Sherif Mostafa

A framework for lean manufacturing implementation

The lean implementation initiatives can be categorised as roadmap, conceptual/implementation framework, descriptive and assessment checklist initiatives. A literature review on the lean initiatives has examined 28 initiatives. A set of rules is proposed to evaluate these initiatives with respect to nine factors impacting lean implementation. The evaluation has proved that the implementation frameworks have highest association with lean factors. However, existing lean initiatives are not demonstrated in a structured nature. The failure in managing lean implementation process is often consolidated to poor mind-set and inadequate understanding of the lean concept itself. In this paper, an attempt has been made to propose a framework to overcome some of the limitations. The proposed framework is constructed as a project-based framework with detailed four implementation phases. Appropriate practices and decision tools are proposed and assigned to each phase. However, the proposed framework is at conceptual stage. It requires further implementation to be validated.

Lean and agile integration within offsite construction using discrete event simulation: A systematic literature review

Purpose The purpose of this study is to systematically analyse and synthesise the existing research published on offsite manufacturing/construction. The study aims to highlight and associate the core elements for adopting the offsite concept in different construction contexts. This ultimately facilitates the enhancement of the offsite uptake. Design/methodology/approach The research study was carried out through a systematic literature review (SLR). The SLR was conducted to identify and understand the existing themes in the offsite research landscape, evaluate contributions and compile knowledge, thereby identifying potential directions of future research. The grand electronic databases were explored to gather literature on the offsite concept, lean and agile principles and simulation. A total of 62 related articles published between 1992 and 2015 have been included in this study. The relevant literature was systematically analysed and synthesised to present the emerging offsite themes. Findings The descriptive and thematic analyses presented in this paper have identified related offsite research studies that have contributed to setting a firm foundation of the offsite concept in different construction contexts. Each of the 62 articles was examined for achieving the aim and objectives of this study, the method of data collection and coverage of offsite themes. The results of the analyses revealed that the articles mostly provide information on the offsite concept and its definitions (53 per cent) and offsite barriers and/or drivers (27 per cent). However, limited attention has been paid to the integration of lean and agile principles (13 per cent) and simulation (7 per cent) within the offsite concept, which are therefore more open to research within the offsite concept. Research limitations/implications The literature review highlights the main themes and components of the offsite construction concept. This forms a solid basis and motivation for researchers and practitioners to build on to enhance the uptake of the offsite concept in different contexts. This study also presents a research roadmap within the offsite concept, along with a recommendation for further research to be conducted using the research framework proposed in this study. The framework could lead to validation of using simulation to integrate lean and agile principles within the offsite concept. Originality/value This paper presents a systematic review of the literature related to offsite construction in different contexts. The emerging components, that is, offsite definitions, drivers and/or barriers, lean and agile principles and simulation have been highlighted and discussed thematically. A research framework that enables pursuit of the integration of lean and agile principles offsite through the lens of simulation has been proposed. The framework is expected to open up new opportunities on the effectiveness of offsite development in different contexts.

Lean thinking for a maintenance process

The maintenance process shares significant operating costs in an organisation. Lean thinking can be incorporated into maintenance activities through applying its principles and practices/tools. Lean maintenance (LM) is a prerequisite for lean manufacturing systems. This research proposes a new structure for LM process based on a systematic literature review of a significant number of related articles that were published on LM. The process structure is designed based on the five lean principles to guide and support organisations to pursue maintenance excellence. This study establishes a scheme for LM tools that are structured into 2 level 4 bundles and 26 lean practices/tools and develops a House of Waste (HoW) to demonstrate the association between maintenance wastes and the LM tools. With a successful accomplishment of the proposed scheme, the performance of a maintenance department can create more improvement opportunities over time to reach the maintenance excellence status.

Chapter 19 Construction and the Circular Economy: Smart and Industrialised Prefabrication

This chapter discusses the profound and influential impact the construction industry has on the national economy, together with the huge negative effect it has on the environment. It argues that by adopting smart and industrialised prefabrication (SAIP), the Australian construction industry, and the construction industry globally, is well positioned to leverage the circular economy to advance future industries with less impact on our natural environment. It discusses aspects of the application of digital technologies, specifically building information modelling, virtualisation, augmented and virtual reality and 3D printing, coupled with reverse logistics as a proponent for advancing the circular economy through smart, digitally enabled, industrialised prefabrication. It further postulates a framework for SAIP for the circular economy.

Application of discrete-event simulation to investigate effects of client order behaviour on off-site manufacturing performance in Australia

ABSTRACT Off-site manufacturing (OSM) has implied capabilities that could enhance housing supply in Australia. The OSM system requires the efficient management of two concurrent working locations: the off-site fabrication facility and the construction site. Client order behaviour impacts on the OSM system. Accordingly, client order information flow is an essential component for efficiently managing this system. This paper investigates the effects of client order behaviour on the performance of OSM within the Australian housebuilding context using discrete-event simulation (DES). The data used to develop the conceptual model were based on a review of 21 related technical documents and interviews with 13 OSM experts in Australia. The operational data used for executing the simulation model were collected through a questionnaire survey of 30 builders as well as three one-day site visits to the fabrication facilities and construction sites of three major building organisations in Australia. The simulation model assisted in experimentation with four scenarios that represent client order interaction in the OSM system in Australia. The model simulation results showed noteworthy improvements in house completion time and the number of completed client orders per year.

Opportunities of Building Information Modelling in Australian Offsite Manufacturing

Offsite Manufacturing (OSM) is a modern construction method for the future of Australian house building due to its potential capacity in meeting the growing housing demand. Previous studies have proved the benefits of OSM in housing supply and quality. However, the application of OSM in Australia is limited to some challenges which could be classified into three groups: managing two working locations, house customer preferences, and house builder’s capacity. With the recent development of the Building Information Modelling (BIM), these challenges could be overcome through using BIM within the OSM supply chain. This paper aimed at discussing the opportunities of applying BIM in OSM in Australia in the light of existing literature using a systematic approach. As a result, the following five main OSM barriers have been identified and analysed with respect to BIM: (1) low level of OSM knowledge, (2) initial cost, (3) negative perception on OSM products, (4) longer lead times and (5) freeze design and specification at early stages. The discussion of integrating BIM to OSM conducted in this study could lead to future research on the five barriers and validity of the integration. Overcoming the barriers could expand the opportunity of OSM adoption in future Australian house building.

Exploring the status, benefits, barriers and opportunities of using BIM for advancing prefabrication practice

Abstract Building information modelling (BIM) has significantly influenced the construction industry. However, the existing BIM tools and frameworks within prefabricated buildings are minimal. This research study aims to identify the opportunities and barriers of integrating BIM in the Australian prefabrication industry. The research was carried out using a mixed method of literature review and questionnaire survey with 30 indudstry professionals. The literature review identified the key challenges associated with prefabricated buildings including construction discipline-specific, fabrication-specific issues and communication-specific issues. The survey results proved that the most significant BIM opportunities are minimizing design errors and discrepancy of final product model between designers and manufacturers and increasing mass customization. The study revealed that seamless and timely information exchange among key project stakeholders via a BIM system was identified as the most critical success factor to adopt BIM in the prefabrication industry. This research provides practical insights into how to utilize BIM effectively for prefabrication in the housing sector. The survey results document the opportunities and barriers to BIM integration and provide professional insights on how BIM can benefit the prefabrication. The study contributes to the body of knowledge on enhancing the productivity/practice of prefabrication through BIM integration within the Australian housing context.

Leagile Strategies for Optimizing the Delivery of Prefabricated House Building Projects

Abstract Australian housing supply has not been responded at a rate commensurate with its growing demand. Residential housing sector is facing this serious shortage issue by actively developing and effectively using new construction material, processes and practices for sustaining its competitive advantage over other construction sectors in the Australian context. The Construction 2020 report confirmed prefabrication/off-site manufacturing (OSM) as a critical vision for the Australian construction industry’s future, as OSM provides opportunities for not only increased productivity and safety, but also decreased cost. It also has the capability of meeting the growing housing demand within the extant level of skilled labour. By combining lean and agile concepts, OSM’s supply responsiveness and efficiency can be intensified. The current research studies the association between demand–supply housing imbalance factors using mixed methods from literature and interviews. Literature has documented four main factors that drive this imbalance: (1) housing completion time; (2) cost of a finished house; (3) customer preferences and (4) level of skilled labour. Interviews with 13 industry professionals identified the four main leagile strategies used to deliver prefabricated building projects. Literature and interview findings supported the development and validation of multicriteria decision-making (MCDM) model comprising and incorporating these factors (and subfactors) and the four leagile strategies. The choice of the appropriate strategy to address the studied factors within the Australian context was optimized using analytic hierarchy process (AHP). The results from the AHP model show the suitability of applying each strategy at different degrees as influenced by the tested factors.

Improving Project Success with Project Portfolio Management Practices

Projects have increasingly become organizations’ strategic initiatives to implement changes and improve organizational performance. Concerned over constrained resources and rapid changes that exist in the project environment, project portfolio management (PPM) can support organizations in prioritizing and selecting the right projects to meet strategic objectives and improve project success rates. This research aims to investigate and analyze the application of PPM in relation to project success in Australia by conducting a questionnaire survey with 64 senior project, program and portfolio managers from industry sectors across Australia. Graph Theoretic Approach (GTA) is employed as an analysis method to generate prioritization of the relationships between PPM practices and project success criteria. Twenty-five PPM practices are grouped into four categories and examined against seven project success criteria. The findings show that each group interacts with success criteria at a diverse range. These provide organizations with implications to benchmark their PPM practices with the current findings, especially those that strongly contribute to success in project implementation and outcomes. Furthermore, the results highlight integrated concepts and application between project success and portfolio management.

Understanding Associations Between Project Team Involvement, Project Design and Project Outcomes: A Case Study of Health Development Projects in Thailand

How a project is designed generally impacts on project implementation and successful outcomes and satisfactory results. Thus, including the project team in the design process at an early stage is deemed necessary. The aim of this research is to understand the relationships between project design and the project team involvement within each project phase. Outcomes of the projects relating to the project designs and levels of involvement are analysed and discussed. The research results are based on survey questionnaires distributed to 75 respondents working in four health development projects in Thailand. The research data was statistically analysed using between-group analysis of variance and correlation analysis to examine differences between the studied groups and connections between research variables. The paper shows that project design and the team involvement associate to application of project management and implementation of project tools as well as other desirable managerial criteria of the studied projects. This research benefits future designs and implementation of health development projects especially in developing countries such as Thailand where improvement of project outcomes are required.