Lean approach in precast concrete component production

Purpose This study applied the lean approach to the reinforcement work process in the component production of industrialised building system precast concrete construction (IBSPCC). The purpose of this paper is to identify and eliminate non-value added (NVA) activities to enhance the efficiency of the production process. Design/methodology/approach Data were collected via a case study of six-storey precast concrete building. A mapping of the reinforcement work process was conducted based on observations using time study technique and time-lapsed video, complemented by semi-structured interviews. Findings Through this application, several NVA activities, such as unnecessary inventory, excessive movement and coordination issues, were identified. Production performance could be enhanced by implementing Just-in-Time, Kanban, and layout improvements, which would address NVA activities. Originality/value This paper focusses on strategies for improving the efficiency of the IBSPCC production process in Malaysian construction by developing a conceptual framework of the lean approach for the reinforcement work process. Certain aspects in the process such as layout and inventory need to be redesigned and simplified by minimising NVA activities.