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Lean approach in precast concrete component production

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journal contribution
posted on 04.03.2019 by Yani Ahmad, Robby Soetanto, Chris Goodier
Purpose – This study applied the lean approach to the reinforcement work process in the component production of industrialised building system precast concrete construction (IBSPCC). The primary aim of the research was to identify and eliminate previously overlooked non-value added (NVA) activities to enhance the efficiency of the production process. Design/Methodology/Approach - Data were collected via a case study of six-storey precast concrete building. A mapping of the reinforcement work process was conducted based on observations using time study technique and time-lapsed video, complemented by semistructured interviews. Findings – Through this application, several previously overlooked NVA activities, such as unnecessary inventory, excessive movement, and coordination issues, were identified. Production performance could be enhanced by implementing Just-in-Time, Kanban, and layout improvements, which would address NVA activities. Research Limitation/Implication – Due to the complexity of the construction process, only specific process elements were observed. To map the complete process, comprehensive observation must be conducted from beginning to end, which, though worthy, would be very time and resource intensive. Originality/Value – This paper focuses on strategies for improving the efficiency of the IBSPCC production process in Malaysian construction by developing a conceptual framework of the lean approach for the reinforcement work process. Certain aspects in the process such as layout and inventory need to be redesigned and simplified by minimising NVA activities



  • Architecture, Building and Civil Engineering

Published in

Built Environment Project and Asset Management


AHMAD, S., SOETANTO, R. and GOODIER, C.I., 2019. Lean approach in precast concrete component production. Built Environment Project and Asset Management, 9 (3), pp.457-470.


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AM (Accepted Manuscript)

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This work is made available according to the conditions of the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International (CC BY-NC-ND 4.0) licence. Full details of this licence are available at: https://creativecommons.org/licenses/by-nc-nd/4.0/

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This paper was accepted for publication in the journal Built Environment Project and Asset Management and the definitive published version is available at https://doi.org/10.1108/BEPAM-02-2018-0051