3rd lean construction academic forum · ali lahouti (michigan state university), ... plus /delta...

7th LCI Academic Forum – Meeting Notes

Originator: T.Abdelhamid of 5 Date Printed: 5/22/2011

Lean Construction Institute ©2011 Date Revised: 5/18/2011

7th Lean Construction

Institute Academic Forum

May 12-13, 2010 – Boulder,

Colorado, USA

Forum Notes

by

Tariq Abdelhamid

Forum Attendees: Ali Lahouti (Michigan State University), Ankur Desai (Michigan State University), Brandon

Langerud (Colorado State University), Cindy Menches (Illinois Institute of Technology), David

Galetka (University of Wisconsin – Stout), David Gunderson (Washington State University),

Dick Bayer (Lean Construction Institute), Don Schafer (Michigan State University), Euysup

Shim (Illinois State University), Farook Hamzeh (Colorado State University), Farzad

Shahbodaghlou (California State University – East Bay), Gerald Boerner (Clark Construction

Company, Lansing, MI), John Kantorowski (Ferris State University), Jose Solis (Texas A&M),

Juan Chen (Illinois Institute of Technology ), Mohamed Hassan (George Mason University),

Richard Livingston (Colorado State University), Sean Williams (Flintco Made), Tariq

Abdelhamid (Michigan State University/ LCI), Tim Becker (Iowa State University).

Forum Location:

Civil Engineering Department, University of Colorado, Boulder, CO – (ECCE 1B41, 1111

Engineering Drive, Boulder, CO 80309).

Forum Schedule:

The schedule was as follows (all times in MDT - Mountain Daylight Time):

Thursday, 5/12/11: Workshop from 8am to 5pm

Friday, 5/13/11: Symposium from 8am to 5pm

Forum Registration/Logistics:

Fees: $250 for faculty, $100 for students. Lunch provided. Lodging, transportation, meals, and

other expenses were the participant responsibility.

Forum Objectives:

1. Presentation of Lean Construction instructional simulation models.

a. Designed for academics and practitioners interested in teaching Lean

Construction.

2. Lean Construction research and teaching symposium, dedicated to:

a. Accounts of Lean Construction research and teaching taking place at LCI, and

at LCI affiliated research centers (P2LS, C2P2ai, Edgility, etc )




Forum Agenda:

1. Day one

a. Brief history of LCI and Academic Forum

b. Overview of Lean Project Delivery System™

c. Variation in Production Systems: Dice Game / Parade of Trades™

d. Pull in Production Systems: Lighting Fixture Simulation; Overview of

LEAPCON Simulation

e. Last Planner® System Simulation: Overview; Pull Plan Example

2. Day two

a. Silent Squares

b. Delta Design (overview only)

c. The status of Lean Construction Teaching and Research: Who’s doing what (

oral only presentations)?

d. MySmartPlan Presentation – Shelley Armato, CEO

e. Research Presentations (15 minutes for talk and 15 minutes for Q&A)

Meeting Highlights:

Day one: Plus /Delta

Plus ∆

Variety of backgrounds Cuter Host(ess)

Comfortable and flexible Handouts for overview material

Good participation and comments Weather

Flexible agenda Didn’t make it to the Delta Design Simulation

Location Buff hard hat not worn more

Participatory

Lower student fees

Games order and selection

Tips about setting up, running, and

debriefing simulations

Didn’t make it to the Delta Design

simulation

Finished on-time




Day two: Discussions

Lean Construction Activities:

- Farzad Shahbodaghlou (California State University – East Bay):

o Lean Construction currently taught as part of an existing course titled: “Current

Issues in Construction Management.”

o Working on creating a dedicated course offering for Lean Construction

o Interested in Supply Chain Management research. [Looking for collaborators]

- Gerald Boerner (Clark Construction Company, Lansing, MI):

o Chairing the R&D Committee of the LCI Michigan Chapter

organizing workshops for Lean Construction

Reaching out to owners to raise awareness about contracting using IPD

o Actively working on Lean Construction conversion at Clark.

Selecting a project for piloting techniques

Investigated trade contractor award process using VSM and found 30 steps

with much duplication.

- Cindy Menches (Illinois Institute of Technology):

o Working to establish LCI Chicago

o Teaching a new graduate course on Lean Construction, slated for January 2012.

o Working on research projects that compliment Lean Construction, with PhD

student Juan Chen :

File sharing protocols to enable automated estimating

How assignment of liability and risk in contracts drives behaviors?

How workers make impromptu changes when their work is disrupted on

the job site?

- Dave Galetka (University of Wisconsin – Stout):

Adding modules of Lean Construction in exisiting courses

Received a grant to pursue a PhD, with a focus on Change Management in

Lean Construction conversions ( phases of change, metrics to measure,

considering to measure benefits of Last Planner® System on

superintendent administrative time.

- Jose Solis (Texas A&M):

o Involved in LCI Houston Chapter and various outreach activities with Lean

Construction.

o Working with colleague Zofia Rybkowski.

o Research focus:

Theoretical foundations of waste vs. value in Lean Construction (can we

find evidence that whatever is not waste is value?)




Understanding flow on projects: laminar versus turbulent

Can entropy explain how projects move from order to disorder, and vice

verse?

- Euysup Shim (Illinois State University):

o Introducing Lean Construction simulation games in existing classes.

o Developed a simulation game for batch size and quality as a variant of Rafael’s

LEAPCON game. Will present it at next year’s LCI Academic Forum.

o Getting involoved in the student chapters to form a Lean Construction group.

o Research:

Studying the problem of overlap between two contractors and the resulting

dependency on the method they each follow.

Investigating batch and buffer sizing methods used by contractors.

- Farook Hamzeh (Colorado State University)

o LCI Colorado

o Introducing Lean Construction ( LPS® and Linear Scheduling) in undergraduate

Construction Scheduling course

o Introducing Lean Construction in graduate course titled Applied Project

Management.

o Research:

IPD implementation in the Federal Sector

BIM practices

Introduce Make-Ready planning to Weekly Work planning

LPS® metrics such as Task Anticipated and Tasks Made Ready and

relation to PPC

Successful factors for implementing LPS®

- Tariq Abdelhamid (Michigan State University)

o LCI Michigan; AGC Lean Construction Forum; LCI Journal; LCI Academic

Forum; Lean/IPD Coach on MSU Project.

o Research:

Book on LC with Alan Mossman

C2P2ai research projects ( www.c2p2ai.msu.edu)

MSU Way ECOS; www.pp.msu.edu/msuway

AGC Lean Construction Education Program (with Enovio Consulting)

Crew actions during unexpected production and safety problems; Work

Crew Design; Impact of Explicit vs. Implicit Instructions on Operations

Execution; Last Planner®

System and Workflow Reliability; Managing

Supply Chain Partners.

http://www.c2p2ai.msu.edu/

http://www.pp.msu.edu/msuway




Lean Construction Presentations:

- Tim Becker (Iowa State University)

o CII Project on indirect cost practices. Tim is proposing to create a Lean

Construction inspired framework for reduction of indirect cost.

- Brandon Langerud (Colorado State University)

o Investigating the levels of implementation of the Last Planner System and how

this relates to project success.

- Don Schafer (Michigan State University)

o Recovering from disruptions at the workface using Resilience Engineering.

- Ankur Desai (Michigan State University)

o Which strategy should be followed by work crews when problems arise on site:

wait for foreman/superintendent or execute a self-generated solution?

- Ali Lahouti (Michigan State University)

o Propose that the LPS® provides the mechanism for more direct and explicit

assignment making.

o How do we test the effectiveness of an explicit instruction (a Signal) in

comparison with less directive one (a Cue) in execution of an assignment?

Day two: Plus /Delta

Plus ∆

Enjoyed student

presentations

More strict timekeeping

MySmartPlan Presentation Not enough time for presentations

Discussions More people

Lights/Facility LCI Website and announcement of events

Dick Bayer attending

Food in room

Seeking input from all

Not cutting off discussions

7th LCI Academic Forum

Tariq Abdelhamid and Dick Bayer

May 12-13, 2011

Boulder, Colorado 1

LCI Academic Forum

http://www.leanconstruction.org/academic.htm

Workshop Agenda

• 8:00 Welcome and Introductions • Brief history of LCI Academic Forum

• Lean Construction Overview

• 9:45 Morning break

• 10:00 Variation in Production Systems • Dice Game / Parade of Trades ™

• noon Lunch

2

LCI Academic Forum


Excerpt from LCI’s Mission

Develop and disseminate new knowledge regarding the management of work in projects.

• Establish common vocabulary, foundational concepts and principles, and fundamental practices of Lean Construction.

3

LCI Academic Forum


Excerpt from LCI’s Academic Forum Mission

• Increase Lean Construction teaching and research in institutions of higher education

• Act as a liaison to industry seeking to establish research and professional development programs.

4

LCI Academic Forum


Lean Construction Institute (LCI)

“Lean Construction is a production management-based approach to project delivery – a new way to design and build capital facilities to maximize value and minimize waste….”

5

LCI Academic Forum


AGC Lean Construction Forum

“Lean Construction is a set of ideas,

practiced by individuals in the construction industry, based in the holistic pursuit of continuous improvements aimed at minimizing costs and maximizing value to clients in all dimensions of the built and natural environment: planning, design, construction, activation, operations, maintenance, salvaging, and recycling.”

6

LCI Academic Forum


Lean Construction:

7

• a comprehensive set of ideas, based in scientific experimentation and holistic process improvement, to manage the process of design and construction to arrive at owner objectives without sacrifices.

(Abdelhamid - class notes 2006)

LCI Academic Forum


Lean Construction:

8

• a comprehensive set of ideas, based in scientific experimentation and holistic process improvement, to manage the process of design and construction to arrive at owner objectives without sacrifices.

LCI Academic Forum


9

• 50% Fewer Injuries

• 20% Cost Savings

• 20% Reduction in Time

Intrinsic Value of Lean

Baker Concrete

LCI Academic Forum


Lean Construction Origins

• Theoretical interest to understand production in construction

• Empirical experiments with productivity improvements and weekly planning failures

10

LCI Academic Forum


Projects: LCI Perspective

11

Organization

Adapted from Lean Construction Institute

LCI Academic Forum


Lean Project Delivery System™

12


Purposes

Design

Criteria

Design

Concepts

Process

Design

Product

Design

Detailed

Engineering

Fabrication

& Logistics

Installation

Commissioning

Operations &

Maintenance

Alteration &

Decommissioning

Project

Definition

Lean Design Lean Supply Lean

Assembly

Lean

Operation

Production Control

Work Structuring Learning

Loops

LCI Academic Forum


Lean Construction

• A systems-based management philosophy and set of practices that maximize value in the delivery of projects to owners by improving collaboration and work methods in all phases.

13

LCI Academic Forum


Lean Construction Evolution

14

Organization


2

1 3

LCI Academic Forum


The Lean Construction Opportunities

15


2. Production system design; Construction as input

during design; Dialectic

Organization

LCI Academic Forum


Lean Construction enabling tools

• Integrated Project Delivery

• Target Value Design (TVD)

• A3s & Choosing By Advantages (CBA)

• Process Design; BIM (Lean Design)

• Offsite fabrication and JIT (Lean Supply)

• Last Planner® System

• Value Chain Mapping; Visual site; 5S; Daily crew huddles (Lean Assembly)

16

LCI Academic Forum


17

Collaborate , Really Collaborate

Increase Relatedness

Conduct the Project as a Network of

Commitments

Tightly Couple

Learning with Action

Optimize the Whole

The Five Big Ideas

Graphics Courtesy of Lean Project

Consulting, Inc. © 2011 All Rights

Reserved

LCI Academic Forum


Implementing Lean Construction

• Leveraging the full benefits of Lean Construction requires the use of Integrated Project Delivery

Tariq Abdelhamid- CMP831- Michigan State University 2008 18

LCI Academic Forum


Integrated Project Delivery Basics

• IPD is a contractual argument that enables the

practice of the full set of Lean Construction

ideals:

• Design informed by construction, maintenance,

and operations

• Moving money across traditional boundaries

• Accounting transparency

19

LCI Academic Forum


Lean vs. non-Lean

20

Non-Lean Lean

Planning Knowing Learning

Scheduling Start Early Finish Early

Project

Management

Trades Cost for

Speed

Reduce Cost and

Increase Speed

Control Tracking &

Reacting

Peering, Clearing,

Steering

Coordination Following Orders Making and

Keeping Promises

The Goal of

Supervision

Point Speed &

100% Utilization

Reduce Variation

& Manage FLOW

LCI Academic Forum


Workshop Agenda

Variation in Production Systems

• Dice Game / Parade of Trades ™

21

LCI Academic Forum


Variation in Action

• Simulated

– http://www.youtube.com/watch?v=Q78Kb4uLAdA&feature=related

• Real

– http://www.youtube.com/watch?v=Suugn-p5C1M

http://www.youtube.com/watch?v=Q78Kb4uLAdA&feature=related




http://www.youtube.com/watch?v=Suugn-p5C1M



LCI Academic Forum


Variation, Lead Time, Capacity Utilization

Wa

it T

ime

100%Capacity Utilization

A

©Lean Construction Institute, 2001

Wait

Tim

e

LCI Academic Forum


Traditional CM View

Current PM practice is

“fixated”on movement

ALONG the curve;

following the Time/Cost

tradeoff

Modified by Tariq Abdelhamid

Wait

Tim

e

100% Capacity Utilization

LCI Academic Forum


Wait

Time

Capacity Utilization 100% 0%

A

B

C

©Lean Construction Institute, 2001

Which way should we try to go?

LCI Academic Forum


Workshop Agenda • 1:00 pm Pull in Production Systems

• Lighting Fixture Simulation

• LEAPCON

• 2:45 Break

• 3:00 Last Planner® System Simulation • Pull Plan Example

• 4:45 Plus/Delta

• 5:00 Adjourn

26

LCI Academic Forum


Workshop Agenda

Pull in Production Systems

• Lighting Fixture Simulation

• LEAPCON

27

LCI Academic Forum


Types of Production Systems

Batch & Queue Continuous

Flow

LCI Academic Forum


Workshop Agenda

Last Planner ®Systems

• Milestone/Phase Plan Simulation

29

LCI Academic Forum


Workshop Agenda • 8:00 am Lean Design: Product and Process Design • Silent Squares

• Delta Design

31

LCI Academic Forum


About TVD

32

• A Lean Construction practice of constraining design and construction of a capital facility to a maximum cost. It is an appropriate practice for all clients with financial constraints (maximum available funds or minimum ROI requirements) that a capital project must meet in order to be considered successful by that client.

LCI Academic Forum


Target Cost Estimated

Maximum

Price

(EMP)

(© W. Lichtig & T. Abdelhamid - 2010)

Allowable

Cost

Business

Case

In-Service

Date

Functional

Program

Innovatio

n

Allowabl

e Cost

Expecte

d Cost

Lean Design and TVD

3rd lean construction academic forum · ali lahouti (michigan state university), ... plus /delta...

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