Layout Optimization Model for the Production Planning of Precast Concrete Building Components

Dong Wang,Igor Martek,Xiaobo Tao,Guiwen Liu,Kaijian Li,Tongjing Wang,Asheem Shrestha

doi:10.3390/su10061807

Abstract

Precast concrete comprises the basic components of modular buildings. The efficiency of precast concrete building component production directly impacts the construction time and cost. In the processes of precast component production, mold setting has a significant influence on the production efficiency and cost, as well as reducing the resource consumption. However, the development of mold setting plans is left to the experience of production staff, with outcomes dependent on the quality of human skill and experience available. This can result in sub-optimal production efficiencies and resource wastage. Accordingly, in order to improve the efficiency of precast component production, this paper proposes an optimization model able to maximize the average utilization rate of pallets used during the molding process. The constraints considered were the order demand, the size of the pallet, layout methods, and the positional relationship of components. A heuristic algorithm was used to identify optimization solutions provided by the model. Through empirical analysis, and as exemplified in the case study, this research is significant in offering a prefabrication production planning model which improves pallet utilization rates, shortens component production time, reduces production costs, and improves the resource utilization. The results clearly demonstrate that the proposed method can facilitate the precast production plan providing strong practical implications for production planners.

Highlights

Prefabrication is the practice of assembling the components of a structure in a factory, or other manufacturing locations, and transporting complete assemblies or sub-assemblies to the construction site where the structure is to be erected
It is well established that production planning is the key element in the precast production process and it is closely related to the production time and cost
This paper evaluates the molding process, a critical process closely related to precast production efficiency and proposes a layout optimization schedule of the components on pallets during the molding process, that (1) improves the utilization rate of the pallets, (2) shortens the manufacturing time, (3) reduces the component manufacturing cost, and (4) saves the resource consumption during the precast production

Summary

Introduction

Prefabrication is the practice of assembling the components of a structure in a factory, or other manufacturing locations, and transporting complete assemblies or sub-assemblies to the construction site where the structure is to be erected. The efficiencies gained in the production process of precast components directly enhance the construction time and cost of buildings. There are several methods to enhance the efficiency of precast components production and to reduce its cost. These methods involve various stages, including precast component design [1,2,3], material management/transshipment [4,5], precast component production planning, precast component inventory control [6,7,8,9], precast component transportation and site assembly [10,11]. Inefficient resource utilization and high production cost are common in the precast industry due to unsuitable and inaccurate planning methods [13,14]. Optimizing the production plan is vital in the precast component production process

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Results

Conclusion