Research Project Information

Research Project Summary Information

Improving Efficiency in Home Manufacturing through concurrent Engineering and Lean Production Methods(ST8276-1)

Manufactured Housing Research Alliance


Concurrent engineering is a design approach that integrates the work of several disciplines simultaneously to develop solutions for a problem. Lean manufacturing is a strategy in which production processes are critically reviewed to eliminate waste and inefficiencies. Concurrent engineering and lean manufacturing techniques show the capacity to improve production efficiencies in several industries, including automotive. Manufactured Housing Research Alliance (MHRA) and U.S. HUD are attempting to introduce these practices to the manufactured- housing industry. Capsys Corporation is a manufacturer of modular multifamily buildings, located in Brooklyn, New York, that wants to apply these practices at its manufacturing plant to try to improve its production efficiency and final products. MHRA is an independent not-for-profit organization established to facilitate collaborative research within the manufactured-housing industry.

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Project Description

MHRA will identify opportunities to improve the productivity of Capsys’ manufacturing operations by establishing benchmarks and new performance targets. It will analyze Capsys’ production processes to identify opportunities to remove inefficiencies and reduce waste, and will identify opportunities to improve the energy efficiency of Capsys’ buildings. A workshop will be conducted to disseminate the project’s results to other New York State home manufacturers.


Factory-built homes are more resource-efficient because their construction generates less waste. Such homes have the potential to be more energy-efficient than site-built homes due to the opportunity for greater system integration. The proposed project could improve the competitiveness of a New York State manufacturer.

Project Results

MHRA and its team collected benchmarking data for Capsys Corporation, to compare its performance to industry averages. Overall, Capsys performed well -- except for its higher-labor costs and lower-inventory turns. MHRA and its team identified several areas where Capsys could reduce its labor costs by: expediting assembly processes; improving both material staging and the maintenance of existing tools; and providing more efficient tools. Capsys could implement these changes at low-to-moderate cost. MHRA and its team also developed a new roof design for Capsys' modular homes that would both reduce the time spent on welding operations and eliminate the need for custom-fabricated components from a third-party supplier.


Manufactured Housing Research Alliance
1776 Broadway, Suite 2205
New York, NY 10019

Principle Investigator

Jordan Dentz

Universities Involved


Project Type:

Product Demonstration

Technologies Types:

Building Systems
Building Construction Methods

NYSERDA Contact Information

Robert Carver


R&D - Buildings Research

Contract Details

Start Date: 1/11/2010
Project Status: Active
Contract Number: ST8276-1

Last Updated: 5/16/2014