Production Improvements in Offsite Construction Facilities Using Simulation and Lean Principles

• Author / Creator

  Brown, Ryan

• To capitalize on the efficiency observed in the manufacturing sector, the industrialization of construction has been used to update traditional construction methods. By applying manufacturing principles to the construction process in offsite construction facilities it is possible to transform traditional construction methods for buildings and building components into a more efficient, cost effective and continually improving process. In this research, three different offsite construction facilities are investigated. The first is a panelized home manufacturer that produces two-dimensional building sections, which are then assembled on-site. Second is a modular home manufacturer; this facility assembles buildings into a volumetric unit before shipping the module to site. The last is a cabinet manufacturing facility that produces custom cabinets for numerous types of buildings. Each of these production types can be made more efficient by industrializing the construction process and applying manufacturing principles. The first three papers in this thesis develop methods to increase production efficiency using various production improvements in offsite construction facilities. The final paper develops a method in which production efficiency and performance can be measured in an offsite construction facility. In each paper, a case study is presented in which current practices of the facility are modelled in a simulated environment and inefficiencies in current production are identified. Based on these inefficiencies, possible solutions to improve production are developed. These proposed solutions include lean process improvements, multi-skilled labour implementation and the use of an innovative roof design. Lastly, the proposed solutions are tested and analyzed through future state simulation to determine the production benefits for the offsite construction facility. The advantages gained from the industrialization of construction are presented through these real-world case studies to validate the feasibility and benefits of construction manufacturing.

• Subjects / Keywords

  • Production Improvements
  • Lean Principles
  • Simulation
  • Offsite Construction

• Graduation date

  Spring 2020

• Type of Item

  Thesis

• Degree

  Master of Science

• DOI

  https://doi.org/10.7939/r3-3nkn-5r11

• License

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