Developing Lean Framework for Offsite-Onsite Integration on Prefabricated Construction Project

Literature review

Coleman (2021) researched the design of a medium-density house in New Zealand that will

utilize decomposable materials to ensure zero waste, aligning with circular economic principles.

Materials, including clay plaster, untreated lumber, and straw and wool padding, were

determined to be decomposable based on the region's climatic conditions. He compared differing

construction methods and identified that prefabricated wood panels provided the best foundation

for the materials. He also created a building information modeling (BIM) model to evaluate the

project's volume and the amount of reusable and decomposable materials. The results from this

model indicated that 81% represented the volume of decomposable materials, and 91% of the

volume was obtained from landfill diversion. From this, we can see the enormous possibility of

reducing waste in projects of similar size. This study provides insights into strategies that can be

used to ensure sustainable building practices with minimal environmental impact.

Finch et al. (2021) conducted a study to assess the possibility of incorporating circular economic

principles into house construction, especially in timber-framed dwellings, to reduce waste and

encourage using lean frameworks in the building sector. They utilized lean frameworks in the

building project to determine the reuse performance of building materials. They identified

critical factors that reduce their circularity, including processed materials and the need for

repairs. Moreover, they used real-life deconstruction assessments to authenticate circularity

valuation standards while recognizing the drawbacks and potential improvements. They

conclude by proposing possible solutions to the identified challenges that align with circular
project ethics. Therefore, this study provides valuable information on sustainable building

measures that ensure waste reduction and minimal environmental footprint in the building sector.

Gade (2022) investigated the contribution of waste reduction in Construction & Demolition

(C&D) to sustainable construction in-house projects, specifically in New Zealand. Gade utilized

a mixed-method approach that entailed onsite observations and semi-controlled interviews,

which aided in illuminating the factors inducing waste generation in C&D and the difficulties

encountered in waste minimization in varying parts of the project construction. The major

findings include recognizing circular economy measures and waste categorization routines,

among others, as substantial influences and problems. The investigation offers a waste reduction

outline and possible solutions to contractors, politicians, and influencers, emphasizing teamwork

to ensure C&D waste reduction. The findings contribute valuable information on practical

building waste reduction methods ensuring eco-friendly construction routines.

Lin (2022) conducted research within New Zealand's housing subdivision to identify problems

encountered in quality assurance policies in the offsite manufacturing of house components.

Using qualitative methods to gather data from industry experts such as local government

officials, engineers, and architects aided in uncovering gaps in quality assurance procedures and

offers a structure that boosts trustworthiness and acceptance in the building sector. The main

points for the structure were derived from analyzing partially controlled interviews. The study

points out issues including offshore product standardization and the significance of unbiased

observer's input regarding quality assurance. Lin emphasizes that companies require an

experienced team and engage with stakeholders during the design phase, particularly after

COVID-19, when third-party inspection organizations can consent to industry processes. The
study's findings ensure that overseas house components pass New Zealand's quality standard test

by implementing effective quality assurance routines promoting offsite manufacturing.

Marriage & Sutherland (2014) investigate a creative method of building in anticipation of the

necessity for reconstruction in the wake of the New Zealand earthquakes that struck Canterbury.

The study's introduction emphasizes the background of the Canterbury quakes, their devastation,

and the ensuing efforts at reconstruction. It underscores the necessity for quick, high-quality, and

effective building techniques, particularly given the current real estate market and the difficulties

an earthquake-prone area presents. The authors suggest a digital fabrication method, focusing on

Building Information Modeling (BIM) for cladding and CNC fabrication of cross-laminated

timber (CLT) structures. Numerous benefits come with this strategy, including excellent quality,

speed, efficiency, and possibly more inexpensive homes. The research explores the specifics of

the Warrander Studio endeavor, reviewing concerns related to onsite and offsite manufacture.

Therefore, they offer insightful information on a progressive approach to building that aims to

achieve long-term sustainability and effectiveness in the construction sector for years and meet

the pressing demands of post-disaster reconstruction.

Masood et al., 2021, investigated the performance of the distribution of prefabricated house-

building (PHB) within New Zealand, where they concentrated on the issues hindering PHB

organizations. Through a qualitative approach, they utilized wide-ranging surveys where

participants included were PHB experts and companies. They uncovered 19 crucial influences

impacting performance and categorized them under six performance scopes. The results show

that issues mainly relate to price and quality, pointing out the significance of supplier routine in

procurement. This research accentuates the unique landscape of PHB supply chains in contrast to

outdated construction, where the modern era has created new challenges, such as the adoption of
creative business methods and inadequate supply chain capability. The results shed light on the

dynamics of the developing PHB market and can be used to guide government regulations,

industry roadmaps, and strategic goals that support sustainable building methods.

With an emphasis on important performance-influencing variables, Masood et al. (2023)

examine the relations and efficiency of distribution networks for prefabricated house-building

(PHB) in New Zealand. A Matrice d'Impacts Croisés Multiplication Appliqués à un Classement

(MICMAC) technique, together with interpretive structural modeling (ISM), are used in this

study to identify and establish the interrelationships between the important performance

dimensions (time, quality, cost, delivery, features, and innovation). Performance dynamics in

PHB organizations can be drawn from current literature elements and integrated with industry

experts' feedback. The study suggests important performance approaches for PHB enterprises,

especially those engaged in the production and assembly of steel products, by classifying critical

performance parameters and evaluating their driving and dependency power. Understanding the

complex workings of PHB supply chains is aided by this research, which also provides insightful

information for formulating strategies to overcome significant obstacles and improve competitive

edge in the housing market.

Another study by Masood et al. (2023) attempts to comprehend industry attitudes concerning

interpretation, sales expansion, creativity, dispersion, and the role of makers by examining the

supply chain viewpoint of prefabricated house-building (PHB) distribution in New Zealand.

They employ an exploratory qualitative research approach, including interviews and semi-

structured questionnaires with participants in the supply chain, including manufacturers and

other people with essential PHB industry expertise. The study offers multiple viewpoints on the

PHB sector in New Zealand, which is helpful for scholars and practitioners. Therefore, it helps to
formalize plans of action, policies, strategies, and programs that support the national adoption of

PHB.

In 2021, Munir et al. investigated the prefabricated house-building (PHB) distribution in New

Zealand from a supply chain perspective to comprehend industry views on innovation diffusion,

growth, market share, conceptualization, and producer roles. The study uses an in-depth

qualitative research approach, including interviews and semi-structured questionnaires with

participants in the supply chain, comprising manufacturers and those that don't have pertinent

PHB industry expertise. Important discoveries include opinions on revenue and growth,

prevalent terms employed by supply chain participants, PHB spread by category patterns, and

producers' crucial role in PHB initiatives. The study offers multiple viewpoints on the PHB

sector within New Zealand, which is helpful for scholars and practitioners. It helps to formalize

plans of action, policies, strategies, and programs that support the national adoption of PHB.

Nesarnobari et al. (2022) examine New Zealand's prefabricated housing supply chain to improve

its ability to handle long-term performance-related problems in the building industry and the

housing shortage. The study uses a thorough analytical method to investigate gaps in integrating

prefabricated housing with various building approaches and identify issues restricting the

prefabricated sector's capabilities to meet housing supply requirements. It also integrates

bibliometric search and qualitative discussion. Important supply chain interruptions include

stakeholder mistrust, a lack of workers, onsite assembly delays, and hazards, including cargo

delays and the effects of calamities like the COVID-19 outbreak. The research highlights the

necessity of enhancing supply chain management (SCM) to tackle these obstacles and amplify

the effectiveness of readymade housing delivery. The significance of supply chain integration

and stakeholder collaboration is highlighted to maximize data and resource circulation, promptly
respond to changes in demand or design, and surmount obstacles impeding the adoption of

prefabrication.

Purchase et al. (2021) examine the idea of the Circular Economy (CE) as it relates to the

management of waste from construction and demolition (C&D), emphasizing the advantages,

difficulties, and lessons learned. C&D trash has historically been treated as low-value material

and dumped in landfills. Still, as people become more conscious of sustainability, they become

more interested in using CE principles to reduce their adverse environmental effects. The report

highlights the need for an international framework to support the adoption of CE by identifying

obstacles to its implementation in the C&D industry, including legal, technological, community,

behavioral, and financial concerns. The review also looks at the advantages of employing

recycled materials in buildings, focusing on the positive effects on the environment, the

economy, and society. The review employed various methodologies, such as literature analysis,

cost-benefit evaluations, and interviews with professionals in the field. The results indicate that

applying CE principles to the construction industry can significantly impact the environment and

the economy. However, doing so will require cooperation from all parties involved to remove

obstacles and provide incentives for waste reduction.

Roy et al. (2022) examine the effects of steel roofing and cladding products—widely used in

New Zealand—on the environment, paying particular attention to their life cycle and recycling

procedures. They use the Environmental Product Declaration (EPD) and life cycle assessment

(LCA) approach, taking into account modules C1–C4 and D, to measure the environmental

consequences of the steel products. We compare two comparable items, Product A and Product

B, where Product B uses resources sourced locally and Product A uses materials imported.

Product A has more negative effects regarding the possibility of global warming (GWP) and
photochemical ozone creation potential (POCP). In contrast, according to the study, Product B

performs better regarding ozone depletion, acidification, and eutrophication. Nevertheless, both

items have an overall positive effect on the environment after recycling. Additionally, the study

assesses the importance of appropriate material recycling and demonstrates that recycling

significantly lessens environmental effects, especially GWP and POCP. Therefore, from the

results, we can see an emphasis on the significance of reusing steel roofing and paneling to

reduce detrimental environmental consequences and support the idea of a circular economy.

Another research by Taylor et al. (2023) examined how building materials affected carbon

emissions in New Zealand's residential construction to assist the nation's sustainability

objectives. They examined the foundations, cladding, framing, roofing, and other building

envelope components during an extensive life-cycle assessment (LCA) of five case study houses.

As a result, they discovered that while construction energy was the highest contributor to

emissions, materials such as timber, concrete blocks, and steel roofs had minor emissions, and

steel roofing had the highest recyclability potential. For a more comprehensive understanding of

sustainability in construction, future studies could investigate the environmental effects of offsite

prefabrication and consider pragmatic factors like constructability and cost of operational energy

use.

Al-Radhi et al. (2023) evaluated the thermal efficiency of different building materials used in

homes through a systematic assessment of the literature, with a particular emphasis on the

context of New Zealand. They analyzed over 190 journal papers and examined wood, concrete,

cold-formed steel, bricks, phase-changing substances, and composite materials. While wood is

still the most common building material in New Zealand, the evaluation pointed out that

alternative materials, such as concrete and phase-change materials, have the potential to provide
better thermal performance. These technologies and materials haven't been widely utilized in

New Zealand. Additionally, the paper discussed the global context of energy-efficient

construction and its relevance to New Zealand's goal of achieving net-zero carbon emissions.

The study emphasized the need to incorporate the latest approaches and techniques to enhance

energy efficiency in residential buildings, aligning with international efforts to reduce carbon

emissions.

Berry et al. (2022) examined whether a circular economy could be applied to plastic trash

produced in New Zealand's building industry, particularly in Auckland. It brought attention to

how much construction and demolition (C&D) debris—of which plastic garbage makes up a

significant portion—goes into landfills. The study employed trash audits to examine the types of

plastic waste, where they come from, and whether they can be recycled or used again. One of the

places included in the audit was a newly constructed secondary school. The results showed that

the most common types of plastic trash were polyethylene (PE) and polyvinyl chloride (PVC),

which came from building materials, packaging, and building protection. Therefore, they

contributed to developing approaches to environmentally friendly waste disposal techniques,

which align with the fundamental goal of promoting a circular economy by illuminating the traits

and sources of plastic trash in the construction industry.

Burke et al. (2023) examine how decisions about supply chain management (SCM) and product

design might be integrated to move toward a circular economy (CE) model. The research finds

significant topics such as business model innovation, circular supply chain management, end-of-

life perspective in product design, and sustainable company principles through thematic analysis

of 15 semi-structured interviews conducted in New Zealand. The results shed light on the

prospects and difficulties of implementing CE principles, notably supply chain disruptions and
economic sustainability. The report emphasizes the challenges of shifting to a circular economy,

such as conflicting opinions regarding the financial advantages of circular product design and

worries about consumer acceptability and supply chain effectiveness. Thus, the study accentuates

the significance of considering ecological sustainability and circular economy standards in

project design and execution. It also offers complementing observations regarding sustainable

practices and problems within the larger construction industry supply chain.

References

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