Integrated Framework and Impact Assessment of Design for Manufacture and Assembly (DFMA) In Modular Home Manufacturing Facilities: A Case Study

Abstract

The growing demand for sustainable and efficient construction practices has led to an increased interest in modular construction, with Design for Manufacture and Assembly (DfMA) emerging as a pivotal approach to enhance efficiency in the production process. Despite its potential, the integration of DfMA in modular home construction faces significant challenges, including the lack of a structured methodology for its implementation and the need for alignment between design, manufacturing, and assembly processes. This paper introduces methodologies for data collection to inform the re-engineering of the design process. By including design considerations, manufacturing processes, and assembly methodologies, the methodologies aim to optimize the entire production lifecycle with the implementation of DfMA principles as the core focus. Key elements include modular design standardization and streamline assembly processes to achieve improved efficiency, cost-effectiveness, and quality. The methodology is partially validated through an industry case study with a modular home manufacturer in New Brunswick, Canada, and real-world implementation to understand the effectiveness and practicality, as well as the challenges encountered to inform continuing research efforts. This paper contributes to the evolving field of modular construction by presenting a novel assessment approach that integrates DfMA principles into modular home production facilities. The proposed methods not only serve as a guide for industry practitioners but also provides a basis for further research and development in advancing sustainable and efficient construction practices.