Productivity-Based Management System for Offsite Manufacturing: Case Study of Noralta Lodge

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Large-scale projects entail a zero-tolerance policy in regards to on-time project delivery and project quality. Severe winter conditions in Canada challenge conventional on-site construction activities and raise the risk of project delays and deficiencies. Industrialized (modularized) construction stands as an alternative that provides high quality products in a timely manner. Moreover, modular construction offers manufactured building components in a controlled environment, which ensures that quality standards remain consistent regardless of weather conditions. Once manufactured, modular units are then shipped to the site to be assembled. Two major geographical phases are common in offsite construction: the manufacturing phase, and the on-site installation phase. Consequently, management teams face challenges related to productivity and optimum work sequence in both phases. Traditional project planning and control methods consider the duration of a task as a static entity resulting from the direct relationship between the sizes of the crews on-site and labour productivity. Learning curves, skill-based tasklabour matrices, and resource levelling techniques are factors that imply the dynamic nature of construction tasks; delays in one task may affect other subsequent tasks both directly and indirectly. The Productivity-Based Management System (PBMS) provides opportunities to increase the production rates of task duration, and decrease actual task duration. The proposed research introduces a framework for a PBMS to manage and control the on-site phase of modular construction. In this research, the PBMS is developed, implemented, and then applied to a 1,700- bedroom workforce camp in Fort McMurray, Alberta, Canada.