Facility layout design for modular construction manufacturing: A comparison based on simulation and optimization

• Published in: Automation in construction 2023-03, Vol.147, p.104713, Article 104713
• Main Authors: Yang, Zhongze, Lu, Weisheng
• Format: Article
• Language: English
• Subjects: Facility layout design; Modular construction; Multi-objective optimization; Non-dominated sorting genetic algorithm; Offsite construction; Simulation-based comparison
• ISSN: 0926-5805; 1872-7891
• DOI: 10.1016/j.autcon.2022.104713

With modular construction reviving around the world, a significant portion of on-site works is now mass-produced as modules in factories, shifting Modular Construction Manufacturing (MCM) from a traditional oxymoron to an upfront challenge for project or production managers. Nevertheless, little is known about such MCM in a factory, e.g., the production line layout. This paper identifies the optimal Facility Layout Design (FLD) for MCM in a factory by simulating and optimizing a real-life case. Firstly, the workflows and schedules of MCM are collected and re-engineered into nine categories. Then, data is collected and implemented to five candidate FLDs for simulation and optimization. The results show that ‘cellular layout’ has the most output and ‘product layout’ is the most economical selection in the case factory. This research sheds light on the uncharted area of MCM. It also calls for more studies to examine Industry 4.0 advances in transforming the traditional construction industry. •Five facility layout designs for modular construction manufacturing are considered•Discrete Event Simulation and Multi-Objective Optimization are performed•‘Cellular layout’ is most efficient for steel and concrete hybrid modular construction•‘Product layout’ is most economical for the same type of modular construction•The research opened a new avenue to enhance modular construction manufacturing