Unlocking Peak Efficiency in Modular Construction: A Case Study in Rapid Process Improvement

The Challenge: A Factory Struggling with Bottlenecks

A modular construction factory, despite its skilled workforce and advanced equipment, faced crippling inefficiencies—idle workers waiting for materials, disorganized tools causing delays, and bottlenecks slowing down production. Every delay compounded across the production line, limiting throughput, increasing costs, and threatening profitability.

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The Solution: A Two-Day Kaizen Blitz with Lean & DMAIC

When traditional problem-solving approaches failed to deliver fast results, the factory turned to my rapid process improvement services, designed specifically for offsite manufacturing. Through a Kaizen Blitz, I applied Lean Manufacturing and DMAIC (Define, Measure, Analyze, Improve, Control) principles to uncover hidden wastes and implement high-impact solutions in just two days.

• Day 1: In-depth analysis of cycle times, identifying and eliminating wasted motion, waiting, and poor tool administration.

• Day 2: Immediate process optimizations, hands-on team training, and implementation of streamlined workflows.​

 

The Results: Faster Throughput, Higher Productivity

• Gluing process cycle time cut from 65 minutes to 21 minutes (68% improvement).

• Electrical wiring process reduced from 35 minutes to 13 minutes (63% improvement).

• Increased factory-wide throughput without additional labor or capital investment.

• Sustainable process control through updated Standard Operating Procedures (SOPs).​

 

The Competitive Advantage: Rapid, Measurable Improvement for Offsite Factories

My approach enables modular factories to maximize productivity, reduce costs, and meet growing demand without overhauling operations. By targeting the 9 Offsite Wastes, I help manufacturers streamline production, scale operations, and gain a competitive edge.