What is Lean Construction? Lean construction is a set principles and tools to facilitate planning and control, maximize value and minimize waste throughout the construction process. Owner Architect/Engineer General Vendors Subcontractors

The History of LEAN Henry Ford- Father of Mass Production Empire State Building 14.5 Months Predictable Flow Used Integrated Team Location Based Schedule Analytics Standardization Best Practice Deployment “Flow “ Production C.A.N.D.O (Clearing Up, Arranging, Neatness, Discipline, Ongoing improvement) LEAN Journey 1900 1905 1910 1915 1920 1925 1930 1935 1940 1945

The History of LEAN U.S. Auto Industry Awoken To “LEAN Manufacturing” Taiichi Ohno — Father of the Toyota Production System (TPS) Eliyahu Goldratt - Kaoru Ishikawa - Joseph Juran - Edwards Deming Just-In-Time (JIT) Continuous Improvement Respect for People 7 Types of Waste 5S Program Total Quality Management (TQM) Theory of Constraints (TOC) 1950 1955 1960 1965 1970 1975 1980 1985 1990 1990 1950 1955 1960 1965 1970 1975 1980 1985 1990 1995

Integrated Project Delivery (IPD) The History of LEAN Integrated Project Delivery (IPD) Lean Construction Institute Last Planner System TM Construction Teams Start to use with great success. Glenn Greg Ballard & Howell Sutter’s 5 Big Ideas AGC Lean Construction Forum Created 1997 2000 2002 2003 2004 2005 2006 2008 2010 2011

Why LEAN? – The “way we have always done it” is not working

LEAN Principles and Tools Waste- 8 Types 5S Visual Work Place Reliable Promises Electronic Documents

What is Waste? 8. Under-utilized Talent

Waste in Construction Current Manufacturing Current Construction

5S Everything On Wheels Nothing Hits the Ground Subcontractor Laydown Areas Continuous Cleaning Sustaining the Plan

Visual Work Place Clear Signage - Restroom, Lunch, & Staging Area Owner Signage - Include Project Goals or Condition of Satisfaction (CoS) Clear Signage - Restroom, Lunch, & Staging Area Owner Signage - Include Project Goals or Condition of Satisfaction (CoS) Boards and Lists Color Coding Site Boards and Lists- Get the files out of the computer and into the open

Subcontractor laydown areas and S5 organization Visual Work Place Subcontractor laydown areas and S5 organization Set expectation early and often. Get the information in places the field staff have access to it. Color Coding of Floor- Visual work is used in pull planning to talk about batch sizing. Establish flow and direction. Logistic plan should be posted on project.

Reliable Promises- Pull Planning Pull Planning provides project alignment and schedule buy in with subcontractors. Pull Planning is just a different way of running a foreman’s meeting Daily Forman Huddles- Tracking Percent Promise Complete (PPC) Breakout Meeting- Addressing Complex Issues in Smaller Groups

Reliable Promises- Constraint Log The Theory of Constraints (TOC) is a management paradigm that views any manageable system as being limited in achieving more of its goals by a very small number of constraints. There is always at least one constraint, and TOC uses a focusing process to identify the constraint and restructure the rest of the organization around it. Constraint Log – a list of constraints with identification of an individual promising to resolve the item by an agreed date. Typically developed during a review of the Six Week Look Ahead Plan when it is discovered that activities are not constraint free.

Reliable Promises- Plan, Do, Check Act & A3

Everything Lives in the Cloud Electronic Documents Everything Lives in the Cloud Electronic Documents provide the most current information to entire project team and reduce waste and rework. E-Doc’s Tablets - Including Subcontractor Foremen

Electronic Documents- BIM Model as much as possible- The more the better Maximize learning curve prior to work in field Minimize variation created by errors

“It is not necessary to change. Survival is not mandatory” W. Edwards Deming