R&D and P&D at Consera
The goal is to enhance the processes in design, production, and assembly through research and development activities, continually monitor technological advancements, increase cost-effectiveness, achieve fast production and easy assembly, and enhance competitive advantages.
Thus, sustainable, lightweight, scalable, repeatable, competitive, and high-performance products (thermal insulation, lightweight, durability, sound insulation, etc.) with a low carbon footprint are aimed to be produced.
• Process Improvements
• Material Developments
• Energy Efficiency
• Detail Enhancements
• Training
- Process Improvements
- Material Developments
- Energy Efficiency
- Detail Enhancements
- Training
Process Improvement
The efforts encompass the improvement of processes in both the design and production stages, including assembly. Consera adopts the principles of Lean Production in manufacturing and designs its entire structure accordingly, incorporating “DfMA (Design for Manufacturing and Assembly)” principles for design and manufacturing.
In the design process, Consera utilizes the BIM (Building Information Modeling) platform, facilitating interdisciplinary communication, collaboration, and coordination. This not only ensures that all project stakeholders become part of the design process at every moment but also leads to project time reduction and increased efficiency.
Through Research and Development (R&D) activities, Consera standardizes the components used in modular structure design to be as adaptable as possible to various types of structures.
This standardization enhances efficiency and productivity in both design and production.
Consera conducts digital prototyping of products to identify design errors in advance and anticipates potential efficiency losses during production.
Subsequently, the real prototype of the product is created, addressing potential issues during manufacturing, transportation, and assembly in the design phase.
Mechanical and electrical integration at Consera is also performed on the BIM platform, allowing the early detection of potential issues and considering solutions in both the design and production stages to prevent possible losses. In the design phase at Consera, material selections are made to align with module dimensions or vice versa.
This involves choosing lightweight, economically viable materials that meet the necessary criteria, optimizing the production, transportation, and assembly processes.
Consera's ongoing Research and Development activities play a crucial role in shaping the future of modular building technology, serving as a driving force for the continuous development of the company.
Improvement of Manufacturing Processes
Consera evaluates the production process in each project, conducting optimization studies to identify areas for improvement and development for the next project. During these efforts, Consera aims to optimize the production flow by achieving standardization, improving material flow, enhancing the quality control process, reducing labor times, and accelerating production, ultimately reducing production cycle time (takt time).
To deliver economical, high-quality, and fast products, Consera employs advanced production technologies and closely monitors technological advancements, continually striving to make its processes more efficient.
Consera adopts a just-in-time (JIT) production approach, producing based on demand. Consequently, the company continuously develops suppliers, creates material alternatives, reduces stock costs, and produces in response to demand, ensuring the timely supply of needed materials.
The process improvements and standardization at Consera also contribute to the continuous enhancement and development of quality control management processes.
Consera encourages the use of sustainable materials with low carbon footprint and high energy efficiency in its products. The company engages in ongoing research and development activities to promote such practices.
Advantages of R&D and P&D
Consera conducts research and development (R&D) activities to reduce the weight of modules, aiming to create lightweight, environmentally resilient, earthquake-resistant, and cost-effective solutions. The company utilizes high-strength and lightweight composite materials, as well as materials like aerogel that offer high insulation value while occupying minimal space, to produce energy-efficient, environmentally friendly, and sustainable products. Consera contributes to sustainability in the industry by using 100% recyclable steel and lightweight steel profiles in module frameworks, producing environmentally friendly lightweight modules.
Consera prioritizes energy efficiency in its products. By using high-insulation, lightweight materials in module production, the company reduces energy costs. Consera incorporates solar panels, energy recovery systems (such as hot water systems, ventilation systems, etc.), thermal mass (materials that can store and release heat during the day), energy-efficient devices and lighting, and advanced insulation technologies in its products. Ongoing R&D and innovation activities are integral to these processes.
. Consera uses details and components developed entirely in-house in its products, creating a competitive advantage through proprietary know-how. The company distinguishes itself from competitors, becoming globally competitive. With a constant focus on R&D and innovation, Consera recognizes that a firm’s permanence in the industry relies on having proprietary knowledge, patents, and being an innovative, continually evolving, and competitive company. The company has its own testing laboratory, where continuous research is conducted on the relationships between new materials and their interactions both in the structure and the frame.
One of the crucial steps in R&D and innovation activities is the education of human resources. Consera provides internal and external training support at every step, ensuring that human resources are equipped with up-to-date information on modular construction. This approach not only leads to the production of high-quality products with a high efficiency rating but also supports a continuous cycle of R&D activities. Additionally, collaborations with universities and professional associations are developed, resulting in the creation of competitive details and products, as well as contributing to the training of the required human resources.
