Lean prefabrication : a sustainable approach

Abstract

Prefabrication is realised as a novel direction to conquer the chronic problems such as low productivity, high waste production, inferior working conditions and insufficient quality in construction. Despite benefits of prefabrication, inherent issues related to inefficiencies have been identified from its production process. Lean Production Principles are recognised as a paramount concept which enables to address production process related inefficiencies. This study aims to investigate the concept of Lean Prefabrication as means of mitigating inefficiencies in Prefabrication Production Process (PrefabPP) and its effect towards sustainability. Observations and semi-structured interviews were conducted to collect data within selected three case studies in Sri Lanka (prefabrication production yards) targeting executive level professionals who engaged in ‗prefabrication bridge beam production process.‘ The collected data were analysed using code-based content analysis and mapped using tables and matrices. Findings revealed twenty (20) PrefabPP issues, out of which ten (10) were highly severe, four (4) were moderately severe and six (6) were less severe as inefficiency issues. The study revealed that by adopting lean principles into PrefabPP that it will offer eleven (11) key benefits to PrefabPP and its customers. Results also indicated that the application of Lean production Principles to PrefabPP offers long-term benefits to construction by contributing towards sustainability. The study highlights implications to prefabrication companies, construction professionals, researches and those who deal with sustainability issues.