introduction to last planner system 10.17.17_seiler_aia... · introduction to last planner ®...
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OCTOBER 17, 2017
Rich Seiler, Unified Works
Introduction to Last Planner System
LCI Education& Training© LEAN CONSTRUCTION INSTITUTE
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Lean Construction Institute Provider Number H561
Introduction to Last Planner® SystemLCITB.IntrLPS
Presenterdate
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4 LU Credit(s) earned on completion of this course will be reported to AIA CES for AIA members. Certificates of Completion for both AIA members and non-AIA members are available upon request.
This course is registered with AIA CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner ofhandling, using, distributing, or dealing in any material or product._______________________________________Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.
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This introductory training will include an overview to Last Planner®
System (LPS) implementation. LPS integrates Lean principles and is based on conversation leading to reliable commitments by team members. Participants will learn the fundamentals of LPS. The training will include a hand on simulation to revel the importance of removing variation in work flow.
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Course Description
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01. 02. 03. 04.At the end of this presentation, participants will have an overview understanding of each of the 5 levels of Last Planner® System (LPS) and how they inter-relate.
At the end of this presentation, participants will understand the need for reliability on projects and how LPS produces it.
At the end of this presentation, participants will understand the need to reduce variation in work flow and how LPS supports this.
At the end of this presentation, participants will know the basic mechanics of the 5 levels of LPS.
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Learning Objectives
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Lean Journey Road to Mastery
Unaware
Awareness
Understanding
Mastery
Competency
Continuous Learning Loop
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Learning Overview
Why Last Planner® System
LPS Overview
Milestone Planning
Phase Pull Planning
Look Ahead Planning
Weekly Work Planning
Learning
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1.
2.
3.
4.
5.
6.
7.
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Morning Session Agenda
8:00 AM –
8:15 AM –
9:45 AM –
10:00 AM –
11:45 AM –
12:00 PM –
Introductions
Introduction to Last Planner® System
Break 15 minutes
Resume
Plus/Delta
Adjourn
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Discussion Question
What are your dissatisfactions with the way projects are currently planned or
scheduled?
Large Group Discussion 5 min
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Six Tenets of Lean Construction
1
2
3
4
5
6
Respect for people
Optimize the Whole
Generate Value
Eliminate Waste
Focus on Flow
Continuous Improvement
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54%of commitments
made on construction projects were
completed on time
Research Findings from the Early 90’s
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Time —70% were delivered late
70%Delivered Late
20%Delivered On
Time
10%Delivered Early
73%Over Tender
Price
14%On Tender
Price
13%Under Tender
Price
Cost —73% were over budget
Why Use Last Planner® System?
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Correlation of lean intensity to outcomes (% likelihood on best projects)
Completed Ahead ofSchedule
Completed UnderBudget
Low Lean Intensity
3X
2X
Why Use LPS?
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Workflow and Risk
1. Workflow losses are real, lead to adversarial relations, and are difficult to quantify, so…
2. Everyone protects themselves by adding contingency and/or holding back labor to keep utilization high.
3. This further reduces workflow predictability and increases project risk
4. By their/our actions, we increase that risk and shift it along.
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LUM
E O
F W
OR
K
TIME
MUDA: WASTE
MURA: FLUCTUATION
MURI: OVERBURDEN
DEMAND
CAPACITY
Goal: Align Demandwith Capacity to even out workflow/reliability
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1. Traditional planning systems are unable to producepredictable workflow.
2. Workflow reliability directly affects system speed and cost.
3. All plans are forecasts, all forecasts are wrong, further in advance – more wrong, more detail – more wrong.
KEY CONCEPTS:
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1. Improves communication & reliability.
2. Fosters an enjoyable environment, trust, and collaboration.
3. Promotes early stakeholder engagement.
4. Improves visibility of the project plan (transparency).
5. Creates team buy in.
6. Rapid learning through metrics, revealing areas for improvement.
7. Improves planning in both design & construction phases.
Last Planner® System Benefits
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Project is a Promise
A project is a very big promise delivered by
people in an ever changing network of
promises.
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Performance
PERFORMERCUSTOMER
Credit: Dr. Fernando Flores
Preparation
Acceptance
Negotiation
Conditions of
Satisfaction,Time
Request or Offer
Acceptance(2 mutual promises)
Declaration ofSatisfaction
Report of Completion
Basic Action Flow
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Last Planner® System Overview Hand-Offs24
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Discussion Question
What is the objective of planning?Of scheduling?
How are the different?
Large Group Discussion 5 min
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Milestone Planning
Phase “Pull” Planning
Look Ahead Planning
Weekly Work Planning
Learning/Improving
Set milestones
Specify handoffs
Make work ready
Make promises
PPC/Variance
SHOULD
CAN
WILL
DID
5 Connected Conversations
Last Planner® System
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Look Ahead
Phase Pull
Milestone
Weekly
Learning
Milestoneinforms
Phase Pull
Phase Pullinforms
Look Ahead
Look Aheadinforms Weekly
Weeklyinforms
Learning
Learninginforms
Milestone
System
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DAILY HUDDLE
PHASE PULL PLANNING LOOK AHEAD PLANNING
WEEKLY WORK PLANNING
Last Planner® System
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A Last Planner can make the reliable commitment to
complete the work
Person closest to work, with authority to make
decisions creates schedule
Who is the Last Planner?
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Define the overall road map and gain alignment
Identify milestones important to client and stakeholders – especially immovable dates
Informs the Phase Pull Planning
MILESTONE PLANNING
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Phase “Pull” Planning Phase “Pull” Planning
Milestone Planning
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Complete Structure11/8/16
CompleteExterior2/10/17
CompleteFinishes2/13/18
Milestone Planning
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Milestone Planning
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through Floor 35
etc . . .
Floor 14
Floor 13
Floor 12
Floor 11
Floor 10
Floor 9
Floor 8
Floor 7
Floor 6
Floor 5
Floor 4
Floor 3
Floor2
Floor 1
Parade of Trades
01.
02.
03.
04.
05.
The building has 35 floors.
There are seven trades.
Each trade has work on every floor.
The work must be done in sequence, with each trade only able to work on those floors that have been given to them by the previous trade.
The trades mobilize to the site one week apart.
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Parade of TradesHow will you develop the
project schedule?
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Build-out 35 Floors
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Work Sequence
Week 1 Week 2 Week 3 Week 4 Week 5
Build-out 35 Floors
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Distribute score sheets as directed
Chips START in the queue of Layout
Establish queue spaces
Give die to Casework
Move 35 pieces of work through 7 tasks. Work is completed at the end of the week and passed to next trade. Place materials on table as shown.
Layout
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FramingRough
Plumbing
RoughElectrical
DrywallPaint
Casework
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Pass the Die to the LEFT, Pass Chips to the RIGHT !
WEEKCOLUMN 1CAPACITY
NUMBER ON DICE
COLUMN 2CAPACITY
PIECES PASSED
COLUMN 3REMAINING INCOMING
INVENTORY (BACKLOG)AVAILABLE - PASSED
1 3 3 32
2
3
Week 1
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Layout
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RoughElectrical
3
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WEEKCOLUMN 1CAPACITY
NUMBER ON DICE
COLUMN 2CAPACITY
PIECES PASSED
COLUMN 3REMAINING INCOMING
INVENTORY (BACKLOG)AVAILABLE - PASSED
2
3
NO INVENTORY THIS WEEK. DO NOT ROLL – JUST PASS DICE.
Framing
Pass the Die to the LEFT.
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Week 2
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WEEKCOLUMN 1CAPACITY
NUMBER ON DICE
COLUMN 2CAPACITY
PIECES PASSED
COLUMN 3REMAINING INCOMING
INVENTORY (BACKLOG)AVAILABLE - PASSED
1 3 3 32
2 1 1 31
3
Layout
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Week 3
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Layout
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FramingRoughPlumbing
RoughElectrical
Drywall
Paint
Casework
1
31+0
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Casework
It’s your job to keep everyone at the table on the same week
. Announce the week as you get the dice (and to start the game)
Layout
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FramingRough
Plumbing
RoughElectrical
DrywallPaint
Casework
1
3
Layout
You will finish first.
Please tally the results on the Tally Sheet and send it to your right.
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Trade Week Complete
Sum of Available Capacity
Total Column 1
Sum of Remaining Inventory
Total Column 3
Maximum Inventory in any
weekColumn 3
Layout
FramingRough
PlumbingRough
ElectricalDrywall
Paint
CaseworkSum
We’ll ask you to report when everyone’s done
Note the highest amount of Inventory in any week for each trade.
Sum and record the total Remaining Inventory for all Trades except Layout.
Record the week each Trade finishes. Sum and record the Available Capacity for all Trades.
When Work is Complete
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TABLEWEEK
LAYOUT COMPLETE
WEEK PROJECT
COMPLETE
TOTAL USED
CAPACITY
TOTAL REMAINING INVENTORY
MAX INVENTORY
IN ANY WEEK
Blue
Black
Green
Red
Summary
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1.2.2.5.5.6 1.2.3.4.5.6 2.2.3.4.5.5 2.3.3.4.4.5 3.3.3.4.4.41.1.1.6.6.6
AverageWorst
Best
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35
30
25
20
10
10
5
0
Results
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What would be the specific advantages of improved work flow
reliability on your projects?
Group discussion 10 min
Discussion Question
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Milestone Planning
Look Ahead Planning
Weekly Work Planning
Learning/Improving
Set milestones
Specify handoffs
Make work ready
Make promises
PPC/Variance
SHOULD
CAN
WILL
DID
5 Connected Conversations
Phase “Pull” Planning
Phase Pull Planning
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Phase of the work (8-12 wks)
After – add dates and transfer to the Look Ahead Plan
Work out the structure and durations
Informed by the Milestone Plan
Phase “Pull” Planning
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Promise/Request
Promise/Request
Promise/Request
Promise/Request
Promise/Request
Promise/Request
Promise/Request
Promise/Request
Promise/Request
Promise/Request
Work
Information
Pull Creating Flow
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Name
MY PROMISE/ACTIVITY
• What I will Deliver
• Be specific
• Small batch
WORK AREA/ZONE
MY REQUEST/TRIGGER
• What Releases my Work
• Be specific
# Days1 week max
Crew size
Elements of Sticky
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Mike G 5 days4 Crew
Underground Piping Zone 1
Vaults Backfilled
Dave S 3 days3 Crew
Backfill Vaults Zone 1
Vaults Set
Mike G 3 days4 Crew
Vaults Set Zone 1
Vaults on Site
Dave S 3 days3 Crew
Backfill UG PipingZone 1
UG Piping
Pull Example
Promise Promise Promise
Request Request53
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Start at End
54 Start at End
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Pull the Work
55 Pull the Work
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Arrive at the Start
56 Arrive at the Start
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Innovative Pull Planning
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SHOULD
Look Ahead Planning
Specify handoffs
Make work ready
Make promises
PPC/Variance
CAN
WILL
DID
Look Ahead Planning
Set milestones
5 Connected Conversations
Milestone Planning
Phase “Pull” Planning
Weekly Work Planning
Learning/Improving
Look Ahead Planning
Look Ahead Planning
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• Transferred from the Phase Pull Plan to a plan with dates/weeks
• Boards, P6 or other software documentation• Rolling (6-10 wks) Look Ahead to
“make work ready”• Supports Team Meeting Discussion/Action for:• Identify Risk – Risk Log
– High/Medium/Low– Plan to Mitigate
• Identify Constraints – Constraint Log– Plan to Mitigate
• Informs the Weekly Work Plan59
Look Ahead Planning
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Look Ahead Planning
Track PPC & Variance
2 WeeklyWork Plan
Boards
Constraint Log Look
Ahead
5-6 Look Ahead Plan
Boards
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• P6• Microsoft
Project• TouchPlan
• LeanKit• vPlanner• Others
Electronic
Look Ahead Planning
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• P6• Microsoft
Project• TouchPlan
• LeanKit• vPlanner• Others
Electronic
Look Ahead Planning
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Date Promised
DateResolved
Look Ahead Planning
ConstraintDescription
ResponsiblePerson & CO
DateIdentified
DateNeeded
Date Promised
Date Resolved
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Discussion Question
How will looking ahead to remove constraints help your projects?
Discuss amongst selves in small groups
Table discussion 10 min with 5 min report out
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SHOULDMilestone Planning
Phase “Pull” Planning
Learning/Improving
Specify handoffs
Make work ready
Make promises
PPC/Variance
WILL
DID
Milestone Planning
Phase “Pull” Planning
Look Ahead Planning
Learning/Improving
Set milestones
5 Connected Conversations
Milestone Planning
Phase “Pull” Planning
Learning/ImprovingLearning/Improving
CAN
Weekly Work Planning
Weekly Work Planning
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• Informed by the Look Ahead Plan
• Detail work by trade at the Daily Level
• Detail of the current week
• Detail of the next week
• Informs the Daily Huddle
• Take to the field - photo66
Weekly Work Planning
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Weekly Work Plan Informs the Daily Huddle
Weekly Work Planning
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“What, Who & When”
Commitment Description
What & Where?
Who will do it?
When will it be done?
Crew Size?
Weekly Work Planning
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SHOULD
Milestone Planning
Phase “Pull” Planning Specify handoffs
Make work ready
Make promises
PPC/Variance
WILL
DID
Milestone Planning
Phase “Pull” Planning
Look Ahead Planning
Set milestones
5 Connected Conversations
Phase “Pull” Planning
CAN
Weekly Work Planning
Learning/Improving
Learning and Improving
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1. What did I complete?
2. What will I complete?
3. What needs to bere-planned?
4. How can we prevent this from happening again?
Daily Huddle
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Plan Percent Complete
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Reasons for Variance
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Standard Work Available @ LeanConstruction.org
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LPS Construction:
• Pull Plans identify work structure and duration
• Milestones must be clearly defined by expected outcome which will be observable
• Is linear and the flow is “tangible materials”
LPS For DesignLPS Design:
• Pull Plans identify work needed and date needed
• Milestones are often “decision points”
• Milestones must be clearly defined by expected outcome which will describe what know
• Is emerging based on new information and the flow is “information”
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Last Planner System Design
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Milestone Planning
Phase “Pull” Planning
Look Ahead Planning
Weekly Work Planning
Learning/Improving
Set milestones
Specify handoffs
Make work ready
Make promises
PPC/Variance
SHOULD
CAN
WILL
DID
5 Connected Conversations
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Phase Pull Plan/Design
Cycle Planning
Continuously Advance 2-3 Week
Cycles(Should)
Weekly Work Planning
Work Register& Constraint Log
(Can)
Check – in Sessions
Percent PlanComplete PPC
(Did)
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Promise/Request
Promise/Request
Promise/Request
Promise/Request
Promise/Request
Promise/Request
Promise/Request
Promise/Request
Promise/Request
Promise/Request
Work
Information
Pull – Creating Flow
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Phase Pull Planning Design
Pull – Phase Planning
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What new actions or ideas that you learned today can you take
back to your project?
Write down on Take Away Sheet (5 minutes)Share with your neighbor (5 minutes)
Discussion Question
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Lean Journey Road to Mastery
Unaware
Awareness
Understanding
Mastery
Competency
Continuous Learning Loop
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I N T R O D U C T I O N T O L A S T P L A N N E R ® S Y S T E M
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Plus/Delta
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© LEAN CONSTRUCTION INSTITUTE
I N T R O D U C T I O N T O L A S T P L A N N E R ® S Y S T E M
This concludes The American Institute of Architects Continuing Education Systems Course
Lean Construction Institute [email protected]
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