33rd Annual Conference of the International Group for Lean Construction (IGLC 33) - Osaka and Kyoto, Japan - 2025

https://doi.org/10.24928/2025/0163

Understanding the Design Process in Modular Construction Projects Based on Value Stream Mapping

Vanessa C. Cunha1, Carlos T. Formoso2, Louise Amaro3 & Iamara R. Bulhões4

1Master Student, Building Innovation Research Unit (NORIE), Federal University of Rio Grande do Sul (UFRGS), Porto Alegre, Brazil, [email protected], https://orcid.org/0009-0006-5153-5875.
2Professor, Building Innovation Research Unit (NORIE), Universidade Federal do Rio Grande do Sul (UFRGS). Porto Alegre, RS, Brazil, [email protected], orcid.org/0000-0002-4772-3746.
3Ph.D. Student, Building Innovation Research Unit (NORIE), Federal University of Rio Grande do Sul (UFRGS), Porto Alegre, Brazil, [email protected], orcid.org/0000-0002-3412-4584.
4Assistant Professor, Building Innovation Research Unit (NORIE), Federal University of Rio Grande do Sul (UFRGS), Porto Alegre, Brazil, [email protected], orcid.org/0000-0002-1519-0455.

Abstract

Design management in modular construction (MC) faces additional challenges in relation to traditional projects due to compressed lead times, increased customization demands, and interdependency between production units. These factors amplify uncertainty and require continuous decision-making under evolving conditions. Value Stream Mapping (VSM) is a powerful approach for reducing the share of non-value-adding activities of design flows and enhancing cross-sector integration. The main goal of this investigation is a set of guidelines for improving the MC design process, especially regarding planning and control. VSM was used as a diagnostic tool in the design process of a MC company from Brazil, allowing the identification of improvement opportunities in design flow. Design Science Research (DSR) was the methodological approach adopted in this investigation, being structured in iterative cycles of diagnosis, development, and evaluation. Data collection involved semi-structured interviews, direct observations, and interdisciplinary seminars. The proposed future-state VSM highlights opportunities to reduce project lead times by up to 75%, emphasizing collaborative design reviews, set-based design principles, and formal collection of client requirements. Findings suggest that VSM is an effective tool for streamlining workflows, reducing rework, and improving stakeholder coordination. This research contributes both theoretically and practically by advancing knowledge on how to deal with the type of complexity that exists in MC, providing actionable strategies for enhancing design efficiency and predictability.

Keywords

Value Stream Mapping; Design Management; Modular Construction; Process Optimization; Complexity.

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Reference in APA 7th edition format:

Cunha, V. C., Formoso, C. T., Amaro, L. & Bulhões, I. R.. (2025). Understanding the Design Process in Modular Construction Projects Based on Value Stream Mapping. In Seppänen, O., Koskela, L., & Murata , K. (Eds.), Proceedings of the 33rd Annual Conference of the International Group for Lean Construction (IGLC 33) (pp. 799–809). https://doi.org/10.24928/2025/0163

Shortened reference for use in IGLC papers:

Cunha, V. C., Formoso, C. T., Amaro, L. & Bulhões, I. R.. (2025). Understanding the Design Process in Modular Construction Projects Based on Value Stream Mapping. IGLC33. https://doi.org/10.24928/2025/0163

 

Founded in 1993, the IGLC is an international network of researchers from practice and academia in architecture, engineering, and construction (AEC) who feel that the practice, education, and research of the AEC industry have to be radically renewed in order to respond to the global challenges ahead.

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