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Topic Title: Lean in Construction Business
Topic Summary: variation in every process
Created On: 08/17/2012 10:26 AM
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08/17/2012 11:12 AM
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Uday2
Udaivir Jaryal



Hello Everyone,
I work in a construction company in a middle management role. Management decided to follow the LEAN principles about 18 months ago. Started with 6S and It shows a very attractive results in the beginning but recently there is lack of enthusiasm both in management and workforce. As far as 6S that is OK but; it seems to that the attraction toward LEAN events, like Kaizen, VSM etc. is declining. I got a LEAN Level-1 training from Canadian Manufactures and Exporters.
I think the major challenges in construction business are:
. Processes are not 100% similar all the time.
. Man power differ daily and hard to stick with calculated Gant chart/ or timeline.
. Company is big and purchasing process is complicated.
. It is hard to estimate dollar amount after implementation a lean tool or idea.

I am seeking opinions from the forum and anyone from similar the business can also share their ideas.
Thanks
08/17/2012 11:13 AM
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Moderator_Jane
Jane Bulnes-Fowles



Udaivir,

In addition to what ever responses you get from our community, you may also want to look at the Lean Construction Institute.

Jane
08/20/2012 12:26 PM
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leanpassion
Vikas Narkar



Hi Udayvir,

Construction is more or less Project activity and every project is unique. lean tools which are applicable in job shop will be more or less apply to your case too. tools like 5S, Kaizen, external JIT, quick changeover and worker involvement will be useful in your case. In addition to this I suggest critical chain project management (CCPM) a TOC tool will more useful

VN
08/20/2012 12:26 PM
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Joseph Dager



I believe theLean Construction Institute is the best resource for your concerns which Jane mentioned.

One of the driving factors of Lean Construction has been how they have applied Lean Principles to this industry through planning and achieving ROI. Instead of applying flow and waste principles to operations, though they do, they have applied them through planning, via Lean Production Management.

Lean Project Delivery provides three linked opportunities -- "Impeccable Coordination," "Projects as Production Systems," and "Projects as Collective Enterprise." These opportunities are like layers of an onion, with each contributing to optimizing the project rather than each piece. Lean Project Delivery makes available levels of performance not possible under current practice. -LCI


The Last Planner has also been developed from this practice. I would like to add a lesson that I have learned from Lean 3P, Agile and Lean Construction. I do not believe "Events" are on the decline but rather on the increase. We are replacing stage gates, control points and push type planning (Drum-Buffer-Rope could be considered this) with events. Bringing everyone together in one setting, whether in person or virtually, and hammering out the next cycle is on the rise. We are becoming less and less dependent on experts and realizing that "the smartest person in the room is the room" (stole this from someone, but I forget who). Lean construction, The Last Planner has been doing this for over 20 years. I encourage you to investigate the source.

P.S. I recently had Greg Howell co-founder and CEO of the Lean Construction Institute on my podcast that may assist you in understanding how Lean is being used in construction. (Lean Planning, not just for Construction)
08/20/2012 04:57 PM
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PrasadVelaga
Prasad Velaga



Originally posted by: Uday2
.....but; it seems that the attraction toward LEAN events, like Kaizen, VSM etc. is declining. ...... It is hard to estimate dollar amount after implementation a lean tool or idea.


Udaivir,

Does it mean that your current Lean efforts have no significant impact on project lead times and project completion rate? Even a Lean effort that does not increase any value for customer is muda.

Ideally, in project management I would like to have the following conditions:

There are sufficient resources such that no task needs to wait for resources
There is little or no variation within task durations
There is no uncertainty in the system
No tasks are repeated due to poor quality
Tasks are executed without breaks caused by multitasking
No external factors control the project.

The deviations from these conditions along with task precedence (dependency) relations make project management difficult. Lean can reduce rework and the magnitude and variation of each task duration to some extent but I do not know how it can address the critical function, that is, resource-constrained scheduling subject to natural variation and uncertainty.

Prasad
Optisol
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