Pull-Based Simulation Modelling for Modular Construction Supply Chain Analysis: A Case Study in Northern Canada

Modular construction, as an alternative to traditional stick-built construction, allows for schedule overlapping and efficient utilization of resources. In Canada, modular construction techniques are applicable to northern sites where labour and materials are scarce, the shipping season is short, and the method minimizes exposure to harsh winter conditions. However, when a modular construction supply chain gets longer and increasingly complex, analysing and managing it becomes a challenge. Additionally, there is a lack of research in modular scheduling compared to research in production. This paper introduces a case study where a supply chain model with manufacturing coordination was created and applied to analyse the shipment of housing modules from a factory in Southern Canada to communities in Nunavut. The case study was completed in partnership with Nunafab, a company trying to help solve Nunavut’s housing crisis using modular construction. The model uses a pull-based approach, where the inputs are desired completion dates and information about the supply chain and the output is a schedule for module shipment. A discrete event simulation is also used to estimate manufacturing output at the beginning of the supply chain. The results show that the model can replicate a single season of housing module shipment, and work improvement performed on the factory reveals the opportunity to deliver more modules in less time. While having limitations, the proposed model is simple and can be generically applied to analyse similar supply chains. The case study highlights the importance of coordinating modular manufacturing with supply chain research when performing work improvement, and it has led to further collaboration between the researchers and Nunafab.