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Flow & Batch Size
The best batch size is one piece flow, or make one and move one!
Lean Tools
*Slide courtesy of NHMEP
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Creating Flow
• Keep the process flowing.
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POUS (Point of use tool storage)Lean Tools
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Deciding LocationsPOUS
5S
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KANBAN (Pull Systems Min Max and Automatic
Triggers)
Lean Tools
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Getting it right the first time
BIM is a critical part-“Measure twice cut once”
-Build it twice, construct it once
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KAIZENFlat Organizational Culture
Lean Tools
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Getting Better at Getting Better, Part III:
Lean Thinking On Site and In the Office
NESEA Building Energy Boston 2017
ANDREW DEY,Operations Director, Unity Homes
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Waste in Construction
Eastman et al., BIM Handbook, John Wiley and Sons, 2009
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Timeline: Lean in Construction
copyright Ennova 2011
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Lean Manufacturing vs Lean ConstructionSHARED PRINCIPLES
Optimisation of entire system through collaboration and systematic learningContinual improvement and pursuit of perfection involving everyoneFocus on delivering the value desired by the owner/client/end-userCreating flow through eliminating obstacles to creating value and eliminating
processes that create no valueCreating pull production
DIFFERENCES
Construction projects are generally unique (one-of-a-kind) prototypesMultiple contractors/suppliers act have varying contractual relationshipsConstruction environments are typically outdoors and/or difficult to controlGeographic separation of teams adds complexity to coordination and information
sharing
www.ennova.com
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We’re Not Alone!
IGLC
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Most Common Causes of Construction Overruns
• Poor or incomplete design and documentation• Client scope change during construction• Mistakes during construction• Delays in decision making or instructions• Poor communication and information dissemination• Poor planning and scheduling• Weather• Labor skills, availability or disputes• Incorrect material types or quantity
www.ennova.com
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Lean Principles
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Lean on Site: Tools, Process and Culture
ToolsProcess
Culture
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Tools: Site Schedule
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Tools: Site Book
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Tools: Site Signage
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Process: Pre-sheathing Truss Roofs
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Process: Bath Pods
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Process: Last Planner System
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Culture: Early Stakeholder Involvement
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Lean in the Office: Tools, Process and Culture
ToolsProcess
Culture
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Tools: Value Stream MappingIf you can’t describe what you are doing as a process,Then you don’t know what you are doing.
—W. Edwards Deming
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Tools: Value Stream Mapping at Unity
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Tools: SOPs and Checklists
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Process: Flash Meetings (aka “Q-DIP”)
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Process: Obeya - the “Big Room” -and Visual Planning
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Improvement Task Chart
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Progress Through Continuous Improvement
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Culture: “Each of us has two jobs”
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Culture: Shared Leadership
Acela Locomotive
Shinkansen “Bullet” Train
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Lean ProcessInspiring and Empowering People
Raising qualityApplying kanbans, kaizens and Value Stream Mapping
to get rid of muda, mura and muri*
*uneven production) muda, waste mura, overworking muri