3rd Annual Conference of the International Group for Lean Construction
Date: October 16 - 19, 1995
Venue: Albuquerque, New Mexico
Conference Coordinator: Greg Howell , University of New Mexico
Titles of papers presented, with links to abstracts:
Training Field Personnel to Identify Waste and Improvement
Opportunities in Construction Luis F. Alarcon
Moving toward Construction JIT Glenn
Ballard & Greg Howell
Pattern Transfer: Process Influences on Swedish
Construction from the Automobile Industry Jan Broechner
Quality Assurance & Partnering - A lean partnership
Ian M. Eilenberg
The Knowledge Process Deborah Fisher
TQM the Nordic Way Axel Gaarslev
Factors Affecting Project Success in the Piping Function
Greg Howell, Glenn Ballard
Involvement of Customer Requirements in Building Design
Pekka Huovila, Anitti Lakka, Petri Laurikka & Mikko Vainio
Use of the Design Structure Matrix in Construction - Pekka
Huovila, Lauri Koskela, Mika Lautanala, Kari Pietiläinen, Veli-Pekka Tanhuanpää
Lean Construction: An Approach for Sustainable Growth Antonio Sergio
Itri Conte
Lean Production: Goals and Achievements Jan
Eric Johnson
Rapid Construction as a Change Driver in Construction
Companies Lauri Koskela, Petri Laurikka, Mika Lautanala
A Process Approach to Design for Construction Mika
Lautanala
Ultra Fast-track Project Delivery Bob
Miles
Benchmarking, Best Practice - and All That
Sherif Mohamed
Construction Supply-Chains: Case Study and Integrated
Cost and Performance Analysis Bill O'Brien
Characterization of Waste in Building Construction
Products Alfredo Serpell, Adriano Venturi, Jeanette Contreras
Limitation of the Use of Tolerances as a Means for
Stating Quality Requirements in Reinforced Concrete David Seymour, Mazin Shammas-Toma,
Leslie Clark
Schedule Compression: A Case History Peter
Woodward
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Training Field Personnel to Identify Waste and
Improvement Opportunities in Construction
Luis F. Alarcon, Head
Department of Construction Engineering and Management
Escuela de Ingenieria
Pontificia Universidad Catolica de Chile
Casilla 306, Santiago, Chile
Tel: (562)-552-2375 ext. 4245
FAX: (562)-552-4054; Email: lalarconl@ing.puc.cl
An on site training program on quality management and team work was used to educate
construction personnel in a construction company in the mining and industrial construction
market. The middle and upper management of the company was trained to identify non value
adding activities in their work environment, trace their sources and discuss actions to
eliminate or reduce their share in the construction process. This program was carried out
in 4 construction sites, located in mining sites in the north of Chile, and in the home
office of the construction company. A survey specially designed to identify waste, and
sources of waste was applied to about 100 persons which participated in the training
program in the different construction sites. A taxonomy of waste and its sources were
developed to analyze theses results. The most frequent waste types perceived in the
company are discussed and strategies to remove their causes were proposed.
Moving toward Construction JIT
Glenn Ballard
Adjunct Faculty
University of California
4537 Fieldbrook
Oakland CA 94619
Email: ballardz@euler.Berkeley.EDU
Tel: 510 530 8656
Greg Howell
Civil Engineering
University of New Mexico
Albuquerque, NM 87131
Email: howell@unm.edu
Tel: 208 726 1332
The potential benefits of JIT are the same for construction as for manufacturing; i.e.
reduction of production cycle times by reduction of in process inventories. However, the
application of JIT to construction differs substantially from its application to
manufacturing because of the greater complexity and uncertainty of construction.
Reduction of in process inventories reduces project durations, but must follow reduced
variation in the flow of materials and information. An approach to planning (Last Planner
System) is presented as a means for reducing variation, and thus allowing construction
JIT.
Research is proposed to further develop and verify the benefits of the Last Planner
System.
Pattern Transfer: Process Influences on Swedish
Construction from the Automobile Industry
Dr Jan Broechner
Associate Professor,
Head Construction Management Royal Institute of Technology S-100 44
STOCKHOLM, SWEDEN
Tel. no. +46-8 790 79 92
Fax no. +46-8 20 35 41
Email: BROCHNER@ce.kth.se
Sweden differs from other Nordic countries in having a large share of manufacturing
accounted for by automobile production. In this paper, it is shown that since the 1910s,
the process of manufacturing automobiles has served as a paradigm for process change in
Swedish residential and commercial construction. Government policies on construction and
joint action by the construction industry have been influenced explicitly by features of
the automobile design, manufacturing and marketing processes. Direct transfer and
influence has occurred in contractual relations between owners in the automobile industry
and contractors. Over the years, supplier relations or customer relations in the
automobile industry have formed patterns for changes in the construction process:
standardization of components for mass production, functional design logic, limited
customization, mass marketing and recently EDI links to suppliers.
Quality Assurance & Partnering - A lean partnership
Ian M. Eilenberg
Head, Construction Management Unit,
Dept. of Building & Construction Economics,
RMIT,
GPO Box 2476V, Melbourne Australia 3001.
Tel: 61-3-9660 3449
Fax: 61-3-96601939
Email:eilenberg@rmit.edu.au
In the 1950's and 60's in Australia there was a wide spread use of 'system engineering'
which attempted to streamline the way that companies carried out their business. Vast
quantities of paper was produced, with a form for everything. However it did not improve
productivity with respect to the construction project, where disputation, at all levels,
was reaching a new height of expertise, and volume. The establishment of the Institute of
Arbitrators in Australia, in the 1970's was as a result of the need to try and improve the
dispute settling skills of the practitioners. Most of the systems had been reduced to
waste paper.
In the 1990's, as a result of the continuing disputes between the clients and the
contractors, a prevention system was developed making use of social interaction and common
goals. This was given the title 'Partnering'. Yet it did not address the running of the
company itself.
Today there is specific pressure from the Australian Government (Work Smart) and simply
for commercial reasons to both improve the efficiency of the whole construction process,
on site and in the office administration, and to reduce unnecessary costs. Whilst not yet
at the levels of our American cousins, disputation generally only benefits the legal and
para-legal personnel involved. Certainly not the participants.
The use of a good Quality Assurance system and the implementation of Partnering, is now
seen as a relatively inexpensive partnership which will provide a total answer to the
problems that have afflicted the construction industry for so many years.
The Knowledge Process
Deborah Fisher
Associate Professor
University of New Mexico
Tel: 505 277 4929
Fax: 505 277 1988
Email: Dfisher@UNM.EDU
This paper examines the applications and limitations of constructability models
prepared for the Construction Industry Institute (CII) and The National Cooperative
Highway Research Program (NCHRP). The CII model addresses the constructability lessons
learned, processes of collection, analysis and implementation, resulting in a hybrid flow
model of "Best Practices." The NCHRP model utilizes a constructability review
process model using the IDEF technique superimposed on a generic department of
transportation project development process for implementation.
TQM the Nordic Way
Axel Gaarslev
Professor of Construction Management
Head of Department of Construction Management
Technical University of Denmark
Building 115, 2800 Lynby, Denmark
Tel: +45 45 93 66 33 (department)
+45 45 25 16 46 (direct)
Fax: +45 45 88 55 82
Email: ag@ifa.dtu.dk
In 1992 a Nordic group was founded. The group consists of thirteen contractors from the
Nordic countries - among these the largest firms - and four universities/research
institutes, one from each of the following countries: Norway, Sweden, Finland and Denmark.
The goal was to cooperate on improving the standing of both the companies and the research
organizations involved. In the last three years four main activities have been under way:
- Preparing a general development strategy for the companies involved.
- Ways to measure quality standing in the companies.
- Procedure for reengineering through benchmarking.
- Ways of measuring customers' satisfaction.
At the moment the two first activities are documented and will be reported in this
paper. The last two listed are still in progress and the results of the work will probably
be published in the spring of 1996.
The group is at the moment discussing the areas of cooperation for the next two years
and the following topics seem to be of common interest:
- Networking/partnering.
- Environmental management.
The work is performed in a number of small, mixed groups with contractors and
researchers reporting to a plenum at seminars.
Factors Affecting Project Success in the Piping Function
Greg Howell
Associate Professor
University of New Mexico
Albuquerque, NM 87131
Tel: 505 277 2328
Email: howell@unm.edu
Glenn Ballard
Adjunct Faculty
University of California
4537 Fieldbrook
Oakland CA 94619
Tel: 510 530 8656
Email: ballardz@euler.Berkeley.EDU
The flow of work in the piping function from engineering through installation is
examined to identify possibilities for improvement. Data shows that 1) project success
appears to be related to large pre-installation buffers of pipe, 2) the size of buffers is
not related to the extent to which a project is complex, uncertain, or quick, 3) project
success is not related to the extent to which a project is complex, uncertain, or quick,
and 4) work planning systems are unreliable. Two maps are offered which show the impact of
current project controls and contracting for fabrication practices on workflow stability.
Recomendations are offered for improving performance by sizing buffers to the extent of
uncertainty, improving planning system reliability and counteracting current system
dynamics.
Involvement of Customer Requirements in Building
Design - Pekka Huovila, Anitti Lakka, Petri Laurikka & Mikko Vainio
Pekka Huovila
VTT Building Technology
Leader of Research Group Project Planning and Building Design
PO Box 1801, 02044 VTT, Finland
Tel. + 358 0 456 5903 (mob. + 358 40 546 0855)
Fax. + 358 0 456 6251,
Email: Pekka.Huovila@vtt.fi
Customer orientation is becoming an important competitive factor also in construction
industry. Satisfying of varying needs of customers (clients, end-users or internal
customers) is setting new challenges also for building design. Success in making designs
for complicated "high tech buildings" by temporary project organizations may
require systematic working procedures and appropriate tools. Applicability of Quality
Function Deployment (QFD) method, that has been successfully practiced in industrial
product development projects, has been tested in a technology transfer project for
building design.
This paper presents essential findings of that project [1]. QFD was applied in three
construction projects as a team decision making tool to listen to the voice of customer to
achieve common understanding, consensus and commitment in design objectives and design
solutions. The results were encouraging: QFD, although requiring some "extra
work" compared to the tradition of having little customer involvement, provided a
systematic method for the analysis of the customer demands. It also resulted in some
design changes that were appreciated. Finally, some recent examples of further QFD
development and QFD integration are, as found from literature, briefly raised for
discussion: job sharing between the project team and functional departments (QFD &
QFD), functional decomposition and planning of design (QFD & DSM), and strategic
justification of computer-integration technologies (QFD & IDEF0).
Use of the Design Structure Matrix in Construction -
Pekka Huovila, Lauri Koskela, Mika Lautanala, Kari Pietiläinen, Veli-Pekka Tanhuanpää
Pekka Huovila
VTT Building Technology
Leader of Research Group Project Planning and Building Design
PO Box 1801, 02044 VTT, Finland
Tel. + 358 0 456 5903 (mob. + 358 40 546 0855)
Fax. + 358 0 456 6251,
Email: Pekka.Huovila@vtt.fi
The Design Structure Matrix (DSM) is a novel, powerful method for analyzing and
improving design processes, used successfully in product development projects. For
evaluating its usability in construction, the "as-is" design process of a fast
track office building project was modeled using the DSM representation. The method
provided a new, more efficient "should-be" sequencing of design tasks. When
analyzing the problems having occurred in design (monitored independently), it turned out
that the majority of problems are located in process parts less effectively sequenced, as
pinpointed by the method. Thus, the "should-be" solution would probably have
prevented a large share of problems. The paper ends with a discussion of potential uses of
DSM in construction.
Lean Construction: An Approach for Sustainable Growth - Antonio Sergio
Itri Conte
Abstract Pending
Lean Production: Goals and Achievements
Jan Eric Johnson
Arcona
Box 110
S-131 26
Nacka Strand, Sweden
Tel: 468 601 2100
Fax 468 601 2101
Email: jjn@arcona.se
Arcona is developing lean construction as a parallel to lean production as we know it
from other branches. 5 Year goals were set in 1994: 50% reduction of final assembly time,
and 30-40% reduction of fixed costs depending on project type.
A number of activities have been undertaken to achieve these goals. One of the most
important is the selection of and long term cooperation with strategic suppliers. Internal
resources are used for design for it is the most strategic supplier. Second, a network of
three companies covering installation was formed. Work against tough goals is now underway
together with operative goals and measurements.
Improvements can already be seen. Assembly times are substantially reduced, the degree
of prefabrication is higher, our building sites are clean with practically no stores, the
level of planning and control of all activities is very high, security in product quality
is raised and there is no doubt that costs are going down.
Rapid Construction as a Change Driver in Construction
Companies - Lauri Koskela, Petri Laurikka, Mika Lautanala
Lauri Koskela
VTT Building Technology
P.O.Box 1801, 02044 VTT, Finland
Tel: +358 0 456 4556
Fax: +358 0 456 6251
Email: Lauri.Koskela@vtt.fi
In this paper, time based management as an improvement method in a construction company
is considered. The outcome of a continuous drive for construction time reduction is called
Rapid Construction. The difference between Fast Tracking (where speed is a goal in itself)
and Rapid Construction (where speed is also used as a means to achieve other objectives)
is clarified. The theoretical and implementation issues of Rapid Construction are
discussed. The underlying theory is reviewed, the relevant methods analyzed, and suitable
measures presented. The impact of the economic environment on Rapid Construction is
analyzed. Then initial experiences from a project initiated by VTT Building Technology,
aiming at implementation guidelines of Rapid Construction, are presented.
A Process Approach to Design for Construction
Mika Lautanala
VTT Building Technology
P.O.Box 1801
FIN-02044 VTT, FINLAND
Tel. + 358 0 456 6814
Fax + 358 0 456 6251
Email: Mika.Lautanala@vtt.fi http://www.vtt.fi/
Production and construction requirements are often missed or misunderstood in design
stage due to separated design and construction. This causes waste: the product
specification is far from easiest possible to be build and it does not consider the
possibilities which suppliers' capability offers. Traditionally construction requirement
consideration is based on designers' personal experience.
The paper discusses requirements for a process which support consideration of
production requirements in design phases. Then a process to catch construction
requirements into the product specification is proposed. It implements principles of
concurrent engineering and supports continuous improvement. Finally future research needs
are discussed.
Ultra Fast-track Project Delivery
Bob Miles
Mechanical Engineer
IDC
2020 S.W. Fourth Ave, 3rd Floor
Portland, Oregon 97201
Tel: 503 423 3998
Email: rsmiles@ix.netcom.com
Ultra Fast-track design/construct methods are being developed and implemented by the
leading edge of the industry. Design firms, construction companies, equipment suppliers,
and facility owners are redefining the relationships needed to deliver built environments
that are among the most technically complex, in heretofore undreamt of short durations.
The partnering type relationships are designed to leverage the experience of past projects
and to forge long term business and personal relationships.
Project teams with members from each of the partner organizations move from project to
project. The decision making is generally by consensus building. Issues are resolved at
the lowest possible levels. Escalation of issues is possible, but looked upon as an
unfavorable option. Authority levels are built into the systems of the project. Since the
project monetary and psychological incentives are built upon common goals, cooperation and
creative problem solving results. The need for formal ADR processes, if at all, is to set
the framework for these already least desirable actions. Therefore, more times than not
the ADR methods grow from the project team structure, personalities, and management
styles. Many times they are undefined in written form, yet none the less exist. Any formal
form of dispute resolution (including presently held progressive Stepped ADR) is the last
resort. Each of the partners have to much at stake to even consider litigation.
Benchmarking, Best Practice - and All That
Dr. Sherif Mohamed
CSIRO Division of Building
Construction and Engineering
Post Office Box 56,
Highett, Victoria, Australia 3190
Tel: +61 3 252 6041
Fax: +61 3 252 6249
Email: SherifM@dbce.csiro.au
Benchmarking has been in use in various industries for many years. While there have
been many successes, its use has been rather limited in the construction industry. This
paper addresses the benchmarking concept and its application to construction and presents
a three-level framework for benchmarking current practice; internal, project and external
levels. Each benchmarking level is examined in detail with an illustration of the need to
adapt to improve the construction output. A generic definition of benchmarking is used
throughout the paper to ensure applicability to the different and many aspects of the
construction process.
Supply-Chains: Case Study and Integrated Cost and
Performance Analysis
Bill O'Brien
Civil Engineering
Terman Engineering 394
Stanford University
Stanford, CA 94305
Tel: 415 723 9685
Email: wjo@ce.stanford.edu
This paper studies supply-chain performance on a housing project located in Trondheim,
Norway. From this project, we develop a cost and performance model to determine the affect
of uncertain and changing conditions on cost and delivery schedule. This project-specific
model can be used as a basis for more general construction supply-chain models.
Characterization of Waste in Building
Construction Products - Alfredo Serpell, Adriano Venturi, Jeanette Contreras
Alfredo Serpell, Associate Professor
Department of Construction Engineering and Management
Pontificia Universidad Catolica de Chile
Casilla 306, Correo 22, Santiago, Chile
FAX: (562)-552-4054
Email: aserpell@ing.puc.cl
This paper will show statistics of productivity losses in approximately 40 buildings (6
to 15 stories). I am trying to relate these losses to their causes (known and probable)
and also to the stage of planning where they could have been prevented. The data is
collected with the model presented by Glenn Ballard in Santiago.
Limitation of the Use of Tolerances as a Means for
Stating Quality Requirements in Reinforced Concrete
David Seymour, Mazin Shammas-Toma, Leslie Clark;
School of Civil Engineering, University of Birmingham, B 15 2TT UK.
The paper reports an empirical study designed to establish the extent to which adequate
concrete cover to reinforcement in a sample of structures was achieved. It was found that
the standards fell significantly short of those specified. Two kinds of explanation are
considered to account for these findings. The first accepts as given the existing
conventions for specifying quality and looks to identify the reasons for non-compliance.
The second proposes that the conventions used for specifying the required cover are
inappropriate to the conditions of variability and uncertainty standardly met with in
construction. An alternative approach based on the concept of continuous quality
improvement is described and discussed.
Schedule Compression: A Case History
Peter Woodward
Consultant
11000 Candelaria Rd. NE #106 W
Albuquerque, NM 87112
Tel: 505 293 3840
Email: pnwati@swcp.com
A major schedule improvement was made through directed acceleration and careful
development of the project plan. The buyer's goal was to start up an industrial process.
So, we moved up commissioning, starting up the systems the buyer wanted first--before the
construction contract was completed. By accelerating mechanical and electrical rough-in,
we built up an "inventory" of "startable" equipment and systems.
Secondly, we studied our first commissioning sequence to learn how it was structured and
who was responsible for what. Then we planned it in fine detail, advancing it as far into
construction as possible. Third, we planned continuously, with special attention to the
"medium term", a three month horizon, which can be detailed with hard data. Most
planning was done on a one-to-one basis, then routed back to the source individual for
review so they knew they had planned their own work. The original planning schedule was
modified continuously by replacing general logic with more detail or adding new logic as
the job progressed.
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Updated 18.1.1996 by Lauri Koskela
