lean construction problems and solutions

8/19/2019 Lean Construction Problems and Solutions

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Lean ConstructionProblems & Solutions


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Problems Faced• Construction related problems from design to handover, all:

• Design Related• Delay/Constant change in requirements on client side.

• Regular revisions in final design.

• Delay in distribution of revised design to all the parties like

Contractor / Sub-Contractor / PMC / Client.• Delay due to improper clarity of design.

• Planning Related• Delay in receiving approval from concerned parties.

• Delay in placing order for materials required in near future.

• Delay due to improper clarity of material requirements.

• Delay due to improper order of procurement of materials.

• Delay due to untimely arrival of funds.


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Problems Faced

• Storage / Logistics Related• Unexpected / Untimely arrival of requested material to site.

• Improper Storage arrangements and facilities on site.

• Improper Inventorying of materials for immediate access.

• Damage to materials due to improper storage and stocking.

• Storage space issues of bulk & reusable materials on site.

• Workforce Related• Unavailability of skilled workforce.

• Improper / lenient screening of workforce.

• Unskilled workforce masquerading as skilled for better pay.

• Delayed identification and training of such workmen.

• Improper or unplanned mobilization of workforce.

• Expected and Unexpected situations like holidays and accidents.

• Delay because of Improper compensation due to untimelyfunding leading to strikes, non-cooperation etc.


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Problems Faced

• Equipment Related• Delay in mobilizing heavy equipment due to improper planning.

• Unavailability of workforce to complement this equipment.

• Unexpected failure of equipment and related repair time.

• Extra cost incurred due to keeping this heaving equipmentbooked and idle for extended periods.

• Execution Related• Rework and related costs incurred due to constant revisions.

• Cost incurred due to extra training of workforce due tounavailability of skilled workforce.

• Delay and cost incurred in arrival of bulk materials to site due to

excessive demand.• Delay in execution due to improper funding.

• Damage and rework due to low quality materials and also due tomaterials damaged due to over and improper stocking.


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Problems Faced

• Housekeeping Related• Need for constant housekeeping and related cost due to rework.

• Improper management of waste leading to unorganizedscrapyards, and theft of materials, reduction in scrap value ofmaterials.

• Lesser availability of usable space due to stocking and improperwaste collection.

• Minor and Major accidents caused due to unawareness towardssafety related issues caused by loose / unsupervised material onsite.

• Handover Related•

Rework after end user visit due to improper initial execution anddelay in handing over .

• Escalation in cost due to continuous soft housekeeping due todelay in handing over.

• Costs incurred during the defect liability period due to improperinitial effort during execution.


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Lean Construction Techniques

SORTINGSIMPLIFYINGSWEEPING

STANDARDIZINGSELF DISCIPLINGING

The 5 ‘S’ Solution


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Lean Construction Technique

• SORTING

Sort out the necessary from the unnecessary, discard the unnecessary.


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• SIMPLIFYING

Create and identify a place based on how often we use it.


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• SWEEPING

Create a Physical and Visual control of the work area.


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• STANDARDIZING

Create standard ways to keep the work areas organized, clean andorderly and documenting agreements made during the 5S’s.

Have clear instructions for people who deliver goods or materials tothe site.


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Lean Construction Techniques• SELF DISCIPLINING

Follow through with the 5 ‘S’ agreements.

Before

After


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Muda (Waste) Walk

Assume -the best way we do it today is the worst way tomorrow! Find a betterway to do it.

- CEO of Toyota

• Walk around the site, demarcate the waste area and then suggest andimplement at least 2 improvement ideas per month.

See thechange


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Process Mapping and Value Analysis• Map the leading / lifting distance, cycle times etc. of a process and then

categorize them into:

1. Value added

2. Non value added BUT necessary

3. Non value added AND not necessary

• Eliminate all #3’s and look for ways to improve #2’s by making the optimizedmaterial/equipment flow chart; reduce set-up time & ultimately use the 5 ‘S’.

OptimizeAnalyze


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Establishing Visual Control• To put in plain view all tools, parts, plans, schedules and performance

indicators so everyone can see at a glance what is happening.

• Colored hard hats.

• Posted daily/weekly schedules & progress (Progress Meetings).

• Flow chart for how to run payroll.


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Goal of ‘LEAN’ Techniques

Keep Construction Going

Reduce Inventory

Reduce Cost

Improve Quality

Reduce Wastage

PROFIT = REDUCE WASTAGE + SAVE TIME

lean construction problems and solutions

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