Simulation-Based Modular Construction Shop Floor Design for Productivity Optimization

A lack of understanding of the construction process often results in inefficient productivity and resource waste. To address these challenges in the modular construction industry, it is crucial to analyze the production time for each task across different processes and optimize the shop floor accordingly. This paper focuses on the design and optimization of modular construction shop floors to enhance production performance. Lafaete, one of the largest modular construction companies in Brazil, is used as a case study to provide real-world insights and applicability. Three objectives, including (1) conduct an analysis of current shop floor production using the Monte Carlo simulation model, (2) achieve labor and station resource leveling through the application of queuing theory, and (3) forecast future productivity with a spreadsheet model, are achieved in this study. By implementing the proposed solution, we try to improve shop floor production efficiency and optimize the utilization of resources, ultimately contributing to the productivity advancement of the modular construction industry.