Implementation of Production System Design in House Building Projects: a Lean Journey in Chile - Karina Barth - Ph.D. Candidate Marcus Sterzi ...
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Implementation of Production System Design in
House Building Projects: a Lean Journey in Chile
Karina Barth - Ph.D. Candidate
Marcus Sterzi - MSc
Carlos Formoso - PhD
Juan Ignácio Alliende - Eng
Daniela Bertín - Eng
Jorge Del Rio - EngAgents involved
• Largest real estate group in Chile.
• Both development and construction.
• High degree of repetitiveness in its
residential building projects.
• More than a 100 projects in progress and
sells more than 3,000 units per year.
• The company is promoting a major Lean
• Research center in transformation process.
the University.
• Co-Responsible • Lean consultancy company
for the Lean • Responsible for the Lean
Implementation Implementation Program
Program.
2Production System Design (PSD) in Construction
• PSD translates the production strategy into a set of decisions, which establishes a structure
to manage different activities, and creates conditions for control and improvement (Ballard et al.
2001a; Schramm et al. 2006).
• PSD consists of developing operation and process design in alignment with (Ballard et al. 2007):
• product design, • the allocation of resources, and
• the structure of supply chains, • design-for-assembly efforts.
• PSD involves a set of interconnected decisions, considering the need to improve the
production system as a whole (Schramm et al. 2004).
• PSD can potentialize the benefits of the LPS, allowing the early identification of a larger range
of problems (Frandson et al. 2015).
3Aim of the study
• This paper reports the experience of a construction company that has implemented PSD
and the LPS over 3 years, as part of an ongoing Lean implementation program.
• Contributions of this paper:
• the definition of the scope and potential benefits of PSD
• the proposition of a set of practices that can be used along the PSD stages, with
emphasis on location-based planning and control
4Implementation Process and Results
PHASE 01 PHASE 02 PHASE 03
Assessment of existing situation Development and initial testing Implementation of PSD and
– 2017 of the Production Management LPS – 2018/19
System – 2017/18
2 PROJECTS 3 PILOT PROJECTS 5 IMPLEMENTATION PROJECTS
- Construction sites visits for assessing
- Training course on Lean Construction - Implementation of LPS
planning and control system:
Evaluation protocol - Implementation of PSD (emphasis on - Implementation of PSD model
- Participation in planning sessions, location-based planning and control) - Evaluation of results, refinement
interviews and analysis of the - Implementation of LPS and standardization
company’s Lean Supporting Group: consultants and
Company did system
not haveforaplanning andand
systematic - Evaluation of the benefits of the - Evaluation of the benefits of PSD
control company members. Workshop organized by the LSGroup to
explicit PSD. implementation and proposition of through indicators: LPS metrics,
New decision category included to identify and disseminate
batch adherence control,the benefits
rhythm
Lack of understanding of Lean concepts. PSD model
emphasize layout and logistics planning. of implementing
deviation, and cycle timePSD.
variance
Large amount of WIP (based on Batch
Standardized control tools: cycle time, Proposition of a PSD Guidebook.
Completeness Index and Heatmaps).
takt time, WIP and synchronization.
5PSD Company Model
4. Definition of 5. Layout and
1. Analysis and 2. Definition of the execution logistics
3. Definition 7. Identification
definition of resources and strategy planning
of workflows and design of
construction estimation of
critical
sequence production capacity 6. Definition of processes
workflows
(whole project)
Base-unit
8. PSD review
6PSD Company Model: Decision Categories
1. Analysis and definition of construction sequence (base-unit)
2. Definition of resources and estimation of
production capacity (base-unit)
03. Masonry
01. Foundations 02. Structure 04. Roof Structure 05. Roof 06. Facade Cladding
and Plumbing
07. Drywall / Electric 12. Bath and
08. Windows 09. Doors 10. Flooring 11. Painting
Systems Kitchen Artefacts
7PSD Company Model
4. Definition of 5. Layout and
1. Analysis and 2. Definition of the execution logistics
3. Definition 7. Identification
definition of resources and strategy planning
of workflows and design of
construction estimation of
critical
sequence production capacity 6. Definition of processes
workflows
(whole project)
Base-unit
8. PSD review
8PSD Company Model
4. Definition of 5. Layout and
1. Analysis and 2. Definition of the execution logistics
3. Definition 7. Identification
definition of resources and strategy planning
of workflows and design of
construction estimation of
critical
sequence production capacity 6. Definition of processes
workflows
(whole project)
Base-unit
8. PSD review
9PSD Company Model: Decision Categories
4. Definition of the execution strategy
3rd stage 2nd stage 1st stage
4th stage
Execution path of critical processes not
Work areas ("small projects”) and
included in BU: Facades 10
execution path of BU processesPSD Company Model: Decision Categories
5. Layout and logistics planning
11PSD Company Model: Decision Categories
6. Definition of workflows (whole project) LOB PATAGUAS V PRELIMINAR 17.06.2020
ago-2020 set-2020 out-2020 nov-2020 dez-2020 jan-2021 fev-2021 mar-2021 abr-2021 mai-2021 jun-2021 jul-2021 ago-2021 set-2021 out-2021
PISO
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Line of Balance
SEMAN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 LEYENDA
3/8 10/8 17/8 24/8 31/8 7/9 14/9 21/9 28/9 5/10 12/10 19/10 26/10 2/11 9/11 16/11 23/11 30/11 7/12 14/12 21/12 28/12 4/1 11/1 18/1 25/1 1/2 8/2 15/2 22/2 1/3 8/3 15/3 22/3 29/3 5/4 12/4 19/4 26/4 3/5 10/5 17/5 24/5 31/5 7/6 14/6 21/6 28/6 5/7 12/7 19/7 26/7 2/8 9/8 16/8 23/8 30/8 6/9 13/9 20/9
CADA UNA DE LAS ACTIVIDADES DE
2I 1° 2° LOS LOCALES COMERCIALES INICIA
RADIER
with Wagon
TERMINANDO LOS PAREOS
CORRESPONDIENTES
2H 1° 2° MACHONES
System
2G 1° 2° CORONACIÓN
ESTRUCTURA TECHUMBRE
2F 1° 2° CUBIERTA
ESTUCO EXTERIOR
2E 1° 2° ALERO Y FRONTON
YESO 1° Y 2° PISO
2D 1° 2° INST. ESCALA
CIELO FALSO
2C 1° 2° TABIQUE
IMPERMEABILIZACIÓN/TINA
2B 1° 2° VENTANAS
INSTALACION PUERTAS
2A 1° 2° CERAMICA
CARPITERÍA DE TERMINACIÓN
1I 1° 2° REMATE DE YESO
APAREJO
1H 1° 2°
Post delivery PINTURA 1 MANO
MUEBLES COCINA Y CLOSET
1G 1° 2°
activities ARTEFACTO SANITARIO
QUINCALLERIA
1F 1° 2° GRANO EXTERIOR
ALFOMBRA
1 1E 1° 2° REJA METALICA Y BAJADAS DE ALL
EMPAREJAMENTO PATIO FINO/ PASTELONES
1D 1° 2° ENTREGA INTERNA
ENTREGA INMOBILIARIA (2° MANO PINTURA EXTERIOR - 2° MANO
PINTURA INTERIOR - ACCESORIOS - GRIFERIA)
1C 1° 2°
1B 1° 2°
ENTREGA ENTREGA
CARPETA CARPETA
BLOQUE N° 1 BLOQUE N° 2
1A 1° 2°
1st delivery 2nd delivery
12
SEMANA 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
DIA INICIO
MES
3/8 10/8
Buffer = 1 week
ago-2020
1
17/8 24/8 31/8 7/9
2
set-2020
14/9 21/9 28/9 5/10
out-2020
3
12/10 19/10 26/10 2/11
nov-2020
4
9/11 16/11
Buffer = 1 week
23/11 30/11
5
dez-2020
7/12 14/12 21/12 28/12
jan-2021
6
4/1 11/1 18/1
7
fev-2021
25/1 31/1 7/2 14/2
8
mar-2021
21/2 28/2 7/3 14/3
abr-2021
9
21/3 28/3 4/4 11/4
10
mai-2021
18/4 25/4 2/5 9/5 16/5
11
jun-2021
23/5 30/5 6/6 13/6
12
jul-2021
20/6 27/6 5/7 12/7
13
ago-2021
19/7 26/7 2/8 9/8
14
set-2021
16/8 23/8 30/8 6/9
15
out-2021
13/9 20/9
Total dias de actividades 199,0 193,0 273,0 345,0 446,0 418,0 474,0 855,0
stage 705,0 659,0
stage
732,0 495,0 399,0 406,0 117,0PSD Company Model
4. Definition of 5. Layout and
1. Analysis and 2. Definition of the execution logistics
3. Definition 7. Identification
definition of resources and strategy planning
of workflows and design of
construction estimation of
critical
sequence production capacity 6. Definition of processes
workflows
(whole project)
Base-unit
8. PSD review
13PSD Company Model
4. Definition of 5. Layout and
1. Analysis and 2. Definition of the execution logistics
3. Definition 7. Identification
definition of resources and strategy planning
of workflows and design of
construction estimation of
critical
sequence production capacity 6. Definition of processes
workflows
(whole project)
Base-unit
8. PSD review
14Benefits of Implementing PSD
• Formalizing and making explicit
planning decisions:
Key decisions on the design of the
production system were made with the
participation of main stakeholders
• Reduction in uncertainty:
PSD helps identifying production
system limitations and critical
processes. Examples of PSD meetings
15Benefits of Implementing PSD
• Improving planning accuracy: considering multiple alternatives of construction systems and subsystems
• Facilitating the adoption of cycle time and takt time control: provides information in a systematic way
Planed
Executed
Planed
ExecutedBenefits of Implementing PSD
• Increasing engagement of stakeholders
• Improving production stability
Evolution of PPC
Sequence and
WIP controlConclusions
Proposed PSD model X Previous studies:
• It was tested and implemented on several residential projects in a systematic way
• Provides more emphasis on location-based planning and control, layout and
logistics studies during pre-construction stages
• Advances in terms of cycle time, takt time, WIP and synchronization analysis before
construction
• Generates information concerning the production system as a whole
• Produces a set of standardized tools to be used to monitor the implementation of PSD
Data have been collected by the research team and, in the near future, the main results
achieved will be systematically reported.
18THANK YOU! Karina Barth – karina@ldconsulting.com.br Marcus Sterzi - marcus@ldconsulting.com.br
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