In modular construction, building modules are prefabricated in a controlled factory setting before being transported to the site for final assembly. This innovative method significantly streamlines much of the construction process; however, the essential on-site assembly phase introduces its own unique challenges and complexities.
Author Radiana Pit | Copperberg
Photo: Freepik
This is where field service management (FSM) tools become indispensable, providing a solution to manage and coordinate the assembly process with enhanced precision, speed, and efficiency.
FSM solutions are already widely used across industries to streamline field operations, and in modular construction, they have proven invaluable in enhancing coordination, minimizing delays, and improving communication between off-site manufacturers and on-site assembly teams. According to Gomocha’s recent white paper, Modular Construction Meets FSM: A Strategic Blueprint for Enhanced Efficiency and Innovation, the integration drives smoother workflows and ultimately helps companies overcome the final hurdle—assembly—while maintaining high standards of quality and consistency across their projects.
Optimized module delivery with FSM
Once modules are built off-site, their journey to the construction site is critical. Delays, miscommunications, or incorrect deliveries can disrupt the entire project timeline. FSM platforms provide real-time visibility into every aspect of the supply chain, enabling project managers to track modules from the moment they leave the factory until they arrive at the job site. This capability ensures that modules arrive precisely when they are needed, effectively minimizing the risk of scheduling conflicts or delays that could slow down assembly.
For instance, the real-time tracking feature allows teams to continuously monitor modules in transit and make proactive adjustments if unforeseen delays—such as traffic congestion, harsh weather, or logistical issues—arise. Having such transparency and visibility into the delivery status enables managers to avoid bottlenecks and prepare on-site teams for the timely arrival of modules.
Automated scheduling and coordination
Beyond visibility, FSM platforms enable automated scheduling that integrates logistics providers and on-site teams into a unified workflow. By automating the coordination of module deliveries around the construction schedule, the FSM solution can account for potential disruptions such as weather conditions or traffic delays, ensuring that on-site teams are prepared exactly when deliveries arrive.
Automated alerts notify teams of any changes, ensuring that everyone is on the same page. This level of precision prevents modules from arriving too early (which could lead to unnecessary storage costs) or too late (which could stall the project).
Seamless assembly and placement precision
After the modules arrive on-site, the next crucial phase is assembly. Modular structures are designed to fit together seamlessly, and FSM platforms make this process more efficient by integrating with building information modeling (BIM) systems. This integration provides detailed 3D visualizations and installation instructions, helping assembly teams visualize how each module should be positioned before they start the process.
The importance of precision cannot be overstated—placing modules incorrectly could lead to costly rework or structural instability. With FSM’s step-by-step assembly guidance, teams are equipped with accurate instructions that minimize the risk of errors.
Task automation and equipment coordination
Task automation ensures that each module is placed in the correct order. This feature is especially important when multiple modules are involved, as it eliminates the risk of skipping steps or miscommunicating between teams. FSM platforms sequence tasks automatically, ensuring that each module fits according to the architectural plan, which significantly reduces downtime caused by misalignment.
Additionally, FSM platforms streamline the use of specialized equipment like cranes, which are essential for lifting and placing modules. By assigning tasks and providing real-time updates on equipment availability, FSM platforms enable precise coordination between crane operators and assembly teams, ensuring that no time is wasted waiting for machinery to become available. As such, the risk of idle time on-site is minimized and modules are installed much more quickly and safely.
Communication hub for real-time collaboration
Effective communication between off-site manufacturers and on-site teams is essential for keeping modular projects on track. FSM platforms facilitate this collaboration by providing real-time tracking of module status, ensuring that both manufacturers and assembly teams are always aware of the project’s progress.
As modules are transported and assembled, FSM tools provide continuous visibility, allowing teams to monitor deliveries, flag any potential issues, and adapt accordingly. This real-time communication helps avoid miscommunications or delays that could otherwise throw off the project timeline.
Centralized communication channels
FSM platforms create a centralized communication hub where manufacturers can share updates, documents, and assembly instructions. On-site teams can use this hub to report issues or ask questions, facilitating swift resolution of any problems. By removing the need for phone calls, emails, or paperwork, FSM tools enhance the flow of information, reduce downtime, and ensure that assembly stays on schedule.
Communication is further enhanced by the mobile accessibility of these FSM tools. On-site teams can access the FSM platform from mobile devices, allowing them to submit real-time progress reports, update schedules, or request assistance as needed to ensure that information is always up-to-date and available to all project stakeholders.
Solving the common challenges of on-site assembly
Delays in modular construction can occur due to weather conditions, equipment failure, or miscommunication between teams. FSM platforms help prevent these delays by using predictive analytics to anticipate potential issues before they arise. For example, by integrating weather forecasting data, FSM tools can proactively reschedule tasks or adjust delivery times to avoid disruptions caused by storms or other adverse weather conditions.
Predictive maintenance for critical equipment
The health of critical equipment such as cranes and forklifts is another potential risk factor during module assembly. FSM platforms continuously monitor the condition of these machines, predicting when maintenance is required and preventing breakdowns that could delay the project. Predictive maintenance is especially valuable in modular construction, where equipment failure can have a negative domino effect on project execution and timeline.
Addressing human error and ensuring accountability
Another challenge that can arise during the on-site assembly phase is human error. Whether it’s improper module placement, failure to follow guidelines, or miscommunication between teams, mistakes can be costly. Companies can mitigate this risk and ensure accountability at every stage by using FSM platforms that provide detailed task assignments. Teams can thus be given specific tasks that feature real-time progress reporting built into the platform, to ensure that responsibilities are clear and that any issues are promptly addressed.
FSM tools also provide step-by-step guidance that helps reduce the likelihood of errors with access to detailed instructions and checklists for each assembly task. For instance, if a team member encounters an unfamiliar challenge, the FSM platform can offer remote support and training, and enables them to access resources or connect with off-site experts in real-time. Having access to on-site support ensures that tasks are completed correctly and minimizes downtime that can be caused by confusion or lack of expertise.
Transforming modular construction with FSM
From the moment modules leave the factory to the final stages of on-site assembly, FSM solutions streamline operations and enhance collaboration between all stakeholders. For construction companies looking to optimize their processes, increase efficiency, and minimize risk during on-site assembly, the adoption of FSM systems should be the top priority.
As the industry continues to shift towards more modular and scalable solutions, FSM will be the key to unlocking new levels of operational excellence. The integration of FSM is ultimately a strategic approach for the long haul. FSM platforms will play an increasingly central role in ensuring that projects are delivered on time, within budget, and to the highest quality standards. Key future trends will likely involve even deeper integration between FSM platforms and other technologies such as BIM, IoT, and AI for more precise data-driven decision-making, better predictive analytics, and smarter resource allocation.
