This study proposes the improvement of production systems and internal logistics in modular construction, focusing on Blufab, a company specialised in prefabricated bathroom units (PODs). Key challenges identified include unbalanced workflows, inefficient layouts and internal logistics problems. To address these challenges, line balancing methods such as Ranked Positional Weight (RPW) and Largest Candidate Rule (LCR) were applied. Additionally, the factory layout was revised, and line-side delivery strategies were implemented, incorporating Kanban systems, milk-runs and periodic replenishment. A redesigned layout with a conveyor belt reduced material transport inefficiencies. The milk-run system efficiently replenishes materials while meeting ergonomic standards. Kanban facilitated timely critical material replenishment and periodic supply strategies to manage materials with predictable consumption. This research underscores the potential to streamline modular construction production, improving workflow transitions and enhancing alignment between production and logistical processes. By addressing ergonomic considerations and adapting replenishment techniques to material-specific needs, the approach fosters a balanced and responsive production environment.

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Improvement of the Production and Logistics Systems in a Modular Construction Company

  • Ana Carolina Cunha,
  • Ana Catarina Abreu,
  • Ana Luísa Machado,
  • Bárbara Silva,
  • Carolina Dantas,
  • Catarina Wilson,
  • Inês Araújo,
  • Lara Correia,
  • Raquel Dantas,
  • Rui M. Lima

摘要

This study proposes the improvement of production systems and internal logistics in modular construction, focusing on Blufab, a company specialised in prefabricated bathroom units (PODs). Key challenges identified include unbalanced workflows, inefficient layouts and internal logistics problems. To address these challenges, line balancing methods such as Ranked Positional Weight (RPW) and Largest Candidate Rule (LCR) were applied. Additionally, the factory layout was revised, and line-side delivery strategies were implemented, incorporating Kanban systems, milk-runs and periodic replenishment. A redesigned layout with a conveyor belt reduced material transport inefficiencies. The milk-run system efficiently replenishes materials while meeting ergonomic standards. Kanban facilitated timely critical material replenishment and periodic supply strategies to manage materials with predictable consumption. This research underscores the potential to streamline modular construction production, improving workflow transitions and enhancing alignment between production and logistical processes. By addressing ergonomic considerations and adapting replenishment techniques to material-specific needs, the approach fosters a balanced and responsive production environment.