Lean approach in precast concrete component production

• Published in: Built Environment Project and Asset Management
• Main Author: Ahmad S.; Soetanto R.; Goodier C.
• Format: Article
• Language: English
• Published: Emerald Group Holdings Ltd. 2019
• Online Access: https://www.scopus.com/inward/record.uri?eid=2-s2.0-85062971632&doi=10.1108%2fBEPAM-02-2018-0051&partnerID=40&md5=faa3e3779ef0da17cebee1b1cedd3db4

Purpose: This study applied the lean approach to the reinforcement work process in the component production of industrialised building system precast concrete construction (IBSPCC). The purpose of this paper is to identify and eliminate non-value added (NVA) activities to enhance the efficiency of the production process. Design/methodology/approach: Data were collected via a case study of six-storey precast concrete building. A mapping of the reinforcement work process was conducted based on observations using time study technique and time-lapsed video, complemented by semi-structured interviews. Findings: Through this application, several NVA activities, such as unnecessary inventory, excessive movement and coordination issues, were identified. Production performance could be enhanced by implementing Just-in-Time, Kanban, and layout improvements, which would address NVA activities. Research limitations/implications: Due to the complexity of the construction process, only specific process elements were observed. To map the complete process, comprehensive observation must be conducted from beginning to end, which, though worthwhile, would be very time and resource intensive. Originality/value: This paper focusses on strategies for improving the efficiency of the IBSPCC production process in Malaysian construction by developing a conceptual framework of the lean approach for the reinforcement work process. Certain aspects in the process such as layout and inventory need to be redesigned and simplified by minimising NVA activities. © 2019, Emerald Publishing Limited.