Lean-digital transformation in prefabricated construction: a dynamic three-stage pathway configuration

Purpose This study explores how lean and digital technologies can be synergistically integrated to enhance prefabricated construction (PC), particularly under dynamic and complex conditions. It aims to address the research gap concerning the lack of configurational pathways that enable lean-digital synergy across different PC developmental stages. Design/methodology/approach This study adopts a stage-based analytical framework to examine the evolution of lean-digital integration through three stages: primary, intermediate and advanced. A combination of Best-Worst Method (BWM) and fuzzy set Qualitative Comparative Analysis (fsQCA) is employed to identify and evaluate the multiple concurrent causal conditions that influence lean-digital transformation in the PC context. The robustness test is also conducted to validate the results. Findings The analysis reveals that no single factor is sufficient to drive lean-digital transformation. Instead, success depends on specific configurations of multiple interrelated factors. At the primary stage, standardized management and digital information systems lay the groundwork. The intermediate stage emphasizes resource coordination and dynamic decision-making through intelligent operations. The advanced stage, however, focuses on delivering customer value and achieving industry–chain collaboration and continuous improvement. Originality/value This study contributes to the theoretical development of lean–digital integration by identifying the dynamic and stage-specific causal pathways critical to transformation in PC. It offers actionable insights for industry stakeholders to strategically implement lean-digital transformation in the real-world, dynamic construction environments, promoting high-performance outcomes aligned with Construction 4.0.