IMPROVING PRODUCTIVITY OF A PRECAST CONCRETE YARD THROUGH SIMULATION: A CASE STUDY APPROACH

Abstract

Precast yards supply concrete products in the construction industry and their productivity is crucial in handling increasing demand in Singapore. Lean and just-in-time concepts from the manufacturing sector have proven to improve productivity. Although precast yards are within the construction sector, their operations relate more to the manufacturing sector with their controlled environment. Therefore, these concepts are applicable in precast yards. Simulation modelling enables precast yards to analyse change proposals and make informed decisions to improve productivity in a cheaper and easier way. This study aims to evaluate the challenges and potential of improving productivity in a Singapore precast yard through applications of lean and just-in-time concepts, focusing on U-drain production. On-site observations were conducted to record quantitative data for the modelling aspect while interviews were conducted with the managing engineer to record qualitative data for model and proposal verifications. A sample size of 30 U-drains is used. Input analyser in the simulation software was used to analyse the recorded data while Ttest and face verification were used to validate the model. T-test was also used to validate that there is significance difference of completion durations between the existing process and the proposed process. The improvement in productivity is based on a conservative approach and the costs and benefits of conveyor systems in proposed alternative were discussed. Future studies will improve on the extent of productivity improvement through analysing improvements that are not tangible in short time and the quantitative aspect of the cost benefit analysis.