short term planning and lean

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Short Term Planning using Lean Techniques Ed Anderson President www.tokmo.com President Anderson Technical Services, Inc. Igor Starkov President Tokmo Solutions, Inc.

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Page 1: Short Term Planning and Lean

Short Term Planning using Lean Techniques

Ed AndersonPresident

www.tokmo.com

President

Anderson Technical Services, Inc.

Igor Starkov President

Tokmo Solutions, Inc.

Page 2: Short Term Planning and Lean

Current State of Affairs

Why Lean for Short Term Planning?

Lean Methods Overview

1

2

3

Lean Metrics4

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Lean Metrics4

Software Tools5

Questions & Answers / Plus Delta6

Page 3: Short Term Planning and Lean

Business Drivers for Going Lean

• CII Reports:

75% to 90% of field work

is non-value-added

www.tokmo.comwww.tokmo.comCII publication 2004 “Application of Lean Manufacturing Principles to Construction.”

Based upon actual work sampling.

Page 4: Short Term Planning and Lean

Problems Influencing Productivity Ranking Time Loss*

Lack of Materials 1 3

Crew Interference 2 2

Repeat Work 3 2.5

Where Is Waste?

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Repeat Work 3 2.5

Lack of Supervision 4 2

Lack of Equipment/Tools 5 2

*Estimated time loss per problem in a 40-hour week, man/hour

“Construction Productivity Management”, The Chartered Institute of Building, England, 1998.

Page 5: Short Term Planning and Lean

What is this Thing Called “Lean”?

Begins with New Thinking

“If you always DO what you’ve always DONE, you’ll always GET what you’ve always GOT.”

Yogi Berra, Baseball Philosopher

“If you always THINK what you’ve always

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“If you always THINK what you’ve always THOUGHT, then you’ll always DO what you’ve

always DONE, and you’ll always GET what you’ve always GOT.”

Greg Howell, Cofounder Lean Construction Institute

Page 6: Short Term Planning and Lean

Lean Production Planning and Control

• Minimize waste of all resources: labor, materials, time, effort, money, …

• Reduce unpredictability by implementing:– “Pull Planning” - Just-in-Time “Short Term Planning”

– Creating collaborative networks of reliable commitments

– Sound task assignments

– Transparency of activities across the project

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– Transparency of activities across the project

• Visualization: BIM (3D/4D/nD)

• Internet-based collaboration

© View By View, Inc.

Page 7: Short Term Planning and Lean

New Thinking: Traditional vs. Lean

From

Conventional PM/CM

1. Individual task productivity

2. A person is Boss

3. Central Command & Control4. All failures are punished

5. Project post-mortems

To

Lean PM/CM

1. Work FLOW & task sequencing

2. The Project is Boss

3. Decisions made at lowest level4. Leaders allow quick learning

through small failures

5. Daily lessons-learned: “Make new mistakes next week”

www.tokmo.com

6. The more tasks in the master

plan the better

7. People attend classes to

“learn” how to work in teams

8. Cost, schedule, quality, safety

trade-offs are expected

“Make new mistakes next week”6. Start simple, add details when

necessary

7. People are enabled to form

collaborative teams for project benefits

8. The need to make trade-offs are

a myth

Page 6

Page 8: Short Term Planning and Lean

Master Milestone Plan

• Strategic planning

• Project milestones

• Logic

Phase Schedule:

6 week look-ahead

• More detail

• Project components

• Testing logicDrill down from strategic planning into production planning &

Adjust the plan through

“The Last Planner” Hierarchy of

Planning & Production Control

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Planning & Constraint Analysis:

1 & 3 week look-ahead

Daily Work Plans & Planned Percent Complete (PPC)

• Detail tasks

• Decentralized crew scheduling

• Measure PPC

• Learning

• Make Ready needs identification

• Resource management

planning & control by expanding into ever more detail in a rigorous, phased approach

through measured progress and lessons learned• Constraint identification

• Responsibility assigned

• Collaborative “to do” list

• Resource management

• Logistics, logistics, logistics

Page 9: Short Term Planning and Lean

Remove Constraints

Check for ConflictsSound

Make Ready

LeanProcess

NoWaste

Lean Task Management

www.tokmo.comwww.tokmo.com

Remove Constraints

Take Responsibility

Make Ready

Commit

MakeProfit

BeHappy

Page 10: Short Term Planning and Lean

The Last Planner© Reliability Measurement

Percent Plan Complete*:

How reliable you are in planning and making commitments to do work will determine the cost,

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determine the cost, timing, quality and safety of the project.

* Actual # Completed As Promised / # Committed (Promised)

Page 11: Short Term Planning and Lean

The Last Planner© Nonconformance Reporting

Nonconformance:

Instead of trying to “fix” everything, you need a system that tells you where to focus to get the

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focus to get the maximum benefit.

Page 12: Short Term Planning and Lean

The Last Planner© Root Cause Analysis

Root Cause:

Detailed view of nonconformance issues

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Page 13: Short Term Planning and Lean

Other Important Metrics

• Safety

– Much evidence that projects using Lean Project Delivery methods

are much safer

– Identify potential hazards before they occur – proactive approach to safety as part of short-term planning

– Root Cause Analysis helps analyze accidents

– The more constraints are identified the more accurate hazards

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– The more constraints are identified the more accurate hazards

identification becomes and hazards are removed

• Cost, Schedule, & Quality

– Driven by reliable planning and reliable commitments to do work.

Page 14: Short Term Planning and Lean

Software Tools

Locations

Labor

Schedule(P6, MSP)

Tokmo

www.tokmo.com

Locations(IFC, XLS) Systems

Tokmo

Equipment/ToolsMaterials/Products(COBIE)

Page 15: Short Term Planning and Lean

Igor Starkov

Phone: 571-277-6617

Email: [email protected]

Website: www.tokmo.com

www.tokmo.com

Ed Anderson

Phone: 407-473-0260

Email: [email protected]

Page 16: Short Term Planning and Lean

Additional Tools for Decision Support

6D - Materials

5D - Cost Estimating (QTO & ABC)

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6D - Materials Management (COBIE)

4D - Process Visualization

4D* - Locations BasedScheduling

(Line of Balance)