1. Why Production Control is Essential for Lean in Construction Gavin Pearce & Andy Fielding, Costain, Keith Bennett, Bourton Group

2. Purpose of this Presentation
To provide an overview of Collaborative Planning and Production Control (CP/PC) and the purpose
To describe how CP/PC fits within the overall Lean Thinking framework
To discuss how CP/PC provides the stepping stone for construction teams who may struggle with conventional Lean approaches

3. Factory Thinking and Production Thinking Strategy
Common theme is PC

4. Factory Thinking Flywheel

5. What is Production Control
LEAN

6. Collaborative Planning and Production Control
Maps out the process
Identify value and non-value
Removes waste
Production Control
Route cause analysis
Tools and techniques
Measure/monitor performance

7. CP & PC…What is the overall purpose?
To reduce the Design/construction time and effort on the ground whilst at the same time improving programme predictability, without compromising quality, safety or impact on customers

8. Three Key Features of Production Control

9. The step process to understanding Lean
Lean – DMAICT/six Sigma
Lean – 5S, visual mgt
Production Control
Collaborative Planning

10. Elements of Production Control

11. 5. Continually Attack Waste
Lean & Production Control interface
Agreed Programme of work
Resolve Issues to Recover
Capture Performance
5. Continually Attack Waste
Develop Collaborative plan
Create Medium to short term Plan
Create 1 week look ahead
Review Daily Progress
Continuous Improvement
Easy
Capture Issues
Ease of Solution
1. Understand Customer Needs
2. Understand the Processes
3. Create Process Flow
Collaborative Planning
Complex
Improvement Interventions
Production Control
4. Pull Value

12. Integrating CP/PC/Lean
Easy
Complex
Develop Collaborative plan
Create Medium to short term Plan
Create 1 week look ahead
Review Daily Progress
Capture Issues
Capture Performance
Ease of Solution
Improvement Interventions
Continuous Improvement
Resolve Issues to Recover
Collaborative Planning
Production Control
Develop High Level plan
Plan To Protect
Ease Benefits Matrix
Brain Storming
Fishbone
5 Whys
Pareto
Spaghetti Chart
Run Charts
Bar Charts
Visual Displays
3 C’s
Visual Management
8 Wastes
SIPOC
Process Mapping
Ease Benefits
Make Ready Needs
3C’s
5whys
Visual Display
DMAIC
Quad of Aims
Key

13. An Example - Thames Tideway Project
Percent Planned Complete (PPC)

17. Highways sectors Lean and PC dashboard

18. How CP/PC has helped Costain implement Lean
A stepped approach
Simple language easily understood
A less threatening methodology
Addresses the immediate and obvious problems quickly – the programme timescales/constraints
Allows Continuous Improvement (Lean) to be introduced by stealth

19. Questions?