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The principles of lean construction

Lean construction is based on 11 principles detailed below:

1. Minimize activities that do not add value to the product. The idea is to eliminate unnecessary or repetitive steps throughout the production process. However, it is necessary to do this intelligently, since there are activities that do not directly add value, but which are essential for the overall efficiency of the processes.

2. Increase the value of the product according to the customer's needs. At this point, the need to know the target audience in depth is evident.

3. Reduce the variability of products / deliveries. Here there is something especially critical for construction, which traditionally deals with high rates of unforeseen events. But it is possible to adopt some standards to optimize time and reduce losses. Opting for a single system for electrical and hydraulic installations, for example, is a typical action of lean construction, just to mention an example.

4. Reduce the production cycle time. Another typical lean construction action is to focus production efforts on smaller batches, eliminating interdependencies between activities.

5. Simplify by reducing the number of steps or parts of a process;

6. Improve product flexibility, making it more customizable.

7. Improve the transparency of the process. The idea is that the more transparent the management of works at all stages, the simpler the communication and the lower the failure rates.

8. Control the global process, and not just its parts;

9. Introduce continuous improvement in the process;

10. Balance improvements between flow and conversions;

11. Apply benchmarking to keep up with the industry's best practices.

Challenges for implementation

Although it seems simple, implementing lean philosophy is not always easy because it requires a radical change in mentality, values ​​and discipline. Just the introduction of some tools does not necessarily mean successful implementation.

In Brazil, adherence to the methodology is growing. But there are still few companies that are able to apply the lean philosophy in a wide way. The cultural issue, the low industrialization and the scarcity of planning are important obstacles to be overcome.

LEAN CONSTRUCTION: DELIVER PRODUCTS WITH MORE VALUE, IN LESS TIME

By Autodoc

The essence of Lean thinking is directing efforts only to activities that effectively add value to the product or business. It is a continuous flow of analysis of the production process aimed at reducing waste, cycle time and simplifying the process, while seeking to increase the value delivered to the end customer. Lean Construction (Lean Construction, in Portuguese) represents the application of the Lean Production management concept in civil construction.

In the 1940s, with the end of the Second World War, Japan was fragile and faced a shortage of resources. To minimize these problems, Toyota assembled a new production model - known as the Toyota Production System. This model aimed to avoid overproduction, reduce waste of raw materials, time and money, that is, the objective was to generate more productivity and sustainability in the industry.

However, the term Lean Production appeared only in 1990 with the book 'The machine that changed the world' by James Womack, Daniel Jones and Daniel Ross. This work defined the methods applied in the Toyota Production System as Lean Manufacturing. From then on, the concept of lean production started to spread to several sectors of the industry. In 1992, a work by the researcher Lauri Koskela triggered the use of Lean Manufacturing in Civil construction, naming it Lean Construction.

Lean Construction adapts Lean Production principles for civil construction. Adaptation is necessary because civil construction has its own particularities. For example, the fact that it is itinerant rather than concentrated in one place like traditional industry.

Therefore, we conclude that Lean Construction is a recent civil construction methodology. The application of this concept has brought numerous positive impacts to the construction sector.

Conversion Flows

Lean Construction is based on managing 4 conversion streams:

Assembly Flow: it is related to the budget and planning of the schedule of activities that add value to the construction project, such as beams and masonry.

Material Flow: involves all stages between transportation and use of products on the job, that is, transportation, waiting, processing and inspection of materials.

Information flow: it is linked to the administrative issues of the works. Planning, budgeting, project control, customer needs, data inspection, terrain characteristics are some of the points related to the flow of information.

Workflow: this flow determines which activities should be performed by each team at the construction site, aiming at reducing waste based on saving employees' time and workforce.

Lean Construction Principles

Although there is no standard Lean Construction model, and the application of this method varies according to each project and construction company, lean construction is based on some basic principles, understand:

1. REDUCE ACTIVITIES THAT DO NOT ADD VALUE

Activities that do not add value and are not necessary must be discarded! Check the image below for some examples of activities that are considered waste of labor, raw material or time.

2. KNOW YOUR CUSTOMER AND ADD VALUE TO THE PRODUCT FROM HIS NEEDS

It is necessary to know your target audience and identify their needs, so that the strategies outlined and actions taken are based on this, and thus, your product gets more value.

It is important to emphasize that the needs of the identified internal and external client, must be considered during the planning and execution of the project. In addition, during execution, all professionals involved must be aware of the clients' needs for this to guide all their decisions.

3. REDUCING VARIABILITY AND SETTING STANDARDS

Construction processes are marked by variations, whether related to different projects, or within the same ongoing project. Construction time, customer demand, issues related to suppliers and the construction process itself are points susceptible to variation. However, it is important to make an effort to make these variations as small as possible.

The establishment of standards for all sectors involved in the works is extremely important to avoid variability. However, it is important to be aware that unforeseen events may occur and that many established standards must adapt to the peculiarities of each project.

The modular construction system is a good alternative for establishing variability reducing standards. The reduction of variability is important in order to guarantee the uniformity of the project and correspond to the specifications previously established. In addition, with less variation, less time and labor will be wasted.

4. REDUCE CYCLE TIME

This principle originates from the Just In Time concept. The JIT determines that the products must be produced, stored, transported or purchased at the right time and in the exact quantity, according to the demand, without the formation of stocks. The cycle time represents the sum of all production steps (transport, waiting, processing and inspection).

The reduction in cycle time foresees that each step will be executed only at the right time, and the cycle time will be reduced, focusing on production only as necessary. In addition, it is important that the steps have no dependencies on each other to be performed, but that this occurs in parallel. The idea is that more can be done, in less time, without causing waste.

5. PROMOTE TRANSPARENCY IN PROCESSES

Management must ensure transparency with its employees during all stages of the work. Through a transparent relationship between manager and employee, decisions related to problem solving or application of improvements are made more quickly and assertively.

The removal of visual obstacles at the jobsite, implementation of communication channels between employees, alignment meetings between employees involved in the work, exposure of signs and signs with important information and performance indicators collaborate for transparency in the process.

Benefits of Lean Building

The principles mentioned above consist of guidelines for the construction process to become leaner. Although it will not always be possible to apply all of them, when applied, a series of benefits are brought to your company:

Reduced waste of materials and labor: due to the fact that Lean Construction allows for better planning of the work and enhances a lean supply of raw materials, less materials are wasted. In addition, each step is performed in order to avoid rework, which means a reduction in the waste of labor.

Greater productivity: the reduction of rework, simplification and transparency in the processes and the establishment of standards make employees more productive.

Reducing deadlines / Optimizing time: the application of Lean Construction also allows activities to be practiced in order to maintain quality and reduce time. Their works are completed and delivered more quickly, due to the optimization of the time that lean construction allows.

Increased profit: all benefits mentioned above result in increased profit for each project.

Tips for applying Lean Construction

The application of Lean Construction consists of a process of continuous improvement. There are some methods that can contribute to the spread of this concept in your works:

Apply the 5S program. This methodology consists of the application of 5 concepts, which have naming derived from words in the Japanese language:

Have control over each step of your conversion flows, so that it becomes clearer how to optimize them.

Empower, prepare and provoke a change of mentality in your company, in order to spread 'lean thinking' in all involved.

Create a routine for inspection and review of the process, aiming to improve it.

Use construction management software for better site management. Thus, it becomes easier to control the progress of the work, the amount of raw material used and the productivity of the professionals involved, ensuring the quality of the constructions and the fulfillment of deadlines.

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