The impact of product choice on lean homebuilding

Abstract

Purpose

The purpose of this paper is to better define the relationships between product variety and lean production in enabling mass customization in industrialized homebuilding.

Design/methodology/approach

This study includes a case study analysis of two housing plants that instituted lean production systems. For each company, the case study documented the company's background, the product choice offered, the lean implementation approach used, the results obtained, and the effect of product choice on the lean implementation. Using these case study findings, common trends were identified and used to develop guidelines for an effective mass customization strategy for industrialized homebuilders. This paper summarizes the extensive findings for one of the two plants and provides the recommended guidelines developed from common trends identified at both plants.

Findings

Case study findings indicated that product choice does not necessarily make the implementation of lean concepts more difficult. In fact, good lean concepts (e.g. continuous flow, pull system, workload leveling, defect‐free processes, standard tasks, good visual control, and reliable technology) were also good concepts for (or easily accommodated) handling a range of product choice.

Research limitations/implications

Research findings are limited by the small number of plants involved in the study.

Originality/value

The paper makes an important contribution to the understanding of both lean production and mass customization, identifying the lean principles that facilitate mass customization for industrialized homebuilders. Findings also provide useful guidelines for builders interested in better addressing specific customer needs, while managing the operational complexities resulting from product variety.

Citation

Nahmens, I. and Mullens, M. (2009), "The impact of product choice on lean homebuilding", Construction Innovation, Vol. 9 No. 1, pp. 84-100. https://doi.org/10.1108/14714170910931561