Use of safety and lean integrated kaizen to improve performance in modular homebuilding

The two biggest challenges in the construction industry, low productivity and high injury rates, may be addressed simultaneously through the combination of lean production strategies and traditional safety-analysis tools. This case study used Safety and Lean Integrated Kaizen (SLIK) in a modular housing manufacturing facility by applying one lean production tool, kaizen, and a safety-analysis tool, job safety analysis (JSA). The research team used SLIK with the base-framing crew, and the method consisted of analyzing the current process, determining and implementing process improvements, and analyzing the improved process. The changes resulted in a 16% increase in value-added activities and increased the framing crew's overall output by 55%. By making quick, low-cost changes that were intended to improve productivity to the station layout and work design, safety and ergonomic hazards, including reduced trip hazards, pinch points, and back strain, were also reduced or eliminated. These results support the hypothesis that productivity and safety can be improved simultaneously through combined lean and safety tools.