Factory Design for Modular Homebuilding

Utilizing modern industrial technology, modular homebuilding offers the promise of building a higher quality home, faster and at a lower cost. Dr. Mullens uses his 20 years of experience in the industry to examine the theory and practice of modular homebuilding, identifying its strengths and weaknesses and introducing a structured engineering design approach for configuring a high performance modular factory. The book integrates three invaluable sources of knowledge: 1) the practices and experience of current modular producers, many of whom are industry pioneers who helped create and develop the industry, 2) emerging best business practices, such as lean production and mass customization, that are transforming the industry, and 3) current scientific research findings that provide additional insight. The goal of this book is to equip stakeholders inside and outside the industry - factory designers, product designers, operating managers, investors, and researchers - so they can design and operate high performance modular factories. This book is directed to several groups: 1) industry professionals that are responsible for owning, designing and operating a modular factory, 2) advanced undergraduate and graduate students that are studying residential construction, construction science, construction management, building technology or industrial engineering and who are enrolled in courses addressing prefabricated homebuilding, and 3) faculty and students that are engaged in academic research involving prefabricated homebuilding. The book is rich in technical detail. Graphs of benchmarking results document production performance across the industry. Individual production processes are described. A conceptual Value Stream Map is developed to show how product can flow between production processes to create the overall production system. Common production layouts are provided with commentary, including material handling and storage options. Numerous photos are used to document layout and equipment choices.