https://doi.org/10.24928/2026/0243
An adaptive WIP controller framework for dynamic buffer management in modular construction
Nima Moghimi1, Sahar H. Shamaee2, Haitao Yu3, Qipei Mei4, Vicente A. Gonzalez5 & Farook Hamzeh6
1Ph.D. Student, Department of Civil and Environmental Engineering, University of Alberta, Canada, [email protected], orcid.org/0009-0008-4733-12762Graduate Research Assistant, Department of Civil and Environmental Engineering, University of Alberta, Canada, [email protected]
3R&D Lead, Landmark Homes, Edmonton, Canada, [email protected]
4Assistant Professor, Department of Civil and Environmental Engineering, University of Alberta, Canada, [email protected]
5Hal Kvisle Professor and Tier 1 Canada Research Chair in Digital Lean Construction, Infrastructure Human Tech (IHT) Lab, Strategic Projects Insight Centre in Engineering (SPICE), Department of Civil and Environmental Engineering, Faculty of Engineering, University of Alberta, Canada, [email protected], orcid.org/0000-0003-3408-3863
6Professor, Department of Civil and Environmental Engineering, University of Alberta, Canada, [email protected], orcid.org/0000-0002-3986-9534
Abstract
Lean construction principles emphasize maintaining production flow and managing variability to eliminate waste. However, in modular construction, high product mix and strict spatial constraints frequently disrupt this flow, rendering static buffering strategies ineffective. To address this challenge, this paper proposes an Adaptive WIP Control Framework structured in three integrated layers: a Digital Twin for stochastic simulation, an optimization layer for policy development, and a real-time execution layer. At the core of this framework is a novel hysteretic "Store-and-Release" control logic that dynamically regulates Work-in-Process (WIP) based on real-time buffer inventory, transforming the buffer from a passive queue into an active decoupling mechanism. The control logic was evaluated through a simulation-based case study of a prefabricated wall assembly line. Results demonstrate that the adaptive controller reduces downstream workload by 22% compared to unbuffered flow, effectively eliminating starvation waste. Unlike static time-buffers which sacrifice upstream speed for downstream stability, the adaptive approach optimizes total system performance without physical footprint expansion. This research contributes to Lean construction theory by establishing dynamic inventory control as a superior alternative to static scheduling for maintaining reliable flow in off-site construction.
Keywords
Lean Construction, flow, work in progress/process (WIP), buffer/buffer management, modular construction.
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Reference in APA 7th edition format:
Moghimi, N., Shamaee, S. H., Yu, H., Mei, Q., Gonzalez, V. A. & Hamzeh, F.. (2026). An adaptive WIP controller framework for dynamic buffer management in modular construction. In Hamzeh, F., Poshdar, M., & Garcia-Lopez,, N. P. (Eds.), Proceedings of the 34th Annual Conference of the International Group for Lean Construction (IGLC 34) (pp. 811–823). https://doi.org/10.24928/2026/0243
Shortened reference for use in IGLC papers:
Moghimi, N., Shamaee, S. H., Yu, H., Mei, Q., Gonzalez, V. A. & Hamzeh, F.. (2026). An adaptive WIP controller framework for dynamic buffer management in modular construction. IGLC34. https://doi.org/10.24928/2026/0243
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