Benchmarking Automated and Conversional Precast Concrete Fabrication Processes Using Multi-Dimensional Productivity Indicators

Productivity performance in precast concrete fabrication plays a critical role in determining cost efficiency, delivery reliability, and product quality. However, direct and structured benchmarking between automated and conventional fabrication processes remains limited, particularly when productivity is evaluated using multiple performance dimensions rather than single output measures. This study aims to benchmark the productivity performance of automated and conventional precast concrete fabrication processes using a multi-dimensional productivity indicator framework. A comparative case study approach was employed in an operational precast plant, using data obtained from time studies, production and machine logs, quality control and rework records, equipment uptime reports, and semi-structured interviews with production and quality personnel. Productivity performance was assessed across key dimensions, including efficiency, effectiveness, quality, reliability, and resource utilization. The findings show that automated fabrication achieves shorter and more consistent cycle times, lower unplanned downtime, reduced rework rates, and more stable production output compared to conventional processes, which display greater variability and stronger dependence on labor skills and operational discipline. This study contributes a practical and replicable benchmarking approach supported by a structured set of productivity indicators. The results provide valuable insights for precast plant managers in guiding automation and process improvement strategies, and support policy and industry initiatives promoting data-driven and digitally enabled Industrialized Building System (IBS) manufacturing.

Precast concrete fabrication, Productivity benchmarking

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