Application of lean management to modular off-site construction: Impact on the sustainable development dimensions

Abstract

Modular and Off-site Construction (MOC) is increasingly promoted as a sustainable alternative to traditional on-site building methods. Lean Management (LM), with its emphasis on waste reduction, efficiency, and continuous improvement, offers strong potential to support sustainability goals in MOC. However, existing studies often focus narrowly on Lean’s benefits, without systematically exploring its potential drawbacks or dual impacts across sustainability dimensions. This article-based thesis investigates the role of Lean practices in advancing Sustainable Development (SD) within MOC, using a mixed-method approach combining Systematic Literature Review (SLR), expert interviews, and conceptual framework development. A matrix was developed to assess the positive and negative impacts of 14 Lean tools across 16 sustainability metrics, grouped under economic, environmental, and social dimensions. The framework was then validated through expert evaluations using Design Science Research (DSR) methodology. Overall, the results indicate that the positive impacts of Lean practices on the three pillars of sustainable development—economic, environmental, and social—clearly outweigh the negative ones. Tools such as Just-in-Time (JIT), Pull Strategies, and Visual Management are widely used to significantly enhance productivity, optimize material use, and reduce costs. However, caution is needed when applying certain tools like JIT in modular or off-site contexts, as the frequent deliveries required can lead to increased energy consumption and emissions if not carefully managed. These findings underline the importance of contextual implementation to maximize benefits and avoid unintended trade-offs. The final conceptual framework captures these dual effects, offering a nuanced guide for practitioners and policymakers aiming to apply Lean in a sustainabilityoriented MOC context. This thesis contributes to both academic research and construction management practice by proposing a balanced, evidence-based approach to Lean-SD integration in modular construction.

Date	7 Aug 2025
Original language	American English
Awarding Institution	École de technologie supérieure
Supervisor	Silvio Melhado (Supervisor) & Ivanka Iordanova (Co-supervisor)