Materials Today: Proceedings 65 (2022) 1105–1111

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Materials Today: Proceedings

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Application of lean manufacturing using value stream mapping (VSM) in

precast component manufacturing: A case study
Rahima Shabeen Sirajudeen ⇑, K. Aravind Krishnan
College of Engineering Guindy, Anna University, Chennai 600025, India

a r t i c l e i n f o a b s t r a c t

Article history: Prefabrication of structural concrete elements and assembly at site offers advantages such as reduction in
Available online 19 April 2022 construction time, improved quality and reduction of material wastage. These advantages depend on stan-
dardization and good organization of work at the precast component manufacturing unit. The need in a
Keywords: precast factory is to ensure a smooth and delay-less manufacturing process so that wastes can be elimi-
Lean Construction nated and better productivity can be achieved. The aim of this research paper is to apply lean principles
Value stream mapping and lean thinking using value stream mapping to reduce the processing time and increase the production
Precast manufacturing
in a precast component manufacturing unit. A precast component manufacturing unit in Chennai was cho-
7 waste
Lead time
sen for the case study. The precast plant was visited to understand the entire manufacturing process. Value
Productivity stream Map (VSM) of the manufacturing process was created using Lucidchart software. The wastes were
identified based on seven wastes of lean. Changes were proposed to eliminate the waste which included
change in layout of the manufacturing unit and handling devices. Future state map was created for the
improved manufacturing process. Comparison of cycle time and lead time was made for before and after
the proposed changes. The lead time decreased from 1102 to 739 min and the production increased from
33 units to 40 units per day. Also, it is found that the efficiency and effectiveness improved by 49% and
21.2% respectively. The study demonstrates that it is possible to achieve improvement in production of
precast component manufacturing unit using lean principles. Improvements in the reduction of lead time,
reduction of waste and increase in production are achieved with simple techniques.
Copyright Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Advances in Construction Materials and Structures.

1. Introduction Manufacturing sector has been long using lean principles to

Reinforced concrete is the most commonly used construction
material and it is mostly cast onsite. Onsite casting faces challenges
of quality control, lesser production and wastage. Prefabrication is
a technique where the structural components are cast in the fac-
tory. The manufactured components are transported and erected
at site. Prefabricated concrete structural elements can help negate
some of the problems of onsite casting. This technique offers
advantages such as faster construction, better quality, enhanced
safety at site and lesser generation of waste at site. A prefabrication
unit is a manufacturing unit producing the structural components.
Abbreviations: VSM, Value Stream Mapping; EOT, Electric Overhead Traveling.
⇑ Department of Civil Engineering, College of Engineering Guindy, Anna Univer-
sity, Chennai 600025, India
E-mail address: rahima@annauniv.edu (S. Rahima Shabeen).
increase the production, productivity, eliminate waste and
increase value. Similarly, there is a scope for increasing the produc-
tion and value of structural components in a precast factory based
on lean principles. Lean principle refers to the continuous process
of increasing the value of the product by elimination of waste
without compromising on production, productivity and quality.
Value stream mapping (VSM) is one of the tools used for identifica-
tion of waste in manufacturing process. It is a visual diagram of the
flow process which helps to identify the wastes and explore oppor-
tunities for improvement. VSM has been used by researchers in
construction process.
The objective of the study is to use Value stream Mapping
(VSM) to identify the waste and apply lean principles to improve
the production of manufacture of precast component. The scope
of the work incudes (1) physical observation of the manufacturing
process in the precast factory, (2) preparation of current value

https://doi.org/10.1016/j.matpr.2022.04.159
2214-7853/Copyright Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Advances in Construction Materials and Structures.
S. Rahima Shabeen and K. Aravind Krishnan Materials Today: Proceedings 65 (2022) 1105–1111

stream map, (3) identification of wastes, (4) suggestions for tures structural components such as Wall panels, Column, Beam,
improvement and (5) preparation of future state map. Staircase, Retaining wall, Barricades, Boundary walls and Hollow-
core slabs. Observations were made regarding, the plant layout,
the machinery used, the sequence of activities and the time taken
2. Literature review
for each activity by visiting the site and also by interacting with
the staff working there. The typical activities are (A) mould
Many researchers [1–8] have applied lean principles for
assembly and preparation, (B) fixing of rebars, (C) concreting
improving the productivity and efficiency of precast manufactur-
and curing, (D) demoulding and finally (E) transfer to storage
ing process. Ballard et al [1] proposed that improved performance
yard.
can be achieved in precast concrete fabrication by shifting focus to
work flow of the manufacturing process rather than just resource
3.1. Mould assembly and preparation
utilization. The authors also observed that future efforts should
be focused on developing a general theory for engineered-to-
Mould assembly is the beginning of the casting process.
order products in construction industry. Ray et al [2] observed that
Moulds are the formwork on to which the concrete is poured
there is lots of scope to apply lean manufacturing techniques in
and cast. The mould plates are taken from the inventory area
precast concrete industry to identify waste and improve productiv-
and placed on the fixed table using overhead cranes. Mould
ity and value. Deffense and Cachadinha [3] implemented lean tech-
assembly and preparation involves assembling of mould plates
niques such as value stream mapping to identify the waste and 5S,
with the help of bolt and weld connections. The assembly is done
Kanban and just-in-time to improve productivity, reduce expense
based on the shop drawings provided from the design team. The
and increase delivery of units in precast manufacturing factory.
following are the sequence of activities happening at the mould
Peng and Pheng [4] opined that value stream of mapping of precast
assembly.
manufacturing is necessary to address the goals of sustainability.
Kanai and Fontanini [8] used value stream map to identify waste
 Marking dimensions on the fixed table and ensuring that the
in precast manufacturing. The waste elimination was done using
dimensions of mould are within the specified tolerances.
just-in-time concept and Kanban. The manufacturing system was
 Placing the mould plates on the fixed table with the help of
moved from ‘actual’ to ‘pushed system’ to ‘pull system’ and finally
crane operation.
to a ‘just-in-time’ system gradually by thinking lean. The authors
 Checking the level and flatness of the base mould.
observed that value stream map helps in making the flow simpli-
 Checking the mould for cleanliness. Checking whether the
fied and logical, thereby eliminating waste. Value Stream Mapping
mould is free of debris and old mortar.
has also been used in other areas of construction [9,10]. Yu et al [9]
 Making weld or bolt connections to keep mould plates intact.
observed that the delay caused due to conflict in predetermined
Grooves are provided as per shop drawing to have proper joint
schedule and actual schedule of complex process of house con-
with other components while fixing at site.
struction can be reduced by focusing on a stable work/ product
 Applying form oil or mould releasing agent evenly.
flow rather than on individual task. Fontanni et al [10] used value
 Checking the joints and edges for dimensionality.
stram mapping to identify waste in the construction process of
 Drilling holes at marked places on mould side plates to extend
concrete slab in residential buildings. It is observed that use of lean
dowel bars outside the plate.
concepts and value stream mapping has the potential to improve
production and productivity.
3.2. Fixing of rebars
Various manufacturing industries have also used value stream
mapping for identification of waste and improving value. Brown
The next operation is fixing of the rebars into the mould. Fabri-
et al [11] examined the concept of sustainable VSM (Sus-VSM) in
cating the rebar cage involves cutting, bending and formation of
three case studies in manufacturing industry. Venkatraman et al
reinforcement cage as per shop drawings. The reinforcement cage
[12] eliminated the eight wastes and established a single-piece
is made separately and transferred to the mould. The following are
flow manufacturing of crankshaft. Kumar and Kumar [13] applied
the sequence of activities happening during transfer of rebar cage
value stream mapping and other lean techniques to improve the
to the mould.
cycle time of the process of truck body assembly in automobile
industry. Yuan et al[14] developed a discrete event simulation
 Checking whether the rebar size, spacing and lap length are in
(DES) based lean planning and optimization method to improve
accordance with the drawings.
the accuracy of prediction of production time and eliminate unnec-
 Correct positioning and properly securing of rebars, electrical
essary waste in terms of time and resource utilization. Pathania
conduits, lifting inserts inside the mould. The reinforcement
et al [15] used value stream mapping technique to reduce rejection
cage is laid over the mould only after the form oil is dried to cer-
rates and delivery performance in Ferrite core manufacturing unit.
tain degree so as to prevent contamination.
Rathi et al [16] used value stream mapping in water distillation
 Fixing the loop box with the reinforcement cage which is used
plant to minimize work-in-progress inventory and lead time
while lifting the components using crane.
through 5S and Kaizen techniques. Gunaki et al [17] identified
non-value added activities and decreased cycle time by value
3.3. Concreting and curing
stream mapping in die casting industry. Hence, research suggests
that lean principles can be used in variety of sectors to reduce
Next step is concreting. The raw materials collected are fed into
waste and improve value. However, each sector and each manufac-
the mixer before concreting operation is started. The concrete mix-
turing unit has its own challenges and the process improvement
ing and transportation both are computerized and easy to operate.
has to be decided on a case-to-case basis.
The flying bucket system is adopted. The following are the
sequence of activities happening during concreting and curing.
3. Precast wall panel manufacturing
 Checking the concrete grade as per specifications
A partially automated precast factory X was chosen for the  Conducting slump cone test to ascertain the workability of the
study. The factory is located in Chennai and typically manufac- concrete mix from the plant mixer.
1106
S. Rahima Shabeen and K. Aravind Krishnan
 Transporting of the mixed concrete using flying bucket and
spreader machine. The drop height of concrete mix is adjusted
to be not more than 1 m.
 Ensuring proper vibration and compaction of concrete
 Spreading, levelling and finishing of concrete.
 The concrete is allowed to cure for about 6 h.
3.4. Transfer to storage yard
The precast concrete element is moved to the stack yard using a
crane after demoulding. Curing is done for 3 days using sprinkler
system at the stack yard. The finished components are stored in
storage yard. The following are the sequence of activities at the
storage yard.
1. Checking the condition of the finished product.
2. Verifying the critical dimensions.
3. Placing proper identification markings on elements showing
location, member type, size, weight and orientation as per shop
drawing.
4. Checking whether the elements have achieved 75% of their
design concrete strength before delivery at site for erection.
4. Current state map
Current state value stream map was prepared based on the data
collected from site. Fig. 1 shows the current state map with infor-
mation flow, material flow and lead time ladder, created using
Lucidchart software. The sequence of activities are from A to E as
follows: Process A- Mould assembly and Preparation, Process B-
Fixing of Rebars, Process C- Concreting and curing, Process D-
Demoulding and Process E- Transfer to storage yard.
The information flow shows the flow of information between
production team, management team, supplier and customer. The
Fig. 1. Current state map.
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Materials Today: Proceedings 65 (2022) 1105–1111
material flow represents the flow of materials from supply to final
product through various process. The cycle time represents the
time for each process and lead time represents the production time
for entire manufacturing process from order to final product of pre-
cast components. Lead time refers to the time taken for both value
added and non-value added activities whereas cycle time refers to
the time taken for only value added time. The time taken for each
activity in the current manufacturing process is recorded in min-
utes. Tables 3 to 7 lists the activities and the time taken in minutes
for each activity in the process of manufacture of precast wall
component.
The maximum lead time for the current manufacturing process
is 1102 min. Based on time taken for each activity and observation
at the factory, the number of components produced per day at the
current state with 15 fixed tables and 5 tilting tables is 33.
5. Analysis
5.1. Identification of waste
The current state map helped in identifying the wasteful activ-
ities. The identified wastes were categorized based on seven
wastes of lean in Table 1.
5.2. Proposed changes
5.2.1. Change in layout
Existing factory floor layout is shown in Fig. 2a. The layout of
the factory was observed to contribute to the ‘motion’ waste. The
mould-assembly-parts storage area and reinforcement-cage-
making-area were initially at a distance of 150 m which con-
tributed to a longer travel time of the EOT crane (Electric overhead
travelling crane). Therefore a new layout is proposed in such a way
that it is feasible to implement.
S. Rahima Shabeen and K. Aravind Krishnan Materials Today: Proceedings 65 (2022) 1105–1111

Table 1 Table 4
Identification of waste based on lean principles. Fixing of rebars.

Categories of Identified waste Description of activities VA/ Time taken in Time taken in
waste NVA current state future state
(mins) (mins)
Overprocessing Zinc chromate paint was applied to prevent oxidation of
steel when the wall panels were stacked in the storage yard Bar cutting VA 38 38
without delivering to construction site for more than three Bar bending VA 17 17
days which leads to increased time for over-processing the Stirrup making VA 9 9
exposed steel. Reinforcement cage making VA 33 33
Waiting Curing has to be done for 10 h when using water pond Transferring reinforcement NVA 19 10
method which increases the waiting time for the cage to fixed table using
subsequent processes. gantry crane
Motion The Reinforcement cage making area is located at a distance Placing reinforcement cage VA 5 5
of 150 m from the mould table which increases the travel inside mould
time of EOT crane to transfer it to table platform. Also, a Fixing electrical conduits VA 17 17
trolley is used to transfer the reinforcement cage from one Fixing of loop box VA 14 14
bay to another which increases the travel time. Quality controller check VA 11 11
Transport The mould-assembly-parts storage area is also located at a TOTAL LEAD TIME 163 154
distance of 150 m which increases the travel time of EOT TOTAL CYCLE TIME 144 144
crane to transfer it to the table platform.
Defects Damage to mould plates occured while the welded
connection was broken during demoulding process.
Overprocessing Reworking on damaged finished components using epoxy Table 5
injection was done which increases the lead time. The Concreting and curing.
damages occurred mainly during lifting of casted Description of activities VA/ Time taken in Time taken in
components from fixed table after demoulding process. NVA current state future state
Inventory The wall panels were stored for a long time in the storage (mins) (mins)
yards.
Transfer raw materials to NVA 18 18
feeder
Feeding raw materials to NVA 5 5
Table 2 Plant mixer
Proposed changes. Mixing operation VA 2 2
Workability test VA 10 10
Categories of waste Ways to overcome the waste
Flying bucket operation VA 8 8
Inventory By pull planning Spreading of concrete VA 16 16
Waiting Steam curing process can be adopted. manually
Motion Change in layout. Compaction using vibrator VA 15 5
Transport Change in layout manually
Defects Tilting tables can be installed Temporary finishing VA 8 8
Overprocessing Tilting tables can be installed. Initial setting time VA 30 30
Over production Pull planning can be adopted Final finishing of concrete VA 12 12
surface
Curing process by water VA 9 9
ponding
Table 3 Quality controller check VA 6 6
Time taken for mould assembly and preparation. Final setting of concrete by VA 600 360
water ponding method
Description of activities1 VA/ Time taken in Time taken in
TOTAL LEAD TIME 739 480
NVA current state future state
TOTAL CYCLE TIME 716 457
(mins) (mins)
Marking dimensions on VA 23 23
Fixed table
Transfer mould plates from NVA 14 10 Table 6
storage place to fixed Demoulding.
table
Description of activities VA/ Time taken in Time taken in
Cleaning and grinding of NVA 22 22
NVA current state future state
mould plates
(mins) (mins)
Placing mould plates VA 11 11
Welding to support mould NVA 28 15 Compression test of VA 18 18
plates concrete to find strength
Bolt connection of mould NVA 24 12 Breaking weld connections NVA 21 –
plates Removing bolt connections VA 18 9
Fixing grooves according to VA 14 14 Removing mould plates VA 14 7
drawing Identification marking NVA 6 6
Application of mould VA 12 12 using paint
releasing agent Zinc chromate paint for NVA 26 –
Application of retarder for VA 6 6 exposed steel rod
concrete rough surface Quality controller check VA 11 11
Quality controller check VA 8 8 TOTAL LEAD TIME 114 51
TOTAL LEAD TIME 162 133 TOTAL CYCLE TIME 61 45
TOTAL CYCLE TIME 74 74

Fig. 2b shows the new layout. In the proposed layout the The speed of EOT crane is 20 m/min, hence the proposed change
mould-assembly-parts storage area and reinforcement-cage- saves travel time by 4 mins. By changing the location of
making area were shifted to middle of the table platform area reinforcement-cage-making area, the taken time by the trolley to
which decreases the travelling distance of EOT crane to 75 m. transfer the cage is reduced by 5 mins.

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S. Rahima Shabeen and K. Aravind Krishnan Materials Today: Proceedings 65 (2022) 1105–1111

Table 7 which leads to extra processing of steel rod. This is mainly because
Transfer to stack yard. the completed wall panels are stored in the storage yard for a long
Description of VA/ Time taken in current Time taken in future time. If the finished components are delivered to construction site
activities NVA state (mins) state (mins) within three days, then the time taken and the workers required
Epoxy injection to fill NVA 32 – for zinc chromate painting can be eliminated.
any cracks Table 2 shows the proposed changes for the reduction/elimina-
Quality controller VA 18 18 tion of wastes identified by value stream mapping.
check
Gantry Crane VA 23 23
operation
Placing at storage VA 13 13
yard 6. Implementation
TOTAL LEAD TIME 86 54
TOTAL CYCLE TIME 54 54
6.1. Future state map

5.2.2. Tilting table
The second major waste was due to handling problem in the
manufacturing process of precast wall panel. Tilting tables can be
used instead of fixed tables for better handling of the mould and
precast concrete wall panel. Welded connections lead to damage
of the mould plates during reuse. The damage to mould plates
due to welding can be avoided since, tilting tables have magnetic
connections. Further, in a tilting table, only two sides need to be
assembled whereas in fixed table four sides need to be assembled.
Hence the handling time for assembling mould plates can be
reduced to half and the number of workers can be reduced from
4 workers to 2 workers. Additionally, tilting table is capable of
vibrating through power supply. It takes 5 mins for compaction
of poured concrete in vibratory table whereas the manual vibrator
takes 15 mins and needs workers to operate. Hence by using tilting
table, handling time for compaction can be reduced and the work-
ers employed for compaction process can be eliminated. Also, cast-
ing in tilting table eliminates the damage due to lifting of
components after demoulding process. In fixed table, during lifting
of the components bending action takes place which results in
cracks and needs reworking using epoxy injection.
5.2.3. Curing method
The time spent in waiting for previous stage to get completed is
another major waste, causing reduction in production. It takes 10 h
for the curing of the wall panel by water ponding method. Alterna-
tively, steam curing method can be used. Steam curing reduces the
waiting time from 10 h to 6 h.
5.2.4. Pull factor
Waste of over processing was also observed in the plant which
increased the production time. In the current manufacturing pro-
cess, the exposed steel rods are coated with Zinc chromate paint
The time taken for each activity after proposed changes in the
manufacturing process was recorded. The future state map with
information flow, material flow and lead time ladder is created
using Lucidchart software (Fig. 3).
Tables 3 to 7 lists the activities and the time taken in minutes
for each activity in the process of manufacture of precast wall com-
ponent after elimination of waste and implementing the changes.
Maximum lead time after proposed changes in manufacturing pro-
cess is 739 min. Based on time taken after proposed changes and
observations at the factory it was found that the tilting table will
be able to manufacture two components per day. Hence, the num-
ber of components produced per day would to be 40 with the use
of 20 tilting tables.
6.2. Performance evaluation
CPM is continuous leanness measurement process to measure
production efficiency and effectiveness. Efficiency is the ratio of
total time allocated to make one product to the actual time taken
to manufacture that product. Effectiveness is the ratio of actual
number of output to the targeted output for the production pro-
cess. The production target is taken as client’s demand of number
of products per day. In process A, due to changes in plant layout
and replacing fixed table with tilting table, the lead time reduced
from 162 mins to 133 mins. In process B, due to elimination of
use of trolley and change in plant layout, the lead time has reduced
from 163 mins to 154 mins. In process C, the lead time has reduced
from 739 mins to 480 mins due to change in curing method from
water ponding to steam curing and elimination of manual com-
paction process. In process D, due to use of magnetic connections
and tilting table the lead time reduced from 114 mins to 51 mins.
In process E, tilting table usage has reduced lead time from 86 mins
to 54 mins.

Fig. 2. Factory layout (a) Current (b) Future.

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S. Rahima Shabeen and K. Aravind Krishnan
Fig. 3. Future state map.
7. Summary and conclusions
In this study, the data was collected on the manufacturing pro-
cess of a wall panel at a precast manufacturing unit and a current
state value stream map was created using Lucidchart software. The
maximum lead time was 1102 min and the production was
observed to be 33 components per day. Then future state map
was created after the proposed improvement measures for which
the maximum lead time was 739 min and production was 40 per
day components. A leanness measuring metric CPM (Continuous
performance measurement) having two parameters that is effi-
ciency and effectiveness is calculated for current state map and
future state map inorder to evaluate the percentage improvement
in performance. It is found that the efficiency and effectiveness
improved by 49% and 21.2% respectively.
Results from this study clearly demonstrated that by imple-
menting Value stream mapping method the maximum lead time
is reduced and the production is increased. It can also be concluded
that precast plant can implement value stream mapping method
and enhance the value and production.
CRediT authorship contribution statement
S. Rahima Shabeen: Conceptualization, Methodology, Software,
Validation, Resources, Investigation, Data curation, Data curation,
Writing – original draft, Visualization, Supervision, Project admin-
istration, Funding acquisition. K. Aravind Krishnan: Conceptual-
ization, Methodology, Software, Validation, Formal analysis,
Resources, Data curation, Visualization, Project administration,
Funding acquisition.
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Materials Today: Proceedings 65 (2022) 1105–1111
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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