Towards Scalable and Repeatable Production: Process Optimisation in 3D Construction Printing at COBOD = Towards Scalable and Repeatable Production: Process Optimisation in 3D Construction Printing at COBOD

This thesis investigates the optimisation and standardisation of production processes within COBOD International, a leading company in the field of construction 3D printing. The research addresses the challenges arising from the current configuration of the Production Department, where activities are characterised by a high degree of manual work, variability, and dependence on individual expertise. These conditions, while functional in the pioneering phase, risk becoming a bottleneck as the company expands and prepares to relocate to a new production facility. The study is structured into five chapters. The first two provide a literature review on the role of standardisation and continuous improvement, while the third chapter examines the principles and tools of Lean Manufacturing, with particular emphasis on Kaizen, PDCA, and Poka-Yoke. The fourth chapter presents the case study of COBOD, analysing the production processes through qualitative methods such as direct observations, documentary analysis, and process mapping tools (SIPOC, flow charts, Value Stream Mapping). The final chapter develops proposals for standardisation and optimisation, highlighting solutions that can stabilise operations, reduce variability, and ensure scalability in the new production site. The findings suggest that standardisation, when combined with Lean principles, represents not a rigid constraint but a strategic enabler for operational excellence. By embedding error-proofing mechanisms, continuous improvement cycles, and structured work methods, COBOD can enhance efficiency, improve quality, and strengthen resilience, thereby consolidating its position as a global innovator in construction 3D printing.