Case Studies
Jun 15, 2012

Effects of Lean Construction on Sustainability of Modular Homebuilding

Publication: Journal of Architectural Engineering
Volume 18, Issue 2

Abstract

Construction activities and the built environment have an enormous effect on the environment, human health, and the overall economy. Sustainable homebuilding in all three dimensions of economic, environmental, and social effects is attainable through practical innovations and technologies. However, the greatest barrier to the widespread application of sustainable homebuilding is the higher initial costs largely attributable to the learning curve of workers building with these practical innovations and technologies, and the added cost resulting from ill-defined construction processes. To address these challenges and reach the ideal of sustainable construction, this paper proposes the use of lean construction as a viable and effective strategy, in particular the lean tool kaizen. This paper uses several case studies to showcase the effect of lean on the triple bottom line of sustainability in modular homebuilding. Each case study highlights one dimension of sustainability. Lean construction resulted in a significant environmental effect by reducing material waste by 64%, a significant social effect by reducing or eliminating key safety hazards of excessive force, poor posture, and struck-by, and a significant economic effect by reducing production hours by 31%. Findings from this research will contribute to a better understanding of the effect of lean on homebuilding sustainability and will promote lean and safe building techniques in modular homebuilding.

Get full access to this article

View all available purchase options and get full access to this article.

References

Allen, E. E., and Iano, J. (2004). Fundamentals of building construction, materials and methods, 4th Ed., Wiley, New York.
Bae, J., and Kim, Y-W. (2007). “Sustainable value on construction project and application of lean construction methods.” Proc., 15th Annual Conf. of the Int. Group for Lean Construction (IGLC-15), Pasquire, C., and Tzortzopoulos, P., eds., Lean Construction Institute, Ketchum, ID.
Ballard, G., and Howell, G. A. (1998). “What kind of production is construction?Proc., 6th Annual Conf. of the Int. Group for Lean Construction (IGLC-6), Lean Construction Institute, Ketchum, ID, 1–9.
Bergmiller, G. G., and McCright, P. R. (2009). “Parallel models for lean and green operations.” Proc., 2009 Industrial Engineering Research Conf., Institute of Industrial Engineers, Atlanta, GA.
Bruntland, G. (1987). “Our common future: The world commission on environment and development.” Oxford Univ. Press, Oxford.
Carlson, D. O. (1991). “Automated builder: dictionary/encyclopedia of industrialized housing.” Automated Builder Magazine, Publications Division, CMN Associates, Carpinteria, CA.
Dentz, J., and Blanford, M. (2007). “Lean factories cut costs, boost production ”, Automated Builder, July 2007.
Horvath, A. (2004). “Construction materials and the environment.” Annu. Rev. Environ. Resourc., 29, 181–204.
Ikuma, L, and Nahmens, I. (2010). “SLIK operations.” IE Ind. Eng., 42(10), 26–31.
Koskela, L. (1992). Application of the new production philosophy to construction, CIFE Technical Report #72, Stanford Univ., Stanford, CA.
Koskela, L. (1993). “Lean production in construction.” Autom. Constr.AUCOES, 3(1), 47–54.
Koskela, L. (2000). “An exploration towards a production theory and its application to construction.” Ph.D. dissertation, VTT Publications 408, VTT, Espoo, Finland.
Landsbergis, P. A., Cahill, J., and Schnall, P. (1999). “The impact of Lean Production and related new systems of work organization on worker health.” J. Occup. Health Psych., 4(2), 108–130.
Maudgalya, T., Genaidy, A., and Shell, R. (2008). “Productivity—Quality—Costs—Safety: A sustained approach to competitive advantage—A systematic review of the National Safety Council’s case studies in safety and productivity.” Hum. Factors Ergon. Manuf. Serv. Ind., 18(2), 152–179.
Mitropoulos, P., Cupido, G., and Namcoodiri, M. (2007). “Safety as an emergent property of the production system: How lean practices reduce the likelihood of accidents.” Proc., 15th Annual Conf. of the Int. Group for Lean Construction (IGLC-15), Pasquire, C., and Tzortzopoulos, P., eds., Lean Construction Institute, Ketchum, ID.
Movement for Innovation Group. (2001). “Environmental performance indicators for sustainable construction.” Sustainability Working Group Rep.
Mullens, M. (2004). “Production flow and shop floor control: Structuring the modular factory for custom homebuilding.” Proc., NSF Housing Research Agenda Workshop, Vol. 2, Syal, M., Mullens, M., and Hastak, M., eds., National Science Foundation, Arlington, VA.
Nahmens, I. (2007). “Mass customization strategies and their relationship to lean production in the homebuilding industry.” Ph.D. dissertation, Univ. of Central Florida, Orlando, FL.
Nahmens, I. (2009). “From lean to green construction: A natural extension.” Construction Research Congress 2009: Building a Sustainable Future, ASCE, Reston, VA, 1058–1067.
Nahmens, I., and Ikuma, L. H. (2009). “An empirical examination of the relationship between lean construction and safety in the industrial housing industry.” Lean Constr. J., 2009, 1–12.
Nahmens, I., and Mullens, M. (2009). “The impact of product choice on lean homebuilding.” Constr. Innovation: Inf., Process, Manage., 9(1), 84–100.
National Association of Home Builders (NAHB). (2006). “Lean construction.” NAHB Research Center, Marlboro, MD.
Ohno, T. (1988). Toyota Production System, Productivity Press, New York.
Phillipson, M. (2001). “Defining the sustainability of prefabrication and modular process in construction.” Interim Rep. for Dept. of Trade and Industry, BRE Environment Division, Watford, UK, 14–18.
Pulaski, M. (2005). “Alignment of sustainability and constructability, the continuous value enhancement process.” Ph.D. dissertation, The Pennsylvania State Univ., University Park, PA.
Salem, O. and Zimmer, E. (2005). “Application of lean manufacturing principles to construction.” Lean Constr. J., 2(2), 51–54.
Saurin, T. A., Formoso, C. T., and Cambraia, F. B. (2006). “Towards a common language between lean production and safety management.” Proc., 14th Annual Conf. of the Int. Group for Lean Construction (IGLC-14), Lean Construction Institute, Ketchum, ID.
U.S. Census Bureau. (2010). “Characteristics of new housing.” 〈http://www.census.gov/const/www/charindex.html〉 (Nov. 23, 2010).
U.S. Environmental Protection Agency (EPA). (2003). “Lean manufacturing and environment.” 〈http://www.epa.gov/lean/environment〉 (Dec. 13, 2011).
U.S. Environmental Protection Agency (EPA). (2004). “Buildings and the environment: A statistical summary compiled by: U.S. Environmental Protection Agency Green Building Workgroup.” Washington, DC.
U.S. Environmental Protection Agency (EPA). (2008). “Green building: Frequent questions.” 〈http://www.epa.gov/greenbuilding/pubs/faqs.htm〉 (Apr. 16, 2008).
U.S. Environmental Protection Agency. (2011). “Lean in government starter kit.” 〈http://www.epa.gov/lean/toolkit/LeanGovtKitFinal.pdf〉 (Nov. 15, 2011).
Wills, Brett. (2009). Green intentions, Productivity Press, New York.
Womack, J. P., and Jones, D. T. (1996). Lean thinking: Banish waste and create wealth in your corporation, Simon & Shuster, New York, NY.
Womack, J. P., and Jones, D. T. (2005). “Lean consumption.” Harvard Bus. Rev.HABRAX, 83(3), 58–69.
Womack, S. K., Armstrong, T. J., and Liker, J. K. (2009). “Lean job design and musculoskeletal disorder risk: A two plant comparison.” Hum. Factors Ergon. Manuf. Serv. Ind., 19(4), 279–293.
Wong, Y. C., Wong, K. Y., and Ali, A. (2009). “A study on lean manufacturing implementation in the Malaysian electrical and electronics industry.” Eur. J. Sci. Res., 38(4), 521–535.
Wortman, R. (2007). “Modular homes lead industry green building efforts.” 〈http://EzineArticles.com/?expert=Rebekah_Wortman〉 (Aug. 21, 2008).

Information & Authors

Information

Published In

Go to Journal of Architectural Engineering
Journal of Architectural Engineering
Volume 18Issue 2June 2012
Pages: 155 - 163

History

Received: Nov 30, 2010
Accepted: Jul 19, 2011
Published online: Jul 21, 2011
Published in print: Jun 1, 2012
Published ahead of production: Jun 15, 2012

Permissions

Request permissions for this article.

Authors

Affiliations

Isabelina Nahmens [email protected]
Assistant Professor, Dept. of Construction Management and Industrial Engineering, Louisiana State Univ., 3128 Patrick F. Taylor Hall, Baton Rouge, LA 70803 (corresponding author). E-mail: [email protected]
Laura H. Ikuma [email protected]
Assistant Professor, Dept. of Construction Management and Industrial Engineering, Louisiana State Univ., 3128 Patrick F. Taylor Hall, Baton Rouge, LA 70803. E-mail: [email protected]

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.

Cited by

View Options

Get Access

Access content

Please select your options to get access

Log in/Register Log in via your institution (Shibboleth)
ASCE Members: Please log in to see member pricing

Purchase

Save for later Information on ASCE Library Cards
ASCE Library Cards let you download journal articles, proceedings papers, and available book chapters across the entire ASCE Library platform. ASCE Library Cards remain active for 24 months or until all downloads are used. Note: This content will be debited as one download at time of checkout.

Terms of Use: ASCE Library Cards are for individual, personal use only. Reselling, republishing, or forwarding the materials to libraries or reading rooms is prohibited.
ASCE Library Card (5 downloads)
$105.00
Add to cart
ASCE Library Card (20 downloads)
$280.00
Add to cart
Buy Single Article
$35.00
Add to cart

Get Access

Access content

Please select your options to get access

Log in/Register Log in via your institution (Shibboleth)
ASCE Members: Please log in to see member pricing

Purchase

Save for later Information on ASCE Library Cards
ASCE Library Cards let you download journal articles, proceedings papers, and available book chapters across the entire ASCE Library platform. ASCE Library Cards remain active for 24 months or until all downloads are used. Note: This content will be debited as one download at time of checkout.

Terms of Use: ASCE Library Cards are for individual, personal use only. Reselling, republishing, or forwarding the materials to libraries or reading rooms is prohibited.
ASCE Library Card (5 downloads)
$105.00
Add to cart
ASCE Library Card (20 downloads)
$280.00
Add to cart
Buy Single Article
$35.00
Add to cart

Media

Figures

Other

Tables

Share

Share

Copy the content Link

Share with email

Email a colleague

Share