lean construction: increase production and reduce risk

Liberty Mutual Insurance 1

Speaker’s Bio

Lean ConstructionIncrease Production and Reduce Risk

If you have a question during today’s webinar, type your question here

and click send.

A handout of today’s presentation is available here.


We Will Be Recording This Session For Playback

IMPORTANT NOTICE: This GoToWebcast

service includes a feature that allows audio and

any documents and other materials exchanged or

viewed during the session to be recorded. By

participating in this meeting, you agree that your

communications may be monitored or recorded at

any time during the meeting. If you do not

consent to the recording, please disconnect from

this session. An On Demand recording may be

posted so check our SafetyNet > Training >

Recorded Webinars for availability.


Please Help Improve Our Webinars!

Complete our pop-up survey in under 2 minutes!

Lean Construction Thinking

Increase Production and Reduce Risk at the

Same Time

Our risk control service is advisory only. We assume no responsibility for management or control of customer safety activities nor implementation of recommended corrective measures. The

illustrations, instructions and principles contained in the material are general in scope and, to the best of our knowledge, current at the time of publication. No attempt has been made to interpret

any referenced codes, standards, or regulations. Please refer to the appropriate code-, standard-, or regulation-making authority for interpretation or clarification. Only your policy or contract can

give actual terms, conditions and exclusions.


Introducing Your Host

Andrew West, MS, PE, ARM, CRIS

Technical Consultant

New York, NY


What this session is / is not…..

Is Not – an in depth Lean Class

Goals –

– Recognize Lean as you see it on a jobsite, and tailor your

consulting to that.

– Walk away with enough understanding of Lean to start

incorporating.

– Set the stage for learning more about Lean down the road.


Why is this important over-all?

Based on information from Liberty Mutual, the U.S. Bureau of Labor Statistics (BLS), and the National Academy of Social Insurance

2016 Workplace Safety Index– #1 Overexertion - lifting, pushing, pulling, holding, carrying or throwing objects


Why is this important in Construction?

Based on a study of approx. 2,000 disabling injuries ≥ $2,000 each; SIC 1711

Plumbing, Heating A/C



Plaster, Drywall, Insulation

Based on a study of approx. 650 disabling injuries ≥ $2,000 each; SIC 1742



Electrical

Based on a study of approx. 3,000 disabling injuries ≥ $2,000 each; SIC 1731


The Loss Cost StreamM

ea

su

rem

en

t E

ffecti

ven

ess

Incident

Harm

Claim

Cost

Retu

rn o

n In

vestm

en

t

System Variance

Process Failure

Risk

Proactive

Reactive

Effort


Environment

Capability Motivation

Optimized

System

:• Working surfaces• Lighting• Weather• Handrails• Elevated work, etc.

(WHAT WE HAVE)

:

• Training & Education• Do they understand?• Instructions• Orientation• JHA/JSA Review• Physical Capabilities

(WHAT WE KNOW)

:• Safe Behaviors• Avoid short cuts• Use feedback &

coaching• Pressure/Stress• Hurrying• Old habits• Cruise Control

(WHAT WE DO)

Continuous Improvement - Systems View


The End Game

Projects PeopleWant Workplaces

PeopleWant to be In

Futures PeopleWant to Invest In

Business Partner Vendors

Want

Corporate “Neighbor”

Communities Want

Optimized Systems

Safety

(LMI Model)

Risk

Reduction

Efficiency

(Lean Mfg.)Waste

Reduction

Quality

(Six Sigma)Output

Variance

Reduction


Lean focuses on eliminating waste in processes or

systems

Lean is not about eliminating people, but about using

them more wisely

Lean is about working with people to achieve

continuous improvement activities to assist in reducing

cost in an organization

Lean is about understanding what is important to the

customer

What is Lean?


Specify value

Value is defined in relation to the customer

Identify the value stream

Exposes the enormous amounts of waste

Create flow

Reduce Waste (Noise)

Reduce batch size and WIP

Let the customer pull product through the value stream

Make only what the customer has ordered

Seek perfection

Continuously improve quality and eliminate waste

Lean Principles


Forms of Waste – (DOWNTIME)

1. Defects – rejects, repairs, rework, corrections

2. Over-production – making more than required

3. Waiting – wasted time before the next step in a process

4. Non-Utilized Talent – under utilized skill sets. Not

capitalizing on creativity.

5. Transportation - all transport is waste

6. Inventory – does not add value to the product or svc

7. Motion – any movement which does not add value

8. Extra-processing – using more expensive resource

Risk is waste – Waste is not the problem it’s a

symptom of problems in the system

Waste – What we are trying to eliminate


PDCA, DMAIIC, 5S – (Kaizen Events)

1. PDCA– Plan Do Check Act (or Adjust)

2. DMAIIC– Define, Measure, Analyze, Improve, Implement, Control.

3. 5S (actually more like 6S, 7S, 8S…)– Sort, Straighten/set in order, Scrub/Shine/Sweep,

Standardize, Sustain,….safety, supervision, security, etc.

4. LMI Consulting Model– Risk Assessment, Systems Analysis, Integrated Solution,

Performance Measurement

Problem Solving Models or Strategies


1. Sort – Only what is needed, only in the amount needed. When in doubt, throw it out.

2. Straighten / Set in Order – Arrange items so they are easy to use. Labels, maps, sign boards, color coding, outlines.

3. Shine / Sweep / Scrub – Remove dirt, grime. Keep swept and clean. Ongoing inspections and checklists.

4. Standardize – Create a consistent way tasks are done. Charts, visual management, consistency.

5. Sustain – A habit of maintaining correct procedures

More on 5S…


1. Lean is all about reducing waste, and risk is a form of

waste.

2. Works upstream from end to beginning

3. Sketch out the process(es) involved

4. Use Value Stream Mapping to create current state map.

5. Identify where waste is present in each step.

6. Deploy strategies (using those closest to it) for

improvement.

7. Use 5S or model to provide structure to the waste

reduction strategies.

Putting it all together…


8. Develop a future state Value Stream Map (what it will

look like).

9. Utilized metrics to demonstrate that it worked.

10.Take the future state Value Stream Map and further the

5S process (Continuous Improvement)

11.Recognize each win along the way.

12.Maximize the use of good visual management

wherever you can.

Putting it all together…


What is Lean Construction

Lean construction is a philosophy based on the concepts of

lean manufacturing.

It is about managing and improving the construction process to

profitably deliver what the customer needs.

Lean construction is “a way to design production systems to

minimize waste of materials, time and effort in order to

generate the maximum possible amount of value” (Koskela et al.2002)

Designing a production system to achieve the stated ends is

only possible through the collaboration of all project

participants

– Owner, A/E, Constructors, Facility managers, End-user


Lean Construction Priorities

Keep work flowing so that the crews are always

productive installing product

Reduce inventory of material and tools

Reduce costs


Six Goals of Lean Construction

Finished building will deliver maximum functionality

End users will benefit from the lowest optimum cost of

ownership

Inefficiency and waste in the use of labor and materials will be

eliminated

Specialist suppliers will be involved in design from the outset

to achieve integration and constructability

Design and construction will be through a single point of

contact for the most effective coordination and clarity of

responsibility

Current performance and improvement achievements will be

established by measurement


Benefits of Lean Construction

Workplace Standardization

Project Predictability

Clear communication of project plans

Increased profit

Decreased inventory costs

Higher quality product

A well motivated, well trained, flexible and fully engaged

workforce

Increased productivity

Decreased accidents and less sickness absence


Summary of Lean Construction

Lean construction is a different way to see, understand and act

in the world of construction

Lean construction is a philosophy – a comprehensive system

of ideas that lead to the flawless delivery of the built

environment

Lean construction is practiced using the Lean Project Delivery

System, which continues to evolve as more is learned from

practice and research


Task – Delivery + Material Handling


What makes this better? Lean?

Pipe-racks

– Store heaviest material in power zone

– Lighter material on highest and lowest levels


Manual Aids - Caster Size & Maintenance


Manual Aids - A-Frame Carts

Rated for the weight of

material being

moved/transported

Manual Aids - Dollies


Mechanical Assist Equipment

Helps avoid static postures

Use plasterboard lift to avoid physical stress


Mechanical Assist Equipment

Scissor lifts help reduce ascending/descending frequency

Work is completed much more quickly


Task – Workstations Tasks

What are the risk factors?

What injuries might this lead to?


Workstation Considerations

Postures/Material Handling:

– Build workstations up off the floor, and stable

Wasted Motions/Material Handling:

– Keep workstations near the activity they feed

– Lockable wheels allow for easier relocation

Keep waste containers near workstations:– Capture Debris at the Source

– No Double Handling


For Longer Lasting Operations

Build a portable workstation

What are the right heights/features?


Workstations – Height

Adjustment Range

– Heavy work equals 29-39 inches from the floor

Examples of standing workstations: Too high


Workstations – Height

Using a gang box & other material as quick task workstation

Keep work in the power zone

Avoid working on the floor


Kneeling


Kneeling Examples

What are the risk factors?



Kneeling – Practical Solutions

Better practice

Use of knee pads / cushions

– Creative back / shoulder support with padded 5 gallon pail


Often What You Need Is Readily Available


Task: Standing Tasks

What are the risk factors with standing tasks?



People Closest To The Job…….RISK

Standing – Practical Solutions


Standing Tools

Allow some jobs to be done standing up Instead of

kneeling or bent over

– Tie wiring

– Drilling

– shooting studs

– clips


How Could This Storage Be Improved?


Using 5S – A Lean Methodology


How Could This Storage Be Improved?


Is This Better?


Hand/Power Tools?


Aerial Lift Floors?


Pre-Planning and Job Layout

Jobsite Layout

Delivery / Flow of Materials

Transport

Minimize distance between fabrication & Installation

– Spot materials at multiple locations on a large roofing job

Minimize moves between floors and buildings

– Spot material storage around the job using small stockpiles instead of one central one

Maintain adequate clean aisle and access areas

– Mark and maintain aisles for easy movement around the building


Partial pre-fab

Pre-fab mobility

Pre-fab by room

Pre-Fabrication


Pre-Fabrication

Overhead Piping Installation


Pre-Fabrication

Plumbing Assembly

– Built in contractor’s

shop

– Bolted onto this cart

when it’s built off site for

eased mobility once on

our project


Pre-Fabrication

Interior and Exterior framing


Delivery / Materials Flow

Coordinate handling between supplier and field

– Just in time delivery keeps the materiMechanical bending of rebar at

the shop reduces strain injuries at the job site

– Any pre-site fabrication will most likely help

Just in time delivery keeps the material moving and eliminates

double, triple, or more NON-PRODUCTIVE re-handling

– Deliver the rebar the day before it is needed. This will prevent it from

being covered with other materials or needing to be cleaned before

being used


Transport

Keep tools and materials mobile

– Palletizing to allow mechanized handling

– Rolling racks and dollies (wheel size, condition)

– Bulk containers/handling

– Other mobile devices?

Eliminate obstacles from material flow path

– Ensure floor is broom clean

– Material hoist metal plates so four wheeled dollies can more easily and

unimpeded over gaps


Transport

Don't rely on team lifting of heavy items (How??)

– Build and use loading platforms for material delivery and waste removal

– Use powered tailgate/hoists on trucks


Preplanning is How You Win!

When planning material and tool movements:

– Include material handling in every pre-planning discussion

– What can be prefabricated at the shop?

– Involve those who do the work for ideas

– Consider mechanical handling means FIRST

– While finding solutions can be challenging, it is worth it.


Pull Planning Board


Visual Management – Daily Huddle


Lean Construction can be used to improve both efficiency and

safety

– Lean and ergonomics can be complimentary

– Discuss Material Handling (manual and mechanical) in ALL

pre-plans

– Use workers’ knowledge – They are closest to the risk

– Recognize opportunities to integrate:

• Ergonomics/MMH

• Productivity

• Quality

In Closing


Take advantage of Liberty Mutual

SafetyNet™ to reduce risk in your operation

24/7!

SafetyNet™


Risk Control Consulting Center

Speak directly to a consultant

who can:

Recommend practical ways to mitigate

risks and identify exposures

Offer tools, resources, and

training on specific topics related

to your business

Use videos or photos to analyze

exposures and help identify controls

Help you implement safety protocols

Assist with SafetyNet sign-up

Our consultants can answer your questions, such as how to reduce slips and falls, how to prepare for

natural disasters or about state specific requirements.

[email protected]

M-F 8am-8pm ET

CONSULTING CENTER


Thank You For Your Participation!

Help us improve our webinars in under 2 minutes

by completing our pop-up survey!


Questions and Comments

Check our training schedule regularly so you don’t miss a learning opportunity

lean construction: increase production and reduce risk

Documents