UC Berkeley UC Berkeley Electronic Theses and Dissertations Title TAKT TIME PLANNING AS A WORK STRUCTURING METHOD TO IMPROVE CONSTRUCTION WORK FLOW Permalink https://escholarship.org/uc/item/6dp4n4fz Author Frandson, Adam Gene Publication Date 2019 Peer reviewed|Thesis/dissertation eScholarship.org Powered by the California Digital Library University of California TAKT TIME PLANNING AS A WORK STRUCTURING METHOD TO IMPROVE CONSTRUCTION WORK FLOW By Adam Frandson A dissertation submitted in partial satisfaction of the requirements for the degree of Doctor of Philosophy In Engineering – Civil and Environmental Engineering in the GRADUATE DIVISION of the UNIVERSITY OF CALIFORNIA, BERKELEY Committee in charge: Professor Iris D. Tommelein, Chair Professor William C. Ibbs Professor Philip Kaminsky Professor Dana Buntrock Summer 2019 Everything we do in life requires the support of others, and I could not have completed this research without the support of my friends and family. Thank you to my wife for believing in me, supporting me, and for moving away from San Diego to the Bay with me. Thank you to my professors at San Diego State University for my undergraduate education and my professors at University of California on my committee for their guidance in my research and professional life. Thank you to all of the visiting scholars, past PHD students, current PHD students, and industry professionals with whom I have worked these past eight years. Last, thank you to my family and friends for truly believing in me and never batting an eye when I said 12 years ago that I wanted to obtain my doctorate from UC Berkeley. At that time, I didn’t know if I really even believed in myself, so it is only through their support that I am here today. This study was made possible in part by gift contributions from members of the Project Production Systems Laboratory (P2SL) at UC Berkeley. All support is gratefully acknowledged. Any opinions, findings, conclusions, or recommendations expressed in this report are those of the authors, and do not necessarily reflect those of individuals interviewed or contributors to P2SL. All support is gratefully acknowledged. i Takt time planning as a work structuring method to improve construction work flow ..................... I. Acknowledgments................................................................................................................... i II. Table of Contents ................................................................................................................... ii III. List of Figures ....................................................................................................................... ix IV. Glossary ..............................................................................................................................xv V. Abstract ................................................................................................................................1 Introduction ............................................................................................................1 Current Practice ................................................................................................................ 1 Problem Statement ........................................................................................................... 3 Research Scope ................................................................................................................ 3 Significance ...................................................................................................................... 3 Research Objective ........................................................................................................... 5 Research Questions .......................................................................................................... 5 1.6.1 Question 1: What does Takt time planning in construction look like? ........................ 5 1.6.2 Question 2: What are the barriers to designing continuous workflow of construction activities? .................................................................................................................................... 7 1.6.3 Question 3: What are the costs and benefits of using Takt time planning? .................. 8 Dissertation Structure ..................................................................................................... 11 Literature Review .................................................................................................12 Introduction .................................................................................................................... 12 Production Theory .......................................................................................................... 12 2.2.1 Transformation Theory of Production ........................................................................ 13 2.2.2 Flow Theory of Production......................................................................................... 13 2.2.3 Value Generation Theory of Production .................................................................... 14 2.2.4 TFV Theory of Production ......................................................................................... 15 Location-based Planning ................................................................................................ 16 ii 2.3.1 Introduction ................................................................................................................ 16 2.3.2 Line of Balance Scheduling ........................................................................................ 16 2.3.3 Location-based Management System ......................................................................... 27 2.3.4 Space Planning ........................................................................................................... 27 2.3.5 Week-beat Scheduling ................................................................................................ 29 Last Planner System ....................................................................................................... 31 Takt Time ....................................................................................................................... 33 2.5.1 Definition of Takt Time .............................................................................................. 33 2.5.2 Takt Time in Manufacturing....................................................................................... 33 2.5.3 Takt Time Planning in Construction .......................................................................... 33 2.5.4 Takt Time as a Work Structuring Method .................................................................. 35 2.5.5 Complements of Last Planner System and Takt Time Planning ................................ 39 Discussion ...................................................................................................................... 41 Conclusion ...................................................................................................................... 45 Research Method ..................................................................................................46 3.1.1 Introduction ................................................................................................................ 46 3.1.2 Design Science ........................................................................................................... 46 3.1.3 Action Research .......................................................................................................... 47 3.1.4 Case Study Research .................................................................................................. 47 3.1.5 Project Selection ......................................................................................................... 50 3.1.6 Simulation Modeling .................................................................................................. 52 3.1.7 Research Tools Required ............................................................................................ 53 3.1.8 Method Synthesis and Conclusion ............................................................................. 53 First Instantiation of Takt Time Planning ............................................................55 Introduction .................................................................................................................... 55 iii Takt Time Planning Process ........................................................................................... 55 Results ............................................................................................................................ 57 Lessons Learned and Open Questions ........................................................................... 58 Conclusion ...................................................................................................................... 58 Case Study 1: Mills Urgent Care Center ..............................................................59 Introduction .................................................................................................................... 59 Case Study Timeline ...................................................................................................... 59 Takt Time Development for Overhead MEP Rough-in Phase ....................................... 60 Takt Time Development for Inwall MEP Rough-in Phase ...........................................