Production Flow and SFC: Structuring the Modular Factory for Custom Homebuilding.

MRPII 53

Michael A. Mullens 1

Abstract

This paper examines production challenges faced by modular homebuilders, identifies applicable state of the art research in manufacturing systems and lean construction, and proposes future research directions to bridge the gap between current knowledge and industry needs. The greatest production challenge faced by modular manufacturers is how to maximize production capacity and increase quality, while expanding production flexibility to deliver the widening product mix and customization demanded by homebuyers. It is the thesis of this paper that the real underlying challenge is how to identify and manage floating bottlenecks caused by the great variability in process times. The paper presents a vision for modular manufacturing and identifies four interrelated research areas that can contribute to the vision: module design, process and material handling technology, factory configuration, and shop floor control. The proposed research is likely to enhance all segments of homebuilding, including HUD Code manufacturers and site builders.

Keywords:

modular housing, housing production, lean, flow, bottlenecks