Supply chain integration in prefabricated residentialconstruction in New Zealand : a thesis presented in partial fulfilment of the requirements for the degree of Doctor of Philosophy in Construction at Massey University, Albany, New Zealand
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Date
2022
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Massey University
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Abstract
Prefabrication has long been reported as an effective alternative to conventional construction, with wide-ranging beneļ¬ts. It serves as a valuable source of providing time, cost, quality, productivity, health and safety and environmental benefits to residential construction. Although prefabrication has gained much attention, the residential construction industry appears to be taking minimal advantage of prefabrication due to barriers associated with this methodology. Inefficiencies in the supply chain are one of the major issues that hinder the wider uptake of prefabrication in residential construction. However, there has been little research in the literature considering the supply chain and supply chain integration in prefabricated residential construction.
Therefore, this research aims to improve supply chain integration in prefabricated residential construction. The objectives of the research include 1. review and analyse the nature of the processes and supply chain relationships of module and panel manufacturing in New Zealand residential construction; 2. identify the barriers to implementing effective supply chain practices in module and panel manufacturing in New Zealand residential construction; 3. identify the enablers for effective supply chain practices in module and panel manufacturing in New Zealand residential construction; 5. develop and validate a framework to measure and improve the current supply chain practices in module and panel manufacturing in the New Zealand housing sector.
The research used a multi-tiered qualitative approach for data collection. Firstly, twelve semi-structured interviews were conducted to collect data. The collected data was analysed using thematic analysis. Based on the literature review and analysed data maturity model was developed. The developed model was validated through focus group interviews. After validation, three case studies were conducted to benchmark the supply chain integration based on the maturity model.
Key findings emerged from the study: a standardised supply chain network for prefabricated residential construction and module and panel manufacturing was developed; 13 barriers (both internal and external) for supply chain integration in module and panel manufacturing were identified. Enablers (9 enablers) were identified to mitigate the barriers to supply chain integration in module and panel manufacturing; a maturity model was developed to improve supply chain integration continuously. The recommendation can improve the maturity model, widening the scope and applicability for future research. The content of this thesis is beneficial for prefabrication manufacturers to assess their supply chain practices throughout the performance improvement process, for the residential construction industry to encourage residential prefabrication manufacturers to adopt and improve supply chain practices, for government and interested organisations to encourage residential prefabrication manufacturers by implementing favourable regulations and policies relevant prefabrication residential construction.
Keywords: Prefabrication; Residential construction; module and panel manufacturing; supply chain integration; maturity
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Prefabricated house industry, Management, Business logistics, New Zealand