Off-site Manufacturing Research Articles

A comprehensive evaluation of factors influencing offsite construction and BIM integration in the construction industry

PurposeThe construction industry's transformation of prefabrication into large-scale offsite manufacturing continues to grow. While the Offsite Construction (OSC) transition has brought positive changes to the industry, it also presents various challenges. Literature suggests that to address the challenges, advanced technologies such as Building Information Modeling (BIM) can be applied for effective mitigation. Nonetheless, the combined application of BIM and OSC is in its infancy and faces challenges in many countries. This study aims to investigate the factors influencing OSC and BIM integration, including challenges and strategies within the New Zealand construction industry.Design/methodology/approachThis study explores which specific factors impact integration positively or negatively through a comprehensive literature review and confirmatory survey. Factor Analysis (FA) was used as the data analysis method, resulting in eight groups of underlying factors. Next, three Structural Equation Models (SEM) were developed and tested to analyze the impact of latent and observed variables on OSC and BIM integration.FindingsSignificant underlying factors affecting OSC and BIM integration were identified, and recommendations to enhance integration were provided. Specifically, the findings demonstrated that three underlying factors for challenges, two for strategies and three for integration were identified through EFA and confirmed by CFA. This step was followed by SEM, which employed three different path analysis models for integration variables. It clarified that not all variables have similar impacts on integration; some exhibit significant positive or negative effects, while others are not significant at all.Originality/valueThe identified challenges and strategies for OSC and BIM integration and their impact on integration factors can contribute to developing standardized integration guidelines and frameworks to assist stakeholders in focusing on their specific integration goals.

From sustainable macro debris chemical recycling to microplastic reclamation: Overview, research challenges, and outlook

The current surge in plastic waste generation from human activities has led to environmental hazards associated with Sustainable Development Goal (SDG) 6 (Clean Water and Sanitation), from mismanaged polymeric waste and its derived free plastic debris. Chemical recycling enables the effective end-of-life (EoL) of plastic wastes and debris by transforming them into value-added chemicals, reducing their offsite manufacturing's environmental and social risks related to SDG 13 (Climate Action) while mitigating plastic pollution associated with SDG 6, SDG 14 (Life Below Water), and SDG 15 (Life on Land). Herein, this work examines the recent research progress, technological advancements, and policy implications on the chemical recycling of plastic waste and derived debris from macro to micro levels and implications for achieving SDGs. We identify three primary research challenges related to plastic pollution mitigation: 1. Understanding the extent of plastic pollution and consequences by sources originating from human activities; 2. Exploring the sustainable material life cycle of plastics with minimum waste generation, free debris exposure and pollution related to SDGs 14 and 15, and carbon emissions aligned with SDG 13; 3. Indicating the necessary local and global efforts to deploy plastic production, use, and waste management as per sustainable plastic life cycle concepts associated with SDG 12 (Responsible Production and Consumption). Future perspective directions lie in mitigating plastic pollution on both the sources identified by plastic waste and derived debris generation from individual human activity and the sinks associated with free debris exposure to natural environments. Reducing plastic use, waste reuse, repurposing, and recycling can fully mitigate these negative externalities but also generate greenhouse gas emissions, which requires decarbonization under climate commitments.

IoT-BIM and blockchain integration for enhanced data traceability in offsite manufacturing

The transformation of dynamic supply chains within the realm of offsite manufacturing presents a unique and compelling opportunity to effectively respond to shifts in market demand. However, this paradigm shift also entails novel challenges and prospects for streamlining processes, augmenting efficiency, and ultimately driving success across production workflows and logistical operations. Dynamic supply chains necessitate unimpeded access to high-quality, dependable data to facilitate real-time, data-driven decision-making. Furthermore, owing to their inherently intricate nature, these supply chains are subject to a heightened vulnerability to disruptions and delays, surpassing those encountered in traditional supply chains. Against this backdrop, this paper proposes a framework that synthesises the convergence of the Internet of Things (IoT), Building Information Modelling (BIM), and blockchain technology (BCT) into a cohesive and integrated system, thereby optimising the efficiency and transparency of supply chain management operations. The proposed framework takes cognisance of the challenges inherent in ensuring information traceability, mitigating fragmented information, enhancing interoperability, and fortifying reliability throughout the design, production, and implementation phases of assets within dynamic supply chains operating in the offsite manufacturing domain. To illustrate the efficacy of our proposition, we present a framework that exemplifies the seamless integration of a permissioned, open-source distributed ledger, which forms the bedrock of our support infrastructure for IoT and BIM integration.Through rigorous analysis, we showcase the effectiveness of the developed framework in the form of a designed Supply Chain Management Model (SCMM-PDO), which harmonises the physical, digital, and operational layers within a robust system architecture (BCT.IoT-BIM). The integration of these technologies provides a decentralised solution, reinforcing supply chains with improved security, reliability, and quality control mechanisms, thus enhancing the efficiency of the supply chain network. It is anticipated that this transformative integration will yield substantial improvements in key performance indicators (KPIs) such as operational efficiency, cost reduction, and the cultivation of trust and accountability across supply chain activities.The research proposes an IoT and BIM conceptual framework that simulates the dynamic supply chain operations, facilitating real-time analysis and prediction of supply chain participants' behaviours from resources, processes, and assets. Furthermore, the integration of IoT-BIM (digital twinning) with a blockchain-based system, such as Hyperledger Fabric, engenders a secure and transparent framework for the diligent tracking of assets and information throughout the supply chain. The findings of this study offer an all-encompassing conceptual framework for the secure and transparent tracking of asset information by integrating Blockchain-based technologies with IoT and BIM. This research endeavour thus expands the existing body of knowledge, establishing a foundation for future investigations within this proliferating field.

Simulation-based comparison of push- and pull-based planning in panelized construction

Offsite construction involves the prefabrication of construction components in a factory environment, followed by transportation to the construction site for assembly. In planning the sequences for construction tasks, a push approach can maximize the offsite manufacturing capacity, while a pull approach can achieve just-in-time delivery. Both approaches need to consider the logical constraints and resources of offsite construction processes. This complexity fuels a debate of the effectiveness of push- and pull-based planning, highlighting the necessity to study the impacts of these approaches on planning. This study utilizes Discrete-Event Simulation (DES) and Agent-Based Modeling (ABM) approaches to compare planning outcomes for offsite construction. The results demonstrate that the pull-based planning approach resulted in an overall 12.6% reduction in project completion time and an 80.3% reduction in product waiting time, demonstrating pull-based planning as a more efficient solution for offsite construction planning.

Evaluating the Circular Economy Potential of Modular Construction in Developing Economies—A Life Cycle Assessment

Circular economy (CE) is an emergent concept that promotes resource circularity in multiple product systems. Modular construction (MC), an evolving construction technique, which includes an off-site manufacturing environment, increasingly supports CE strategies such as reuse due to the elevated potential for design for disassembly (DfD). Design-stage environmental assessments are paramount in aiding the early decision making of modular construction projects to successfully plan and implement DfD strategies. Research on synergising modular construction, circular economy and environmental sustainability is rare in developing economies. Thus, the current study aims to conduct a design-stage life cycle assessment of a DfD and linear versions of a modular building unit in Sri Lanka to evaluate the potential environmental benefits. The life cycle assessment results highlight that the DfD strategy has the lowest environmental impacts in all categories, with a 63% reduction in global warming potential and an approximately 90% reduction in terms of human toxicity compared to the linear version. Further, it showed the elevated potential of reuse compared to recycling practices in improving the environmental performance. Sensitivity assessment revealed that steel was the most sensitive to the change in reuse percentage among main building materials. The analysis outcomes highlight the importance of long-term thinking, architectural design creativity and industrial and technology development to uptake the CE-driven MC in the Sri Lankan context. Finally, strategies are proposed to support the CE approach in MC in developing regions. Both quantitative and qualitative outcomes provide a basis for construction industry stakeholders, academia, and policy makers to explore further and promote modular construction practices to enhance the circularity of building materials and components in developing regions.

Off-Site Manufacturing: Determining Decision-Making Factors

New technologies like modular construction are expected to increase the market share in developing countries with a high annual growth rate such as in Egypt. Modular construction solutions that have content depending on the process of off-site construction and on-site transportation gained prominence over recent years due to several benefits, especially their positive impact on the environment. Off-site manufacturing (OSM) and traditional technologies like on-site ones differ in many aspects of design, requirements, logistics, engineering, and others. Many researchers studied modular construction and they fall short of investigating modular construction processes comprehensively and completely. In this paper, the barriers and benefits of using off-site manufacturing (OSM) are collected from the previous studies (that focused on mega projects, high quality, and fast-track projects) to be analyzed using a social network analysis (SNA) to promote the implementation of this new technology mainly in high-annual-growth-rate countries. A survey was used to solicit the opinions of construction practitioners to identify the most significant barriers and obstacles, as well as the benefits of using OSM. Also, due to the capabilities of Building Information Modeling (BIM) to manage shared information and increase the cooperation among project parties, the integration of OSM and BIM is investigated as a promising approach to overcome OSM barriers and enhance its utilization. Analyzing the main barriers’ density and finding out the main solution are involved. Applying this case to a real project in Egypt to study the impact of using (OSM) on-site and exporting the data are also involved. With some results related to the other results and disadvantages that were deduced, the most important advantages and most disadvantages emerged, as well as finding ways to solve them and practical application on the ground.

Target-path planning and manufacturability check for robotic CLT machining operations from BIM information

Mass timber is one of the trending construction styles in the last years thanks to its sustainability and offsite manufacturing properties, where cross laminated timber (CLT) is the most common material used. In an effort to link design and manufacturing information in a single location, this study proposes a generative process planning algorithm for CLT machining in robotic environments. The algorithm focuses on automatic feature-based interpretation of the geometry of CLT panels to obtain the targets required to guide the robots for its machining. The method developed detects primitives geometries of the CLT panels, determines the appropriate operations (either sawing, drilling, or milling), select the robot based on manufacturing capabilities (reach and tool availability), and generates the target-path planning for its machining process. The proposed method is tested in a robotic machining station for CLT panels simulated in RobotStudio® as a case study. The results showcase the capabilities of the proposed algorithm to provide manufacturing results out of the process planning process from geometric information available at the design stage. These results include process duration, path planning, resource allocation and utilization. This study provides a framework to include manufacturing information in design decisions to facilitate planning or cost estimations and anticipate issues downstream generated during the design phase.

Identification and Evaluation of the Key Decision Support Factors for Selecting Off-site Construction in Canada: A Building Information Modeling (BIM)-enabled Approach

The construction industry lags behind other sectors in terms of productivity performance, with many megaprojects experiencing cost overruns. While there are various reasons for this, the most significant one is the lack of efficiency. Adopting the off-site construction (OSC) methodology can improve productivity by enhancing project efficiency mainly in terms of time, cost and quality. Although OSC, off-site manufacturing (OSM), Industrialized Building System (IBS), prefabrication, modular, or other similar terms are not novel concepts, it is essential to shift any aspect of construction project activity from traditional onsite methods to a controlled, factory-based and manufacturing concept of production. Industrialization and digital fabrication have gained significant prominence in recent years, as they are perceived as a viable solution to the issues faced by the construction sector. As OSC is gradually gaining interest in building projects, it is crucial to identify and validate the key decision support factors (KDSFs) for selecting an appropriate OSC method from the early design stage. The purpose of this study is to identify, verify, and evaluate the KDSF for selecting OSC in Canada. This study utilized a mixed-methods design, comprising a systematic literature review (SLR) and pilot expert reviews through semi-structured interviews and surveys, to accomplish the research objectives and ensure the validity and reliability of the findings. Twelve interviews were conducted to validate and analyze the KDSFs, which were then prioritized using the mean score (MS) analysis and weighting function. Based on the research methodology, 32 KDSFs were validated and grouped into 7 'dimensions'. Further analysis concluded that the most important 'dimension' in selecting OSC for a building project in Canada is project time which consists of the design period, production time, mobilization and transfer time, as well as the assembly, and construction periods.

Uncertainties affecting the offsite construction supply chain resilience: a systematic literature review

Purpose This paper aims to synthesise the latest literature on supply chain operations of offsite manufacturing in the construction industry to identify and evaluate the uncertainties at each stage of the offsite construction supply chain (OSC-SC) to compile contributions to knowledge and thereby determine the future research directions to improve supply chain resilience (SCR). Design/methodology/approach The study was conducted as a systematic literature review. In total, 99 peer-reviewed journal papers published between 2015 and mid-2022 were shortlisted and analysed through the Preferred Reporting Items for Systematic Reviews and Meta-Analyses guidelines. Findings The bibliometric analysis revealed that the research focusing on supply chain issues and developing best practices in offsite construction adopt case study approaches to investigate the research problems comprehensively. The content analysis revealed the lack of up-to-date knowledge in the construction workforce regarding OSC; low preparedness for the changes brought by the SC uncertainties; the lack of a proper procurement model for OSC; lack of end-to-end visibility of the supply chain to identify uncertainties and lack of national or government standards on OSC-SC, as some of the key problems instigating the identified the uncertainties. Originality/value This study clarifies the current knowledge by systematically presenting uncertainties at each stage of the OSC-SC. Moreover, it provides a framework and proposes that future research should focus specifically on individual/team, organisational, supply chain/network and sector/national/supranational levels to improve SCR.

The development of a lean six sigma and BIM framework for enhancing off-site manufacturing

PurposeThis study aims to improve a construction company's overall project delivery by utilising lean six sigma (LSS) methods combined with building information modelling (BIM) to design, modularise and manufacture various building elements in a controlled factory environment off-site.Design/methodology/approachA case study in a construction company utilised lean six sigma (LSS) methodology and BIM to identify non-value add waste in the construction process and improve sustainability.FindingsAn Irish-based construction company manufacturing modular pipe racks for the pharmaceutical industry utilised LSS to optimise and standardise their off-site manufacturing (OSM) partners process and leverage BIM to design skids which could be manufactured offsite and transported easily with minimal on-site installation and rework required. Productivity was improved, waste was reduced, less energy was consumed, defects were reduced and the project schedule for completion was reduced.Research limitations/implicationsThe case study was carried out on one construction company and one construction product type. Further case studies would ensure more generalisability. However, the implementation was tested on a modular construction company, and the methods used indicate that the generic framework could be applied and customized to any offsite company.Originality/valueThis is one of the few studies on implementing offsite manufacturing (OSM) utilising LSS and BIM in an Irish construction company. The detailed quantitative benefits and cost savings calculations presented as well as the use of the LSM methods and BIM in designing an OSM process can be leveraged by other construction organisations to understand the benefits of OSM. This study can help demonstrate how LSS and BIM can aid the construction industry to be more environmentally friendly.

Volumetric Modular Construction Risks: A Comprehensive Review and Digital-Technology-Coupled Circular Mitigation Strategies

Volumetric modular construction (VMC) has considerable benefits in providing better cost, time, quality, productivity, and sustainability performance. However, the adoption is low, owing to various associated risks. This study aims to identify VMC critical risk factors (CRFs) in project stages and project attributes by conducting a systematic literature review of 91 articles. In the project stages, 31 CRFs were identified based on frequency analyses, and divided into four stages: design and planning, offsite manufacturing, transportation and logistics, and onsite assembly. The project attribute risks were divided into the following categories: implementation and schedule, supply chain and financial, safety and ergonomic, and civil and structural. Overall, design and planning risks were critical, as they are crucial in maintaining the project’s upstream and downstream flow. Finally, the study proposed a mitigation framework for using digital technology-based circular strategies to overcome VMC risks. The framework includes disruptive and emergent digital technologies aiming to mitigate risks in VMC, keeping circularity in action. In terms of theoretical contributions, this research delivers a CRF register and categorical division for professionals to better understand the landscape of VMC risks. In terms of practical contributions, the study guides the practitioners towards strategies to overcome the pertinent risks.

Digitalising modular construction: Enhancement of off-site manufacturing productivity via a manufacturing execution & control (MEC) system

Modular construction facilities operate under tight deadlines making the monitoring of manufacturing progress and delivery for optimal factory-to-site operations a significant challenge. This paper presents an action research study that assisted in enhancing the productivity of a manufacturing execution and control system implemented at a facility in Melbourne, Australia. This system monitors production processes, and shares information for timely, well-informed decision-making using an online platform and a mobile app, developed using lean principles. The results showed significant time and cost savings, quality improvement and increased visibility of inefficiencies and will serve as a helpful reference for construction factory managers wishing to improve their manufacturing systems.

A framework for the evaluation of the decision between onsite and offsite construction using life cycle analysis (LCA) concepts and system dynamics modeling

The decision to choose between onsite and offsite construction is important in the effort toward sustainable construction. Offsite construction is often promoted as an environmentally friendly approach to construction operations. However, previous studies have shown that there is a lack of clarity on the environmental trade-offs between onsite and offsite construction. Factors that can affect the decision to build onsite or offsite include the availability of a local offsite manufacturing facility, the distance of the offsite factory to the final place of use, the proximity of the site to the local supply of material and labor, etc. This study provides a framework to apply the system dynamic modeling technique to evaluate how various factors can affect the environmental impact of the building construction phase (for onsite or offsite construction methods). The system dynamic model (using Vensim software) that was developed provides a platform that allows users to input variables such as the distance that is expected for transportation of labor, material, and equipment to both the onsite facility and the offsite construction location, factors associated with the use of equipment for construction, the distance needed for transportation of building panels or modules from the offsite facility to the final site, etc. Among other things, the model showed that an increase in the distance from the offsite yard to the final construction site increases the total impacts of transportation of completed modules. An increase in the number of trips for the transportation of material to the onsite construction location increases the total impact of onsite construction. In terms of the environmental impact of construction, none of the two methods of construction gives an absolute superiority over the other. The environmental performance of offsite and onsite depends on various associated factors. It is recommended that building practitioners review various factors that are peculiar to their projects to make an informed decision on the best construction methods.

Investigating the New Zealand Off-Site Manufacturing Industry’s Readiness for Automated Compliance Checking

Investigating the New Zealand Off-Site Manufacturing Industry’s Readiness for Automated Compliance Checking

Challenges of offsite construction and BIM implementation: providing a framework for integration in New Zealand

PurposeThe development of prefabrication into full-scale offsite manufacturing processes in the construction industry is paradigm-shifting. Moreover, Building Information Modelling (BIM) is becoming the primary mode of communication and integration in construction projects to facilitate the flow of information. Although research has been performed on BIM and Offsite Construction (OSC), integrating these two concepts remains ambiguous and complex and lacks documentation and structure, especially in New Zealand. Therefore, this paper develops a robust framework for OSC and BIM integration. The study focusses on identifying integration challenges and proposes strategies for overcoming these challenges.Design/methodology/approachThis study applied scientometric analysis, a systematic literature review (SLR) and semi-structured expert interviews to investigate OSC and BIM integration challenges. Multiple themes were investigated and triangulation conducted in this research supports the creation of applicable knowledge in this field.FindingsMultiple gaps, research trends and the pioneer countries in the paper's scope have been identified through scientometric analysis. Then, a classified cluster of challenges for OSC and BIM implementation and integration strategies of OSC and BIM were demonstrated from the findings. The interviews provided comprehensive and complementary data sets and analyses. The findings from the Systematic Literature Review and interview structured the integration framework.Originality/valueThe contribution of this paper to existing knowledge is a developed framework that serves as a guideline for the OSC stakeholders. This framework can assess OSC's alignment with BIM and consolidate strategies for incorporating OSC into a BIM-based project delivery process. The framework consists of 23 strategies categorised into 8 clusters: a policy document, training and professional development, documentation, technology management, governmental development, contract development, accurate definition and detailing and communication. The proposed strategies will streamline integration by reducing potential challenges, thus enhancing project productivity.

Development of a framework for quality assurance of off-site manufactured building components: A case study of the New Zealand housing sector

A shortage of housing is a prominent issue across the globe. Traditional on-site construction methods seem too inefficient to meet the increasing housing demand. As a solution, many countries, including the United States, Germany, Singapore, Japan, Hong Kong and Australia, have introduced off-site manufacturing methods to increase the housing supply. Different from the traditional way of on-site construction, off-site manufacturing is a technique that involves manufacturing building components in a controlled environment. Despite strong government support and industry attempts to increase off-site manufacturing, the current building consenting and inspection processes in New Zealand have significant quality-related issues. Therefore, this study aimed to identify the gaps in current quality assurance processes used in off-site manufacturing and recommend a framework in order to gain credibility and the acceptance of the construction market. The study collected qualitative data from industry experts (e.g., developers, architects, engineers, project managers, quantity surveyors, head contractors and council officers) who had significant experience in current quality assurance regimes in New Zealand prefabrication construction. The key themes for designing the proposed framework were generated using content analysis of the primary data collected from semi-structured interviews with industry experts. The study has found that standardisation in off-shore products regarding the New Zealand Building Code remains the biggest challenge in the consenting process. Quality assurance and inspection test plans are the developer’s responsibility and are typically provided by third-party inspectors. In this post-Covid-19 world-building, consent authorities rely heavily on third-party inspection companies that apply more rigorous auditing. Essentially, the most important parts of quality assurance are to have an experienced team and to adopt a holistic approach by engaging stakeholders early in the design stage. The stakeholders should consider recommendations for mandatory after-service insurance to ensure end-customer interests are protected. The findings of this study can contribute to the early engagement of different stakeholders to ensure overseas manufacturing of building components meets New Zealand quality standards. It is expected that the new quality assurance framework would help to promote off-site manufacturing for the New Zealand housing sector.

The Influence of Organisational Safety Climate Factors on Offsite Manufacturing Safety Performance

The construction industry consistently reports higher fatality and injury rates due to its inherent dynamic nature. As an alternative to traditional construction, offsite manufacturing (OSM) has become a construction method that presents many benefits including optimised schedule, quality control, waste reduction and improved site safety. Contrastingly, recent statistics on OSM indicated that in the USA for instance, the number of safety incidents were higher compared to traditional construction. There is a suggestion that organisations simply shift site-based construction activities to a factory. Therefore, this study aims to investigate the influence of organisational safety climate on OSM safety performance. Initially, a comprehensive literature review was conducted to identify organisational safety climate factors. Following this, 131 questionnaires were collected from Australian OSM practitioners. Finally, a Pearson correlation analysis was performed to examine the influence of organisational safety climate on OSM safety performance. Findings asserted that safety communication has the greatest impact on safety performance. Contrary to traditional construction practice, greater influence from managers was identified over supervisors towards safety performance. The novelty of this research lies in its attempt to comprehend the association between organisational safety climate and safety performance, which may make contribution to OSM safety knowledge and practice.

SWOT Analysis of Offsite Manufacturers of Prefabricated Building Components in Singapore

Despite government’s push for the use of prefabrication in Singapore, the problem is that offsite manufacturers of prefabricated building components (hereinafter referred to as manufactures) appear to be unable to harness their inherent strengths, overcome their weaknesses and external threats to take advantage of the available opportunities in the construction market. The aim of this study is to do a SWOT analysis on Singapore’s manufacturers and develop strategies to enable them to thrive. A structured questionnaire was designed based on extant literature of offsite manufacturing. Quantitative data were collected from 46 project stakeholders via an industry wide survey. It was found that manufacturers’ strengths are their high quality prefabricated products and high productivity. Their weaknesses are the high capital and production costs. Their biggest opportunities are the limited supply of manual site labor and tender evaluation criteria that favour productivity and quality. The threats include lack of control over factors of production, shrinking construction demand, stiff competition and complex designs. The implication is that manufacturers should improve and re-examine their internal operations to overcome their weaknesses and the challenges in their external environment. Production should be streamlined, and partnerships with suppliers and transportation firms should be developed to guard against price fluctuations and inaccurate deliveries. Other recommendations are also offered to help manufacturers harness their strengths and opportunities while minimizing their weaknesses and threats.…

Design-for-Manufacturing-and-Assembly (DfMA) for the construction industry: A review

Applying Design for manufacture and assembly (DfMA) principles in building has gained attention in recent years. Studies reported that the application of DfMA in building projects can significantly enhance overall productivity. However, the literature on DfMA in the construction industry is still limited. This paper aims to provide an updated and comprehensive review of DfMA approach and its applicability in the construction industry. Web of science, and Google Scholar databases were used to obtain relevant articles from the literature. The study is based on a systematic review of 52 selected articles through search keywords for DfMA. The bibliometric results mapped the research publications by year, journal, and country in which the DfMA study is conducted. The thematic analysis results revealed the research themes and trends. In conclusion, the DfMA literature has increasingly focused on integration and sharing of information during project life-cycle to optimize design, manufacturing, and assembly, and to address issues relating to the integration of off-site manufacturing with on-site assembly. Finally, the review is concluded by providing recommendations for researchers and practitioners, and by identifying future works and opportunities for the application of DfMA in the construction industry. The results of this paper can help future theoretical and empirical research and developments.

Assembly Solution for Modular Buildings: Development of an Automated Connecting Device for Light-Framed Structures

The prefabricated construction industry, also known as off-site construction, has been operating in North America for several years now and differs from traditional construction in its much shorter project timelines, lower costs, and increased build quality. However, the lack of a suitable and efficient assembly solution has been identified by many as a barrier to the use of off-site construction for larger buildings. To maximise the benefits of off-site manufacturing for multistorey buildings, an automated connection solution is presented in this paper. A new plug-in self-locking device was developed according to the following product design phases: on-site observations, definition of the problem and product specifications, solution generation, prototyping, fabrication, and testing. The plug-in self-locking device allows the assembly process to be accelerated by eliminating the fastening steps and a higher completion of modules off-site to be achieved. The design bears the compressive, tensile, and shear loads and contributes to the load path of the building.