Evaluation of application of lean principles to precast concrete bridge beam production process

Although prefabrication is becoming popular as an approach to conquer the chronic problems in construction, it has inherent issues related to inefficiencies in its production process. To address these production process related inefficiencies, lean production principles (LPP) can be applied. Hence, this paper aims to investigate the application of LPP to the precast concrete bridge beam production process (PCBBPP). The research collected data within three selected case studies by observing PCBBPP and interviewing executive-level professionals, to map the process, to identify conversion activities and their efficiency enhancing methods, and to record flow activities and their associate waste, waste causes, and elimination/minimization methods. The research analysed data by using code-based content analysis, and the findings are presented by using tables, matrices, and maps. The results revealed 103 activities associated with PCBBPP, of which 59 are conversion activities. Among 44 flow activities, 17 can be eliminated. The results also indicated several methods and techniques to eliminate/ minimize flow activities and enhance the efficiency of PCBBPP conversion activities to enable implementation of LPP in prefabrication yards. By applying LPP to PCBBPP, several long-term benefits were revealed that contribute to sustainable construction. These results are useful for prefabrication companies and those who deal with sustainability issues.