Lean Apartment Construction Workshop LEAPCON Lean Apartment Construction Workshop

Apartment Construction 22 פברואר, 2006 בנייה רזה Apartment Construction Drywall Ceilings HVAC Flooring Design Changes (c) 2006 Dr. Rafael Sacks, Technion

Simulation setup 2 3 4 5 6 7 8 Building floors and apartments 22 פברואר, 2006 בנייה רזה Simulation setup Material Store Building floors and apartments Crane Client Rep 1 3 2 4 5 7 6 8 2 9 11 10 12 3 13 15 14 16 4 17 19 18 20 5 21 23 22 24 6 25 27 26 28 7 29 31 30 32 8 HVAC team Drywall team Flooring team Quality Control Ceiling team Project Manager Design Changes Client Changes Rep Client (c) 2006 Dr. Rafael Sacks, Technion

Production Plan (Gantt Chart) 22 פברואר, 2006 בנייה רזה Production Plan (Gantt Chart) (c) 2006 Dr. Rafael Sacks, Technion

Results for 2 groups Round Completed (units) 22 פברואר, 2006 בנייה רזה Results for 2 groups Round Completed (units) Defective apartments (units) Time to first apartment with changes (min.) W.I.P. (units) Throughput (units/min.) Cash flow ($) Cycle time (min.) Conventional (1) (2) (3) Lean (4) (5) (c) 2006 Dr. Rafael Sacks, Technion

Discussion between rounds: Difficulties with the system 22 פברואר, 2006 בנייה רזה Discussion between rounds: Difficulties with the system Management Team: What did you feel during the game? Were you busy? Did you manage to implement your plan? Were you in control? Drywall team: Were you busy? HVAC team Bottleneck, Cycle time, WIP, Push What is the meaning of cycle time for apartment construction in real projects? How would you improve the process? (c) 2006 Dr. Rafael Sacks, Technion

Discussion after the second round 22 פברואר, 2006 Discussion after the second round בנייה רזה Management Team: What did you feel during the game? Were you busy? Did you manage to implement your plan? Were you in control? Drywall team: Were you busy? Was your productivity improved? HVAC team Bottleneck, Cycle time, WIP, Push What is the meaning of cycle time for apartment construction in real projects? How would you improve the process? (c) 2006 Dr. Rafael Sacks, Technion

LEAPCON – typical results 22 פברואר, 2006 LEAPCON – typical results בנייה רזה (c) 2006 Dr. Rafael Sacks, Technion

LEAPCON - Cash Flows LEAPCON Simulation F: Lean 21:04 LEAPCON - Cash Flows $(20,000) $(15,000) $(10,000) $(5,000) $0 $5,000 $10,000 $15,000 $20,000 0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00 20.00 22.00 24.00 Simulation Time (min.sec) Cash Flow F': Lean, no customization F: Lean A': Conventional, no customization A: Conventional LEAPCON Simulation www.technion.ac.il/~cvsacks/tech-leap.htm

LEAPCON Users around the world 21:04

Background Reading “The Goal” Eli Goldratt www.leanconstruction.org 21:04 Background Reading “The Goal” Eli Goldratt www.leanconstruction.org “Lean Thinking” Womack and Jones www.iglc.net “The Critical Chain” Eli Goldratt “Factory Physics” Hopp and Spearman Sacks, R., Esquenazi, A., and Goldin, M., (2007). ‘LEAPCON: Simulation of Lean Construction of High-rise Apartment Buildings’, Journal of Construction Engineering and Management, Vol. 133 No. 7 pp. 529-539.