Integrated lean concepts and continuous/discrete-event simulation to examine productivity improvement in door assembly-line for residential buildings

Abstract

Efforts within the construction-manufacturing domain to improve assembly-line operations have benefited from paradigms emerging in the late-1990s such as lean manufacturing. This study investigates lean concept solutions to enhance productivity prior to capital investments. The investigation is carried on a case study of a single-door assembly line for residential buildings. Lean improvements are examined through an integrated continuous/discrete-event simulation approach, aiming to increase the productivity of the assembly line. The proposed simulation model incorporates factors representing the system reliability. Continuous simulation modelling, using state variable technique, is implemented to facilitate the observation of door unites in targeted sections to track the accumulation levels in these particular sections of the assembly line. In addition, proposed solutions for productivity improvements are implemented within the simulation model, such as introducing advanced alternatives for the automated stations and adding parallel stations. The effect on the productivity of the assembly line was successfully evaluated after the implantation of the proposed improvements in the simulation model. Relevant approaches can be implemented to evaluate and improve modular construction assembly lines prior to incurring capital investment.

Keywords:

• Construction
• lean
• simulation
• assembly line

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Funding

The authors are grateful for the support of the Natural Sciences and Engineering Research Council of Canada (NSERC) and All Weather Windows (Grant file no. IRCPJ 407964-10).