an experiment in takt time - lean construction institute presentation...• 44 to 32 days • slowed...

16th LCI Congress | San Francisco, CA | October 7-10, 2014

An Experiment in Takt Time


Introduction to Project • 7,500 SF Gut and Remodel• Downtown San Mateo, CA• OSHPD Project• Occupied Building/ Operational Hospital • IFOA-IPD Contract with Trade Partners• Last Planner• Pull Scheduling • BIM Modeling


Why Takt Time?

• P2SL looking for small project• James Pease of Sutter Health

recommended P2SL for Pankow


What is Takt time?

• German word for beat• Match production rate to

demand rate

Operation 1 Operation 2 Operation 3 Operation 4

Cycle timeTakt time

Dura

tion


Takt Time


Takt-time planning process

• Adapted from Ballard and Tommelein (1998) white paper on continuous flow

Data Collection

Zone / Work definition

Rough balancing

Team agreements

Fine balancing


Flow Summary

1

3

2

4

Fire sprinkler Duct Piping

DrywallElectrical

Are these work flows compatible?


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10

Operation1

Operation2

Operation3

Operation4

Average Activity Durations

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10

Operation1

Operation2

Operation3

Operation4

Updated Durations

Takt-time planning process

• Adapted from Ballard and Tommelein (1998) white paper on continuous flow

Data Collection

Zone / Work definition

Rough balancing

Team agreements

Fine balancing

Sequence Details:- Rough in electrical before top of wall drywall

- “I can install prefab walls in 4 days, but only if entire space is clear.”


Line of Balance Scheduling• What is Line of Balance?• What does it have to do with Takt Time?


Line of balance scheduling

• Optimize the schedule• Used it for pull planning• Did not use the full BIM, still improved

the schedule significantly• Line of balance scheduling IS NOT

takt-time planning Zone 1

Zone 2

Zone 3

Zone 4

Time


Dreams to Field• How did we implement Takt Time and Line of Balance in the field?

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&docid=XKaOrmUjYu3UxM&tbnid=iY1cx9RdkG-QeM:&ved=0CAUQjRw&url=http://pinuppickspenup.com/tag/david-sedaris/&ei=pVEGVOO1Ksz8oQTM6oGICQ&psig=AFQjCNGF7nkVP-zinWHqqvSFGuWepdKCMQ&ust=1409786566479123

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&docid=XKaOrmUjYu3UxM&tbnid=iY1cx9RdkG-QeM:&ved=0CAUQjRw&url=http://pinuppickspenup.com/tag/david-sedaris/&ei=pVEGVOO1Ksz8oQTM6oGICQ&psig=AFQjCNGF7nkVP-zinWHqqvSFGuWepdKCMQ&ust=1409786566479123


Overhead Phase LOB

• Begins with Layout on the floor, ends with duct insulation, plumbing chlorinated and all overhead conduit installed.

• 44 days total


Individual Trade Workflows

Duct Sequence: 2,1,3,6,5,4

Piping Sequence: 2,1,3,6,5,4

Electrical Sequence: 5,4,1,2,3,6


Overhead LOB


Controlling the schedule

• Last Planner system• Visual plan system in the field• Goal: Communicate where

people are actually working, how fast they are, and if they need to speed up or slow down


Communicating and controlling the space schedule

10/4/2014 17

Daily progress reports and space schedule displayed via whiteboard


Interactive Daily Reports and Color Up


Continuous Improvement of the Plan

• Initially structured with 4-day takt time, but this needed to be adapted.


Continuous Improvement of the Plan

• Printed out 11x17 of the LOB schedule and worked with the trades to reschedule w/ a pencil and ruler

• Took out 8 days in the schedule due to changing the sequence and crews


Current Inwall Phase LOB

•Now: 29 day sequence. (initially 37 with 4-day takt).


Overhead Phase SummaryTakt Time Planning Results

• 44 to 32 days • Slowed down some trades,

redirected some trades, sped up others, identified Last Responsible moment to speed up or slow down

• “9/10 when we accelerate, this costs us money. We’ve gone so much faster on this job and it hasn’t cost us a dime”- PM Jeff Stewart of Southland


Trade Partners Panel• Thoughts when first introduced to Takt Time and Line of Balance• Benefits and Draw Backs?• Opinion of Daily Color Ups and Reports• Effect on working conditions • Ownership of space/ cooperation • Crew Sizes/ Hours Spent compared to original estimate• Material Management


Final Thoughts and Lessons Learned• Data of Findings (PPC)• Success of Project• Calculated Risk• Final Perspective of Takt Time• Incorporating Owner Change Order and saving time


Questions?

P2SL

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&docid=Ks-wTW5dMV7EgM&tbnid=fJPSxfWsHdxHJM:&ved=0CAUQjRw&url=http://pankow.chemtel.net/&ei=01L_U8fjHIi7ogTmyYHoAQ&bvm=bv.74035653,d.cGE&psig=AFQjCNE-51Oh3GKLRGhEsGFCpMywsXO8GA&ust=1409328188955671




http://www.sutterhealth.org/

http://www.sutterhealth.org/

an experiment in takt time - lean construction institute presentation...• 44 to 32 days • slowed...

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