Title page for ETD etd-03292012-193752

Type of Document Master's Thesis
Author James, Joel
Author's Email Address jjame37@lsu.edu
URN etd-03292012-193752
Title Impact of Lean Production on Workers Exposure to Risk in Modular Home Building Manufacturing
Degree Master of Science in Industrial Engineering (M.S.I.E.)
Department Construction Management and Industrial Engineering
Advisory Committee
Advisor Name Title
Ikuma, Laura Committee Chair
Aghazadeh, Fereydoun Committee Member
Nahmens, Isabelina Committee Member
  • Lean
  • Kaizen
  • Job Safety Analysis
Date of Defense 2012-03-09
Availability unrestricted
The construction industry records the highest number of work-related injuries and fatalities in

the United States according to the Bureau of Labor Statistics. Workers’ exposure to risk may

be affected by implementing Lean concepts. This study describes the effects on worker’s

safety environment after a Kaizen event, a Lean tool, conducted in three workstations within

a modular home manufacturer: base-framing, sheet-rock hanging, and painting. The effects

of Lean on safety hazards at each of the three workstations were determined by conducting a

Job Safety Analysis (JSA) before and after each Kaizen. Based on the JSAs a risk assessment

tool (questionnaire) was developed to determine the workers’ exposure to risk before and

after each Kaizen. This study also focused on determining the reliability of the risk

assessment tool. Twelve students with prior knowledge of safety and four certified safety

experts completed the questionnaire by rating probability and severity of a list of hazards

potentially present in each workstation. According to students there was a significant

reduction in risk values for base-framing station and sheet-rock hanging station. Whereas,

according to safety experts significant reduction in risk values was confined to base-framing

station. Based on the reliability analysis the risk assessment tool was reliable in measuring

risk at each of the three work station as per safety experts, and as per students the reliability

was confined to only sheet-rock hanging station. As per the reliability analysis the finding of

safety experts should be supported. The safety experts supported the finding that Lean

showed significant reduction in risk values in base-framing station. Thus, it could be

concluded from the study that Kaizen could occasionally reduce or eliminate specific safety


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