How To Implement Lean Construction

Let’s get started with what Lean is. Although I’ve covered this before, it’s worth revisiting. Lean construction is built on four foundational principles: 

1. Respect for People and Resources: This means valuing every team member and optimizing resource usage.
2. Stability and Flow: Ensuring consistent and predictable project progress.
3. Total Participation with Visual Systems: Engaging the entire team through clear and visual management systems.
4. Quality and Continuous Improvement: Striving for excellence and always seeking ways to enhance processes.

If you prefer a more tangible breakdown, here it is:

• Respect for People: Treating everyone involved with dignity and ensuring their well-being.
• 5S and Elimination of the Eight Wastes: Organizing workspaces for efficiency and removing non-value-adding activities.
• Overburden and Unevenness: Managing workloads to avoid burnout and ensuring balanced workflows.
• One Piece or One Process Flow: Streamlining processes for smoother operations.
• Flowing Together on a Takt Time: Synchronizing work rhythms to maintain steady progress.
• Visual Systems for the Entire Project Team: Using visual tools to keep everyone informed and aligned.
• Delivering Quality and Improving Continuously: Focusing on high standards and ongoing enhancements.

Where to Learn Lean Construction Practices

To implement Lean construction, you need to start by learning about it. Here are some steps to get you started:

1. Lean Training: Enroll in training programs offered by various organizations such as AGC, LCI, Elevate, and Nicolas Modak’s hubs. You can also read books on Lean construction to deepen your understanding.
2. Takt Planning: Takt is a German word for rhythm, symbolizing trades moving through zones in sequence. Learn to create schedules that show trades flowing in a consistent, diagonal line, enabling you to measure progress and implement Lean systems effectively. For detailed guidance, read “Takt Planning” by Jason Schroeder.
3. Last Planner System: Once you have your takt plan, involve your team in updating sequences, removing roadblocks, and creating weekly work plans collaboratively. For more insights, read “The Lean Builder” by Keyan Zandy and Joe Donarumo.
4. Lean Manufacturing Insights from Paul Akers: Paul Akers’ book “2 Second Lean” is a great resource for understanding Lean principles in a simple, engaging way. His videos and systems are invaluable for those new to Lean.

Implementing Lean Construction

Once you’ve learned the basics, here’s how to implement Lean construction effectively:

1. Experiment on Your Own Projects: Apply Lean principles to your projects and track the results.
2. Align with the Right Company: Ensure your company supports and invests in Lean practices to sustain your efforts.
3. Integrate Lean into Business Systems: Align your company’s systems with Lean actions, tools, processes, and culture to support project success.
4. Train Everyone: Comprehensive training for all team members on Lean systems is crucial. This may take time, but it’s essential for effective implementation.
5. Motivate Your Team: Recognize top performers, share successes, and create a culture that supports Lean behaviors. Measure the right things to drive desired outcomes.
6. Provide Necessary Tools and Resources: Ensure your team has the time, training, tools, and resources needed to implement Lean practices effectively.
7. Create Anchor Projects: Implement Lean on key projects with the best opportunities and teams. Highlight these successes to build momentum.
8. Make Your Successes Famous: Share your Lean successes through pictures, videos, industry talks, and social media. This builds ownership and encourages others to follow suit.
9. Encourage Responsible Scaling: Support and expand Lean practices across projects and teams gradually and sustainably.
10. Regular Tours and Reviews: Maintain Lean habits by regularly touring projects and showcasing your successes. This keeps the team motivated and accountable.

Important Analogy to Understand About Making Changes

To successfully implement Lean, use the analogy from the book “Switch.” Imagine you have a rider (your intellect) steering an elephant (your motivation) along a path (your circumstances). For effective change:

• The rider (knowledge) needs to know how to implement Lean.
• The elephant (motivation) must want to embrace Lean.
• The path (circumstances) must be clear and conducive to Lean practices.

Without all three elements, change will be challenging.