Flow Production of Pipe Spool Fabrication: Simulation to Support Implementation of Lean Technique

Abstract

Pipe spool fabrication is an important stage in industrial construction project delivery. It is a complex production system characterized by product uniqueness and high product mix, which pose challenges to the analysis and improvement of this system. This research applies lean production principles and flow production to shop fabrication, and uses a simulation-based approach as a tool to facilitate its implementation. The work described in the paper is based on a real case study undertaken with an Edmonton-based industrial construction contractor. The traditional batch-and-queue fabrication system and the new cell-based work flow fabrication systems were compared and analyzed. Simulation models were built to experiment with the old and new production systems and quantitatively test the effects of lean principles on the performance of the systems. The developed simulation-based approach proves a practical and more powerful tool than the value stream map for modeling and for quantitatively evaluating the performance of a complex and dynamic spool fabrication shop.