Exploring the critical production risk factors for modular integrated construction projects

Purpose The factory production stage constitutes the bridge in the supply chains of modular integrated construction (MiC) projects. It embodies the fundamental differences between MiC and site-based construction. However, there is a poverty of knowledge of the uncertainties and risk events at the production stage. This study aims to investigate the critical production risk factors (PRFs) for MiC projects. Design/methodology/approach Comprehensive literature research and expert review identified and validated 22 candidate PRFs for MiC projects. A structured questionnaire survey was then used to gather opinions of domain experts in 18 countries on the relative impact of the validated PRFs for MiC projects. The collected data were analysed using multiple statistical techniques. Findings Statistical analysis identified nine critical PRFs for MiC projects. The top five include dimensional conflicts between modules during production; delays in production materials procurement; defective design; design information gap between designer and manufacturer; and limited capacity of manufacturers. Originality/value The study addressed the gap associated with identifying critical risk factors peculiar to the factory production stage of MiC projects. Its novelty lies in providing an opposite assessment of severities and prioritization of critical PRFs for MiC projects. The prioritized critical PRFs for MiC projects may inform resource allocation. Thus, it provides valuable information to MiC production specialists and project managers in their production risk planning and management strategies. The identified PRFs contribute to the theoretical checklist of MiC supply chain risk factors and may assist practitioners in assessing the severity levels of the PRFs of their MiC projects.