LCM® Takt Planning in Building Construction September 26 -27, 2017, UC Berkeley Clark Kerr Campus Patrick Theis Agenda – LCM® Takt Planning in Building Construction LCM® Simulation – Day 1 Time Subject Expert 9:00 – 9:15 am Welcome and Introduction Iris & Samir Challenges in projects and the potential of Lean Construction with emphasis on 9:15 – 9:45 am Samir, Iris, Patrick Takt planning 9:45 – 10:00 am Coffee Break 10:00 – 12:00 am Simulation Round 1 - The traditional project approach Group activity 12:00 – 1:00 pm Lunchbreak 1:00 – 1:30 pm Takt planning Introduction Patrick Production Planning Step 1 – Overall Process Analysis Presentation and 1:30 – 2:30 pm Patrick Workshop 2:30 – 2:45 pm Coffee & Dessert Break Simulation Round 2 - Optimized construction sequence with elimination of 2:45 – 3:45 pm Group Activity waste and adapted process sequence played in the LCM Simulation 3:45 – 4:30 pm Production Planning Step 2: The Process and Takt Planning Presentation Patrick 4:30 – 5:00 pm Wrap up of the day and discussion Samir, Patrick 2 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis Agenda – LCM® Takt Planning in Building Construction LCM® Simulation – Day 2 Time Subject Expert 9:00 – 9:15 am Summary of Day 1 Samir, Patrick Production Planning Step 2: The process and takt planning presentation and 9:15 – 10:30 am Patrick workshop 10:30 – 10:45 am Coffee Break Production Planning Step 3: The Detailed Takt Planning Board on site 10:45 – 12:00 am Group activity Presentation and Workshop 12:00 – 12:45 pm Lunchbreak 12:45 – 1:15 pm Takt Planning with vPlanner (Overview) Samir 1:15 – 2:00 pm Simulation Round 3 – Takted production plan on site Group Activity 2:00 – 2:15 pm Coffee & Dessert Break Takt presentations by Dan Murphy (Turner) – 20 Min 2:15 – 3:15 pm Dan, James & Patricia James Pease (Sutter) – 20 Min Patricia Tillmann (UCSF) – 20 Min 3:15 – 3:45 pm Takt planning for None Repititive Work & the Work Density Method Iris 3:45 – 4:30 pm Open discussion and Takt Planning and its application to projects All Speaker 3 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis “Progress in the construction sector has not only stopped, it has gone backwards.” The Empire State Building Completion time: 1 year and 45 days (1930-31) ▪ Is such a project realistic nowadays? ▪ The Economist magazine on waste in construction processes: ▪ 30% rework ▪ 60% wasted workforce ▪ 10% wasted material 4 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis Challenges in projects: overview ▪ traditional approach in project management ▪ complex schedules ▪ complexity and intangibility ▪ teams/subcontractors and their special interests ▪ special characteristics fragmentation uniqueness change ▪ what is really the focus 5 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis Agenda – LCM® Takt Planning in Building Construction LCM® Simulation – Day 1 Time Subject Expert 9:00 – 9:15 am Welcome and Introduction Iris & Samir Challenges in projects and the potential of Lean Construction with emphasis on 9:15 – 9:45 am Samir, Iris, Patrick Takt planning 9:45 – 10:00 am Coffee Break 10:00 – 12:00 am Simulation Round 1 - The traditional project approach Group activity 12:00 – 1:00 pm Lunchbreak 1:00 – 1:30 pm Takt planning Introduction Patrick Production Planning Step 1 – Overall Process Analysis Presentation and 1:30 – 2:30 pm Patrick Workshop 2:30 – 2:45 pm Coffee & Dessert Break Simulation Round 2 - Optimized construction sequence with elimination of 2:45 – 3:45 pm Group Activity waste and adapted process sequence played in the LCM Simulation 3:45 – 4:30 pm Production Planning Step 2: The Process and Takt Planning Presentation Patrick 4:30 – 5:00 pm Wrap up of the day and discussion Samir, Patrick 6 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis The LCM simulation 7 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis What is waste? What is Waste is anything beyond the absolute Waste? minimum resources needed to add value to a product or service 8 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis Simulation Round 1 The traditional project approach Simulation Waste identification 9 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis Agenda – LCM® Takt Planning in Building Construction LCM® Simulation – Day 1 Time Subject Expert 9:00 – 9:15 am Welcome and Introduction Iris & Samir Challenges in projects and the potential of Lean Construction with emphasis on 9:15 – 9:45 am Samir, Iris, Patrick Takt planning 9:45 – 10:00 am Coffee Break 10:00 – 12:00 am Simulation Round 1 - The traditional project approach Group activity 12:00 – 1:00 pm Lunchbreak 1:00 – 1:30 pm Takt planning Introduction Patrick Production Planning Step 1 – Overall Process Analysis Presentation and 1:30 – 2:30 pm Patrick Workshop 2:30 – 2:45 pm Coffee & Dessert Break Simulation Round 2 - Optimized construction sequence with elimination of 2:45 – 3:45 pm Group Activity waste and adapted process sequence played in the LCM Simulation 3:45 – 4:30 pm Production Planning Step 2: The Process and Takt Planning Presentation Patrick 4:30 – 5:00 pm Wrap up of the day and discussion Samir, Patrick 10 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis Lean is about identifying and eliminating problems Problems are often covered by increase use of resources - Lean Management helps to identify and eliminate the causes Traditional approach Lean Management Capacity and time Problems Problems Problems Problems Many resources are used to Create transparency – Problems have been cover problems Reduce water reduced or eliminated CIP* Problems are Problems Causes are permanently hidden! become visible/clear! eliminated! *CIP = Continuous Improvement Process 11 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis Lean principles: the Toyota production system Profit increase Optimizing cashflow Flexibility Cost Reduction Staff Quality Flow principle Levelling Pull-system Zero defects as per Client‘s (one-piece flow) & Takt planning principle Request Visual Management 5S Kaizen Waste reduction (in terms of „Muda“) Standards Staff qualification 12 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis Lean principles: the flow principle By „value stream“ we understand all activities (both, value-adding and non- value adding) which are necessary to produce a product or deliver a service ▪ The production flow from raw materials to delivery ▪ The development from product concept to start of production 13 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis Lean principles: customer takt time The customer rhythm is the average time in which a finished unit exits a value system ▪ The takt time is the rhythm of customer demand. ▪ The takt time indicates how much time a particular activity should take in order to meet customer demand in time. Customer needs Production Equalisation Takt! Takt! Takt! Fluctuations Production on Takt Customer call-offs Customer takt cycle time 14 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis Lean principles: pull system „produce only what is needed, only when it is needed and only in the amount needed“ Toyota ▪ Modern productions are designed as a pulling system. Based on the customer's order the production process is scheduled and controlled ▪ This ensures that only what the customer really wants is produced in the required quantity ▪ Usually the system controls itself, there is no additional coordination effort required 15 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis Lean principles: zero defects A quality check is carried out on each process. There are no faulty or unfinished units transferred to the next process ▪ Accept no error ▪ Make no mistakes ▪ Pass down no fault ▪ Direct feedback and troubleshooting to find root of problem ▪ Introduction of standards and error prevention (Poka-Yoke) ▪ Errors are promptly made transparent and are resolved 16 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis The aim of takt planning is to achieve a constant workload and performance throughout the entire duration of the project ▪ The aim of the takt planning is a constant workload and performance troughout the entire duration of the project ▪ This avoids “last minute actions” & “Firefighting” at the end of the project From the acceleration of production ... towards daily goals or goals at the At the end of the project ... end of a shift Planned Performance Aim of the Project Planned Performance Aim of the Project Daily Goals 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 Weeks Weeks 17 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis The transformation begins with the modification to a process train ▪ From a “chaotic train” with high latency times, stockpiles and inflexible wagons which run with different speed, overtake or block each other… ▪ … towards to a “process train” which consists of wagons that run at the same speed and thus accident- free. No buffers are needed! 18 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis The takt time is determined and recorded on the construction site using the planning board ▪ The workload of a project is optimally balanced. The cycle time of a team (“required time”) corresponds to the takt time. ▪ Results of different cycle times: Aim takt time („available time“) cycle time („needed time“) Latency or Overtime or additional Constant load overproduction staff 19 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis At Drees & Sommer we define Lean Construction Management as follows „Lean Construction Management (LCM) is an innovative tool for smooth site processes free of obstacles. The simple and clear production system for the site achieves a stability and acceleration that usually is not achievable “ 20 September, 26 - 27 , 2017, LCM Simulation, Patrick Theis Lean Construction Management – LCM Agile Project Delivery Design to Build to Targets Lean Design Targets Production Management ▪ Agile Design Management ▪ Modularisation ▪ Lean Site Management ▪ Target Value Design (TVD) ▪ Takt Analysis and Takt Planning ▪ Building Information Modelling ▪ BIM on Site (BIM) ▪ Lean Site Logistics and Supply Chain Product Management Definition ▪ Standardisation and Prefabrication ▪ Lean Commissioning Design Construction Com.