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

由于工业应用中对临时结构的需求减少，行业合作伙伴正在寻求通过增加住宅模块化建筑来使其产品线多样化。他们需要调整他们的起草过程，工厂布局，设备和流程，以有效的方式提供多样化的产品线。根据申请人的专业领域和行业合作伙伴的需求，有多个领域的潜在合作可以改善C&V的生产过程。这些包括设计，工厂布局和工艺改进，数量起飞和机械设计。这些领域的改进将使合作伙伴能够建立一个有效的制造过程，从而提高他们作为工业和住宅市场的模块化建筑商的竞争力。本研究的目的总结如下：(1)评估当前的制造生产过程，找出需要改进的目标领域；(2)通过时间研究，收集待改进区域的详细信息；(3)提出工厂布局的变更，以帮助改善生产流程，减少工艺浪费；(4)提出工作站内的工艺变更建议；(5)提出框架解决方案；(6)通过使用BIM改进制图流程，提高效率并实现数量起飞的自动化。通过该项目，高素质人才（HQP）将获得精益、模拟、项目管理和规划领域的理论专业知识和实践经验。与行业合作伙伴的合作将允许直接技术转移，因为HQP将研究工艺并验证工厂实施的改进，并将与工厂的管理、计划和生产人员定期联系。提高模块化建筑的效率将有助于加拿大的模块化建筑制造业保持竞争力，并提供价格合理、质量高的产品。使用建筑制造方法确保经济适用房的有效交付的改进将有助于展示加拿大模块化产业的潜力，以减少浪费和提高质量。

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.