This research project presented a new workflow, the BIM-RFID-LAP workflow, to improve the management of material flow processes. The new workflow is designed to systematically use regularly updated detailed look-ahead plans when using BIM and RFID technologies. Because of the incorporation of look-ahead plans, the entire material flow processes can be managed with a high granularity and information transparency into detailed construction processes. The existing gaps found in conventional use of BIM and RFID technologies have, therefore, been addressed. Its implementation will help realize the Industry 4.0 vision. The workflow is supported by the use of an integrated database system. In this system, information on material properties and delivery status is collected from BIM software and RFID tags, and automatically linked with a short-term look-ahead plan. The integrated system consists of:1) a task planning module; 2) an ETO component estimation module; 3) a material ordering module; 4) a production module; 5) a location tracking module; 6) a delivery service module; 7) a quality inspection module; 8) a re-shipping module; 9) a material status module; and 10) a change request module, each of which facilitates an automated sub-process when planning and controlling the flow of materials in construction projects.

The software system enables the contractors to better observe on-site status and differences between the actual and planned material requirements, as well as to alert suppliers if necessary. It, therefore, helps both contractors and suppliers proactively track actual material demands and supply, which eliminates the time needed for correcting wrong deliveries because of changes on the selection of materials or changes on the actual material need time. The BIM-RFID-LAP workflow is shown by simulating how the material flow processes would be managed during the construction of repetitive ETO elements in an office building project. Through 500 discrete event simulation runs, it was found that the BIM-RFID-LAP workflow is able to reduce the average floor construction time for the example by 16.1% compared with the BIM-RFID-TRA workflow. Though more data can be collected from multiple projects for the process simulations, the simulation results derived from the stochastic simulating framework are sufficient to provide an overview of the differences between two workflows. The simulation results also provide the evidence to show the potential of using look-ahead plans to improve the existing practice of applications of integrated BIM and RFID technology. It is considered, therefore, a solid demonstration of complementing advanced Industry 4.0 technology with Lean principles to fill the gaps in the state-of-the-art.

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