Implementation of Lean manufacturing begins with the development of value stream maps, which depict process flow in the production line. However, the application of value stream mapping (VSM) in modular manufacturing has various shortcomings, due to the variety of products and the level of customization demanded. One of the challenges is assessing the production rate variations in modular manufacturing activities and resource movements within work stations along the production line. VSM also falls short of verifying prior to implementation that the proposed state will meet the efficiency demands for a variety of products. This research presents a model of resource optimization to develop the VSM, considering variety as an inevitable element in modular construction, and also evaluates the value stream prior to implementation. The methodology provides an efficient method to formulate a set of rules to quantify productivity rate, probabilistic duration, and resource requirements for fabrication of wall components. A simulation model is also generated in order to evaluate the proposed VSM. Current- and future-state maps of the factory production line are compared to prove the effectiveness of the proposed methodology. The proposed methodology is validated by a case study – a residential modular factory located in Edmonton, AB, Canada.
Modular Building, Lean, Production Line, Value Stream Mapping, Product Variation, Resource Optimization, Simulation