Lean Foundations & Philosophy - 9 Project life cycle overview and waste points (EN) - video Dailymotion

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Transcript

00:00Welcome, this is an explainer from all of us here at Unified Consulting Solutions.

00:05Today, we are going to tackle a problem that, let's be honest, everyone in construction knows

00:09way too well. We're talking about those hidden points of waste, you know, the ones that just

00:14drain the time, the money, and honestly, the morale right out of our projects. We're going

00:18to break down the whole project lifecycle to pinpoint exactly where things go sideways and,

00:23much more importantly, how we can start to fix them. So think about this for a second.

00:28Have you ever been on a job site that just feels, well, chaotic? You know the scene. People are

00:35being moved around, not because the plan says so, but just to keep them busy. This quote right here,

00:41it absolutely nails it. It's a problem so common that it actually has a name, the bungee effect.

00:47It's that feeling of being stretched and pulled in all these different directions. And let me tell

00:52you, it is a huge symptom of a much deeper problem. All right, so here's our game plan for today.

00:59First, we'll look at the reality on the job site, the problem. Then, we'll diagnose the cause,

01:05all that waste. After that, we'll get into the solution, the lean philosophy and a really powerful

01:11blueprint called the last planner system. And finally, we'll look at the real world impact and

01:16give you a clear next step. So by the time we're done here, you're going to be able to spot things

01:21like the bungee effect from a mile away. You'll know how to talk about the eight wastes of lean,

01:26and you'll really get the difference between push and pull planning. But the big thing,

01:30you'll understand how a system like the last planner system can bring some serious predictability back

01:34into your projects. Okay, let's dive right in. Section one, the reality of the job site. And look,

01:41we've all been there, right? It's a place with a ton of energy, but also a ton of, well,

01:46unpredictability. And that kind of chaos, that's the perfect breeding ground for the bungee effect.

01:51So what exactly is this bungee effect? Well, think of it as a really bad side effect of a low

01:58planning environment. The old school mindset is, hey, we've got people on the clock, we got to keep

02:02them busy, right? But what happens when the plan gets interrupted? Instead of pausing and figuring

02:08things out, we just force trades into other areas to avoid any downtime. The problem is this doesn't

02:13just mess up the logical flow of work. It pulls everyone's focus away from what's actually

02:17important. And that kicks off this whole chain reaction of bad consequences. You see, the bungee

02:23effect is just the symptom. To really find a cure, we have to diagnose the disease. And that means

02:29learning to see and to name all the systemic waste that's just baked into traditional construction

02:34management. You've got to name your enemy before you can defeat it. And to fight that waste, we first

02:40have to give it a name. Lean gives us a really specific language for this, the eight wastes. And

02:46we're not just talking about the obvious stuff like defects or rework. No, it's so much more. Think

02:52about the time your crew spends just waiting for materials or the wasted motion of hunting for a tool

02:57that's not where it should be. It's the excess inventory that's just cluttering up the site.

03:02And this one is huge. It's about not using the skills and the brains of the people who are

03:07actually doing the work. All of these things, they soak up resources, but they create absolutely

03:13zero value for the customer. This right here, this is the fundamental difference in thinking.

03:18It's like a tale of two mindsets. On one side, you've got the traditional push system. It's all

03:24based on a big long-term forecast. And the main goal is resource efficiency, which is just a fancy way of

03:29saying keep everyone busy. But on the other side, you have the lean mindset. It uses a pull system.

03:35It's based on actual demand. And the focus is on flow efficiency, keeping the work moving smoothly.

03:41See the difference? It's a shift from siloed separate teams to integrated ones. And from these

03:46rigid long-term plans to short-term execution, you can actually count on.

03:49Okay, so we've laid out the problem. We know the root causes. The big question is,

03:55how do we get out of this cycle of waste and chaos? How do we finally escape?

04:00Well, the answer isn't just about buying a new tool or some fancy software. It's much deeper than that.

04:07It's a completely new way of thinking. It's a philosophy called lean. Now, it started in manufacturing,

04:13but it has turned out to be incredibly powerful for construction. And at the heart of lean are

04:18these five core principles. It all starts with value. You have to define what the customer actually

04:24values. Then, the value stream. You map out every single step and you are ruthless about eliminating

04:30those eight wastes we just talked about. Third is flow. You have to make the important value-creating

04:35steps happen without any interruptions. Fourth, pull. You switch to a system where the next step in

04:40the process signals when it's ready. And finally, perfection. A constant pursuit of getting better.

04:46What's known as Kaizen. Now, philosophy is great, but you need a practical blueprint, right? Something

04:52you can actually use on a project. And that, that is where the last planner system or LPS comes into

04:58play. It is the real world operational framework for making lean happen in construction. Think of the

05:05system working like a funnel, getting more and more detailed as you go. You start at the top with a big

05:09picture, the master schedule. Then, you break that down into major chunks with phase scheduling. Now,

05:15here's where the magic really starts. The look-ahead plan. This is where you scan the next few weeks to

05:19get work ready. That feeds directly into the weekly work plan, which is a solid commitment from the

05:23team. And the whole thing is closed by the learning loop, where we figure out what went right, what

05:28went wrong, and how we can get better next week. So let's talk about that look-ahead plan, because it's

05:33really the proactive engine of the whole system. Instead of just waiting for problems to pop up,

05:38the team is constantly looking three to six weeks into the future and asking one simple question.

05:44What could stop this work from happening? Do we have the materials, the right machinery? Do we have

05:49all the info we need? Is the previous trade done with their work? By finding and clearing these roadblocks

05:54before the work is supposed to start, we make sure that everything on our weekly plan is actually

05:59ready to go. And that brings us to the weekly work plan. The key here is who makes it, the last

06:05planners. These are the people closest to the work, the foreman. And the power of their plan is in this

06:11really simple but strict language. Should, can, and will. Should is what the schedule says we should

06:17do. Can is the list of work that is 100% ready to go, all roadblocks removed. And will, that is the

06:24list of tasks the team is committing to get done this week. And here's the golden rule. A task only gets

06:29on the will list if it's already on the can list. That one little rule is what makes the plan so

06:34reliable. Okay, so how do we know if all this is actually working? How do we know if our planning

06:39is getting better? Simple. We measure it. And the metric we use is called percent planned complete

06:44or PPC. Now, this is super important. This is not a grade. It is not a tool to blame people. It's

06:51just a simple, powerful number. If we committed to doing 10 things and we got eight of them done,

06:55our PPC is 80%. The two we didn't finish, that's not a failure. That's our lesson for the week.

07:01We dig into why they didn't get done so we can be even more reliable next week.

07:05It creates this amazing cycle of continuous learning. All right, so the theory sounds good,

07:10right? But the big question is, does this stuff actually work in the real world? Let's take a look

07:15at the impact. This is where we go from talking about waste to seeing real value being created.

07:20And trust me, the results can be pretty dramatic. Just take a look at this. It's a case study from a

07:25major construction project in India. Before they started using the last planner system,

07:30their average percent plan complete was just over 52%. Think about that. That's basically a coin toss

07:37whether the work plan for the week will actually get done. Imagine how frustrating that is. But after

07:42they implemented LPS, they were consistently hitting over 80%. That is a massive transformation

07:48from total chaos to real predictability, a world where the team can actually trust the plan.

07:53And you know, the benefits go way beyond just that one number. When your workflow is predictable,

08:00everything gets better. You cut down on waste, you save money, and quality goes up because people

08:05aren't constantly rushing. A calm, organized site is a safer site, period. And maybe the biggest benefit

08:11of all, it builds this incredible culture of collaboration, one that's based on making and

08:15keeping promises. It fundamentally changes how the whole team works together.

08:19All right, we have covered a ton of ground here. We started with the chaos of the bungee effect

08:25and ended up with a structured system for creating flow. So let's do a quick summary of the key

08:30takeaways and talk about your next step. So let's bring it all home. The number one thing to remember

08:36is that chaos on a job site isn't just how it is. It's a clear sign of systemic waste. The lean philosophy

08:42gives us a new way to see and fight that waste by shifting our thinking from a push to a pull system.

08:48The last planner system is the hands-on practical way to make that happen, creating real reliability

08:53through commitment. And by measuring our PPC, we create a feedback loop to get better week after

08:58week after week. The bottom line, you get a better project in every single way you can measure it.

09:04Look, adopting this way of thinking is definitely a journey, not a destination. And to help you continue

09:09on that journey, all of us here at Unified Consulting Solutions and our work is guided by Dr.

09:14Murimutu K. We'd like to invite you to join our professional community over on LinkedIn. It's a

09:19fantastic place to share what you're learning and ask questions. The link is right down in the

09:23description for you. And for any of you who want to go even deeper and check out the source material

09:28for yourselves, we've put all the key references right here on the screen. Hey, thank you so much

09:33for joining us today. We really look forward to seeing you over in the UCS community.

Lean Foundations & Philosophy - 9 Project life cycle overview and waste points (EN)

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