Cost-Optimized Transport Planning for Prefabricated Modules with the Implementation of the Just-in-Time Strategy
Publication: Journal of Construction Engineering and Management
Volume 150, Issue 8
Abstract
Modular integrated construction (MiC) has witnessed increasing adoption in worldwide building projects, driven by various benefits, including improved construction efficiency, reduced on-site labor hours, and minimized waste and pollution. The construction industry has recognized the transportation of prefabricated modules as a huge obstacle to the wide implementation of MiC. In practice, transport planning of prefabricated modules is usually intuitively decided by general contractors based on experience. Intuitive decisions cannot ensure the just-in-time (JIT) module delivery, thereby incurring additional costs of early and late delivery. Motivated by this challenge, this study endeavors to design cost-minimized transportation plans for prefabricated modules using mathematical programming methodology. An integer programming model and a tailored solution method are proposed. Then, we use data from two real building projects in Hong Kong as model inputs to demonstrate the computation of optimal module transport plans using the proposed methodology. Numerical results show that, if the JIT strategy is not considered in module transport planning, the actual total transportation costs will be 21.74% higher than the expected ones. Comparative costs of JIT implementation and nonimplementation indicate the significance of the JIT strategy. Additionally, our proposed method can achieve punctual module delivery and reduce the overall transportation expenses by 10.13%, implying considerable cost savings.
Get full access to this article
View all available purchase options and get full access to this article.
Data Availability Statement
All data, models, or code that support the findings of this study are available from the corresponding author upon reasonable request.
Acknowledgments
This work was supported by the National Natural Science Foundation of China (Grant Nos. 72201229 and 72361137006) and the Research Grants Council of the Hong Kong Special Administrative Region, China (Project No. 25211722).
References
Bertram, N., S. Fuchs, J. Mischke, R. Palter, G. Strube, and J. Woetzel. 2019. “Modular construction: From projects to products.” Accessed February 17, 2024. https://www.mckinsey.com/capabilities/operations/our-insights/modular-construction-from-projects-to-products.
Building and Construction Authority. 2023. “Prefabricated prefinished volumetric construction (PPVC).” Accessed September 2, 2023. https://www1.bca.gov.sg/buildsg/productivity/design-for-manufacturing-and-assembly-dfma/prefabricated-prefinished-volumetric-construction-ppvc.
Building and Construction Authority. 2024a. “Design for manufacturing and assembly (DfMA)—Prefabricated prefinished volumetric construction.” Accessed February 17, 2024. https://www1.bca.gov.sg/docs/default-source/docs-corp-news-and-publications/publications/for-industry/ppvc_guidebook.pdf.
Building and Construction Authority. 2024b. “Precast concrete elements.” Accessed February 17, 2024. https://www1.bca.gov.sg/docs/default-source/docs-corp-buildsg/quality/precastappendixb-combined.pdf.
Chen, G., J. Huang, J. Wang, J. Wei, W. Shou, Z. Cao, W. Pan, and J. Zhou. 2023. “Optimal procurement strategy for off-site prefabricated components considering construction schedule and cost.” Autom. Constr. 147 (Mar): 104726. https://doi.org/10.1016/j.autcon.2022.104726.
Construction Industry Council. 2018. “Potential utilisation of prefabrication yards and prefabricated components in Hong Kong.” Accessed September 2, 2023. https://www.cic.hk/files/page/56/Potential%20Utilisation%20of%20Prefabrication%20Yards%20and%20Prefabricated%20Components%20in%20HK.pdf.
Construction Industry Council. 2020. “Reference material on logistics and transport for modular integrated construction projects.” Accessed September 2, 2023. https://mic.cic.hk/files/Information/2/File/Logistics_and_Transport_for_MiC_Projects.pdf.
Construction Industry Council. 2021. “Reference materials—Logistics and transport for MiC projects.” Accessed September 2, 2023. https://www.cic.hk/files/page/51/202111214%20Logistics%20%26%20Transport%20for%20MiC%20Projects.pdf.
Construction Industry Council. 2023a. “MiC projects.” Accessed February 17, 2024. https://mic.cic.hk/en/MicProjects.
Construction Industry Council. 2023b. “Statutory requirements for modular integrated construction projects.” Accessed February 17, 2024. https://www.cic.hk/files/page/51/20231030%20Statutory%20Requirements%20for%20MiC%20Projects.pdf.
Dan, Y., and G. Liu. 2023. “Integrated scheduling optimization of production and transportation for precast component with delivery time window.” Eng. Constr. Archit. Manage. https://doi.org/10.1108/ECAM-09-2022-0871.
Du, J., Y. Xue, V. Sugumaran, M. Hu, and P. Dong. 2023. “Improved biogeography-based optimization algorithm for lean production scheduling of prefabricated components.” Eng. Constr. Archit. Manage. 30 (4): 1601–1635. https://doi.org/10.1108/ECAM-04-2021-0311.
Fang, Y., and S. T. Ng. 2019. “Genetic algorithm for determining the construction logistics of precast components.” Eng. Constr. Archit. Manage. 26 (10): 2289–2306. https://doi.org/10.1108/ECAM-09-2018-0386.
Heravi, G., M. Rostami, and M. F. Kebria. 2020. “Energy consumption and carbon emissions assessment of integrated production and erection of buildings’ prefabricated steel frames using lean techniques.” J. Cleaner Prod. 253 (May): 120045. https://doi.org/10.1016/j.jclepro.2020.120045.
Hong, J., G. Q. Shen, Z. Li, B. Zhang, and W. Zhang. 2018. “Barriers to promoting prefabricated construction in China: A cost–benefit analysis.” J. Cleaner Prod. 172 (May): 649–660. https://doi.org/10.1016/j.jclepro.2017.10.171.
Hong Kong Consumer Council. 2023. “Oil price watch.” Accessed September 2, 2023. https://oil-price.consumer.org.hk/en/diesel.
Hsu, P.-Y., P. Angeloudis, and M. Aurisicchio. 2018. “Optimal logistics planning for modular construction using two-stage stochastic programming.” Autom. Constr. 94 (Oct): 47–61. https://doi.org/10.1016/j.autcon.2018.05.029.
Hussein, M., and T. Zayed. 2021. “Critical factors for successful implementation of just-in-time concept in modular integrated construction: A systematic review and meta-analysis.” J. Cleaner Prod. 284 (Feb): 124716. https://doi.org/10.1016/j.jclepro.2020.124716.
Karam, A., and K. H. Reinau. 2021. “Evaluating the effects of the a-double vehicle combinations if introduced to a line-haul freight transport network.” Sustainability 13 (15): 8622. https://doi.org/10.3390/su13158622.
Kong, L., H. Li, H. Luo, L. Ding, X. Luo, and M. Skitmore. 2017. “Optimal single-machine batch scheduling for the manufacture, transportation and JIT assembly of precast construction with changeover costs within due dates.” Autom. Constr. 81 (Sep): 34–43. https://doi.org/10.1016/j.autcon.2017.03.016.
Kong, L., H. Li, H. Luo, L. Ding, and X. Zhang. 2018. “Sustainable performance of just-in-time (JIT) management in time-dependent batch delivery scheduling of precast construction.” J. Cleaner Prod. 193 (Aug): 684–701. https://doi.org/10.1016/j.jclepro.2018.05.037.
Koskela, L. 1992. Application of the new production philosophy to construction.. Standford, CA: Stanford Univ.
Liu, G., R. Huang, K. Li, A. Shrestha, and X. Fu. 2022. “Greenhouse gas emissions management in prefabrication and modular construction based on earned value management.” J. Constr. Eng. Manage. 148 (6): 04022034. https://doi.org/10.1061/(ASCE)CO.1943-7862.0002268.
Lu, W., and H. Yuan. 2013. “Investigating waste reduction potential in the upstream processes of offshore prefabrication construction.” Renewable Sustainable Energy Rev. 28 (Dec): 804–811. https://doi.org/10.1016/j.rser.2013.08.048.
Lu, Y., and Y. Zhu. 2021. “Integrating hoisting efficiency into construction site layout plan model for prefabricated construction.” J. Constr. Eng. Manage. 147 (10): 04021130. https://doi.org/10.1061/(ASCE)CO.1943-7862.0002158.
Nie, Q., S. Liu, Q. Qian, Z. Tan, and H. Wang. 2021. “Optimization of the Sino-Europe transport networks under uncertain demand.” Asia-Pacific J. Oper. Res. 38 (3): 2140019. https://doi.org/10.1142/S0217595921400194.
Niu, Y., W. Lu, D. Liu, K. Chen, C. Anumba, and G. G. Huang. 2017. “An SCO-enabled logistics and supply chain–management system in construction.” J. Constr. Eng. Manage. 143 (3): 04016103. https://doi.org/10.1061/(ASCE)CO.1943-7862.0001232.
Poon, C. S., A. T. W. Yu, A. Wong, and R. Yip. 2013. “Quantifying the impact of construction waste charging scheme on construction waste management in Hong Kong.” J. Constr. Eng. Manage. 139 (5): 466–479. https://doi.org/10.1061/(ASCE)CO.1943-7862.0000631.
Si, T., H. X. Li, Z. Lei, H. Liu, and S. Han. 2021. “A dynamic just-in-time component delivery framework for off-site construction.” Adv. Civ. Eng. 2021 (Jun): 1–19. https://doi.org/10.1155/2021/9953732.
Song, Y., X. Wang, G. Wright, D. Thatcher, P. Wu, and P. Felix. 2019. “Traffic volume prediction with segment-based regression kriging and its implementation in assessing the impact of heavy vehicles.” IEEE Trans. Intell. Transp. Syst. 20 (1): 232–243. https://doi.org/10.1109/TITS.2018.2805817.
Sun, Y., J. Wang, J. Wu, W. Shi, D. Ji, X. Wang, and X. Zhao. 2020. “Constraints hindering the development of high-rise modular buildings.” Appl. Sci. 10 (20): 7159. https://doi.org/10.3390/app10207159.
Tan, Z., H. Li, H. Wang, and Q. Qian. 2021. “Maritime container shipping fleet deployment considering demand uncertainty.” Asia-Pacific J. Oper. Res. 38 (3): 2140026. https://doi.org/10.1142/S0217595921400261.
The Legislative Council. 2022. “Promotion of Lego-like construction method in Singapore.” Accessed February 17, 2024. https://www.legco.gov.hk/research-publications/english/essentials-2022ise01-promotion-of-lego-like-construction-method-in-singapore.htm.
Transport Department. 2023. “Traffic aids drawings (2nd generation).” Accessed September 2, 2023. https://data.gov.hk/en-data/dataset/hk-td-tis_16-traffic-aids-drawings-v2.
Wang, H., L. Liao, W. Yi, and L. Zhen. 2023a. “Transportation scheduling for modules used in modular integrated construction.” Int. J. Prod. Res. 62 (11): 3918–3931. https://doi.org/10.1080/00207543.2023.2251602.
Wang, H., W. Yi, X. Tian, and L. Zhen. 2023b. “Prescriptive analytics for intelligent transportation systems with uncertain demand.” J. Transp. Eng. 149 (12): 04023118. https://doi.org/10.1061/JTEPBS.TEENG-8068.
Wang, H., W. Yi, and L. Zhen. 2024. “Optimal policy for scheduling automated guided vehicles in large-scale intelligent transportation systems.” Transp. Res. Part A 179: 103910. https://doi.org/10.1016/j.tra.2023.103910.
Wang, H., W. Yi, L. Zhen, H. Wang, and A. C. Chan. 2023c. “Automated generation of stacking plans for prefabricated panels transported by A-frame trailers.” Adv. Eng. Inf. 57 (Aug): 102077. https://doi.org/10.1016/j.aei.2023.102077.
Xie, Y., H. Wang, G. Liu, and H. Lu. 2023. “Just-in-time precast production scheduling using dominance rule-based genetic algorithm.” IEEE Trans. Neural Networks Learn. Syst. 34 (9): 5283–5297. https://doi.org/10.1109/TNNLS.2022.3217318.
Xu, Z., T. Zayed, and Y. Niu. 2020. “Comparative analysis of modular construction practices in mainland China, Hong Kong and Singapore.” J. Cleaner Prod. 245 (Feb): 118861. https://doi.org/10.1016/j.jclepro.2019.118861.
Yang, Y., M. Pan, and W. Pan. 2022. “Integrated offsite logistics scheduling approach for high-rise modular building projects.” J. Constr. Eng. Manage. 148 (6): 04022032. https://doi.org/10.1061/(ASCE)CO.1943-7862.0002280.
Yang, Y., M. Pan, W. Pan, and Z. Zhang. 2021. “Sources of uncertainties in offsite logistics of modular construction for high-rise building projects.” J. Manage. Eng. 37 (3): 04021011. https://doi.org/10.1061/(ASCE)ME.1943-5479.0000905.
Yi, W., H. Wang, L. Zhen, and A. P. C. Chan. 2024. “Optimal tri-level government–manufacturers–contractors subsidy plan: Maximizing local prefabricated product usage and minimizing transport emissions.” IEEE Trans. Eng. Manage. 71: 3530–3553. https://doi.org/10.1109/TEM.2023.3346409.
Yi, W., H. Wang, L. Zhen, and Y. Liu. 2023a. “Automated generation of horizontal precast slab stacking plans.” J. Constr. Eng. Manage. 149 (12): 04023121. https://doi.org/10.1061/JCEMD4.COENG-13424.
Yi, W., H. Wang, R. Zhong, and L. Zhen. 2023b. “Balancing economical and environmental trade-off in modular construction yard planning: Models and properties.” Cleaner Logist. Supply Chain 9 (Dec): 100121. https://doi.org/10.1016/j.clscn.2023.100121.
Yi, W., S. Wang, and A. Zhang. 2020. “Optimal transportation planning for prefabricated products in construction.” Comput.-Aided Civ. Infrastruct. Eng. 35 (4): 342–353. https://doi.org/10.1111/mice.12504.
Yi, W., S. Wu, L. Zhen, and G. Chawynski. 2021. “Bi-level programming subsidy design for promoting sustainable prefabricated product logistics.” Cleaner Logist. Supply Chain 1 (Oct): 100005. https://doi.org/10.1016/j.clscn.2021.100005.
Zhang, H., and L. Yu. 2020. “Dynamic transportation planning for prefabricated component supply chain.” Eng. Constr. Archit. Manage. 27 (9): 2553–2576. https://doi.org/10.1108/ECAM-12-2019-0674.
Zhen, L., X. He, H. Wang, G. Laporte, and Z. Tan. 2022. “Decision models for personal shopper platform operations optimization.” Transp. Res. Part C 142: 103782. https://doi.org/10.1016/j.trc.2022.103782.
Zheng, Z., M. Pan, Y. Yang, and W. Pan. 2023. “Motion planning for efficient and safe module transportation in modular integrated construction.” Comput.-Aided Civ. Infrastruct. Eng. 38 (5): 580–600. https://doi.org/10.1111/mice.12835.
Zhu, D., H. Du, Y. Sun, and N. Cao. 2018. “Research on path planning model based on short-term traffic flow prediction in intelligent transportation system.” Sensors 18 (12): 4275. https://doi.org/10.3390/s18124275.
Zhu, S., H. Wang, X. Zhang, X. He, and Z. Tan. 2022. “A decision model on human-robot collaborative routing for automatic logistics.” Adv. Eng. Inf. 53 (Aug): 101681. https://doi.org/10.1016/j.aei.2022.101681.
Information & Authors
Information
Published In
Journal of Construction Engineering and Management
Volume 150 • Issue 8 • August 2024
Copyright
© 2024 American Society of Civil Engineers.
History
Received: Dec 21, 2023
Accepted: Mar 12, 2024
Published online: Jun 8, 2024
Published in print: Aug 1, 2024
Discussion open until: Nov 8, 2024
Authors
Metrics & Citations
Metrics
Citations
Download citation
If you have the appropriate software installed, you can download article citation data to the citation manager of your choice. Simply select your manager software from the list below and click Download.