Process improvement for a modular construction manufacturer through the use of lean tools, automation, and improved plant layout

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Due to decreased demand for temporary structures in industrial applications, the industry partner is seeking to diversify their product line with the addition of residential modular buildings. They need to adapt their drafting process, plant layout, equipment, and processes to deliver a diversified product line in an efficient manner. Based on the areas of expertise of the applicant and the needs of the industry partner, there are multiple areas of potential collaboration to improve C&V's production process. These include design, plant layout and process improvement, quantity take-off, and machinery design. Improvement in these areas will position the partner to establish an efficient manufacturing process that boosts their competitiveness as a modular builder in both the industrial and residential markets. The objectives of this research are summarized as follows: (1) assess the current manufacturing production process to identify target areas for improvement; (2) collect detailed information through time study for the areas targeted for improvement; (3) propose changes to plant layout to help improve the production flow and reduce process waste; (4) propose process changes within workstations; (5) propose framing solutions; and (6) improve the drafting process through the use of BIM to increase efficiency and allow automation of quantity takeoff. Through this project, highly qualified personnel (HQP) will gain both theoretical expertise and practical experience in the areas of Lean, simulation, and project management and planning. The collaboration with the industry partner will allow for direct technology transfer as HQP will study the process and validate the improvements implemented in the plant, and will be in regular contact with management, planning, and production personnel at the plant. Improving the efficiency of modular construction will help Canada's modular construction manufacturing industry to remain competitive and to offer product that is affordable and of high quality. Improvements to ensure the efficient delivery of affordable homes using a construction manufacturing approach will aid in demonstrating the potential of the modular industry in Canada to produce homes with less waste and improved quality.