Ain Shams Engineering Journal 12 (2021) 1153–1162

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Ain Shams Engineering Journal

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Architectural Engineering

A study of lean construction and visual management tools through

cluster analysis
Subhav Singh ⇑, Kaushal Kumar
Department of Civil Engineering, K R Mangalam University, Gurgaon, India
Department of Mechanical Engineering, K R Mangalam University, Gurgaon, India

a r t i c l e i n f o a b s t r a c t

Article history: There are various Lean tools available to increase the value of construction projects, this paper mainly
Received 18 January 2020 talks about the Visual Management tools that help in improving the efficiency and value of the construc-
Revised 1 April 2020 tion project. The methodology adopted for the study is to collect the data using structured survey on the
Accepted 19 April 2020
usefulness and importance of 12 lean tool and techniques identified from the literature review. A five
Available online 18 July 2020
point likert scale have been used for collection of data from pan India basis. A total of 153 valid response
were received and analysed using Excel spread sheets and SPSS 23 software. Reliability analysis, relative
Keywords:
importance index, cluster analysis were performed on the data collected. The findings of the study con-
Lean construction
Visual management
cludes that the most significant and important lean tool and techniques were Big rooms, 5S, LPS, and BIM
Construction management having a RII value of 92%, 91%, 90%, and 88% respectively.
Project management Ó 2020 The Authors. Published by Elsevier B.V. on behalf of Faculty of Engineering, Ain Shams University.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-
nd/4.0/).

1. Introduction Transportation Waiting [5] (see Figs. 1–7 and Tables 1–5).

The term Lean Construction is developed after the ground-

1.1. Visual management
breaking success of Lean concepts in the manufacturing industry
implemented by Toyota [1]. Lean Principles came into play after
The Construction industry is the much-fragmented industry
understanding the demerits/drawbacks of craft & mass production
where a large number of stakeholders are involved in every single
[2]. Lean Principles is all about reducing waste (Muda) and maxi-
project. The bad thing about this is not all the stakeholders travel
mizing the value [3]. The value mentioned here is the relation
together through the entire project, every contractor has their
between time, cost, quality and function [4]. To achieve this, the
own specialization and they will contribute their role towards that
perception of clients should be understood at the initial stage,
and leave the work to his following contractor. Hence a proper
which is mainly supported by 14 principles [5] and various Lean
communication and relation are not maintained among the
Tools. Talking about wastes, there are seven types of wastes identi-
involved stakeholders in the project, which ultimately leads to
fied, which acts as a hindrance for the successful completion of the
the decrease in value of the project [5]. The main moto of Visual
project. The identified wastes are
Management is to enhance the extensive flow of information
Rework
within the workplace and removing the barriers in the flow of
Inventory
information [6,7].
Over Production
In order to increase the value, these wastes should be identified
Processing Over Motion
and eliminated in the workplace. One of the effective tools for elim-
inating these wastes is Visual Management. Visual Management is
⇑ Corresponding author. a Lean Tool that makes important information visible to all. It
E-mail address: er.subhav@hotmail.com (S. Singh). shows the information through visual signals instead of texts,
which makes easier to understand for every stakeholder involved
in the project. The design should be displayed in an emphasized
manner so that it can be quickly grasped and communicated among
the stakeholders, in order to increase the efficiency, value, and clar-
Production and hosting by Elsevier
ity [8–10].

https://doi.org/10.1016/j.asej.2020.04.019
2090-4479/Ó 2020 The Authors. Published by Elsevier B.V. on behalf of Faculty of Engineering, Ain Shams University.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
1154 S. Singh, K. Kumar / Ain Shams Engineering Journal 12 (2021) 1153–1162
Fig. 1. Sample project performance chart.
Visual Management increases,
I. Communication
II. Transparency
III. Self-management Capabilities of the stakeholders [5,11].
The Visual Management helps one to know about 5W & 1H
(Who, What, When, Where, Why & How) within 5 min of examin-
ing the visual workplace. Visual Management Boards are kept in the
heart of the workplace, with all the relevant data in an updated
manner. Every day in the workplace, work starts with a 15-
minute meeting with the help of Visual Management Board, where
responsible employees are required to update the Visual Manage-
ment Boards before the start of the meeting, so that in meeting they
can decide what are the deliverables, constraints, demands etc., of
the project [12–16].
Another reason for practising Visual Management is everyone in
the workplace may not be familiar with a common language like
Fig. 2. Sample big room organizational chart.
Years
60
50
40
30
20
10
0
25-30 years old 31-40 years old 41-50 years old 51-60 years old Above 60 years
Fig. 3. Age demography analysis of the respondents.
English, so that any information displayed through the help of lan-
guages might not reach out everyone, in addition to this the time
taken by an individual in reading the information and understand-
ing them will be more, and we can’t assure that they had under-
stood the correct meaning that the management is trying to
convey through the displayed information. In order to overcome
these issues, Visual Management is practised in the workplace,
which helps to grasp the information in a faster and effective man-
ner [17–20].
Visual management makes the organization more transparent
[10,11,21] by making the information available to every stake-
holder involved in the project. Through visual management, all
the information that every stakeholder required to know is dis-
played so that it helps in increasing the self-management, as one
can go through the displayed information and understand the situ-
ation in an effective manner. Visual management also increases the
team coordination, as daily meetings were conducted including the
necessary stakeholders so that everyone can raise their own
demand to increase the value of the project and an effective solu-
tion can be drawn with the help of those meetings, it also helps
in increasing the relation/understandings among the involved
stakeholders. Visual management helps in maintaining better pro-
mises as a proper monitor is been kept on the schedule and neces-
sary timely steps are taken in order to prevent all possible risks and
delays associated with the project. The control for the management
is also made easier through visual management, as because the
workplace is very well organized with the help of visual manage-
ment tools. The workplace environment can be improved through
the help of visual management [10,11,21–23].
There are many Visual Management Tools available and some of
them are,
Numbers
70
60
50
40
30
20
10
0
North India South India East India West India
Fig. 4. Project location of the respondents.
 S. Singh, K. Kumar / Ain Shams Engineering Journal 12 (2021) 1153–1162 1155

Years
45
40
35
30
25
20
15
10
5
0
0-5 years 6-10 years 11-15 years 16-20 years 21-25 years Above 25
years

Fig. 5. Years of experience of the respondents.

Fig. 7. Cluster size.

1.1.1. Standard signs with specific colors (display boards)

Fig. 6. Model summary.
These are signboards with a combination of standard signs along
with specific colour. Some of the types of signboards are as follows,
Table 1.1 Sample Components and Purpose of Display Boards.

1.1.2. Colour coding

Standard Signs with Specific Colors (Display Boards) Colour
It is a reliable and efficient way to organize different items pre-
Coding
sent in the workplace and visually locate them if something is being
Visual Display of Data in the form of Graph 5S
misplaced, few examples are,
Augmented Construction Field Visualization BIM
Collaborative Process Mapping/LPS End Product Sampling
(1) Colour Coding for Pipes (Different colours for different pipes
Heijunka
based on their function, example Water pipes can be coded
Big Room
with blue colour)
(2) Coloured Sticky Notes or Colored Magnets are used in Visual
Signalling (Andon)
Management Boards like production boards in order to mon-
itor, track, notify and update the process and project status. A
Response Guiding (Kanban)
sample format is described below:
Mistake Proofing (Poka-yoke) [4]

Table 1
Sample components and purpose of display boards.

Purpose Sign Shape Colour

Communicating an Order Circle a. Red & Black on White (Prohibition) b. White on Black (Mandatory) Example:
a. Don’t Cross
b. Wear Helmet
Communicating a Warning Triangle a. Black on Yellow (Caution) b. White on Red Example:
(Danger) a. High Voltage Electricity
b. Danger for Life
Communicating an Information Rectangle a. White on Blue b. White on Green Example:
(General Information) (Emergency) a. Process Description
b. Fire Exit
1156 S. Singh, K. Kumar / Ain Shams Engineering Journal 12 (2021) 1153–1162

Table 2 Sort
Color coding.

< one week One – four weeks > one month Set in Order
Red Color Tag High Priority Shine
Yellow Color Tag Medium Priority Standardize
Green Color Tag Less Priority or Completed Sustain [30]

1.1.5. Augmented construction field visualization

Augmented Construction Field Visualization is all about project-
ing a 3D model of the proposed design of the upcoming structure
Table 3 with all functions in the proposed site with the help of a mobile
Type and purpose of graph and chart. device, virtual reality, etc., With the help of Augmented Construc-
Type Purpose
tion Field Visualization contractors can emphasize on the project
progress, method of execution to achieve the desired output. The
Line Chart To represent the nature of data over a period of time
Column Chart To compare the data in order to identify the performance
contractors can also motivate their employees and labours by dis-
playing the virtual prototype of the proposed structure which is
going to be stable in the future. So, the stakeholders will get a clear
picture of the structure which is going to be constructed. If any
changes are supposed to made by the client on seeing the output
Table 4
of Augmented Construction Field Visualization, it’s easy to make
Reliability analysis.
in this stage as not much manpower, the cost will occur in this
Cronbach’s alpha value No of attributes No of samples stage when compared to the execution stage [30–32].
0.869 12 153

(3) The successor can pull the information from the predecessor
by viewing the updated Visual Management Board. This
makes the entire workplace more transparent thereby elim-
inating the chances of delay in conveying of information and
moreover any of the stakeholders can understand the situa-
tion that is prevailing in the workplace by examining the
Visual Management Board for 5 min [24,25].
1.1.6. BIM
BIM is a 3D model which helps Architecture, Engineering, Con-
struction (AEC) professionals to plan, design and construct on a
common platform and manage them effectively. For example, a
software called Navisworks can take output from various software’s
like Revit, MEP consultants etc. and feed them in a common plat-
form where quantification can be done, clash detection can be done
which helps in sorting the errors in a design stage through effective
design, which ultimately results in increasing the value of the pro-
ject [33–35].

1.1.3. Visual display of data in the form of graph 1.1.7. Collaborative process mapping/LPS
Representing information’s in the form of numbers will be very Last Planner System is a holistic system, that involves the plan-
vague, it makes difficult for everyone to understand the data repre- ning team to prepare a plan for the work that needs to be per-
sented. Hence these data should be represented in the form of formed in the fore coming weeks. It has five major parts namely
graphs for a better and quick understanding [26,27]. Some forms
of graphs with their functions are listed below: Master Planning
Phase Planning
1.1.4. 5S Make Ready Planning
5S is a workplace organization technique, used for organizing Weekly Work
and setting up the quality of the workplace. It is a tool for cleaning, Planning Learning
sorting and arranging the workplace. 5S helps in improving effi-
ciency by eliminating waste [28,29]. 5S was initially developed in The planning team should be ready with the above-mentioned
Japan means plan/schedule so that the possible hindrances can be identified,

Table 5
RII value.

Sr. No. Sum of the scores Number of responses RII value Lean tools/technique
1 707 153 92% Big Rooms
2 693 153 91% 5S
3 689 153 90% LPS
4 671 153 88% BIM
5 659 153 86% Display Boards
6 651 153 85% Augmented Construction Field Visualization
7 648 153 85% Poka-Yoke / Mistake Proofing
8 641 153 84% Color Coding
9 632 153 83% Kanban cards
10 576 153 75% End Product Sampling
11 557 153 73% Andon
12 553 153 72% Heijunka
 S. Singh, K. Kumar / Ain Shams Engineering Journal 12 (2021) 1153–1162
and proper mitigation measure can be taken in order to perform the
work seamlessly thereby increasing the value of the project. The
LPS is also called as Pull Planning.
1.1.8. Heijunka
Heijunka helps in reducing overproduction, it helps in producing
according to the customer needs, which helps in the reduction of
inventories and facilities. This helps in increasing the value of the
project. Heijunka can be done with the help of LPS as the quantity
of inventory required is been determined with the help LPS and
that much inventory can be procured and stored in the facility if
required. Heijunka also promotes the Just in Time procurement
practice, which helps in reducing the facility space for storing the
inventories. This also reduces the risk of damages in the inventory
when stored in the facility [36,37].
1.1.9. Big room
The big room is an important lean tool were all the information
regarding the project is displayed with the help of display boards,
colour coding, LPS, everything is displayed there. Hurdle meetings
take place in the big room which is a 15-minute standup meeting,
where construction professionals come and discuss the problems,
schedule, cost etc., which they are facing in the site with the help
of the various visual tools displayed in the big room. The big room
helps to a greater extent in improving the efficiency of the project.
The big room is made available to all the respective stakeholders
and all the information about the project, LPS, status, the progress
of the project etc., every detail is made visible, so that the organiza-
tion becomes more transparent and risks can be avoided, resulting
in increasing the value of the project [36–38].
1.1.9.1. Andon. Andon is a visual aid which helps in throwing light
on areas where action to be taken. If any flaw is identified in a con-
struction process the work should be stopped and proper attention
should be given there so as to encounter the issue. This is done with
the help of caution lights in the place which is turned on when a
flaw is encountered. So that proper action can be taken by the
responsible or authorized person in order to stop further progres-
sion of the flaw and to mitigate the flaw [33,34].
1.1.10. Poka-Yoke
Poka-Yoke is also called a mistake-proofing. It helps in reducing
the mistake at the origin, rather than taking a mitigation plan after
encountering the risk. This helps in reducing the cost, time and
resources which is been incorporated to mitigate the risk. In other
words, poka-yoke is making sure that all attributes which are
required to start a process are readily available and a proper miti-
gation plan to mitigate if any risk arouses during the process. It
helps in preventing errors that are supposed to happen in a process
[30,33,35].
2. Literature review
Visual Management is a Lean Tool which mainly helps in
improving the efficiency of the construction if utilized effectively.
Communication is one of the main hindrances for improving the
value of the project, which can be improved through Visual Man-
agement and its tools. Visual Management helps in the seamless
flow of communication between all stakeholders by displaying
the necessary information in display boards. Other than communi-
cation, operation and process can also be controlled in real-time
with the help of Visual Management [1,23,30,33,35,39,40]. VM also
increases the project transparency, which eliminates almost all
1157
possible variations, abnormalities, wastes etc., thereby enhancing
the efficiency of the project [41].
There are various factors which can improve the efficiency of the
construction project. There are around 15 factors listed [42,41,4]. As
there are plenty of Visual Management Tools available in the Lean
house, the factors listed are clubbed under 9 groups because each
tool has a specific purpose to perform. The groups are namely,
Administration
Work Environment
Culture
Human Resource
Compliance
Management
Planning
Rework
Transparency
[4].
These factors can be enhanced with the help of Visual Manage-
ment. The success of Visual Management completely depends on to
what depth the stakeholders understanding interaction with Visual
Management tools. Visual management helps in increasing the
transparency of the workplace, it also helps in enhancing the self-
management by making the information available to all stake-
holder involved in the project. the visual management also
increases the plan percentage complete as it helps in working in
accordance with the commitments made by the organization
[17,29,31,42,43].
The control for the management is made easier and also the
workplace conditions were also improved as because of proper
alignment through the application of visual management tools [10].
Visual management helps in increasing the transparency, disci-
pline, job facilitation, continuous improvement of the project, orga-
nization, and its workplace [11]. it also helps in improving the
organizational performance by aligning & combining the organiza-
tional mission, vision, values, objectives etc. with the necessary
stakeholders, the process of work, work environment, etc. [11].
Visual management helps in maintaining the consistency among
all levels of the project, which helps in preparing an effective look-
ahead plan with underpinning the risks associated with them and
also the respective mitigation plan for those risks [23]. Unlike the
manufacturing industry, the construction industry is much frag-
mented and the number of stakeholders, clients involved in every
project is considerably very large. Moreover, all the contractors
won’t travel together in all the stages of the project. every contrac-
tor has their own specialization and they perform their task and
leave the next to their successors. Hence it’s very difficult to estab-
lish proper communication and relation between them which ulti-
mately leads to the decrease in the value of the project
[13,17,43,44]. hence in order to enhance the communication and
make the respective stakeholders about the situation prevailing in
the site every information is made visible to the stakeholders,
thereby making the organization more transparent [22].
3. Research methodology
The research methodology adopted for this study has used both
a quantitative and qualitative approach. The qualitative approach is
done through personal interviews with selected professionals and
employees, whereas the quantitative approach is done through reli-
1158 S. Singh, K. Kumar / Ain Shams Engineering Journal 12 (2021) 1153–1162
 S. Singh, K. Kumar / Ain Shams Engineering Journal 12 (2021) 1153–1162
ability analysis, RII (relative importance index), and cluster analysis
[45,46,4]. A typical flowchart of the research method is as follows,
Questionnaire Survey
3.1. Questionnaire survey process
3.2. Questionnaire format
For this study a structured questionnaire survey used and the
data is collected using both modes of data collection i.e. Online sur-
vey and on-site data collection using the hard copy of question-
naires. The questionnaire mainly divided into three parts:
1159
The introductory part, the main questionnaire using all the
attributed identified from the literature review, and lastly the feed-
back section about the questionnaire and the study.
The respondents were requested to provide their responses
about the applicability of Visual management tools on the horizon-
tal side and the factors were listed on the vertical side of the excel
spreadsheets of the questionnaire. on the basis of a Likert scale
ranging from 1 to 5, where
1 – Not Applicable
2- Less Applicable
3- Applicable
4- Highly Applicable
5 – Most Applicable
3.2.1. Sample size
The structured questionnaire survey has been shared with 725
people associated directly and indirectly with the Indian construc-
tion industry. The population selected for the study is the mix of
professionals working with contractors, developers, PMC’s, inde-
pendent consultants, government bodies, and academic profession-
als working in the same field. A total of 153 complete and valid
forms were received with a response rate of 21%.
4. Data analysis and results
The data from the collected questionnaire were extracted and
analyzed with the help of Microsoft Excel. Comparing the value
increasing factors and the listed tools from the received data, the
following result is drawn.
4.1. Reliability analysis
Years of experience of the respondents
4.2. Relative importance index (RII)
RII is one of the best tools to analysed and prioritise the set of
attributes on the basis of their weighted average values. RII is very
much useful in defining the attributes and giving them the value on
the basis of the Likert scale values given by the respondents. RII
have been used in project management and construction manage-
ment by a number of researcher and it is highly reliable to predict
the most important attributes from a list of attributes [47–53].
4.2.1. The most significant lean tool/techniques
The most significant lean tool and techniques based on the RII
value were Big rooms, 5S, and LPS having a RII value of 92%, 91%,
and 90% respectively.
4.2.2. The significant lean tool and techniques
The significant lean tool and techniques based on the RII value
were BIM, Display boards, and Augmented Construction Field Visu-
alization having a RII value of 88%, 86%, and 85% respectively.
4.2.3. The least significant lean tool and techniques
The significant lean tool and techniques based on the RII value
were Poka-Yoke / Mistake Proofing, Color Coding, Kanban cards,
End Product Sampling, Andon, and Heijunka having a RII value of
85%, 84%, 83%, 75%, 73%, and 72%respectively.
4.3. Two-step cluster analysis
Cluster analysis have been used for the current study because of
its benefits to partition the data on the basis of explorer tree anal-
ysis within the data. This technique used on a group of data set
1160 S. Singh, K. Kumar / Ain Shams Engineering Journal 12 (2021) 1153–1162

Fig. 8. Predictor importance.

which is closely inherent and homogeneous with other attributes of proposed 6 clusters. The cluster quality is fair refer the model sum-
the group. For this study the cluster analysis has been performed mary figure).
using SPSS 23.
Out of 12 attributes the first six as attributes has been selected
4.3.2. Cluster sizes
on the basis of their a value and two step class train within the
The two step clustereing proposed 6 clusters. The size of the lar-
groups has been performed [54–58].
gest cluster is 32.9%, and the smallest cluster is 3.9%.

4.3.1. Model summary cluster analysis 4.3.3. Predictor importance

The model summary of cluster analysis is having six input vari- The predictor importance is clearly demonstrate the importance
ables (highest ranked attributes on the basis of RII value), and it of BIM and shows that it is having a value of 1, followed by Aug-

Fig. 9. Cluster sizes.

 S. Singh, K. Kumar / Ain Shams Engineering Journal 12 (2021) 1153–1162
mented Construction Field Visulaization, and 5S. Fig. 8 predictor
importance
4.3.4. Clusters on the basis of inputs
Fig. 9 cluster sizes
5. Conclusion
The application of visual management is gaining its presence in
the construction industry due to its value increasing the potential
of the project. but still many of the sites lack visual management
due to lack of knowledge about visual management, they were
not aware of the pros of visual management and its role in increas-
ing value to the project and benefiting the organization. Through
visual management we can achieve a barricade less communication
i.e. one-piece flow (flow of information between the respective
stakeholders without any break or hurdles), the transparency of
the organization will be increased as there is no blockage in the
information sharing, the information grasping capacity of the
stakeholders is increased as all the necessary data of the project
is made visible to all the stakeholders in the project so that they
can examine the displayed data in display boards and understand
the situation, and act accordingly. Work becomes easier with the
help of visual management because the entire workplace remains
organized with the application of visual management tools and
the workplace to remains clean and tidy. The studies on visual
management are found to be lesser-known topics that would con-
tribute to the lean community if pursued. Hence I conclude by say-
ing that visual management helps a lot in enhancing the value
increasing factors of the construction sites. There are plenty of lean
visual management tools available in the industry, each having
their own characteristics like 5S is used for organizing the work-
place, BIM for a 3D view of the entire plan, etc. Visual management
1161
will contribute a lot to the construction industry in the future, as
contractors are nowadays becoming aware of visual management
and its role in increasing the value of the project.
The most common visual management tool used in the Indian
construction industry is 5S, Display Boards, Color Coding, Kanban
Cards, and Big Room. The Big room itself consists of other tools like
Display Boards, Color Coding Kanban Cards. Heijunka is the lesser-
known tool among the available visual management tools, which
will contribute more to the increasing value of the project if uti-
lized/implemented properly.
The findings of the RII validate the fact that the use of BIM is not
that much popular among the construction industry professional as
a Lean toll, on the other hand the finding of cluster analysis tells us
that importance of BIM over all other tools and techniques. In the
predictor importance it shows the highest impact on all other Lean
tools with a predictor value of approx. 1.
5.1. Recommendations
Use of Heijunka visual management tool can be encouraged, it
helps in increasing the value of the project by reducing the inven-
tories and facilities.
Big Rooms is always equipped with other visual management
tools like display boards, colour coding, LPS, Kanban cards etc.
Motivational factors for employees like identification of best-
performed employees and displaying their achievement in the dis-
play boards and making them visible among other employees
which encourage others to perform well.
Proper training of every stakeholder about the available visual
management tools and making them aware of their functions and
outcomes on their application.
Appendix A
1162 S. Singh, K. Kumar / Ain Shams Engineering Journal 12 (2021) 1153–1162

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