lean_journey-value_stream_ · pdf filethis session incorporates testimonies and case studies...

Please comply with the Lean Construction Institute’s Usage Policies and Attribution Guidelines at http://www.leanconstruction.org/usage.pdf

when using this file. Thank you.

http://www.leanconstruction.org/usage.pdf

Provider Name: Lean Construction Institute

Provider Number – H561

Course Name: Improving the Way we Work: Implementation of Lean on Projects, Case Studies and Lessons Learned. Course Number – 20121011PM

Course Speakers: Jason Schulist, Ryan Seckinger, Larry Smith, Nick Bagatelos, Jamie Vasquez, Sue Klawans, Dave MacNeel Course Date: October 11, 2012

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 of handling, 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.

This presentation is protected by US and International Copyright laws. Reproduction, distribution, display and use of the presentation without written

permission of the speaker is prohibited.

© Lean Construction Institute 2012

Copyright Materials

This session incorporates testimonies and case studies from participants in projects that used lean methodologies to improve the design, construction, and overall journey of their facilities and change the way they deliver a project. The case studies will dive deep into specific tools and techniques that will improve the quality of buildings, create a safer and more reliable work environment, and improve the design and construction practice.

Course Description

Learning Objectives

1) To show how a road map looks to effectively make a lean transformation while clarifying the importance of how there is a balance between standardization and innovation. 2) Examine Case Studies from multiple projects and comparing traditional methods to the lean method while incorporating weekly work plan, educating subcontractors on lean methodology, and creating an open environment for collaboration. 3) Focusing on team engagement in the early stages of conceptual design, owner/operator target setting, mapping design build approach, use of project metrics to verify achievement of team targets, integrated communication and innovation through leveraging of Building Information Modeling and 3-dimensional modeling tools to expedite the plan approval process. 4) Will help attendees see how Lean can alter the way their company operates through changes in problem solving, coordination, and standardization.

At the end of the this course, participants will be able to:

Lean TransformationLean TransformationValue Stream Mapping Across an Organization

Our Five Year Lean Journeyy

• 5S program – “Just get started”5S p og a Just get sta ted• Top down support with company wide

buy in – “Scotty becomes a believer”buy in – Scotty becomes a believer• Standardization through Mapping –

“This is not a car”This is not a car• The Role of Innovation and Continuous

I t “Y ti ”Improvement – “You are creative”

5S Fabrication Shopp

Continuous Improvementp

VSM for Fabrication

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

� � � � � � � � � ��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

� ��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

VSM for Field Installation

8

Day

Hr

60

Hr

Min

60

Min

Sec 3175 Bowers

1Z020

Hr Min Sec 3175 BowersProjecct

40Customer Daily Demand Item

Z030

Sierra Aluminum

1

Extrusions To Shop

Glass To Shop

Z160

Viracon

1

Field Activities Shown are For 1-4 Man Crew. Job Requires 2

Crews Installing units.

Bagatelos Manufacturing Facility

4 Bunks Per Truck 5 Units Per BunkTruck Delivers to Site

#$%&'(

)*%+"

%,‐'.)

$%#(

$%12*+‐23'+4%+"%5647#+2"

(

%966%#(

$%:'

;%,‐44%0"

‐%<4++2(

=%>(2+*

1Associates Staff

10Batch Size Item

15Cycle Time Min

1.50Cycle Time Per Item Min12 00Activity Takt Time Min

Pull Materials for Cutting

A050 1

2Associates Staff

10Batch Size Item

30Cycle Time Min


Cut Material

A060 1

4Associates Staff

10Batch Size Item

30Cycle Time Min


Fabricate Material

A070 1

4Associates Staff

10Batch Size Item

60Cycle Time Min


Assemble Frame

A080 1

4Associates Staff

10Batch Size Item

30Cycle Time Min


Glaze Frame

A100 1

1Associates Staff

10Batch Size Item

60Cycle Time Min


Caulk Frame

A110 1

2Associates Staff

20Batch Size Item

240Cycle Time Min


Shipping

A120 1

2Associates Staff

20Batch Size Item

30Cycle Time Min


Off Load/Distribute Units

A130 1

4Associates Staff

40Batch Size Item

20Cycle Time Min


Install Units

A140 1

!"#

/00%!"#

$

8‐#$4

%

15.00 Min

12.00Activity Takt Time Min1.50Assoc. Time Per Item Min

1.50Activity VA Per Item Min1.00Daily Associate Time Hr

30.00 Min



30.00 Min



60.00 Min



30.00 Min



60.00 Min



240.00 Min



30.00 Min



20.00 Min



Z010

Time Summary

12.00Takt Time Min

515.00Total Value Added Min

1.07Lead Time Day

100.00Value Added Percent %

1

Project TimelinesjPRINTED: Thursday, September 20, 2012JULY 1, 2012 TO JULY 1 2013

Page 1 of 4

LEG

EN

D = Milestone Complete

= Milestone at Risk

= Milestone Delayed

= Milestone accelerated

= Milestone on Schedule

Dep

artm

ents PROJECT

MGMT.

ENGINEERINGDEPT.

CW- PROD. ENG.DEPT.

ACM- PROD. ENG.DEPT.

SHOP FABDEPT.

FIELDCREW

7 Feb, 2013 - 21 Feb, 2013Schedule Change XXX-001 = Open Issue / Constraint

XXX-001 = Closed Issue / Constraint

Oth

er P

artn

ers GENERAL

CONTRACTOR

ARCHITECT

TRADEPARTNERS

VENDORS

1-Jul-12 1-Jul-13

1 Aug, 2012 1 Sep, 2012 1 Oct, 2012 1 Nov, 2012 1 Dec, 2012 1 Jan, 2013 1 Feb, 2013 1 Mar, 2013 1 Apr, 2013 1 May, 2013 1 Jun, 2013

Job#: 262Project: Sutter WCC

Client: Boldt

Today

1-Jul-12 1-Jul-13


Job#: 273Project: SJ RMC

Client: Skanska USA.

Job#: 290

Today

Today

1-Jul-12 1-Jul-13


Job#: 290Project: RivCon

Client: Turner Const.


Job#: 292Project: Bowers

Client: JM O’Neill

Today

3 Dec, 2012

Complete CWFab. Release

8 Aug, 2012

CompletePermit Dwgs

5 Oct, 2012

CompleteShop Dwgs.

3 Dec, 2012

Complete ACMFab. Release

14 Jan, 2013

CompleteFabrication

15 Oct, 2012

Place AllMaterialOrders 19 Oct, 2012

Dwg / Dims/ Calcs100% Approved

22 Jan, 2013

CompleteInstall (North)

11 Mar, 2013

CompleteInstall(South)

3 Dec, 2012

Start FieldLayout (West)5 Oct, 2012

CompleteStructural Calcs.

18 Dec, 2012

Start FieldLayout(South)

28 Jan, 2013

CompleteInstall(East) 16 May, 2013

CompleteProject

1 May, 2013

CompleteInteriorWork4 Dec, 2012

StartFabrication

24 Dec, 2012

Start FieldLayout(East) 15 May, 2013

CompletePunch List

8 Oct, 2012

Input LogiKalStart

Material Tak-offs17 Dec, 2012

Start FieldLayout

(Bell Tower)7 Dec, 2012

Recv. GlassOn-Site

28 Feb, 2013

CompleteInstall

(Bell Tower) 28 Mar, 2013

CompleteInstall (West)

15 Apr, 2013

Start InteriorWork30 Nov, 2012

Recv. Materials

31 Dec, 2012

Start ProjectDelivery

20 Nov, 2012

Start FieldLayout (North)

31 Aug, 2012 - 28 Sep, 2012(Delay)ACM Infill Panels

28 Sep, 2012 - 28 Oct, 2012(Delay)ACM Grid Panels

1 Nov, 2012 - 14 Nov, 2012(Delay)ACM Seismic Panels

1-Jul-12 1-Jul-13

1-Jul-12 1-Jul-13


Job#: 293Project: 140 New Montg.

Client: Plant Const.

Today

28 Sep, 2012

Complete FabDocs for

ACM Infill Panels28 Oct, 2012


ACM Grid Panels

292-001

14 Nov, 2012


ACM Seismic Panels1 Sep, 2012

Complete FabDocs for Lobby

CW7 Sep, 2012

Start FieldInstallation(Lobby CW)

8 Oct, 2012

Complt. FieldInstallation (Lobby CW)

7 Sep, 2012

Start FieldInstallation

(ACM Panels)24 Oct, 2012

Complt. FieldInstallation

(ACM Panels)10 Sep, 2012

Recv. ACMMaterial Order

9 Jul, 2012


(North Level 1&2)3 Aug, 2012


(East Level 1&2)2 Aug, 2012


(North Level 1&2)28 Aug, 2012


(East Level 1&2)29 Aug, 2012


(South Level 1&2)21 Sep, 2012


(West Level 1&2)11 Sep, 2012


(South Level 1&2)12 Sep, 2012


(West Level 1&2)

Recv. Start Complt. Recv. Recv. Recv. Recv. Recv. Recv. Recv Recv. Recv. Recv. Recv. Recv. Recv.Start Complt. Start Complt. Start Complt. Start Complt. Start Complt. Start Complt. Start Complt. Start Complt. Start Complt. Start Complt. Start Complt. Start Complt. Start Complt. Start Complt. Start Complt. Start Complt. Start Complt.

28 Sep, 2012Truck 1

29 Sep, 2012

WindowInstallFloor 2

8 Oct, 2012

pWindowInstallFloor 2 12 Oct, 2012

WindowsTruck 2

26 Oct, 2012

WindowsTruck 3

9 Nov, 2012

WindowsTruck 4

23 Nov, 2012

WindowsTruck 5

7 Dec, 2012

WindowsTruck 6

21 Dec, 2012

WindowsTruck 7

4 Jan, 2013

Recv.WindowsTruck 8

18 Jan, 2013

WindowsTruck 9

1 Feb, 2013

Recv.WindowsTruck 10

15 Feb, 2013

WindowsTruck 11

1 Mar, 2013

WindowsTruck 12

15 Mar, 2013

Recv.WindowsTruck 13

29 Mar, 2013

WindowsTruck 14

9 Oct, 2012


17 Oct, 2012

pWindowInstallFloor 3

18 Oct, 2012


26 Oct, 2012


27 Oct, 2012


5 Nov, 2012


10 Nov, 2012


19 Nov, 2012


20 Nov, 2012


28 Nov, 2012


8 Dec, 2012


17 Dec, 2012

Complt.WindowInstallFloor 8

22 Dec, 2012


31 Dec, 2012

Complt.WindowInstallFloor 9

1 Jan, 2013

StartWindowInstall

Floor 109 Jan, 2013

pWindowInstall

Floor 1010 Jan, 2013

WindowInstall


pWindowInstall


StartWindowInstall


Complt.WindowInstall


StartWindowInstall

Floor 136 Feb, 2013

pWindowInstall

Floor 137 Feb, 2013

StartWindowInstall

Floor 1415 Feb, 2013



WindowInstall


pWindowInstall


WindowInstall

Floor 166 Mar, 2013

pWindowInstall

Floor 167 Mar, 2013

StartWindowInstall

Floor 1715 Mar, 2013



StartWindowInstall




StartWindowInstall

Floor 193 Apr, 2013

pWindowInstall

Floor 19

Constraints on Timeline

Work Order ReleaseBIQ and QA/QC ProcessBIQ and QA/QC Process

Project. ManagementIssues RFF

(Request for Fabrication)

RFFTransmittal

STANDARD WORK PROCESS (SWP)WORK ORDER RELEASE

Using LogiKalPRIMARY DEPARTMENT: PRODUCTION ENGINEERING

Revised: Sept. 17, 2012

Transmittal

Is RFF Complete and

Ready forProcessing?

No

Are There

Yes

N

Are ThereData Base

Errors?Yes Present to Department

Manager for Direction

No

Are ThereOther Errors? Yes Present to Department

Manager for Direction

Do Shop Drawings Need

Revisions?Yes

Yes

Engineering Dept.To Revise Shop

Drawings as Reqd.

No

Yes Enter Work Scope into LogiKal

Prepare Optimized Cut List QA/QC

Cut ListDoes Cut List Pass QA/QC? Yes

No

Is There a Material Impact?

Yes Present issue to PM for Direction

NoAre There

Input Errors? No

Can RFF be Processed through

LogiKal?No

See SWP forWork Order Release

Not Using LogiKal

Prepare Assembly Lists

QA/QCAssembly

Lists

Does Assy. List Pass QA/QC? Yes

No

NoMake RequiredCorrections

Make ManualRevision /

Corrections toAssembly Lists

Prepare Fab.Drawings

QA/QCFab.

Drawings

Do Fab. Dwgs.Pass QA/QC? Yes

Does Work Order

Yes

Work Order Hand-OffMeeting with

Production Manager

Prepare MFG’sAssembly

Instructions

Prepare WorkOrder Document

CompileWork Order

Package

Does Work OrderPackage

Pass QA/QC?No

Make RequiredCorrections

QA/QCWork Order

Package

Questions?

This concludes The American Institute of Architects Continuing Education Systems Course

Lean Construction Institute [email protected]

lean_journey-value_stream_ · pdf filethis session incorporates testimonies and case studies...

Documents