Production Monitoring and Process Improvement for Floor Panel Manufacturing

Abstract

Panelized home construction allows for the construction of homes to be completed in a factory, but in only two dimensions, compared to the three dimensional module that is produced in modular construction facilities. Keeping the panels detached until they reach the final destination permits for more efficient transport of panels and allows the factory to be divided into more specialized areas. This paper presents a case study of an established panelized home manufacturer, where the floor production area is identified as an area for potential process improvement. Possible areas for process improvement are identified by conducting a time study, carrying out observation, and constructing a simulation model in which potential process improvements can be tested. Opportunities are identified for process improvement, and the anticipated results of implementing certain changes are quantified through the use of simulation in order to aid management in making decisions regarding which changes are to be implemented and in what order. Some possible areas for improvement of the floor production area, including reducing the waiting time for the multi-function bridge by manually applying glue, aligning the joists in the correct orientation prior to their reaching the floor jig to eliminate the need to rotate the joists, and installing a bridge for sheathing board delivery that eliminates the time spent walking to retrieve the sheathing boards.