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Learning To See Work Flow - An Application of Lean Concepts To Precast Concrete Fabrication
Learning To See Work Flow - An Application of Lean Concepts To Precast Concrete Fabrication
Learning to see work flow: an application of lean concepts to precast concrete fabrication
Glenn BallardNigel HarperTodd Zabelle
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To cite this document:
Glenn BallardNigel HarperTodd Zabelle, (2003),"Learning to see work flow: an application of lean concepts to precast
concrete fabrication", Engineering, Construction and Architectural Management, Vol. 10 Iss 1 pp. 6 - 14
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Low Sui Pheng, Choong Joo Chuan, (2001),"Just-in-time management in precast concrete construction: a survey of
the readiness of main contractors in Singapore", Integrated Manufacturing Systems, Vol. 12 Iss 6 pp. 416-429 http://
dx.doi.org/10.1108/EUM0000000006107
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Peter Hines, Matthias Holweg, Nick Rich, (2004),"Learning to evolve: A review of contemporary lean thinking",
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dx.doi.org/10.1108/01443570410558049
Thaís da C.L. Alves, Colin Milberg, Kenneth D. Walsh, (2012),"Exploring lean construction practice, research,
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(5) The overall work flow through the factory Figure 2 Malling make ready process
was structured around a decoupling
buffer[7] (Figure 1) in response to low
demand reliability from projects. Precast
elements (walls, beams, columns, etc.)
were made ready in accordance with
project programmes, but were released to
the factory floor for actual production
when triggered by a call off, a specific
request for delivery made seven calendar
days prior to need.
(6) After it was observed that drawing errors
were common and that as much as a
week's production was often required
before achieving production quality and
quantity targets on new designs, steps
were taken to ensure adequate review of
drawings for accuracy and buildability
prior to assignment for production. The
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8
Learning to see work flow Engineering, Construction and Architectural Management
Glenn Ballard, Nigel Harper and Todd Zabelle Volume 10 . Number 1 . 2003 . 6-14
(7) Workforce supervision was engaged in Plate 1 Shear walls production cell
leadership of factory restructuring.
(8) Direct workers were engaged in the
restructuring of cell production processes
(described in the next section).
(9) A quality of work life (QWL) council was
formed to periodically evaluate
orderliness, safety, and working
conditions and to recommend
improvements. The QWL council charter
was to conduct site evaluations bi-weekly,
make changes within the power of council
members to improve QWL, and advise
management regarding changes beyond
council member powers. Quality of work
life includes safety, orderliness of working
areas, and the conditions in which
workers work, take breaks, move on and placed rebar mats in moulds. Steelfixers
off the job, etc. It also includes cultural (reinforcing ironworkers) kept three mats
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issues such as managerial practices and tied and ready for placement. When a mat
reward system issues; e.g. the extent to was taken, they tied another. This pull
which individuals are encouraged to make mechanism prevented build up of work-in-
suggestions and the extent to which those process inventory, keeping cycle times low
suggestions are taken seriously. The site and increasing cell robustness and flexibility.
evaluation process consists of examining Once ready for concrete, moulds were filled
each production cell and other areas of immediately, as opposed to the previous
the site and evaluating each by
practice of batching pours late in the day.
completing an evaluation form. Charts
The new system produced three shear walls
are prepared and posted by management
in every three hour period because three
so all plant workers can see the council's
individual walls proceeded through each of
QWL evaluation and how it improves or
the process steps in each of those three hour
deteriorates over time. The QWL council
periods. Further, work flow was controlled
consists of four to five people at a time,
locally, by the workers in the cell, each of
rotating at least every two months, drawn
whom learned to ``see'' how the entire system
from production cell leaders and other
members of the workforce. was performing.
Although workers in the production cells
were not given a choice about whether or not
to change how work was done, they were
Structuring production cells
given a voice in deciding how to make the
In February 2001, experiments were changes that had been determined by
performed in two production cells, shear walls management. Prior to implementation of the
and nap Ts, to demonstrate the feasibility and new production system design in the cell, a
benefits of lean production concepts, meeting was held with all cell workers to
including one piece flow and pull. Plate 1 explain the plan, to go through a learning
shows the shear wall cell and a mould being exercise intended to communicate lean
prepared for filling with concrete. concepts (Airplane Game ± details available
A process flow chart for the shear walls at: www.leanconstruction.org) (Plate 2), and
production cell, shown in Figure 3, reveals to solicit their agreement to the following
the new flow oriented design of that guidelines, observance of which would move
production system, which then served as a each cell towards self management:
model for other cells[8]. Redesign began by . follow the sequence;
structuring for that output rate demanded by . inspect your own work;
the client project, which needed to have nine . do not get more than one step ahead of
shear walls delivered each day for an your ``customer'' ± do one at a time;
indefinite period. Three two-person teams . help others maintain workflow;
9
Learning to see work flow Engineering, Construction and Architectural Management
Glenn Ballard, Nigel Harper and Todd Zabelle Volume 10 . Number 1 . 2003 . 6-14
Plate 2 Workers playing the airplane game . move inventoried materials to the
workplace to reduce unnecessary
movement and material handling;
. acquire additional trailers needed to ship
the increased number of shear walls
produced each day;
. clear the work area; and
. get additional chains for the overhead
crane.
Results achieved
. a third of a day (varying somewhat the production cells where the initial
with transport distance) to strike, experiments were performed, i.e. NAP Ts
load, and deliver. and shear walls.
(2) The shear wall production cell had (6) A number of actions and changes
previously averaged 3.2 walls per day, with signaled a shift in management
12 workers. In the first week the new philosophy toward employee involvement
structure was used in the cell, the number of and empowerment; specifically:
workers was increased to 14 and an average . formation of the Quality of Work Life
of six walls per day was achieved. That Council and immediate action on its
amounts to a productivity improvement of first recommendations;
59 per cent. By the third week, the number . involvement of factory personnel in
of workers was back down to 12 and design and implementation of
average daily output was nine, an increase process improvements; and
in productivity from the pre-experiment . making direct workers responsible for
level (3.2/day) of 181 per cent. controlling work flow within their
(3) The Ts production cell was restructured production cells.
in a very similar way, resulting in an (7) Production system robustness was
improvement from a baseline of nine Ts increased in direct consequence of
per day to 18 Ts per day, an increase in reducing cycle time. The ability to rapidly
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productivity of 100 per cent. No change recover from disruption was illustrated
was made in the number of workers. during the Malling experiment when a
(4) One piece flow and pull concepts were shear wall element had been mismarked
rapidly extended to other production and sent to a project for erection. The
cells. In consequence, factory throughput project discovered the error, alerted
as measured by revenue, shown in Malling, which was able to fabricate and
Figure 4, changed from an average weekly deliver the correct element the next day, a
rate of £130,000 sterling prior to consequence of having radically reduced
February 2001 to an average weekly rate the manufacturing cycle time[9] within
of approximately £260,000 sterling the factory. Since the factory production
afterwards, with an increase in workforce schedule is fixed only one day in advance,
from 115 to 122. it was not necessary to ``break in line'' in
(5) Quantitative measurements of quality order to react so rapidly. In fact, nothing
were not available at that time, however, unusual was required at all. The day's
construction sites reported an release to the shear wall production cell
improvement in quality, specifically from simply included the needed element in
11
Learning to see work flow Engineering, Construction and Architectural Management
Glenn Ballard, Nigel Harper and Todd Zabelle Volume 10 . Number 1 . 2003 . 6-14
first position, ensuring that it would That is true for Malling and for fabrication
emerge first from the manufacturing systems in general. The relevant production
process. No orders were interrupted or systems in the Malling case include:
delayed, no additional resources were . the factory-plus-project production system;
expended. The system recovered from the . the factory production system; and
upset and returned to normal. . the individual cell production systems.
(8) Continuous improvement was
Making work flow smoothly and reliably is the
successfully launched.
first step in performance improvement at
Additional improvement initiatives are every level in the production system complex.
underway at Malling, including: For example, demand reliability on the
. Make demand more reliable by factory is a function of the lead time and
application of work flow control to quality of requests for delivery received from
O'Rourke projects. its customer, the construction sites.
. Train workforce to be multiskilled and The secret to making work flow reliable is
possibly uplift pay for each additional skill for the people doing the work to control work
acquired. flow, rather than relying on schedules or a
. Fully implement 3D CADD (the boss to tell them what to do next. Without
software they intend to use is IDEAS changing how rebar was cut or bent, how
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They came to understand that resource that are types of fixed position manufacturing;
utilization and production rates are functions where workers move through the partially
of production system design and control and completed product rather than vice versa.
that, consequently, designing the system for However, in this initiative, techniques such
flow and empowering workers to control work as one piece flow and pull were also applied.
flow is decisive. Substantial improvement in performance can
To what extent can this approach and be achieved through the application of these
results be duplicated in other fabrication lean production concepts and techniques to
processes? Fabrication shops often have fabrication of standard and semi-standard
multiple flows, at least some of which can be products such as structural precast walls,
structured as line flows with fixed processing beams, and columns. The key is to restructure
sequences, and so can directly apply and control production with attention to work
techniques such as one piece flow and pull, as flow rather than to resource utilization.
illustrated in the Malling experiment. Even Even though some fabrication and assembly
though the individual structural precast processes cannot be structured as line flows,
elements moving through the Malling factory they can still be improved through designing
tended to be different one from another, they and controlling those processes for value
all went through the same sequence of generation and waste reduction[11]. Research
processing steps. If elements can be mixed to is now under way exploring various types of
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yield a stable average processing duration over engineered-to-order products to see what
a relatively short time period, then lean concepts and techniques can help reduce lead
production techniques can be applied to such times and achieve other performance
``semi-standard'' products. For example, improvements that increase customer and
stakeholder value, while minimizing waste.
sheet metal shops can structure the
fabrication of straight run duct as a line flow
(Holzemer et al., 2000). Whether or not some
or all of duct fitting fabrication can be Notes
structured as line flows is under investigation.
1 Lead time and cycle time reduction are central to
Included in the IGLC research initiative the success of the Toyota production system (Ohno,
previously mentioned are: 1988; Shingo, 1992). The term ``lean production''
. Precast concrete. was coined by a member of the research team
whose work is reported in Womack et al. (1990).
. HVAC sheet metal duct.
Goldratt and Cox (1986) also developed major
. Plumbing. elements of his production management thinking
. High purity piping. around lead time reduction and shortened cycle
. Industrial piping. times. For current thinking on the role of lead time
. Pipe supports. reduction in product development and
manufacturing, see Thomke and Reinertsen (1998)
. Structural steel. and Lin and Hui (1997) respectively.
. Curtain wall. 2 Last planner is a hierarchical planning and control
. Elevators. system designed for dynamic projects. Last planner
. Switchgear. can be summarized in the following general principles:
. Limit master schedules to major milestones and
who would like to collaborate in this area of (typically) six week lookahead, screen for
constraints, and advance only if constraints can
research are invited to contact the first author. be removed in time.
. Try to make only quality assignments; i.e.
interdependence and uncertainty in construction, 2nd ed., Management & Organization Series,
see Crichton (1966). McGraw-Hill International Editions, New York, NY,
4 For another ``lean'' approach to fabrication shop p. 698.
improvement, see Skinner (1999). Howell, G. and Ballard, G. (1999), Design of Construction
5 For more on managing by means versus managing Operations, Lean Construction Institute White Paper
by results, see the work of H. Thomas Johnson, No. 4, Ketchum, Idaho, p. 9, available at:
especially Johnson & BroÈms (2000). www.leanconstruction.org
6 5S is a set of practices employed in manufacturing Johnson, H.T. and BroÈms, A. (2000), Profit Beyond
facilities to organize the physical workplace, often Measure, The Free Press, New York, NY, p. 256.
in preparation for changes in process. Koskela, L. (2000), ``An exploration towards a production
7 One of the primary functions of inventory is to theory and its application to construction'',
buffer against work flow variability. For a study of PhD dissertation, Helsinki University of Technology,
inventory buffers in sheet metal fabrication, see Helsinki, p. 296.
Tommelein and Weissenberger (1999). Lin, Z. and Hui, C. (1997), ``Adapting to the changing
8 The flow chart is modeled after Toyota's materials environment: a theoretical comparison of decision
and information flow diagrams. For details, see making proficiency of lean and mass organization
Rother and Shook (1998), who use the term ``value systems'', Computational & Mathematical
stream maps''. Organization Theory, Vol. 3 No. 2, pp. 113-42.
9 Manufacturing cycle time is the time it takes for a Ohno, T. (1988), The Toyota Production System: Beyond
product to be transformed from raw material to Large Scale Production, (Ohno, T. with Mito, S.,
finished product. In this case, the starting point is translated by Joseph P. Schmelzeis), Productivity
release of an element to the factory for production. Press, Cambridge, MA, p. 124.
Lead time is that amount of time in advance of Rother, M. and Shook, J. (1998), Learning to See: Value
Stream Mapping to Add Value and Eliminate Muda,
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14
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