CONS8140 - Lean and Six Sigma Implementation in Construction Project

This report details the benefits of Lean and Six Sigma in a 20-unit residential housing project, focusing on improvements in efficiency, quality, and waste reduction. It introduces Lean construction principles, including the 5S system (Sort, Set in Order, Shine, Standardize, Sustain) and the Last Planner System (LPS), highlighting their roles in enhancing workflow and collaboration. The report identifies the eight wastes in construction and suggests methods for their elimination. Practical studies, including cycle time analysis and sigma level calculation, are included to demonstrate the application and effectiveness of Lean Six Sigma methodologies. The report also includes a constrain log form. The report is addressed to senior management to consider the implementation of Lean principles to improve project outcomes.

Running head: LEAN AND SIX SIGMA IN CONSTRUCTION REPORT
1
Lean And Six Sigma In Construction
First Name Last Name
Institution

LEAN AND SIX SIGMA IN CONSTRUCTION REPORT
2
Table of contents
Table of Figures. ......................................................................................................... 2
Introduction. ................................................................................................................ 3
Executive Summary. ................................................................................................... 4
Introduction to Lean Construction. ..............................................................................6
The 5S System. ...........................................................................................................10
Benefits of 5S: ............................................................................................................11
Last Planner System. (LPS) ........................................................................................12
The Elements of LPS...................................................................................................13
Constrain log – Constrain Log Form...........................................................................19
Study 1 Attachment A: Identified Activities & Exemplar Rate. .................................20
Study 1 Attachment B: Observation Exemplar Rates. .................................................20
Study 2 Attachment C: Cycle time analysis of backhoe and dump truck operation. ...22
Study 3 Attachment D: Sigma Level Calculation of Tile Work. .................................23
Reference. .................................................................................................................... 24

LEAN AND SIX SIGMA IN CONSTRUCTION REPORT
3
Table of Figures.
Table 1 Constrain Log Form. ........................................................................................ 19
Table 2 Exemplar rate. .................................................................................................. 20
Table 3 Observation Exemplar Rate. ............................................................................ 20

LEAN AND SIX SIGMA IN CONSTRUCTION REPORT
4
Introduction
This report is addressed to the senior management and describes in detail the benefits of lean
construction for a residential housing (20) project. A pilot project will entail the commencement
with 5S, that is, the last planner system while analyzing certain activities during the pilot project.
Given the noted concern of budget constraints by the owner, achieving a high performing store
bearing both the best architectural finishes (aesthetics) attracting customers and structural,
mechanical & electrical high performance, including energy efficiency and lower maintenance
and replacement costs can be achieved by adopting Lean into the organization.

LEAN AND SIX SIGMA IN CONSTRUCTION REPORT
5
Executive summary
Project commencement date:
Date of project completion:
Aspect considered in Lean
approach
Project achievement/
realizations
1. Adoption of 5S System to the
Residential housing (20)
Project construction site.
a) Expanded efficiency
b) Enhanced quality
c) Progressed execution–
less putting out fires
d) Smoother operation–
enhanced persistent
streams
e) Diminished working
expenses
f) Productive Safe Work
Practices
g) Lessening Waste
h) Saves money on Total
Labor Costs
2. Adopting Last Planner
System to the Residential
Project.
a) Improves
correspondence in
the different
parties/ exchanges
working for the
task.
b) It creates a stream
of work locality
and office.
c) It encourages trust
and coordinated

LEAN AND SIX SIGMA IN CONSTRUCTION REPORT
6
effort between
everybody
included, making
it a cooperation.
d) It advances
exchange
accomplice
commitment and
close
coordination.
e) Improves task
plan visibility
f) Promotes constant
enhancement.

LEAN AND SIX SIGMA IN CONSTRUCTION REPORT
7
a) Introduction to Lean Construction.
Lean is a new and developing idea. The term Lean was in reality originally used to portray the
generation standards connected in car fabricating. It was begat by John F Krafcik amid his time
at MIT Sloan to depict a generation strategy he saw at vehicle fabricating plants that could create
an extensive variety of models while as yet keeping up the most elevated amounts of efficiency
and quality. The key approaches connected at the most gainful plants, which have turned into the
reason for Lean Construction standards and the most recent 30 years of Lean investigations and
arrangements include:
 Work process standardization as a result eliminating waste
 Decentralized process enhancement responsibilities– specialists as more than pinions in a
machine adaptability and adaptability towards upgrades
 Without a moment to spare stock system eliminate waste
 High accentuation on collaboration – regard, common trust and peer advancement
Lean procedures are intended to evacuate variety and make a nonstop work process to drive huge
enhancement in consistency and firmly energizes regard for all individuals included." Of course,
as Lean administration turns out to be all the more generally received in the construction works,
a portion of the advantages that the assembling business experienced are currently advancing
into how development groups work and tasks are executed.
i. Benefits of lean construction.
a) Efficient/ Productive Safe Work Practices
Executing lean practices into construction starts with an investigation of how a task is finished.
When the activity is surely knew, lean practices will rearrange the procedure, diminishing
movement and the time it takes to finish the assignment.
b) Decreasing Waste
Lean development attempts to limit waste however much as could be expected. Instead of
tossing disposed of materials into the rubbish, lean building endeavors develop ways to diminish
the task's mismanagement of physical materials to set aside extra cash.
c) Tasks Are Finished Faster

LEAN AND SIX SIGMA IN CONSTRUCTION REPORT
8
Proficiency saves time and money for a building site. The quicker an undertaking is over, the
earlier you can sign on a new customer. Once lean construction is secured, you can manage tasks
more opportune than you could before actualizing lean practices.
d) Saves money on Total Labor Costs
When representatives are remunerated on an hourly principle, it is best for a construction
firm to finish nevertheless considerably in every hour as may perhaps be estimated. If forms
are upgraded and effective, they use less time and stretch the time-based payment further.
ii. The Eight Wastes in Construction and their elimination on site.
The Seven Wastes in development (or seven mudas of lean development or lean assembling), as
indicated by Lean writing, are illustrated beneath, alongside basic approaches to evade them and
an eighth waste that is rising in the development business:
1) Transportation
While this sort of waste can't be wiped out completely, transportation can be limited as it not just
adds time to the entire development process yet opens the material to dealing with harm. This
can include development starting with one jobsite then onto the next, or from a yard to a material
laydown territory and afterward again to the real work region.
2) Inventory
Whereas having some stock close by is important to keep the task moving, these materials ought
to be limited however much as could be expected as they will in general require a reasonable
piece of dealing with (labor) and storage room.
3) Motion
This incorporates time spent searching for an apparatus or record, and in addition strolling
additional yards because of an ineffectively planned work region. With 70 percent of a crafts
persons’ day squandered on field coordination, it's critical you use development administration
innovation to diminish this number drastically.
4) Waiting
This likewise applies to anybody on the undertaking sitting tight for data, for example, field
work force sitting tight for an arrangement or a RFI, a scheduler sitting tight for advancement
updates, or finance sitting tight for time sheets.
5) Overproduction

LEAN AND SIX SIGMA IN CONSTRUCTION REPORT
9
The way toward creating material too early or requesting additional material due to low quality,
instead of creating and conveying the appropriate measure of material at the time it is required.
Indeed, assembling or requesting excessively material causes squander, however so does having
stock arrive nearby before it is required?
6) Over-Processing
This identifies with coordination and authoritative work processes on a construction project that
prompts twofold information passage, for example, different marks on structures, arranging field
notes into a report, repetitive every day logs, and sending messages with illustrations and RFIs.
7) Defects
Having an authentic record of all site issues and one place to track punch things on-the-fly will
enable you to limit the commonness of imperfections. For instance, a deck material not
introduced per determinations or a completed divider harmed by the electrical temporary worker
would fall under the class of Defects.
8) Skills and Underutilized Talent
This isn't one of the customary Seven Wastes (or seven mudas) found in Lean writing, however
it is acknowledged as an extra waste regularly found in the business, and diverts the normal
mental helper from "TIM WOOD" to "TIM WOODS". Neglecting to make utilization of
relationship building abilities', inventiveness, or learning on the venture is an extra waste
regularly found in the business.
iii. 6 Principles of Lean Construction
There are various apparatuses including the Last Planner System, Integrated Project Delivery,
Building Information Modeling, 5s, and Kaizen Events that can be utilized in mix to accomplish
lean. A developing number of development firms are grasping the Lean technique that
underscores amplifying an incentive for the client while limiting waste. Obviously, it is a lot less
demanding to create repeatable, forecastable outcomes in the controlled condition of an
industrial facility floor than in the more capricious universe of development. There are, anyway
guiding principles that assistance firms accomplish bring down costs, diminished development

LEAN AND SIX SIGMA IN CONSTRUCTION REPORT
10
times, greater profitability and productive undertaking administration. They speak to an all-
encompassing way to deal with the development procedure.
a) Recognize Value from the Customer's Point of View
The conventional way to deal with development centers around what the client needs you to
assemble – what's incorporated into the plans and details. Lean development, then again,
perceives that what the client esteems is more profound than that. It isn't just about what to
fabricate, however why. Genuinely understanding an incentive from the client's perspective
requires an alternate dimension of trust, built up right off the bat in the arranging periods of a
venture.
b) Characterize the Value Stream
When you have an unmistakable comprehension of significant worth from the client's
perspective, you can spread out the majority of the procedures important to convey that esteem.
This is known as the Value stream. For every movement, the essential work, data, hardware, and
materials are characterized. Any means or assets that don't include value are evacuated.
c) Dispose of Waste
An essential objective of Lean development is disposing of or limiting waste at each chance.
Lean development targets eight noteworthy sorts of waste as already discussed in the preceding
section.
d) Stream of Work Processes
When one a player in the venture stretches out beyond calendar, it is basic to let everybody know
so changes can be made to keep away from the losses of pausing, movement, and abundance
stock. The perfect condition of a Lean development venture is a persistent, continuous work
process that is solid and unsurprising.
e) Pull Planning and Scheduling
Making solid work procedures depend on upon work being achieved dependent on downstream
interest. Members impart and work together intimately with one another to decide the calendar of
errands.
f) Persistent Improvement

LEAN AND SIX SIGMA IN CONSTRUCTION REPORT
11
The development industry isn't invulnerable to the inclination to stick to old traditions and
compete with change, yet the various benefits of the Lean approach are confident to an ever
swelling number of corporations to go up contrary to the test.
b) The 5S System.
5S framework is a strategy utilized for setting up and keeping nature of workplace in an
organization. This system can oversee space, human exertion, time, quality and money to make
the final result with less blames and make the site a very much arranged, taught also, clean work
environment. 5S is a framework to diminish wastage and enhance quality and profitability
through checking a sorted out condition and acquire all the more firm outcomes.
The 5S are as per the following:
i. Set all together (Seiton)
ii. Sort (Seiri)
iii. Shine (Seiso)
iv. Standardize (Seiketsu)
v. Sustain (Shitsuke)
The fundamental stage in 5S is put the things where they give the best help to the work. The
second stage is choosing what is basic in the workplace and what is not. The third stage is
examination, fixing and cleaning things to discover and evacuate the root reasons for waste and
soil. The fourth stage is group working and the individuals must have agreement on typical and
better approach for work. Basically executing SORT can have quick results that show an
organization's promise to change, while the utilization of the different components can
drastically enhance efficiency and lessen both waste and lead time. The effective execution of 5S
requires that everybody comprehend why it is being utilized and what the normal outcomes are,
as the evacuation of commonplace/ familiar (albeit unneeded) things and the rearrangement of
procedures can be to a great degree agitating.
i. Benefits of the 5S system
Executing 5S lean assembling preparing has various different advantages, these include:

LEAN AND SIX SIGMA IN CONSTRUCTION REPORT
12
Figure 1. The 5S and the accompanying benefits.
1. Expanded Productivity
Each association progresses in the direction of accomplishing expanded profitability, all things
considered, efficiency builds the general rate of profitability. Contending evacuation of pointless
things alongside proficient working environment augmentation is adequate to help create
enhanced profitability with insignificant wastage of time. Less time spent looking through
pointless things implies additional time spent working.
2. Enhanced Safety
Enhanced security is one more advantage of 5S usage. A perfect working environment condition,
particularly in an assembling unit can result in critical decrease in the quantity of wounds
supported by specialists. Regularly, unattended compound spills expands the odds of slips and
falls. In opposition to this, following deliberate techniques of cleaning, confines the likelihood of
all such lamentable incidents. Likewise, the decrease in pointless travel through the workspace
condition further limits the danger of supporting wounds by restricting presentation to perilous
substances somewhere else in the office. This consequently capacities to expand the lesson of
representatives, as lessened occurrences of wounds pass on business' anxiety for specialist
security.
3. Decrease in Waste
Actualizing 5S will likewise yield a reasonable decrease in lost and broken things in the work
environment. A reasonable and sorted out working environment with appropriate marking gives
laborers the adaptability to supplant harmed things in the assigned spots, along these lines