Improving the Efficiency, Productivity, and Cost-Effectiveness of Modular Design and Construction Processes

This thesis provides a methodology to incorporate building information modeling (BIM), lean construction, and simulation modelling into a cohesive package in the context of modular manufacturing. BIM was used to construct a three dimensional model from which the wall and object properties were extracted. The methodology provides an efficient and effective method of estimating wall fabrication and erection probabilistic productivity rates by completing and analysing a time study to produce a realistic model for validating proposed changes to the process design to decrease time and cost requirements. The methodology of this thesis was explored though a case study of a modular manufacturing company to illustrate the functionality of the simulation model and its benefits for decision making. A current state and future state model of the wall fabrication and wall erection stations was created based on the findings of a detailed kaizen. By altering the fabrication station layout to the future state, a 10.1% decrease in overall module wall fabrication and erection was predicted with a 5.2% reduction in overall man hour requirements in comparison to current state simulation values.