Automation in Modular Construction: The Robotic Revolution or Human Precision?

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In modular construction, there is a growing movement to embrace automation and robotics (A&R) within factory settings. Proponents argue that A&R can significantly speed up the production of essential components like wall panels, floor structures, and roof systems. However, the question remains: What happens once these components are built? And more importantly, is automation the solution to all the challenges faced by modular construction factories today?

all photos – Brave Control Solutions

The Promise of Automation: Faster and More Efficient Production

The allure of automation in modular construction is undeniable. Robotics and automated systems can work at a speed and precision unmatched by human hands when it comes to repetitive tasks. In the production of wall panels, for example, A&R systems can assemble the framework, apply sheathing, and even cut openings for doors and windows with pinpoint accuracy. These systems can be designed to handle various floor and roof structures, minimizing errors and speeding up the production process.

Imagine a factory outfitted with robotic arms that assemble a wall in half the time it takes human workers. These robotic systems work tirelessly, don’t require breaks, and can continue production long after the traditional eight-hour shift has ended. For a factory owner, the advantages of this efficiency are clear: faster production rates mean higher output, which can lead to increased profitability and the ability to meet tight deadlines.

But the real question is: what happens after these components leave the hands of the robots?

People Power: The Heart of Modular Assembly

While automation can handle many tasks efficiently, it’s important to remember that the magic of modular construction doesn’t end with robotic precision. After the wall panels, floor systems, and roof structures are complete, the next phase of the process requires the skill and ingenuity of human workers. Cranes—operated by skilled human operators—lift these finished components to designated areas of the factory, where people, real human beings, take over.

At this point, human labor becomes essential to turning these individual components into six-sided volumetric modules. From here on, it’s the expertise of workers that brings the rough module to life. Electricians, plumbers, and HVAC specialists (MEP trades) install the essential systems that make the module functional. Other workers install insulation, drywall, windows, and doors. They carefully apply siding and ensure that each module is up to code and ready for delivery to its final destination.

It’s clear that while automation plays a critical role in speeding up initial production, the final stages of modular construction still rely heavily on human craftsmanship. This raises an important question: should every modular factory fully embrace A&R?

Does Every Modular Factory Need Automation?

When asked whether I would incorporate A&R into a factory if I were an owner, my answer is always, “It depends.” Modular construction is a complex industry, and the decision to invest in automation is not one-size-fits-all. There are several factors factory owners must consider before diving headfirst into the world of robotics.

The first question to ask is: does the factory need automation, and if so, why? For some factories, the answer may be yes. Automation can help address issues like labor shortages, particularly when it comes to tasks that are repetitive and don’t require specialized skills. A&R systems can fill in the gaps where unskilled workers might be in short supply, allowing factories to maintain or even increase production levels without sacrificing quality.

However, for other factories, the decision to invest in A&R may be more complex. The factory must have enough physical space to accommodate the robotic systems. A factory might need an additional 10,000 to 20,000 square feet to install A&R, depending on the scale of automation being considered. If the factory doesn’t have the space or resources to expand, the investment in A&R could be more of a burden than a benefit.

And then there’s the cost factor. Automation is a significant financial commitment, not just in terms of purchasing the machinery, but also in hiring skilled technicians to operate, maintain, and repair the systems. This kind of investment requires long-term planning, and the factory must be ready to absorb both the initial costs and the ongoing maintenance expenses.

In essence, automation is not a quick fix. It requires a careful analysis of whether the benefits—such as increased production speed and reduced reliance on unskilled labor—outweigh the challenges, including the need for space, financial resources, and trained personnel.

Replacing Unskilled Labor with Robotics

One of the most compelling reasons to consider automation in modular construction is the declining availability of unskilled labor. The construction industry as a whole has been grappling with labor shortages for years, and modular construction is no exception. A&R can step in where unskilled workers are becoming harder to find. Tasks like cutting, assembling, and lifting large components can be done more efficiently with robotics, reducing the factory’s dependence on a shrinking labor pool.

However, it’s crucial to note that A&R is most beneficial when applied at the right point in the production process. At the beginning of the assembly line, where components like wall panels and floor systems are being fabricated, robots can perform repetitive tasks with precision. But as the module moves down the line, human expertise becomes irreplaceable.

Skilled workers are needed for the intricate tasks of installing MEP systems, fitting doors and windows, and ensuring that the module meets all regulatory standards. This is where automation can’t compete—at least, not yet. The vanishing skilled labor pool at the end of the production line is where automation can do the most good, but only when combined with human oversight and expertise.

Modcoach Note

So, does every modular factory need automation? The answer, as always, depends on the specific needs of the factory and its production goals. Automation and robotics can be incredibly valuable tools for speeding up production and compensating for labor shortages. However, the human element remains critical to the success of modular construction.

For factory owners considering A&R, the key is to strike a balance. Use automation where it makes the most sense—such as in repetitive tasks at the beginning of the production process—and rely on human skill and expertise for the more intricate work that requires flexibility and problem-solving. With the right combination of automation and human power, modular factories can continue to innovate and grow while maintaining the quality and craftsmanship that makes modular construction unique.

The future of modular construction may indeed be more automated, but it will always require the touch of a human hand.

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