Lean approach in precast concrete component production

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