23rd International Conference of the

TOC Practitioners Alliance - TOCPA

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21-22 March, 2016, Tennessee, USA

CCPM and Lean Construction

Nerius Jasinavicius,
TOC sprendimai, Lithuania
March, 2016

Nerius Jasinavicius

Founder of TOC sprendimai

Founding Member of TOCPA
Consultant for unique clients
TOCICO certified SC, TP
Certified Management
Consultant (ICMCI)

nerius@toc.lt

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Typical Construction
environment

Lots of stakeholders
High degree of uncertainty
Delays
Chaotic project meetings on sites
Big staff turnover
Waves of activities
Looks like nobody keeps promises
Distrust (Not-Me mentality)
Clients look for the ways not to pay
Very low cooperation between client, architects and
contractors

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

The challenge
In todays business management world there are so
many buzzwords the best and only really working
methodologies:
LEAN
SixSigma
TPS
TOC
WBS
Etc
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23rd International Conference of the TOC Practitioners Alliance - TOCPA

What is Lean Construction

Lean Design and Construction is a production

management-based approach to project delivery -- a new
way to design and build capital facilities.
Lean Construction extends from the objectives of a lean
production system - maximize value and minimize waste to specific techniques, and applies them in a new project
delivery process.
Source: www.leanconstruction.org

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Lean Construction elements

Integrated Project Delivery (IPD) is a registered business
mark by Lean Construction Institute. Primary IPD team
members include the architect, key technical consultants,
general contractor and key subcontractors. Using IPD,
project participants can overcome key organizational and
contractual problems. The IPD approach to contracting
aligns project objectives with the interests of key
participants.
Lean Constructions main tool for making design and
construction processes more predictable is the Last
Planner System and its derivatives.

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Last Planner

The Last Planner (sometimes referred to as the Last Planner System) is a

production planning system designed to produce predictable work flow and
rapid learning in programming, design, construction and commissioning of
projects.
The five elements of the Last Planner:
Master Scheduling (setting milestones and strategy; identification of long
lead items);
Phase "Pull" planning (specify handoffs; identify operational conflicts);
Make Work Ready Planning (look ahead planning to ensure that work is
made ready for installation; re-planning as necessary);
Weekly Work Planning (commitments to perform work in a certain manner
and a certain sequence); and
Learning (measuring percent of plan complete (PPC), deep dive into
reasons for failure, developing and implementing lessons learned).
Source: www.leanconstruction.org

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Start of the project

Company (sub-contractor) has been warned twice by

General Contractor
REAL CHANCE of loosing the contract (and all
consequences)
Typical solutions (over-time, more resources, etc.) did not
work

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

What is necessary for

successful construction project
We know what is the final product/result
Deliverables
We know what is necessary for the final product/result
Bill of Materials
Technology
Resources
We have a sound plan
We execute the plan

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Do we know what is the final

product/result ?
The answer was
Kind of
Lets spend some time on
really understanding what
should be the result
Yes, but its risky (!!!)

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Do we know what is necessary

for the final product/result ?
The answer was
Kind of
Now we know the final
product, lets build WBS and
Master Schedule
We cannot have all the
specifications now
Do we need to know it now ?
Detailed plan dilemma

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Lets build the plan (PERT)

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

PERT visualisation

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Lets build the plan (CCPM)

Master Scheduling (setting

milestones and strategy;
identification of long lead
items);
Phase "Pull" planning (specify
handoffs; identify operational
conflicts);

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Operational weekly planning

Make Work Ready Planning

(look ahead planning to
ensure that work is made
ready for installation; replanning as necessary);
Weekly Work Planning
(commitments to perform work
in a certain manner and a
certain sequence);

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Progress control

From LPS measuring percent of plan complete (PPC),

deep dive into reasons for failure, developing and
implementing lessons learned
Therefore it is common to think that as long as we are
completing some tasks, we are making the progress.
But how true is that ?

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Weekly planning and

progress control

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

The problem: delayed Critical

Chain Task

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Focused efforts to increase the

speed (Kaizen)

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Major milestone ON TIME

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Some realizations

Last Planner concept is very useful in creating project

plan, but be aware of PPC short-falls
CCPM helps to focus weekly planning on critical tasks and
ensuring full kit
CCPM helps to focus LEAN improvement efforts
Old habits die hard

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Thank you !

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23rd International Conference of the TOC Practitioners Alliance - TOCPA