Lean Concepts & Principles - 13 Basics of production systems in construction (EN) - video Dailymotion

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Transcript

00:00Welcome to Unified Consulting Solutions.

00:02You know, in construction, we all face this one massive, frustrating challenge, right?

00:07It's that gap between the beautiful plan we have on paper and the messy reality out on site.

00:13Well, today, we're going to explore a powerful way of thinking that can help you close that gap for good.

00:19So, what we're going to do is explore how a simple shift in your perspective,

00:23you know, from trying to manage a chaotic, unpredictable project

00:26to instead steering a smooth, efficient production system can totally transform your outcomes.

00:32It's really about moving from that tangled mess of complexity to clear, predictable progress.

00:39Okay, so here's our goal for you today.

00:41We want to give you a really practical framework.

00:44By the end of our time together, you'll get what a production system is all about in construction,

00:49you'll see how it makes things safer and better quality-wise,

00:52and you'll grasp the huge, huge opportunity this presents,

00:56especially for us here in India.

00:59All right, so here's how we've laid it all out for you.

01:01We'll start with the problem, then talk about this new way of seeing things as production.

01:06After that, we'll get into the principles of flow,

01:08see how that connects to safety and quality,

01:10and wrap up with what this means for India.

01:12So, let's jump right in.

01:14Section 1. The Construction Dilemma.

01:17And it really is a dilemma, isn't it?

01:19That gap between what we plan and what actually happens.

01:22You know, for decades, our whole industry has been built on the Critical Path Method, or CPM.

01:28And look, it's not about tool.

01:30It's actually excellent for what it was designed for.

01:32You know, creating that big, high-level master schedule

01:35and setting those all-important contractual milestones.

01:37It gives us the big picture.

01:39But.

01:40And this is the big but.

01:42Here's the core issue.

01:44That master schedule, it assumes everything is going to flow in a nice, neat, predictable line.

01:49The reality on site, as you know, is anything but predictable.

01:53Every single day is filled with variability.

01:55Late materials, crew no-shows, design changes, you name it.

01:59And that rigid CPM plan just can't handle it.

02:02That's where the gap between plan and reality comes from.

02:05And here in India, that gap has a staggering cost.

02:09Think about this.

02:10Issues like supply chain problems and just inefficient processes

02:14can lead to project delays of up to 40%.

02:1740%.

02:18Now, the key thing to understand is this isn't because we have bad planners.

02:22It's not a failure of the people.

02:24It's a failure of the entire paradigm we're using to manage the work.

02:28So, if the old way is broken, what's the solution?

02:32Well, it's all about a massive shift in how we think.

02:35This brings us to our next section, seeing construction as production.

02:39So, what if we just stopped managing construction

02:42like it's a series of totally unique, one-off projects?

02:45What if, instead, we started managing it as a production system?

02:49This is the core idea.

02:52Think of every construction site as a temporary factory,

02:55a system designed to deliver one specific product,

02:58whether that's a skyscraper, a bridge, or a road.

03:00And this really shows the difference in mindset.

03:03See, a project mindset focuses on just getting tasks done.

03:08It asks, did we finish the activity for today?

03:11But a production mindset looks at the whole system.

03:14It focuses on transformation, flow, and value.

03:18It asks, is the entire system working smoothly to eliminate waste?

03:21It's a much bigger, more powerful way of looking at things.

03:25And in a lean production system,

03:28everything, and I mean everything, starts with value.

03:31And here's the key.

03:33Value is always defined from the customer's point of view.

03:36It's not just about, did we build it to the spec sheet?

03:38No, it's about things like schedule certainty,

03:41the quality of the final product,

03:42and even the total cost of owning that building.

03:45That's what the customer truly values.

03:47So, if value is what we want to create,

03:49then waste is what we have to destroy.

03:52Lean thinking gives us a great way to spot it

03:54with these eight wastes.

03:55And you can remember them with the acronym downtime.

03:58We're talking about defects, overproduction,

04:00weighting, I mean, how much weighting happens on a site,

04:03non-utilized talent, transportation, inventory,

04:07motion, extra processing.

04:09All of these things cost you money,

04:10but add zero value to the customer.

04:12They are the enemy of productivity.

04:15Okay, so spotting waste is the first step,

04:17but how do you get rid of it?

04:18Well, that requires mastering the principles of flow,

04:22which is our next section.

04:24We're moving from a push to a pull system.

04:27These five principles are basically

04:28your roadmap to getting lean.

04:31We've already talked about step one, define value.

04:33Step two is to map the value stream,

04:36actually visualize your whole process.

04:38Then the magic happens.

04:40You create flow, establish pull,

04:42and finally, always pursue perfection.

04:44It's a continuous cycle.

04:45Now, this is a game changer.

04:49Think about it.

04:50A push system, which is traditional construction,

04:52is like an overflowing inbox.

04:55We just keep pushing work onto the site based on a schedule,

04:57creating huge piles of work in progress, or WIP.

05:01A pull system is different.

05:03It's like a just-in-time delivery.

05:05Work is only released when the next person in line

05:07is actually ready for it.

05:08No more chaos, no more pileups.

05:10So, how do you do this in the real world of construction?

05:14The most powerful tool we have

05:15is the Last Planner System, or LPS.

05:18The genius of LPS is that it brings the people

05:21actually doing the work,

05:23the foreman, the trade partners,

05:24the last planners, into the planning process.

05:27They're the ones who know what's really possible.

05:30It's all about collaborative planning

05:32and making reliable promises.

05:34And here's where it gets really interesting.

05:37Creating this smooth, reliable workflow,

05:38it's not just about being faster or more efficient.

05:41It creates what we call the triple payoff,

05:44because it has a huge impact

05:45on two of the most important things on any site,

05:48safety and quality.

05:49The legendary W. Edwards Deming put it perfectly.

05:53He said, quality isn't just up to the worker.

05:56It's management's job, your job,

05:58to create a system where good work can actually happen.

06:02And a smooth, predictable process flow,

06:04well, that is the system.

06:05Just think about a chaotic site versus a calm one.

06:09On a chaotic site, you're constantly firefighting,

06:11rushing around, fixing problems.

06:13And when people rush, they take shortcuts,

06:15and that's when accidents happen.

06:17But in a system with predictable flow,

06:19the work is calm, it's organized.

06:21And a calm, organized site is a much, much safer site.

06:24And this isn't just a nice idea.

06:26The numbers prove it.

06:28Get this.

06:29Studies from sites that really focus

06:31on optimizing their workflow

06:32have seen a 22% drop in accidents.

06:3722%.

06:38Better flow literally means better safety.

06:41It's a direct connection.

06:42So, all of this brings us to the most important part.

06:47What does this mean for us, right here in India?

06:50This is your next step.

06:52This is our call to action.

06:55Now, if you look at the state of lean in India today,

06:58adoption is still pretty low, maybe 10, 20%.

07:01But listen, that's not a weakness.

07:03That's a massive 80 to 90% untapped potential.

07:07That's your competitive advantage

07:08waiting right there for you to grab it.

07:11And the timing could not be better.

07:13With the huge national infrastructure pipeline,

07:16we're talking 1,111 lakh crore.

07:19The demand for efficient project delivery

07:21is absolutely off the charts.

07:23And we already know this works here.

07:25We have proof from Indian pilot projects

07:27showing an 18% ROI.

07:28The opportunity is real, and it's happening right now.

07:32Okay, so let's wrap this up with the key takeaways.

07:35First, shift your mindset from project to production system.

07:39Second, get laser-focused on customer value

07:42and eliminating those eight wastes.

07:44Third, start using pull systems

07:46like the last planner system to create real flow.

07:48And finally, never forget that this reliable flow

07:51is the engine that drives everything,

07:53safety, quality, and predictability.

07:55Look, the shift to a production mindset

07:58isn't just some academic idea.

08:00It is, without a doubt,

08:02the single greatest opportunity

08:03for the Indian construction industry today.

08:06So the real question is,

08:08are you ready to be the one to lead that change?

08:11And for anyone who wants to go deeper,

08:13here are some of the key references we used.

08:15They are fantastic resources

08:17to continue your learning journey.

08:18Let's keep this conversation going.

08:22We'd love for you to join

08:23our Unified Consulting Solutions community on LinkedIn

08:26to connect with other professionals

08:27who are driving this change.

08:29The link is right there in the description below.

08:32On behalf of Dr. Mari Muthukay

08:33and the entire team,

08:35thank you for joining us.

08:36Let's go build a leaner future together.

08:39Thank you for joining us.

Lean Concepts & Principles - 13 Basics of production systems in construction (EN)

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