Ilke Homes Tolerance Study
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Ilke Homes Ltd
Knaresborough, North Yorkshire, UK
Manufacturing Tolerance Study
2021
Confidential
Project Description
Ilke Homes was established in 2017 with its objective to supply Category 1 volumetric
LGSF residential modules for vertically integrated deployment.
Ilke Homes was established in 2017 as a manufacturer and supplier of light gauge steel frame Category 1 volumetric modular houses and apartments to the residential sector. The Ilke Homes system was a true 'turnkey' volumetric solution, as such the fabric of the building including internal and external finishes were designed, manufactured, and installed by ilke Homes in a controlled factory environment.
Following the fit-out of its manufacturing facility, by December 2018 module production commenced with output increasing year on year. During the ramp period, several consistent quality challenges were identified and prior to the development and implementation of a new façade system, APPLY was consulted with regard to the accuracy of the Ilke Homes system and how this may be contributing to repetitive quality issues and devalue the planned product development.
Description of our Work
APPLY proposed a tolerance study and measurement plan to assess the manufacturing and site installation processes.
To gain a full understanding of the Ilke Homes manufacturing operation we:
Reviewed the design and procurement processes for the outsourced light gauge steel components.
Reviewed the assembly operations at the factory.
Reviewed the installation processes on site.
APPLY developed an illustrated end to end measurement plan which defined the rationale, method, and data set size to best inform where loss of accuracy could be taking place.
WHERE: in the manufacturing process.
WHAT: should be measured.
WHY: it should be measured.
BATCH: number of minimum repetitions to generate statistical data.
SUPPORTING DATA: any data to which the measurements obtained may be checked.
ACCURACY: the level of measurement accuracy required
The collected data was used to verify 2 primary assumptions:
1. That manufactured components could be assembled within defined limits including:
Optimising tolerances for each component.
Understanding how part variations compound during assembly operations.
Identifying critical features for the products’ intended function that required enhanced tolerances.
Assessing the cost and risk impact of too tight tolerances (cost increase) and too loose (quality risk).
Driving improved communication between design, manufacture, and assembly teams, and providing a data-driven foundation for decision making.
2. That the production process did not reduce the accuracy of component parts and identified areas for further investigation and improvement such as:
Handling of LGSF Wall and ceiling panels between boarding operations and module assembly.
Inversion of floor cassettes prior to box assembly
Placement and extent of physical support to the floor cassette and locating assistance of wall panels during module assembly (box build).
During the 5 years of Ilke Homes operations, APPLY collaborated with the team to provide Design for Manufacture and Assembly services around product and process development, installation, and accreditation.
Ilke Homes ceased trading in June 2023 having completed over 1,000 homes in 5 years.
In January 2024, following the collapse of Ilke Homes and several other MMC companies in the UK, (including L&G Modular Homes and House by Urban Splash) during 2022 and 2023, the House of Lords Built Environment Committee highlighted that the UK Government needed to take a more coherent and determined approach to addressing barriers affecting adoption of MMC: "If the Government wants the sector to be a success, it needs to take a step back, acquire a better understanding of how it works and the help that it needs, set achievable goals and develop a coherent strategy."