Lean Methodologies and Techniques for Modular Construction: Chronological and Critical Review

TLDR

Modular construction builds factory‑made modules that are transported and assembled on site, combining manufacturing and construction and offering opportunities for lean production, which has historically improved productivity and quality but has yet to reach its full potential in the modular building industry. The study systematically reviews how lean techniques can be implemented across all stages of modular building production, from design to on‑site assembly. It compiles a chronological, comprehensive review of lean methodologies and tools from manufacturing and traditional construction to explore their interface with modular construction. The review offers practitioners an overview of lean strategies, highlighting potential benefits and obstacles for future case studies.

Abstract

Modular construction uses building modules manufactured inside the controlled environment of factories to be transported and assembled on site. Modular construction can be considered as a hybrid of manufacturing and construction, and in many ways lends itself to lean production. Lean production, originating in the automotive industry, permits significant improvements in terms of productivity and quality. The latest challenge of lean production is its implementation in the modular building industry, where the full potential in terms of productivity is yet to be achieved. The paper discusses the implementation of lean techniques in the modular building industry, including all the production process stages (i.e., design, manufacturing, transportation, assembly on site, and supply chain) through a systematic review. Moreover, the paper provides a chronological and comprehensive review of lean methodologies and tools in manufacturing and traditional construction industries to further investigate the interface of lean and modular construction. This may assist practitioners with an overview of lean strategies and associated potential benefits and obstacles for future case studies.