Please comply with the Lean Construction Institute’s … · Please comply with the Lean...
Transcript of Please comply with the Lean Construction Institute’s … · Please comply with the Lean...
Please comply with the Lean Construction Institute’s Usage Policies and Attribution Guidelines at http://www.leanconstruction.org/usage.pdf
when using this file. Thank you.
General Outline
• Overview
• Production Management Process
• The Skender Journey
• Panel Discussion
• Plus / Delta & Questions
Purposes
Design Criteria
Design Concepts
PROJECT DEFINITION
Process Design
Product Design
LEAN DESIGN
Detailed Scopes/
Engineering
Procurement Logistics
LEAN SUPPLY
Commiss-ioning
Installation LEAN
PRODUCTION
Operation Maintenance
Alteration Decomm.
USE
Ballard, 2000 adapted by Afshan Barshan
Lean Project Delivery System
Work Structuring Production Control
Lean Construction – Definition
“A way to design production systems to minimize waste
of materials, time, and effort in order to generate the maximum possible amount of value.”
Koskela, L., Howell, G., Ballard, G., and Tommelein, I. (2002)
Forms of Waste
• Rework/Corrections – Redo designs, task work
• Transportation – Material handling, information ‘hand-offs’
• Motion – Looking for, obtaining items such as prints, tools, materials
• Waiting – For materials, instructions, email, phone call
• Inventory – Raw, work-in-process, finished
• Overproduction – Producing more than the client ordered
• Overprocessing – More than what the customer is willing to pay
• Underutilized Human Resources - Lack of workforce involvement
Production Management
GC Project Team GC &Trade Contract Schedule Key Trades input Not very detailed
Minimum 6 weeks Superintendent & Trade
Foremen Constraint Analysis Quality Milestones Daily Monitoring and
Updating Accountability
Lean / Pull Schedule Pull challenge duration
sequence & logistics 1st Step in Building
Reliability
Last Planners
Master Schedule`
Lookahead Schedule
Phase Schedule
Master Schedule Phase Schedule
Lookahead Schedule
Master Schedule Checklist
Project promise met Key Milestones identified Developed by Project Team Weather Contingency considered Phase Schedule development Procurement Activities Detail of Schedule Changes to Schedule Owner Confidence
• Working meetings with Last Planners
• Typical Phases: • Preconstruction • Site • Substructure • Shell/Core/Rough/Skin • Finishes
Master Schedule Lookahead Schedule
Phase Schedule
The Process
The Process
• Challenging in an open forum: • Durations • Sequencing • Coordination • Confirmation of milestones • Constraints
• Input into the Master Schedule
and Lookahead Schedules
Master Schedule Lookahead Schedule
Phase Schedule
• Encourage input/opinions • Work backwards - PULL • ‘Ideal’ schedule • Plan agreed by ‘team’ • Commitments to execute
the plan by ‘team’ • Decide as a team how to
spend ‘float’ • Use information to
generate Lookahead
Master Schedule Lookahead Schedule
Phase Schedule
Network of Commitments
• Defining the phase • Getting the ‘right’ people • Meeting preparation • Getting them in action • The “Strong” Facilitator • The PULL concept • Setting time for the next
phase event • Training participants on
Production System • Is one Phase meeting
enough?
Phase Scheduling Issues Master Schedule Lookahead
Schedule Phase
Schedule
Goal of Lookahead Master Schedule Lookahead Schedule
Phase Schedule
• Maximize reliability
• Shape work flow and rate
• Match work flow and capacity
• Get it right the first time (quality)
How to Achieve Master Schedule Lookahead Schedule
Phase Schedule
• Drive Accountability • Focus on task hands-off – quality/ready/clean/safe • Screen for constraints • Develop detailed plans for work to be done • Maintain backlog of ready work • Team approach to managing short term coordination • Use strategic buffers • Can be done vs. Will be done
How to Measure Master Schedule Lookahead Schedule
Phase Schedule
Performance Measurements
• Monitor – DAILY • Update – WEEKLY
• Measure Success-Planned Percent Complete (PPC)
PPC
• Monitors all planned activities
• “On schedule” does not mean 100% PPC
• Track parties responsible for variances, some of which could lead to delays – and quickly correct them .before they become larger issues
• Hold parties accountable to their commitment
Measuring Success Master Schedule Lookahead
Schedule Phase
Schedule
Measuring Success
10 12 6 9
23 23 34 35 38
31 31 40
50 55
70 65
74 77
65 74 73
94
141
0
20
40
60
80
100
120
140
160
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
5/30
/11
6/6/
11
6/13
/11
6/20
/11
6/27
/11
7/4/
11
7/11
/11
7/18
/11
7/25
/11
8/1/
11
8/8/
11
8/15
/11
8/22
/11
8/29
/11
9/5/
11
9/12
/11
9/19
/11
9/26
/11
10/3
/11
10/1
0/11
10/1
7/11
10/2
4/11
10/3
1/11
11/7
/11
11/1
4/11
11/2
1/11
11/2
8/11
12/5
/11
12/1
2/11
12/1
9/11
PPC
Weeks
Activities PPC Weighted Average
Activ
ities
• Record weekly PPC
• Track major impacts on productivity
• Patterns emerge
• Future budgeting strategies
• Incentive programs for subcontractor “buy-in” to improve production
Measuring Success Master Schedule Lookahead
Schedule Phase
Schedule
• Improved response time
• Increased notification time by trades for future delays
• Fewer “extras”
• Controlled schedule variances
• Better pricing on future projects
• Improved safety
• Quality assurance
Benefits of Lookahead Master Schedule Lookahead Schedule
Phase Schedule
• Explode scheduled activities into assignment-level detail that can be measured daily
• Screen the constraints on each assigned task within the lookahead window
• Make assigned tasks ready by removing constraints
• Balance load and capacity by providing uniform workflow for productivity and profitability
• Update phase or master schedules as needed
• Learn: measure and improve performance
Lookahead Process Master Schedule Lookahead
Schedule Phase
Schedule
To Succeed
• Commitment • Culture – Improvement = Change • Partnership • Educating Clients • Attitude - If better is possible good is not
enough!!
Project Background
• Scope • ICU Refurbishment • Inpatient Unit Refresh
• Project Team • NMH • Gensler • SCC • Trades
• Contract - GMP
Project PPC
19
77
135 141
168 100%
97%
95%
89%
92%
0
20
40
60
80
100
120
140
160
180
82%
84%
86%
88%
90%
92%
94%
96%
98%
100%
10/1
0/11
10/1
7/11
10/2
4/11
10/3
1/11
11/7
/11
11/1
4/11
11/2
1/11
11/2
8/11
12/5
/11
12/1
2/11
12/1
9/11
12/2
6/11
1/2/
12
1/9/
12
1/16
/12
1/23
/12
1/30
/12
2/6/
12
2/13
/12
2/20
/12
2/27
/12
PPC
Weeks
Activities PPC Weighted Average
Activ
ities