Research Project Information

Research Project Summary Information

Improving Efficiency in N.Y.S Home Manufacturing through the Application of Lean Production Methods(ST9318-1)

Manufactured Housing Research Alliance


Lean manufacturing is a strategy in which production processes are critically evaluated to eliminate waste and inefficiencies. Lean manufacturing practices have been demonstrated to improve production efficiencies in several industries, such as the automotive industry. Under a previous NYSERDA agreement, the Manufactured Housing Research Alliance (MHRA) and US Department of Housing and Urban Development (HUD) introduced these practices to Capsys Corporation, a manufacturer of steel-framed modular buildings, located in Brooklyn. MHRA would like to build on this earlier project by working with a wood-framed modular builder in New York State.

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Project Description

The Contractor (MHRA) will apply lean production practices at Chelsea Modular Homes, Inc. Manufacturing staff will receive training for implementing lean production practices in their facility. Benchmarks and new performance targets will be established for Chelsea’s manufacturing operation. Chelsea’s production processes will be evaluated for line imbalances, scheduling problems, and bottlenecks. Identified problem areas will undergo "rapid process improvement" exercises to eliminate or reduce their impacts on Chelsea’s manufacturing operation. A workshop will be conducted for other NYS home manufacturers to disseminate the project’s results.


This project is expected to improve the competitiveness of a New York State modular home manufacturer against out–of-state competitors. 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 because greater opportunity exists for system integration.

Project Results

Chelsea improved productivity in their wall-build department and reduced defects in their finished drywall process by 85%. Significant productivity gains could be achieved by Chelsea if a commitment is made to continue the use of lean production and concurrent engineering practices. A workshop was held to present the results of this project to other New York modular builders.


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: ST9318-1

Last Updated: 5/16/2014