Lean Homebuilding Using Modular Technology

Abstract

This study focused on the application of lean production principles to modular homebuilding. To organize the effort, a kaizen blitz was used in a brief but intense attack on construction waste and inefficiency. Two factors made this effort unique. First, the home builder used factory-built modules, which dictated that the kaizen blitz improvement team must be extended up the supply chain to include both the modular manufacturer and builder and down the supply chain to include subcontractors. Second, conventional concepts of continuous flow and batch production were extended to a project-oriented construction environment. This article described how these issues were resolved and presented results that included substantial reductions in construction cycle time and significant improvements in safety, quality, productivity, and energy efficiency.

Additional information

Notes on contributors

Michael A. Mullens

Michael A. Mullens is an Associate Professor, Department of Industrial Engineering and Management Systems, and founder and Principal Investigator of the UCF Housing Constructability Lab, University of Central Florida, Orlando, FL

Mark E. Kelley

Mark E. Kelley, III, is a founding member of the Hickory Consortium and founder of Building Science Engineering, Harvard, MA.