mortenson's lean journey
TRANSCRIPT
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LEAN CONCEPTS ACROSS DELIVERY METHODS:
MORTENSON’S LEAN JOURNEY
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Agenda
Mortenson’s Lean Journey What does Lean mean to Mortenson?
Review of Mortenson’s Lean Timeline
Lean in Construction – 9 Tools
8 Types of Waste - DOWNTIME
Q & A
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LEAN is a journey in which we strive to maximize value for our customers through the elimination of waste.
LEAN is not a tool but a philosophy and a culture.
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May 1996 CCI Identifies
Lean Opportunities
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005
1997 Started work
with Lean Construction
Institute
April 2004 General Dynamics Electric Boat Tour
Modularization Culture of Continuous Improvement
2005 Kaizen Events
Deck Pour Process Reduce Man
Power by 50%
January 2005 Boeing Tour
Kaizen Process
History of the Mortenson Production System (MPS)
Educational Tactical
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2005 2006 2007 2008 2009 2010 2011 2012 2013
April 2006 Virginia Mason
Value Steam Mapping
2012 Benchmarking with Linbeck Last Planner
System
History of the Mortenson Production System (MPS)
2013 Exempla St. Joe’s
Multi Trade Prefabrication
Educational Tactical
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Chicago’s Journey
2006 • Projects
Utilize IWP
2010 • Use of
Prefabricated Assemblies
2011 • Prefabrication
Plans Developed for Each Project
2012 • Rapid
Process Improvement Events
2013 • Advocate Good
Shepherd • Valparaiso University
Residence Hall
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Lean in Construction: Tools
Value Stream Mapping
Target Value Budgeting Process Mapping
Pull Planning Gemba Kaizen Standard Work
Five S’s Kitting Modularization / Prefabrication
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Value Stream Mapping – Vision Alignment
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Target Value Budgeting
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Process Mapping
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Pull Planning
Specifies handoffs and communicates quality, safety and efficiency performance
Promotes a team approach to efficiently sequence work
Optimizes team productivity
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Gemba Kaizen – CIP Concrete
Event Results Safety – 7 Hazards Quality – 3 Issues Efficiency – 14 Opportunities
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Gemba Kaizen – Solar Panel Supports
Using Orteca mounted laser receiver to stop driving hammer when design height is reached.
5.3 height failures per tracker 5 man hours per tracker to fix
out-of-spec piles.
Before
Pile driving to the specified height.
Laser receivers on Orteco machines are not working. Pile heights are out of spec approximately 5.3 times per tracker.
Adjustable elevation rod with receiver attached was built. Ground person now holds rod for a visual reading on the design height of the pile.
QC issues dropped from 5.3 height issues per tracker to .75 height issues per tracker Potential Savings of:
$2.7 Mill. in Potential Re-Work Costs 40,000 Re-Work MHs
After
OPERATION ISSUE ACTIONS TAKEN RESULTS
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Standard Work – Best Practice Database
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LEAN & 5S
5 S
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5 S- Sort
Sort through everything in each work area Keep what is necessary Move materials, tools, equipment , etc. that are
not frequently used to a separate storage area Discard Items that are not used
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5 S- Straighten
A place for everything and everything in it's place…with everything properly identified and labeled
Organize, arrange, and identify everything in a work area for the most efficient and effective retrieval and return to its proper place
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5 S- Shine
Regular cleaning and inspection makes one’s work easier… To identify and correct problems early To maintain equipment in order to minimize equipment failure To monitor levels of tool, parts, and equipment to minimize downtime while
waiting for new supplies to be delivered.
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5 S- Standardize
Establishment of a work structure that will support the new practice(s) and avoid slipping back into old work habits
Educate fellow workers on “what right looks like” Use labels, signs, posters and banners as visual aids
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5 S- Sustain
Implement a formal system for monitoring the results
Continue to educate people about maintaining standards
Make any needed changes in the standards and provide training that addresses those changes
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Kitting – Tool Kits
Reduced inventory levels Operator effectiveness
Decreased unpacking, walking, searching Reduced overall deliveries Less space required for material storage Quality and part shortage issues caught upstream
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Prefabrication / Modularization
Significant Time savings Higher Quality Reduced Punch List Better Safety Clean project site – less waste
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Prefabrication / Modularization – Bathroom Pod Installation
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Prefabrication – Multi-Trade Racks at Shop
Quality - controlled environment Temperature, moisture, lighting
Safety - no fall hazards Assembly line efficiencies
Easy access to materials and tools
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Prefabrication of Multi-Trade Racks on Site
Multi Trade Racks (MTR’s) – Lessons Learned
Zone Planning - Decide early what a typical cross section of a rack looks like
Early Coordination of recessed objects in ceilings
Every rack is different
Keep zones of the racks open for “pass thru” systems
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Prefabrication – Wall Panels
Allowed the team to develop the interface details between panels Critical side and vertical interfaces Penetrations thru barrier system
Allowed for coordination process to be simplified Panel location, overall dimensions, and opening RO’s, only
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Assembly line for head wall construction
Prefabrication - Headwalls
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Prefabrication – Headwalls
Using the plywood template to locate all of the in-wall boxes
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Prefabrication – Headwalls
Finished head walls stacked by type
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Prefabrication - Headwalls
Clamping the head wall frame to the patient room wall
Prefabrication allowed 18% efficiency gains
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Work that is not specifically asked for by the customer.
Any movement of man and/or equipment that does not add value to the process.
Storing product as a result of overproduction.
Unnecessary movement of a product between processes.
Producing something either before it is needed or in too great a quantity.
Driving Waste (Muda) Out of the Process
Waiting for parts, machines, people.
Errors that result in rework and increased costs.
verproduction O
Failing to use the people or resources effectively.
aiting W on-utilized resources N ransportation T nventory I otion M xcess processing E
efects D
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Virtual Mock-Ups NO
efects D
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Cost Modeling + QTO NO verproduction O
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DWF Exports (from Revit Models)
Primavera P6 Schedule
Sychro Visual Schedule
Building Information
Schedule Information
University of Iowa Hancher Auditorium Architecture: Pelli Clark Pellia Structure: Thorton Tomesetti
4D Modeling NO aiting W
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4D Modeling NO aiting W
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Collaboration Tools NO on-utilized resources N
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Just In Time Delivery NO EXTRA ransportation T
9,400 tons of steel erected in 9 months Just in Time delivery – no laydown No truck staging outside of fence Picked from truck hung in place
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Model Based Estimates NO nventory I
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BIM in Field NO EXTRA otion M
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Collaboration Portal NO xcess processing E
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Open Discussion
Q & A
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Lean Construction Institute – Lean in Practice
A Case Study of The University of Chicago Administration Building
Patrick Wilson Larry Arndt Peter Rumpf
Nathan Cool Don Semple Benjamin Rubach
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Project Overview – U of C Portal Project
Renovation of a prominent building on campus that houses executive officers of the University
Construction Budget - $5.5 million CMAR
Overall Project Schedule – 9 months
Primary work on two floors (7,500 SF/floor)
Lower Level (Mechanical Rooms) 1st Floor Lobby and South Offices
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Project Overview – U of C Portal Project
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• Develop Standard IWP • Scope of Work • Pre-planning Meetings
What is the Process?
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• Develop Standard IWP • Scope of Work • Pre-planning Meetings
What is the Process?
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• Develop Standard IWP • Scope of Work • Pre-planning Meetings
What is the Process?
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• Develop Standard IWP • Scope of Work • Pre-planning Meetings
What is the Process?
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• Develop Standard IWP • Scope of Work • Pre-planning Meetings
What is the Process?
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• Develop Standard IWP • Scope of Work • Pre-planning Meetings
What is the Process?
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• Develop Standard IWP • Scope of Work • Pre-planning Meetings
What is the Process?
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Design Intent Modeling
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Design Phase Coordination
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Design Phase Coordination
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Existing Conditions Documentation – Laser Scan
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Existing Conditions Documentation – Laser Scan
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Construction / Fabrication Modeling
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Design Assist Review
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Level of Development (LOD)
LOD 100: The Model Element may be graphically represented in the Model with a symbol or other generic representation, but does not satisfy the requirements for LOD 200.
LOD 200: The Model Element is graphically represented within the Model as a generic system, object, or assembly with approximate quantities, size, shape, location, and orientation.
LOD 300: The Model Element is graphically represented within the Model as a specific system, object or assembly in terms of quantity, size, shape, location, and orientation.
LOD 350: The Model Element is graphically represented within the Model as a specific system, object, or assembly in terms of quantity, size, shape, orientation, and interfaces with other building systems.
Schematic Design
Design Development
Construction Documents
Coordinated Construction Documents
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Design Intent Model
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Construction / Fabrication Model
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Curtain Wall Design Intent Model (LOD 350)
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Curtain Wall Installation
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Curtain Wall Installation
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Prefabrication - General Conditions
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Lessons Learned
Undocumented existing conditions conflicted with MEP intent
Design phase coordination issues had to be dealt with by the construction coordination team
Need to develop Model Progression Specification to align LOD of design intent with construction schedule and final model use
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Open Discussion
Q & A
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Panel Discussion Questions
How do contracting arrangements engender the collaboration needed for virtual design and construction?
How do we provide more value through the design assist delivery model?
What design deliverables are required? Model only? Paper only? Performance specification?