products, ensuring the integrity of our deckboards during shipping is of utmost importance to maintain our reputation and customer trust.

• Innovative Solutions: We pride ourselves on innovation. Exploring advanced strapping technologies and collaborating with industry partners could lead to groundbreaking solutions that revolutionize deckboard shipping practices.

• Customer Satisfaction: Customer satisfaction drives our business. Addressing the challenges of shipping-related damages aligns with our commitment to delivering products that meet and exceed customer expectations.

• Holistic Approach: Solving this issue requires a holistic approach that encompasses packaging design, secure strapping methods, and railcar modifications. We're ready to engage in multi-faceted strategies for a comprehensive solution.

• Sustainability Considerations: While tackling shipping challenges, we should also consider sustainable materials and practices to align with our environmental commitments as a responsible company.

• Data-Driven Solutions: Collecting data on shipping-related damages will enable us to make informed decisions, optimize shipping practices, and minimize waste, ultimately improving cost-efficiency.

• Collaborative Partnerships: Collaborating with railcar providers and industry experts will leverage collective knowledge and expertise, enhancing our problem-solving capabilities.

• Employee Training: Providing our employees and partners involved in the shipping process with specialized training can ensure consistent, secure loading practices and contribute to reducing product damage.

Problem Statement:  How do we create consistency in the building supply chain?

What Companies are Doing Now to Solve the Problem: 

• Relying on historical data.  Focusing on patterns and pattern changes

• Industry experts/economists 

• Long term planning using data that is out there

Things to Think About: 

1. How can we account for seasonality, sudden changes in demand levels, price cutting maneuvers of the competition and large swings of the economy?

2. So many items that go into the supply chain that are inconsistent at best: Demand, Machinery, Interest Rates, Capital Improvement, Permitting, Resource Allocation

3. The other big piece here is Forecasting (i.e. Random Lengths) 

4. The commoditization of lumber is a massive problem with building, how could we standardize?

Problem Statement: 

The process of making veneer creates cores, chips, bark, saw dust, fish tails, rejected veneers/LVL, and more. How might we develop a use for these residuals in a higher-value product or process?

Comments from Businesses:

• There are currently various uses for these residuals, for example: cores go into landscape timbers, and chips can be used for the pulp and paper industry. We are looking for innovative uses for our wood waste.

Things to Think About:

1. What are new use cases that make good use of residual wood waste?

2. How can we re-use or re-image alternative uses or sales channels?

3. How can we minimize the amount of residuals created through efficiencies in manufacturing?

4. How can we improve our chip quality and/or demand for existing or new markets?

Some examples of innovative uses of wood waste/biomass are bio-fuel, bio-based adhesive, textiles, wood pellets, wood fiber insulation, biochar, 3d printing.

Problem Statement: 

Homebuilding projects generate a large amount of data, but this data is often underutilized. How can we use analytics and machine learning to extract valuable insights from this data and improve decision-making?

Things to Think About:

1. Data Integration: How can we integrate data from various sources (e.g., project management systems, financial systems, sensor data) to create a comprehensive view of each project?

2. Descriptive Analytics: How can we use analytics to understand what has happened in past projects and why?

3. Predictive Analytics: How can we use machine learning to predict what will happen in future projects based on past data?

4. Prescriptive Analytics: How can we use analytics to recommend optimal actions based on the data?

5. Data Visualization: How can we present these insights in a way that is easy for decision-makers to understand and act upon?

Problem Statement: How do we mainline or more rapidly adopt Cross Laminated Timber as as country?

What Companies are Doing Now to Solve the Problem:

• Wait it out.  Were currently encountering some growing pains here, waiting months or longer for material

• New factories are coming online and major timber companies are showing serious interest in becoming players (see Katerra, Vaagen)

• Demand is not the problem here

• Wood is coming from Oregon

• West coast suppliers are starting to be maxed out, some European manufacturers are starting to fill the gap

• The US has a very limited number of mass timber suppliers, so customers pay a premium in dollars and time to access supply

Things to Think About: 

1. Mass timbers supply chain is not like those of concrete, steel and traditional framing.  Mass timber must be made to order and cut to certain dimensions

2. There is no off the shelf way to buy mass timber

3. How do we get past code compliance/acceptance? 

4. Very hard to switch suppliers, if your manufacturer falls behind, there are few alternatives

5. Even if supply problem is solved, how do you solve delivery (trucks and rail)

6. Mass timber projects can command rent premiums $7 higher per square foot or more.

7. How to standardize manufacturing, similar to lumber (dimensional lumber)

Problem Statement: Winter is hard for construction in Idaho, and much of the Northwest. Often times if a construction project begins in the winter, it isn't weatherproof and disaster clean-up is called to a project to eliminate mold. This clean-up can be expensive, often $4,000+, and often continues into the Spring with the rain.

Comments from Businesses:

•  Is there an anti-microbial  coating that can be applied either before install or onsite to prevent mold from growing?

• Moisture gets trapped inside, especially in the attics and crawl spaces.

• Can we design some type of inexpensive air flow system for crawl spaces.

• Quality control is a moisture meter, but you can't always catch everything with this tool.  

• Often flagged at the point of inspection, which creates a larger issue as it causes concern for buyers.
  
  

Things to Think About:

1.  Could be a seasonal service.

2. Could look to other cities, such as Seattle, to see what they do. They are more careful about the materials they use.

3. Please note that OSB/EWP manufacturers will not provide warranty on any products that have had secondary treatments, such as coatings, finishes, or other materials including damage due to chemicals or application methods.

Problem Statement:
How can we optimize (both Dealer and Distribution) our return process to make everyone involved happy?

Comments from Businesses: Every week we have returns, returns are a part of the business. We have a very thorough return process, which involves an appropriate time frame for orders to be returned, our outside sellers to check product quality, and a restock fee.

• What is an acceptable return at the dealer level may not be acceptable at the distribution level.

• Our customers may credit their customer before distribution have checked the product.

• Damaged product, how do we know where damage occurs? Should we be held responsible for damaged goods as distribution?

Things to Think About:

1. You always want to do right for the customers, but where do we draw the line?

2. How can we create a system where everyone is taken care of?

3. How can we minimize returns in general?

4. When the product comes back to our yard how do we provide credits in a timely manner?

5. How can we take the strain off our operations personnel who are receiving in returns, rechecking quality, and putting away material?

Problem Statement: Optimizing setup and installation processes when utilizing construction materials to minimize labor-intensive tasks and streamline efficiency.

Comments from Businesses: 

• Reducing setup time is crucial for profitability in construction projects.

• Streamlining installation processes can significantly cut down on overall project timelines.

• Labor costs associated with setup and installation often eat into profit margins.

• Efficient utilization of materials can positively impact project completion rates.

• Minimizing manual labor during setup and installation improves worker safety and reduces on-site accidents.

Things to Think About: 

1. Material Selection: Explore materials that require minimal setup or can be easily pre-assembled off-site.

2. Technology Integration: Investigate technologies like prefabrication or modular construction to reduce on-site installation time.

3. Training and Skill Set: Consider training workers in efficient installation methods to cut down on unnecessary labor.

4. Workflow Analysis: Assess the current setup and installation processes to identify bottlenecks and areas for improvement.

5. Equipment Utilization: Invest in specialized tools or equipment that can expedite setup and installation procedures.

6. Supplier Collaboration: Collaborate with suppliers to explore materials designed for quicker installation or those offering setup assistance.

7. Regulatory Compliance: Ensure any changes made align with safety regulations and building codes.

Example: 

• Drywall sheets:  They're a hassle to haul, install, etc. Could a cart be developed that has a specific drill setup that hauls the sheet, finds the stud for you, and drives the 12 screws at a time into the studs.

Problem Statement: The City of Boise recently passed a new Zoning Code, the Modern Zoning Code, and is looking for innovative ways to ensure accessible and affordable housing for all through pre-approved, modular home designs.

Please note: There are two parts to this problem statement, and students are welcome to select either to try and solve.

1. How do we fast-track the home construction process through pre-approved plans that align with the City of Boise's Modern Zoning Code? How can we build homes with better floor plans that can be scaled/repeated and modular? How do we keep these homes functional, aesthetically pleasing, and aligned with Boise's style(s)?

2. How do we incorporate technology to allow those ready to build an opportunity to work with the pre-approved designs, and customize within the pre-approved selections, while remaining aligned with city code?

Things to Think About: Boise stands at the forefront of change with its Modern Zoning Code. The challenge at hand is to revolutionize the way homes are designed and built in response to this new landscape.

1. How do we design modular homes that align with zoning codes for accelerated yet high-quality construction?

2. What makes an optimal floor plan and how do we seamlessly blend modern living with Boise's charm?

3. How do we create adaptable designs for multi-family homes, embracing scalability without sacrificing stability?

4. What is Boise's "style"? How do we craft homes that integrate harmoniously with the city's architectural character, reflecting Boise's unique styles.

5. How do we ensure this is sustainable? Can we source materials that balance accessibility and eco-friendliness while upholding durability standards?

6. What kind of technology would need to be developed to allow for customization within the pre-approved plans?

Resources:

• Modern Zoning Code - Traditional Residential (R-1C)

• Modern Zoning Code - Compact Residential (R-2)

• Examples: 

Florida City, Florida

Norfolk, Virginia

Problem Statement: We are contemplating the implementation of a proactive mitigation strategy to anticipate and address potential delays in the supply chain. However, adopting an overly aggressive proactive approach poses the challenge that not all items are equally susceptible to disruptions. Therefore, we are seeking a predictive or insightful method to analyze sales data and identify potential lapses in the supply chain before they occur. Such an approach would enable all stakeholders to make better preparations and necessary accommodations.

Comments from the Business: 

• The recurring issue faced by our company revolves around supply chain bottlenecks and the subsequent snowball effect on timely deliveries. 

• Our procurement process often involves quoting and purchasing products weeks or even months ahead of their scheduled arrival, and there are numerous complex steps involved in getting these products to the end customers. 

• A big issue with something on the more aggressively proactive side is that not all items fall victim to disruptions.

Things to Think About:

1. Past Data Analysis: Explore historical sales and supply chain data to identify patterns and trends related to disruptions and delays. Analyzing past incidents will provide insights into potential areas that need mitigation.

2. Collaboration and Communication: Effective communication between all parties involved in the supply chain is crucial. Engage in open dialogue with suppliers, logistics partners, and other stakeholders to understand potential challenges and work together to address them.

3. Technology Solutions: Explore the possibility of utilizing advanced technologies such as Artificial Intelligence (AI) and Machine Learning (ML) algorithms to predict supply chain disruptions based on various parameters like demand fluctuations, transportation issues, or supplier reliability.

4. Risk Assessment: Conduct a comprehensive risk assessment to identify vulnerable points in the supply chain and prioritize resources and efforts accordingly.

5. Inventory Management: Efficient inventory management practices can help buffer against supply chain disruptions. Consider maintaining safety stock levels for critical items.

6. Diversification of Suppliers: Reducing reliance on a single supplier can mitigate the impact of disruptions. Exploring multiple supplier options can enhance the resilience of the supply chain.

7. Continuity Planning: Develop contingency plans to address potential supply chain lapses and ensure minimal disruption to customer service.

8. Demand Forecasting: Accurate demand forecasting plays a significant role in managing the supply chain effectively. Utilize data-driven approaches to predict customer demand and adjust procurement accordingly.

9. Monitoring and Tracking: Implement real-time tracking and monitoring systems to have better visibility into the movement of products through the supply chain. Early detection of delays allows for swift action.

10. Post-Disruption Analysis: After any supply chain disruptions occur, conduct a thorough analysis to learn from the event and make necessary improvements to prevent similar issues in the future.

11. Industry Best Practices: Benchmark against industry best practices and consider adopting successful strategies used by other businesses facing similar supply chain challenges.

Problem Statement: Whether building, manufacturing, lumber yard, retail, or distribution -  how do you retain long term key employees? How do we keep good people in our industry?

Things to Think About:

1. Retaining long term key employees takes more than a good financial package. What other items help our industry achieve this?

2. How do you give your key long-term employees the feeling of ownership?

3. Will listening to your employees and giving them a voice in your business provide long term retention?

4. Is retention of long-term team members a goal you want to achieve?  

5. What is needed to take an employee from a beginner to a finisher?

6. Is retention a problem for you with key employees?