Efficiency and Performance in Offsite Construction – Synchronising the Manufacturing and Construction Processes

El-adaway I., Assaad R., Hastak M., Needy K. and Abdul Nabi M.

Chapter 9 in Building a Body of Knowledge in Modern Methods of Construction and Offsite Construction, 2025, pp 229-257 from World Scientific Publishing Co. Pte. Ltd.

Abstract: Offsite construction — also known as prefabrication, pre-assembly, modularisation, or pre-manufacturing — has been gaining popularity within the architectural, engineering, and construction (AEC) industry. Due to the numerous benefits of offsite construction methods, project stakeholders constantly explore how to leverage and make the best use of offsite construction technologies to improve the performance of their construction and infrastructure projects. Despite that the opportunities of offsite construction methods have been well publicised and understood, benefits gained can be undermined if the implemented offsite construction operations are not optimised. Thus, this chapter addresses different challenges related to the people, process, and technology aspects of offsite construction methods experienced in the AEC industry. Moreover, this book chapter provides an overview of the methods and practices needed to achieve optimal offsite construction efficiency and performance. Based on expert opinions collected from surveys and interviews, this chapter offers a framework for offsite construction performance improvements and enhanced project execution by considering and integrating different aspects required for offsite construction transformation, management, and success. The provided framework includes guidance on offsite construction typologies, types of offsite construction components, types of offsite construction structures, labor skillset for offsite construction, labor skill level for offsite construction, factors affecting labor productivity in offsite construction facilities, offsite construction training programs, investments in offsite construction technologies, needed offsite construction workforce occupations, distribution of work between onsite and offsite, distribution of work between human labor and automated offsite construction systems, and recommended offsite construction practices, among others. Finally, this chapter examines how to synchronise the manufacturing and construction processes and how to move from a disorganised offsite construction approach to fully- automated and technology-driven offsite manufacturing systems. Some of the key findings, takeaways, and recommended strategies include relying on modularisation, standardised offsite construction components, high-skilled labor, and multi-skilled workforce. Also, companies are recommended to invest in different technologies to achieve superior performance of their offsite construction operations. Ultimately, this book chapter concludes that organisations need to focus on integrating the people, process, and technology aspects of offsite construction operations in order to improve the offsite construction efficiency and performance well as to synchronise the manufacturing and construction processes.

Keywords: Modern Methods Of Construction; Offsite Construction; Prefabrication; Digital Technology; Sustainability; Circular Economy; Supply Chain; Procurement; Health & Safety; Risk; Capacity and Capability; Offsite Manufacturing; Preassembly; Innovation (search for similar items in EconPapers)
JEL-codes: D24 L7 L74 M11 (search for similar items in EconPapers)
Date: 2025
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