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Prefabrication and Off-Site Production 505
reducing the amount of labour required. Worker well-being is easier to control in the
factory; for example, it is easier to identify and address problems. Poor posture position of
workers and heavy lifting can be reduced and difficult tasks can be undertaken by specially
designed machinery. Worker skills are applied in the factory, not on the site, which provides
the opportunity for the development of skills specific to an allocated function on the production
line. Thus development of worker skills may be easier in a factory setting, although
this has to be offset against potential boredom of the worker engaged in highly repetitive tasks.
Control of the quality of materials
Given the high volume of production, manufacturers are able to purchase large quantities
of materials and are able to demand high-quality standards from their suppliers. Materials
can be thoroughly inspected at the time of delivery to the factory, and all materials used
in the assembly of a unit are known, recorded and traceable. Such demands may be difficult
to achieve for small contractors and small developments. It is also easy to check that the
customer is getting what they pay for. Such quality control is harder to implement with
more traditional construction, quality checks are rarely as rigorous and it is difficult to
prove that the contractor and subcontractors have used the materials specified (indeed it
is not uncommon for materials to be substituted for cheaper alternatives during construction,
sometimes without the knowledge of those responsible for overseeing the quality of
the constructed works). There is also less chance of theft of materials from the site and so
site security can be reduced and is needed for a shorter period. Furthermore, the amount
of material waste generated on the site (and sent to landfill) should be reduced, if not
eliminated, with manufacturers recycling the majority of their waste. The use of lean production,
or lean manufacturing, techniques will also help to eliminate waste (both material
and process) during assembly in the factory.
Innovation
The use of prefabricated units should provide a wonderful opportunity to innovate, both
in the technologies used, the management of the processes, and the architectural style of
the building. Cartwright Pickard Architects and Yorkon have developed some particularly
innovative prefabricated structures that are starting to challenge ideas of what a prefabricated
building looks like (http://www.yorkon.co.uk). While there are a few examples of
innovative designs, the current situation appears to be geared to rather familiar and conservative
designs, but there is no reason why this cannot be improved as architects, technologists
and engineers work closely with manufacturers to explore the potential of off-site
production.
Other advantages
Other advantages include:
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Fast assembly time on site (time is required in the factory) – ‘fast-track construction’
Improved cost control and financial certainty
Clear quality standards
Lean production methods can be utilised (less process and product waste)
Warranties are available
Improved safety and worker well-being
Less disruption to neighbouring buildings