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

https://doi.org/10.24928/2025/0189

A Lean Approach to Productivity Improvement in Roof Panel Manufacturing for Modular Off-site Construction Using DfMA and Emerging Technologies

Amirhossein Mehdipoor1, Arash Rohani Hajiagha2, Sahar Mehdipoorkaloorazi3 & Ivanka Iordanova4

1Research Officer, National Research Council (NRC) Canada, Ottawa, Canada, [email protected], https://orcid.org/0000-0002-9889-2478
2Graduate Student, Department of Construction Engineering, École de Technologie Supérieure (ÉTS), Montreal, Canada, [email protected]
3Engineer, Falcon Structures Inc., Montreal, Canada, [email protected].
4Professor, Department of Construction Engineering, École de Technologie Supérieure (ÉTS), Montreal, Canada, [email protected], https://orcid.org/0000-0002-4596-2604

Abstract

The study investigates the application of Lean Construction principles to enhance productivity in modular off-site construction, specifically focusing on roof panel production. A systematic framework was developed, emphasizing Standardization, Elimination of Waste, Continuous Improvement, and Minimization of Time and Effort, which was tested through a real-world case study. Conducted at a modular offsite construction project in Montreal, Canada, the study involved light gauge steel structure panels covering a total gross floor area of 2,500 square meters. The adoption of lean practices resulted in a notable 32% improvement in labor productivity. Key strategies contributing to this success included the use of Design for Manufacture and Assembly tools, semi-automation, augmented reality for quality checks, and the 5S methodology (Sort, Set in order, Shine, Standardize, and Sustain). These strategies collectively minimized waste, streamlined production processes, and enhanced labor efficiency. The findings validate the effectiveness of the proposed framework and offer a replicable model for future modular construction projects aiming for productivity enhancement. By integrating these lean principles, the study provides a proper approach to improving efficiency and quality in modular construction environments, setting a benchmark for subsequent projects in the industry.

Keywords

Lean Construction Principles, Modular Off-site Construction, Productivity, DfMA

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Reference in APA 7th edition format:

Mehdipoor, A., Hajiagha, A. R., Mehdipoorkaloorazi, S. & Iordanova, I.. (2025). A Lean Approach to Productivity Improvement in Roof Panel Manufacturing for Modular Off-site Construction Using DfMA and Emerging Technologies. In Seppänen, O., Koskela, L., & Murata , K. (Eds.), Proceedings of the 33rd Annual Conference of the International Group for Lean Construction (IGLC 33) (pp. 787–798). https://doi.org/10.24928/2025/0189

Shortened reference for use in IGLC papers:

Mehdipoor, A., Hajiagha, A. R., Mehdipoorkaloorazi, S. & Iordanova, I.. (2025). A Lean Approach to Productivity Improvement in Roof Panel Manufacturing for Modular Off-site Construction Using DfMA and Emerging Technologies. IGLC33. https://doi.org/10.24928/2025/0189

 

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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