Lean construction and simulation for performance improvement: a case study of reinforcement process

Purpose - This research seeks to evaluate the impact of applying lean construction principles on the performance of reinforcement operations using a discrete-event simulation (DES) approach. Design/methodology/approach - Process mapping of reinforcements operations was first established through field observation and interviews with construction managers involved in the selected project. Subsequently, quantitative data were gathered and then used to identify the best probabilistic density functions for each activity duration based on the fit-quality tests. Upon testing the validity of the real-world model, a lean simulation model was developed, using ARENA software, to investigate the impact of lean construction principles on the performance of such processes. Findings - Lean principles are effective in enhancing the performance of the selected construction process. Output performance measurements for real-world model and lean model revealed that lean construction principles led to 41% improvement in process productivity, 14% enhancement in process efficiency and 17% reduction in cycle time. Research limitations/implications - The statistical findings only represent the process under study (reinforcement process) and cannot be generalized to other construction activities. In order to draw generalizable conclusions, future works are needed to extend this study to different project sizes and more complex construction processes (e.g. bricklaying process and concrete pouring operations). Moreover, there are other factors such as labor skills, rework and uncertainty, site conditions that require further analyses for leaner construction projects. Originality/value - The methodology and the techniques presented in this work can be used for decision making by analyzing various lean construction scenarios and evaluating their impacts on performance outcomes of any construction process prior to real-world implementation.