A LEAN APPROACH TO PRODUCTIVITY IMPROVEMENT IN ROOF PANEL MANUFACTURING FOR MODULAR OFF-SITE CONSTRUCTION USING DFMA AND EMERGING TECHNOLOGIES

Abstract

The study investigates the application of Lean Construction principles to enhance productivity in modular off-site construction, specifically focusing on roof panel production. A systematic framework was developed, emphasizing Standardization, Elimination of Waste, Continuous Improvement, and Minimization of Time and Effort, which was tested through a real-world case study. Conducted at a modular offsite construction project in Montreal, Canada, the study involved light gauge steel structure panels covering a total gross floor area of 2,500 square meters. The adoption of lean practices resulted in a notable 32% improvement in labor productivity. Key strategies contributing to this success included the use of Design for Manufacture and Assembly tools, semi-automation, augmented reality for quality checks, and the 5S methodology (Sort, Set in order, Shine, Standardize, and Sustain). These strategies collectively minimized waste, streamlined production processes, and enhanced labor efficiency. The findings validate the effectiveness of the proposed framework and offer a replicable model for future modular construction projects aiming for productivity enhancement. By integrating these lean principles, the study provides a proper approach to improving efficiency and quality in modular construction environments, setting a benchmark for subsequent projects in the industry.