Lean construction analysis of concrete pouring process using value stream mapping and Arena based simulation model

Abstract

An important challenge for the construction industry is how to reduce non-value adding activities which produce waste. Many researchers have attempted to resolve it to enhance the performance of this industry. However, the concrete pouring process (CPP) has not been adequately investigated in this regard. Accordingly, the present study aims to examine how to apply the lean manufacturing concepts to CPP effectively determine different wastes generated during operations, the main cause of the waste generation, and the strategies to minimize or mitigate the generation of the waste. Mixed value stream mapping (VSM) and computer simulation are applied to identify and eliminate wastes in a CPP case study by using lean principles and time-frame formulation through takt time calculation. Based on the future VSM improvements, findings showed that that production lead time (PLT) reduced from 11 days to 7 days, and the value-added time decreased from 38.2 min to 22.5 min. Takt time also was reduced from 138 s to 93 s. Our results are a valuable resource for construction managers and engineers to improve the concrete pouring process’s productivity in a cost-effective and timely manner.