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Lean logistics,
lessons learnt from Japan
Adrian Blumenthal, Special Projects Director, Constructing Excellence
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What we found out from a
product and service view Scoping Study Results, Japanese Corporations, Compared to UK Construction Industry
KPI's: Average and Demo Projects
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
Clie
nt sat
isfa
ction
prod
uct
Clie
nt sat
isfa
ction
serv
ice
Project p
redictiability tim
e
Project p
redictab
ility co
st
Saf
ety
Produ
ctivity
Profitab
lilty
Def
ects
Con
stru
ction
time
Con
stru
ction
cost
UK Construction Indicators 2006
Benchm
ark
Socre
in r
ela
tion to U
K c
onstr
uction
ind
ustr
y Japan
Average UK
Demo Projects
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Japan/United Kingdom
– Economic Comparisons
1500 1081 City centre A/C offices £M2
2300 2167 Hotels (hi quality) £MS
1400 880 Shopping Centres £MS
550 853 Factories warehouses industrial £M2
13.50 17.96 As above – Skilled £PH
11.07 14.16 As above- Semi Skilled £PH
10.10 11.62 Labour All In Rate (gross cost of
employment- unskilled £PH
United Kingdom Japan Comparison Economics, Building-
29/02/08 (G and T )
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Japan/United Kingdom
– Economic Comparisons
310 237 Carcassing Timber £Tonne
22 8 Glass 6 mm £M2
11 6 Concrete blocks £M2
230 335 Common Bricks 100mm £/1000
235 203 Plaster £tonne
20 12 Sand Coarse £tonne
29 10 Aggregate all grades £tonne
United Kingdom Japan Comparison Economics, Building-
29/02/08 (G and T )
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85 54 Concrete 20N/mm2 £M3
105 38 Cement £tonne
750 670 Structural steel £tonne
650 322 Rebar/tonne supplied to site £ tonne
Some more- overall 28% cheaper
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Simple Processes:
• The Key is Logistics, information, materials and people first part
of the plan
• Everyone participates in Quality Management it’s the constitution
• Use PDCA cycle
• Use data and facts as the basis for planning
• Prefabricate all that you can
• Japanese process for construction: Plan, study, design, construct-
what's ours?
• Plan for early Finish!!!
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Logistics of information and People
The Quality Board:
Waste streams Clock
Logistics and daily
plan section
Safety info
Handover and company information
400 men briefed at 7.45am each day by PM
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Logistics of People and Info
• Achieving zero defects on all projects (visual management) and
handover process done publicly
• All problems dealt with immediately
• 7.45am presentation on daily plan to all members of the team
• 10am meetings every day to discuss next day
• Safety meetings every day to review
“hot spots” called KY!!!!
• New starters all have health check
Blood pressure monitor
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Logistics of Materials On Site Prefabrication
Floor Slab and Services
prefabrication yard Floor Prefab in Place
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Logistics of people and materials: Hoist on inside of building, computers log
and charge all usage
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Waste material and environment: When it’s combined it’s waste, when separated
it’s a resource, Japanese wide Policy
4 R’s What’s this concept of Skips!
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Logistics of information: Quality in all that we do; Promotes Health and
Safety
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Pragmatic View for Health and
Safety
Pragmatic approach to safety
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Quality checking and progress
monitoring
Quality:
photographic logs and quality
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Quality board:
photograph everythingProject:
Trade: Date: Floor: Area: Drawing ref: Checked by: Approved
by: Date:
Comments:
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Design and Construction
Cost
Quality
Delivery
Safety and
Environment
Production techniques used for design
Early feed forward of design to Construction
Feed back of Construction technology to design
Unification of the responsibility for the guarantee of quality OFD
Effective VE by scrupulous information exchange
Shortening of construction time through collaboration
Tackling the technology that considers Safety and
Environment from the design Stage