iIntegrating Lean Construction

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3.  Lean construction main objective is
to maximizes value and reduces
waste.
 It applies specific techniques in an
innovative project delivery approach.
 including:
1. supply chain management,
2. Just-In-Time techniques.

5.  As well as the open sharing of
information between all the parties
involved in the production process.
 Lean manufacturing is an outgrowth
of the Toyota Production system.
 Developed by Taichii Ohno in Toyota
in the 1950s.

6.  It is based on lean manufacturing,
of the Toyota Production system.
 Ohno learnt from mass production at Ford
Motor manufacturing facilities in the U.S.
and witnessed high level of waste during
production.

7. Ohno identified several wastes
in mass production systems
in car industry such as:
1. overproducing
2. waiting time
3. transporting

8. also, in other areas such as:
1. processing methods;
2. unnecessary stock on hand;
3. unnecessary motion;
4. defective goods;
5. failure to meet customers’ needs;
6. high waste through out the process.

9.  Womack and Jones (1996) suggested that there
are five key principles that need to be monitored
when lean construction systems are applied in
construction. Those are:
 Value-clarifying the customer’s needs;
 the supply chain involvement in all stages, from
inception to completion;
 By clarifying activities or products
that signify value.

10. Value stream: By mapping the
whole value stream
 establishing cooperation between all
parties involved;
 identifying and eliminating waste;
 From taking such steps the
construction process can be
improved.

11. Flow:
 Business flow includes project information
such as:
1. specifications
2. contracts
3. plans, etc.
 Job site flow involves the activities and the
way they have to be carried out.
 Supply flow refers to the materials used in
a project.

12. Pull:
 The efforts of all participants provides
smooth pulls during the construction
process.
Perfection:
 Use of best methods of work instructions
and best procedures.
 Introduction of best quality control
methods.

14.  A large proportion of the high cost in
construction work is as a result of
excessive labour costs.
 These costs can be reduced if
productivity on site is increased by
improving labour efficiency.

15.  The difficulties in managing
manpower on a large scale may
result in productivity loss
(Thomas and Jansma, 1985).
 There are four main factors that
affect labour productivity;
 The duration of worker’s effort.

16.  The intensity of worker’s effort.
 The effectiveness of worker’s
effort combined with the
technology used.
 The efficiency of worker’s effort,
which can be described as a
measure of how much the worker
is utilising his ability.

17.  Work on a complex project (e.g. such
as the construction of a major
shopping centre) becomes more
difficult as the project advances.
 Off-site pre-fabrication units will
reduce the number of labour hours
required.

18. Other factors such as:
the level of skill amongst the
workers;
the length of the workday;
Innovative work practices can
increase productivity.

19.  Employment practice has an impact on
the cohesiveness amongst the workforce.
Some of the Important contributors towards
Labour productivity are:
 a culture of cohesiveness
 common goal
 strong sense of a team working
 towards a common goal

20.  A culture of team working involving all workers is
to achieve a common goal.
 A common goal on construction site is to
achieve KPIs.
 Labour productivity can also be improved if
operatives on site avoid conflict.
 Conflict on site can hamper the progress of
work.
 Team working reduces conflict and will greatly
facilitate increased productivity.

21.  The importance of a directly or indirectly
employed workforce.
 and the effect on the dynamics of
productivity is reiterated in several
research work.
 The growth in the construction sector is
relatively stagnant.
 The job security can be very bad during
any recession for construction workforce.

23.  Materials management is an important
process.
 It is about how to reduce waste
 Improve productivity
 Follow a Sustainable development
 It is about how a building is designed and
how materials are estimated?
 It is about how materials are acquired and
how the packaging is specified.

24.  It is about how the delivery schedule is
designed.
 It is about how contractors plan materials
use and how they manage previously
used materials and cuts.
 It is about how waste is managed for use
elsewhere or recycling rather than being
discarded in a landfill.

25.  Often on site usable or reusable pieces of
material can be seen in a construction site.
-Examples
 lighting ballasts,
 electrical switches
 plasterboards damaged under the rain/bad
handling/storage etc.
 Torn bags of cement,
 Broken tiles, bricks, blocks,
 various lengths of piping and conduit.
 And many more.

26. Cost of Waste
 The cost of waste is more than simply the cost of
getting it to a landfill and dumping it.
The cost of waste is:
 Original cost of material
 Delivery cost
 Handling cost
 Management cost
 Cleanup cost
 Waste hauling cost
 Tipping fee
=Total cost of construction waste

27. Materials use
 materials reuse,
 reduction and recycling
 begins in the planning stages of a project.
1. It starts with the architect,
2. proceeds through the engineer, the
estimator, the purchaser,
3. The construction manager
4. finally the contractors.

28.  Materials cost control often starts with a
plan.
 Once the material is on site and especially
once its been cut, it is too late to plan.
 With carefully well planned operational
procedures and construction practices, a
plan can be developed and implemented
to save significant costs in materials.

30.  Waste management on site should follow a
hierarchy and have a policy of identifying why,
how and where waste are occurring.
 Waste stream identification.
The Government construction site waste
hierarchy are as follow:
 Reduce the amount of waste produced

31. Re-use the material where
possible
Recycle the material where
possible
Recovery of any component parts
or materials
Disposal as the last resort

33. Standard components
 Off-cut waste can be very high on a
construction project,
 Often, project dimensions may be fixed
without taking into account of the standard
sizes that solid materials are produced in.
Benefits of using standard sizes include:

34. Cost savings;
Improved site management;
Minimization of waste and
associated environmental
impacts;
Time can be saved;
Reduction in accidents on site;
Sites can be kept cleaner.