2. GO LEAN AND GREEN
Ritu Ahuja – Assistant Professor, Amity university
3. Contents
1. Abstract ........................................................................................................................................... 4
2. Introduction...................................................................................................................................... 4
3. Wastes in Construction Industry ..................................................................................................... 9
4. The Practical Relationship Between Lean Methods And Sustainable Impacts- The Lean Delivery
Phases .............................................................................................................................................. 10
5. Conclusion and Recommendation ................................................................................................ 13
6. References .................................................................................................................................... 13
7. Author‟s Profile .............................................................................................................................. 15
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4. 1. Abstract
Lean construction is a new production philosophy which would bring in revolutionary changes in the
construction industry. The Lean principles emphasise on eliminating process and material wastes and
which can further result to the green construction which emphasise on the energy efficiency and the
cost efficiency.
The project aims to study the novel concept of „Lean Construction‟ in the world. Another intention is to
examine how current Lean construction tools and methods impact the construction and operation of
sustainable facilities. The Lean and green Construction philosophy can tremendously improve the
needs and result in high productivity of the construction industry. The paper also finds out how these
Lean construction tools and methods have evolved to contribute to green construction. In order to
achieve the project aim, there are four main objectives:
1. To investigate the concept of lean and its application to the construction industry.
2. To define sustainability and identify its application to the construction industry.
3. To establish a link between the lean and sustainability.
The Lean principles emphasise on eliminating process and material wastes and which can further
result to the green construction which emphasise on the energy efficiency and the cost efficiency.
2. Introduction
The construction industry plays a significant role in economic growth, both directly through its
activities, and indirectly through the provision of buildings and infrastructures for the smooth
functioning of businesses. However, the construction industry is highly challenged as a 3D‟s industry
– dirty, dangerous and demanding.
The construction industry lags 10 years behind the manufacturing industry because of the several
reasons. The primary reason being its fragmented approach rather than an integrated approach. The
second important reason is that the construction industry is far more complex than the manufacturing
and thus the technical innovations are required to be more developed to be significantly implemented.
Lean construction is a new production philosophy which would bring in revolutionary changes in the
construction industry.
LEAN APPROACH – DEFINITION AND NEED
Lean production focuses on eliminating waste and maximizing productivity through the pull system,
employee involvement, continuous improvement, etc. Much has been discussed about the waste
elimination and productivity improvement that can be achieved by applying the lean concept.
However, as the consideration of the environment is becoming an increasingly important part of the
construction culture, there is a need to investigate the applicability of the lean concept to achieve
environmental sustainability, which is often used interchangeably with the term “green”.
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5. Lean philosophy is all about designing and operating the right resources at the right time with right
systems. The most essential and important objective of lean philosophy is to identify, eliminate waste
and achieving the customer needs in all respects. Two very important construction tools are added
under lean construction are the production control and structuring of the work. . Lean construction is
about gaining the control through coordination between stakeholders and the team members to
improve the performance, delivery and value for everyone involved in the project.
According to the Lean construction Institute, LCI, lean construction is a production management
based approach to project delivery. It is a new way to design and build capital facilities. Lean has
already caused a major change in manufacturing industry and when applied to the construction
industry, lean changes the way of working throughout the delivery process. Lean construction has
successfully resulted into maximising the value and minimising the waste in the construction process.
Lean significantly contributes to the efficiency of the construction industry. It helps the industry to
reveal and support customer purposes. The application of lean in the construction process has
resulted into structuring of the work throughout the process and the improvement of performance of
the project. Lean construction assures to deliver reliable work between specialists in design, supply
and assembly, thus delivering Value to the customers and reducing the waste.
The lean principles include:
• Establishing good terms within the team comprising of owners, architects, contractors,
subcontractors and suppliers;
• Emphasising on the process design, and thus combining project design.
• Stopping production rather than spoiling the construction process;
• Enhancing participation of all the team members in a project, thus decentralising decision making.
The Lean construction is different from the typical construction in many aspects. In the typical
construction, the conversion activity takes place, that is, every input is converted into output through a
process. The typical construction focuses on the finishing the things thus achieving the efficiency but
lacks in the value. The typical construction aims to achieve efficiency by implementing new
technology whereas the lean approach focuses on eliminating or reduction of non-value adding
activities and increasing the efficiency of the process through continuous improvement. The efficiency
in Lean approach is improved by redesigning the process.
Lean construction is different from current construction management because it aims at increased
performance at the project level, it possess and focuses on a clear set of objectives for the delivery
process, its designed the process and the product simultaneously and, it looks towards the efficient
productivity throughout the life cycle of the project.
GREEN CONSTRUCTION – SUSTAINABLE CONSTRUCTION – DEFINITION AND NEED
As the world is becoming increasingly concerned about the environment and surrounding, there is a
tremendous focus on all the industries including the construction industry to adopt the proactive
approach to green construction.
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6. Sustainability in construction will not only benefit individuals but also contribute to the global issues.
Sustainability in construction can only be achieved by rethinking operation in four major areas, i.e.,
Energy, Materials, Waste and Pollution. The construction industry can have a better sustainable
approach towards energy by reducing the energy consumption and by using the renewable sources
of energy. The sustainable approach has to be from the very start of the project, that is, from the
design stage by creating energy efficient designs, using the local materials and reducing the cost and
energy of transportation, by recycling maximum and reducing the energy of transport and disposing of
the waste.
Green construction refers to the planning and management of a project that result into minimising the
impact of construction process on the environment. The impact of the construction process on the
environment can be reduced in the following ways:
1. By enhancing and improving the efficiency of the process.
2. By conservation of water, energy and other resources during the construction process.
3. By reducing the amount of waste during the construction process and minimising other
activities that might lead to reduce the costs and maximise the productivity of a project.
The term sustainable construction refers to the ecological, social and economic issues of the building.
The goal of sustainable construction is to create and operate a healthy built environment based on
resource efficiency and ecological design. The sustainable construction and the economic
development has a major impact on land, materials, energy, water, human/ social capital and the
living environment. The construction industry thus can be directly and indirectly linked to the several
aspects of sustainability. The two most important organizations that have recently come up as a part
of growing green building movement are LEEDS ( Leadership In Energy and Environment Design),
GBI ( Green Building Initiative).
The figure 1 shows the evolution and challenges of the sustainable construction concept in a global
context.
Figure 1. Challenges of sustainable construction in a global context
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7. The Figure 2 below shows the framework for sustainable construction development in 1994 by Task
group 16 (Sustainable Construction) of the CIB for the purpose of enhancing major contribution of the
built environment to the attainment of sustainable development.
Deconstruction Phase
Modification
Maintenance
Use & Operation
Construction
Design
Development
Planning
Resources
Land Materials Water Energy Ecosystems
1. Reduce
2. Reuse
3.Recycle
4.Protect Nature
5. Eliminate Toxics
6.Life- Cycle costing
7. Quality
Principles
Figure 2: Framework for Sustainable Construction
The Figure 2 clearly defines the different phases involved in construction process, the resources
required and the principles of sustainable construction. The closed loop defines the reuse and the
recycling of the materials instead of defining them as waste during the construction process. The
materials used in construction are not completely recyclable. The recyclable materials should be
chosen such, that they are non toxic and protect the nature.
The sustainable construction aims to adopt the high- performance green building delivery system
which seeks to ensure that the project is designed, built and handed over for operation in a cost-
effective manner. This high- performance delivery system can be a success only if there is a close
collaboration among building owners, developers, architects, engineers, constructors, facility
managers and all the other members involved in the project. The three major project delivery methods
include the Design-bid-build, Design- build and Contractor selection Method. Amongst three delivery
methods, Design-build is the most commonly and fast growing method.
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8. While traditional design and construction focuses on cost, performance and quality objectives,
sustainable design and construction adds to these criteria minimization of resource depletion,
minimization of environmental degradation, and creating a healthy built environment (Kibert 1994).
The shift to sustainability can be seen as a new paradigm (vanegas et al. 1996) where sustainable
objectives are within the building design and construction industry considered for decision making at
all stages of the life cycle of the facility.
The key elements of sustainable construction can be listed as:
- Reducing the use energy sources
- To conserve the natural areas and landforms.
- Satisfying the needs of the user, adaptable and flexible.
- Extended service life
- Local resources usage
- Efficient land use
- Saving water consumption
- Contributing to the urban development
- Maintaining the quality of the built environment.
The principles of Sustainable construction contribute to:
- Recycling resources.
- Reducing the consumption and use of resources
- Reusing the resources
- Protection of Nature
- Removing Toxics
- Evaluating and applying the Life Cycle costing
- Maintaining the Quality throughout.
In terms of the principle for sustainable construction, various efforts have been made to examine
several definitions of sustainability in an attempt to enunciate principles to be upheld in attaining
sustainable construction. Amongst the published work relating to the principles of sustainable
construction are Kilbert (1994), Hill (1994), Lindle (1994), Hill and Bowen (1997), Robbert (1995),
Graham (2000) Long (2001), and DETR, (2000). A few examples are listed below:
DETR (2000) Profitability and competitiveness, customers and clients satisfaction and best value,
respect and treat stakeholders fairly, enhance and protect the natural environment, and minimise
impact on energy consumption and natural resources.
Hill and Bowen (1997) - Social pillar: improve the quality of life, provision for social self determination
and cultural diversity, protect and promote human health through a healthy and safe working
environment and etc.
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9. Economic pillar: ensure financial affordability, employment creation, adopt full-cost accounting,
enhance competitiveness, sustainable supply chain management.
Biophysical pillar: waste management, prudent use of the four generic construction resources (water,
energy, material and land), avoid environmental pollution and etc.
Technical pillar: construct durable, functional, quality structure and etc.
These four principles are contained within a set of over-arching, process-oriented principles (e.g. prior
impact assessment of activities).
Miyatake (1996); CIB (1999) Minimisation of resource consumption, maximisation of resources reuse,
use of renewable and recyclable resources, protection of the natural environment, create a healthy
and non-toxic environment, and pursue quality in creating the built environment.
3. Wastes in Construction Industry
Reduction and removal of waste is an important part of lean and green construction. Using the
material resources efficiently can lead to sustainable waste management. Waste is hardly ever
recognised by the project managers which is the major cause of loss of efficiency and productivity
(Koskela 1992). Figure 3 identifies the seven forms of waste which are over production, conveyance,
inventory, processing, waiting, correction and motion.
Figure 3. Forms of Waste
We can reduce the level of waste production in the construction industry by designing such a way that
minimum waste is generated, by increasing the efficiency of the production process, by using the just-
in- time tool to prevent the wastage of unused material, by recycling materials wherever possible and
by educating the staff about waste reduction and material recycling.
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10. 4. The Practical Relationship Between Lean Methods And
Sustainable Impacts- The Lean Delivery Phases
The Lean Project Delivery system consists of four interconnecting phases extending from Project
definition to Design, supply and assembly. (Figure 4)
The Project Definition consists of three different modules: Needs and Value Determination, Design
Criteria and Conceptual design. Defining value and waste is critical in Lean production. Value
management aims to maximize value and eliminate waste. Minimal building impact, maximum
building system efficiency, energy efficiency, waste reduction, and a healthy, productive environment
for occupants are the key features of the lean and green construction. The social impact of facilities
has been one of the critical concerns in the architecture industry. It is hard to measure the social
impacts of facilities on humans and communities. Lean construction needs to identify sustainable
values including economic, environmental and social values as important factors in implementing
sustainable construction.
Lean Design is a process that includes various construction techniques and materials to produce
value to an owner. This process is very important considering the impacts to the overall life of a
facility. The green facilities can only be applied to its best in a design contributing to sustainable
construction only if the use of green materials, resources and the construction technologies is
comprehensively coordinated with each other.
Figure 4. The Lean Project Delivery System
In order to minimize environmental impacts and energy consumption during construction of
sustainable facilities, several Lean design methods could be implemented: Integrated Design (Whole
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11. system design), Design for Maintainability (DFM), Set-based Design, Target Costing, and 3D
Modeling.
Lean Supply: Just-in-time (JIT) could also be regarded either as an environmentally-friendly method
or the opposite. Just-in-time reduces damage and materials (Riley et al., 2005). Moreover, this
method may reduce the various sources of extra inventory but at the same time, however, the
frequent transportation of inventory and materials may cause volatile organic compounds and CO2
emissions. Even though applications in the manufacturing industry and construction industry are not
exactly the same, we need to notice the probabilities and possibilities of bad environmental impacts
from Lean adaptation. The consideration from the holistic perspective is required to increase the
sustainability of a construction project.
Lean Assembly: One of the most successful procurement methods that can be adopted to achieve
sustainability is the Prefabrication. Economic, social, and environmental indicators from (Horman et al,
2005) examined the impacts of prefabrication for purposes of sustainability using these indicators
(Horman et al., 2005 in Luo et al., 2005). The features of prefabrication on sustainable constructions
include:
• Increased potential of improved supply chain integration of green materials
• Safer working conditions.
• Reduced environmental impact due to transferring workers, machines, staked materials,
temporary structures and onsite activities to a prefabrication plant
• Easier recycling of materials in an off-site environment
• Enhanced flexibility and adaptability
• Reduced overall life cycle cost
• Reduced economic impact in local communities.
Prefabrication may have both sustainable benefits and disadvantages depending on the exact
conditions of a project. These impacts fall into three categories: economic, social, and environmental.
Thus, economically, one advantage is the reduced cost of prefabricated units as opposed to on-site
units. Socially the working conditions are safer and more stable in prefabricated construction than
they are on-site. Environmentally, this method may improve the supply chain for green materials, one
aspect of green facilities. Yet, there are some problems as well. Economically, and socially, less local
labour is needed, thus the salaries of the workers do not contribute to the local economy.
Environmentally, this process may consume more energy for transportation of prefabricated products
and emit more air pollution.
Kaizen, which means continuous improvement in Japanese, is a core component of Lean production
not only for economic purposes, but also for social and environmental purposes in sustainable
construction. Kaizen plays a key role in improving the current status for sustainable construction. All
sustainable indicators may be improved through Kaizen.
Another potential tool for sustainable perfection is Kaikaku. Kaikaku (Kaizen events), means a rapid
process of improvement, is a team activity designed to eliminate waste and make rapid changes for
product and process improvement in the workplace. This strategy is employed to get workers with
multiple organizational functions on different levels to unite in improving processes and addressing
problems. When implementing chosen improvements, the team rapidly employs inexpensive solutions
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12. usually within three days. Kaikaku can create reduced pollution and material waste.
Figure 5. Lean Methods and Sustainable Impacts
Figure 5 illustrates a quantitative assessment of the previously discussed methods on the
sustainability of a construction project. Most lean construction methods provide positive economic
impacts for sustainable facilities while showing several no-impacts or negative impacts on social and
environmental aspects. The table shows concrete relationships between the Lean construction
methods and the sustainable construction of a facility, while several Lean construction practices reveal
no relationship or negative relationships.
The Lean principles emphasise on eliminating process and material wastes and which can further
result to the green construction which emphasise on the energy efficiency and the cost efficiency. The
Lean and green Construction philosophy can tremendously improve the needs and result in high
productivity of the construction industry. The lean and green theories both complement each other.
The green construction in addition to the theories of lean construction also focuses on the recycling,
reusing of the resources thus making the process and the project cost efficient and most productive.
Figure 6. Relationship between sustainable development and Lean production
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13. In the figure 6, the four interconnecting phases of the Lean Project Delivery System (LPDS) extending
from project definition to design, supply, and assembly are used to illustrate the Lean construction
process (Ballard, 2000). Addressing sustainable issues, such as economic, social, and environmental
values as the requirements of an owner, Lean may act from the project definition to the construction
phase for a sustainable facility.
5. Conclusion and Recommendation
The research tries to bring out the need for the implementation of lean philosophy in the construction
industry. Lean Construction should be adapted and considered as it can solve many problems of the
construction industry and the project management as the cost over run, poor quality and the delays.
It has been insisted that the Lean philosophies offer the conceptual basis, and lean construction
methods and tools have great possibilities for sustainable construction (Huovila and Koskela,
1998).The sustainability in a project can be achieved by following the lean principles. The lean
philosophy not only provides the economic value to the process, but, can also provide the social and
environmental value. This can be achieved by following and improving the green project management
facilities. The lean and green philosophies together can give help the construction industry more
efficient. To make a project lean and green, the research brings out the three key impacts of lean
construction methods to achieve sustainability:
1. Economic value in a project can be achieved by reduction of cost, saving of resources, by
minimising the operation cost and maximising the productivity of the process.
2. Social Value can be achieved by making the workplace safe, by being loyal among the team
members and the stakeholders, by keeping in mind the community welfare and happiness.
3. Environmental Value can be achieved by minimizing the resource depletion, by saving and
preserving the resources and by the removal of waste thus, preventing the environment from
pollution.
The importance of environmental aspects cannot be separated from the lean construction as they add
value to each other when combined and used correctly. The methods of lean construction should be
extended to environmental planning to help improving the efficiency of the production management
process.
In this paper, most of the lean construction methods and the green construction methods are studied
and examined. Although there are many other lean construction methods which are not been
examined for sustainability, but if studied in future, will surely have a possibility for sustainable
purpose.
6. References
[1] Ballard G., Howell G. (1994), “Implementing lean construction: Improving downstream
performance”.
[2] Ballard G., Howell G. (1998), “Implementing lean construction: Understanding and Action”,
Presented at the Annual Conf. International Group for Lean Construction.
[3] Ballard, G. (2000). “Lean project delivery system.” Lean Construction Institute White Paper No.
8, Lean Construction Institute, Ketchum, Id.
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14. [4] Ballard G & Howell AG. (2003) Lean Project Management. Building Research and Information,
31(2), 119-113
[5] Bourdeau, L., Huovila, P., Lanting, R., and Gilham, A. (1998), “Sustainable Development and the
Future of Construction- A comparison of visions from various countries” . CIB Report 225,
Rotterdam.
[6] Charles J. Kibert (2008), Sustainable Construction, Green building Design and Delivery, second
edition.
[7] Cusumano, M.A. (1994). “The Limits of „Lean‟,” Sloan Management Review, vol. 35, no. 4,
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(Conference proceedings)
[9] Green S. D; “The Future of Lean Construction: A Brave New World”, International Conference on
Lean Construction; Brighton; 2000. (Conference proceedings)
[10] Helper, S. and Clifford, P. (1997). “Can Green Be Lean?” paper presented to the Academy of
Management meetings, Boston, MA
[11] Horman, M.J., Riley, D., Pulaski, M.H., and Leyenberger, C. (2004). "Lean and Green: Integrating
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[12] Howell G.A.(1999), “ What is Lean Construction-1999” 26-28 July 1999, University of California,
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[13] Howell G.A.; Ballard G. (1999), “Bringing light to the dark side of Lean Construction”, International
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[14] Huovila, P. and Koskela, L. (1998). “Contribution of the Principles of Lean Construction to Meet
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[18] Wu Peng and Low Sui Pheng (2011), “Lean and green: emerging issues in the construction
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15. 7. Author’s Profile
I, Ar. Ritu Ahuja, am currently working as an Assistant
Professor at Amity School of Architecture and
Planning, Amity University, Noida – 201301, Uttar
Pradesh, India. I am a post graduate in Construction
Project Management from University of Manchester,
UK. I have worked as a Project coordinator for two
years in the Indian Construction Industry and now
hope to start with my PhD research soon in Lean and
Green construction.
Email: rahuja@amity.edu, rituahuja1985@gmail.com
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