Lean approach in precast concrete component production

Abstract

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 primary aim of the research was to identify and eliminate previously overlooked 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 semistructured interviews. Findings -Through this application, several previously overlooked 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 Limitation/Implication -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 worthy, would be very time and resource intensive. Originality/Value -This paper focuses 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. Keywords Industrialised building system (IBS), precast concrete construction (PCC), nonvalue added (NVA) activity, lean approach, reinforcement work process, process improvement. Paper type Case study positioned and assembled into a structure with minimal additional site work" (CIDB et al., 2010). Different terms such as off-site, modern methods of construction (MMC), prefabrication and preassembly, are sometimes described as IBS, but there are important distinctions between them (Kamar et al., 2011). This IBS definition focuses on building with structural components (e.g. columns, beams and walls/panels); comprises six types of structural system (precast, steel, timber, formwork, blockwork and innovative system based on wall components). IBS public CIDB , must achieve a minimum of 70 points (IBS score), and based on an assessment of the structural systems (precast beam, column and steel), wall systems (e.g. glass, dry partition, block work and precast panel) and other simplified construction solutions. A higher score reflects a higher reduction of waste labour and cost.Several comparative studies between IBSPCC) and conventional construction (CC) have revealed that IBSPCC can increase labour productivity, speed up construction, and increase quality. Nevertheless, most of these studies concentrated on the on-site assembly process. For example, Abdul Kadir et al. (2006) and Gunawan (2013), compared CC with IBSPCC and concluded that IBSPCC has the...

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