Case Study: National Renewable Energy Laboratory achieves more efficient off-site construction modeling with AnyLogic

Simulating Off-Site Construction Factories to Deliver Energy-Efficient Modular Buildings

The National Renewable Energy Laboratory (NREL) needed a way to improve productivity in off-site construction while supporting the delivery of affordable, energy-efficient, low-carbon modular buildings. Working with AnyLogic, NREL used simulation and digital twin concepts to better understand how a modular building factory operates, including labor, material handling, cycle times, and downtime.

AnyLogic’s multimethod simulation modeling helped NREL build a near-real-time factory model using data from processes, worker movements, schedules, and material flow. The result was a detailed baseline of the factory and a tool for what-if scenario analysis to compare productivity trade-offs and future changes. The approach showed that off-site construction can be modeled in depth and supports decisions aimed at improving efficiency; the case study notes that modular construction can be up to 40% faster to build.

National Renewable Energy Laboratory

Ankur Podder

Research Engineer