How Do Lean Principles Link Better Offsite Prefabrication and Onsite Construction?

“We wanted to achieve greater consistency and certainty in project delivery. There were too many unknown factors in the attainment of our targets, so we started our journey with Lean by using the Last Planner System. Working with a private training provider, we first tested the platform on key projects while supporting upskilling in it for our staff and contractors. We then rolled it out at a business-wide level after we saw the impact on project delivery and staff buy-in. One fed the other, which created synergy and consistency almost immediately.” 

“In the wake of Covid-19, there was a real opportunity for us to get involved with the rapid-build emergency healthcare projects countrywide.  We were contracted to design and build two emergency ward blocks in University Hospital Limerick and Croom Hospital. By utilising all our expertise in MMC while enthusing an unyielding focus on collaboration in delivering these critical bed spaces within 16 weeks, we demonstrated that this new way of working provides a collaborative platform to achieve certainty in delivery. Clancy partnered with Remagin Ireland as our offsite contractor for the structure and from this success went on to build the largest ever student accommodation development in Cork City at that time.” 

“We want to get to a point of consistency with all our sites across the country, regardless of who we partner with, where all onsite processes are intertwined and the variable circumstances site-to-site are accounted for before works begin and seamlessly as the project progresses through the necessary stages to successful completion.” 

“At Clancy, we certainly aim to keep increasing our knowledge of MMC. Apprentices and subcontractors coming into the industry also need this training in Lean and MMC. And that training needs to be made appealing enough to negate the upfront costs and the time workers are away from the site.” 

“Fundamentally it’s still the same processes in traditional construction and MMC. Steel is still steel, and water and air still move in the same way. MMC just means more planning in advance and better integrated operational processes for, often, faster and higher-quality project delivery. I keep manufacturers and installers very engaged in how we do things. They need to understand what they are building AND why they're building that way. With Clancy’s focus on skills development, they are excellent at mentoring others through new learning.” 

“This experience meant changed my approach to construction site management. I became much more focused on preparation and early issue resolution, with a strong emphasis on ensuring design details are complete, interfaces with other trades are pre-coordinated, and the site is readied before installation. This proactive approach helps maximise the advantages of prefabrication, reduces delays on site, and improves overall project delivery.” 

“Based on my experience, I would encourage anyone considering offsite construction to embrace the change. Success in this area is driven by developing skills in planning, coordination and early decision-making, rather than fixes onsite as needed. It’s not just an alternative system for building.”