23rd International Conference of the TOC Practitioners Alliance - TOCPA www.tocpractice.com
21-22 March, 2016, Tennessee, USA
CCPM and Lean Construction
Nerius Jasinavicius, TOC sprendimai, Lithuania March, 2016
Nerius Jasinavicius
• • • • •
Founder of TOC sprendimai Founding Member of TOCPA Consultant for unique clients TOCICO certified SC, TP Certified Management Consultant (ICMCI)
[email protected]
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
Typical Construction environment • • • • • • • •
Lots of stakeholders High degree of uncertainty Delays Chaotic project meetings on sites Big staff turnover Waves of activities Looks like nobody keeps promises Distrust (Not-Me mentality) • Clients look for the ways not to pay • Very low cooperation between client, architects and contractors
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
The challenge In today‘s business management world there are so many buzzwords the best and only really working methodologies: • LEAN • SixSigma • TPS • TOC • WBS • Etc…… www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
What is Lean Construction
• Lean Design and Construction is a production management-based approach to project delivery -- a new way to design and build capital facilities. • Lean Construction extends from the objectives of a lean production system - maximize value and minimize waste to specific techniques, and applies them in a new project delivery process. Source: www.leanconstruction.org
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
Lean Construction elements • Integrated Project Delivery (IPD) is a registered business mark by Lean Construction Institute. Primary IPD team members include the architect, key technical consultants, general contractor and key subcontractors. Using IPD, project participants can overcome key organizational and contractual problems. The IPD approach to contracting aligns project objectives with the interests of key participants. • Lean Construction’s main tool for making design and construction processes more predictable is the Last Planner System® and it’s derivatives.
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
Last Planner® •
•
The Last Planner® (sometimes referred to as the Last Planner® System) is a production planning system designed to produce predictable work flow and rapid learning in programming, design, construction and commissioning of projects. The five elements of the Last Planner®: • Master Scheduling (setting milestones and strategy; identification of long lead items); • Phase "Pull" planning (specify handoffs; identify operational conflicts); • Make Work Ready Planning (look ahead planning to ensure that work is made ready for installation; re-planning as necessary); • Weekly Work Planning (commitments to perform work in a certain manner and a certain sequence); and • Learning (measuring percent of plan complete (PPC), deep dive into reasons for failure, developing and implementing lessons learned). Source: www.leanconstruction.org
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
Start of the project
• Company (sub-contractor) has been warned twice by General Contractor • REAL CHANCE of loosing the contract (and all consequences) • Typical solutions (over-time, more resources, etc.) did not work
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
What is necessary for successful construction project • We know what is the final product/result • Deliverables • We know what is necessary for the final product/result • Bill of Materials • Technology • Resources • We have a sound plan • We execute the plan
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
Do we know what is the final product/result ? • The answer was Kind of … • Let’s spend some time on really understanding what should be the result • Yes, but … it’s risky (!!!)
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
Do we know what is necessary for the final product/result ? • The answer was Kind of … • Now we know the final product, let’s build WBS and Master Schedule • We cannot have all the specifications now • Do we need to know it now ? • Detailed plan dilemma
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
Let’s build the plan (PERT)
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
PERT visualisation
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
Let’s build the plan (CCPM)
• Master Scheduling (setting milestones and strategy; identification of long lead items); • Phase "Pull" planning (specify handoffs; identify operational conflicts);
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
Operational weekly planning
• Make Work Ready Planning (look ahead planning to ensure that work is made ready for installation; replanning as necessary); • Weekly Work Planning (commitments to perform work in a certain manner and a certain sequence);
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
Progress control
• From LPS – measuring percent of plan complete (PPC), deep dive into reasons for failure, developing and implementing lessons learned • Therefore it is common to think that as long as we are completing some tasks, we are making the progress. • But how true is that ?
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
Weekly planning and progress control
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
The problem: delayed Critical Chain Task
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
Focused efforts to increase the speed (Kaizen)
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
Major milestone – ON TIME
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
Some realizations
• Last Planner concept is very useful in creating project plan, but be aware of PPC short-falls • CCPM helps to focus weekly planning on critical tasks and ensuring full kit • CCPM helps to focus LEAN improvement efforts • Old habits die hard
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
Thank you !
www.tocpractice.com
23rd International Conference of the TOC Practitioners Alliance - TOCPA
