In this blog, I’m going to talk to you about the overall framework for the Integrated Production Control System (IPCS). You’ll see how everything works together and what key components you need to have on your project for success. If you’re interested in gaining a global perspective and understanding what it takes to implement this system, you’ve come to the right place.
What To Understand About Systems
First of all, I want to share that I’m writing this from a beautiful recording studio that I absolutely love, thanks to Nate Woodbury and his fantastic team at Be the Hero. While here, I’ve been reflecting on how an HVAC system operates as a cohesive unit.
A system is only effective when all its components work together. You can’t simply say, “I have a thermostat on the wall, so my HVAC system works.” No! You need a complete system that includes everything—from the thermostat and controls cabling to the unit, condenser, exhaust, gas supply, and even the walls that keep the air inside. If one element fails, the entire system collapses.
This is a crucial point that people often miss about Lean Construction. They hear directives like, “Go implement a pull plan,” without realizing that these are individual elements that must fit into a larger system. In this blog, I will explain the Integrated Production Control System and guide you through its implementation, especially as we prepare for the release of the upcoming book, Elevating Construction First Planners, which will help you integrate this system into every aspect of your project.
External Factors of the IPCS
The first part of this system involves understanding external factors. Here’s a breakdown:
- Paradigm: The owner of your project must genuinely care about people and aim to build a Lean operation. This mindset is critical among your team members and the owner’s representatives.
- Goals: You need a clearly defined goal for the system. Sometimes, project stakeholders have different agendas—like rushing or cutting budgets to boost their own reputations—rather than focusing on completing the project on time.
- Structure: Having the right structure for your project is essential. This is often dictated by the owner and includes the appropriate rules for operation.
These external factors must be established for you to do your job effectively.
Pre-Construction Efforts of the IPCS
Next, let’s discuss pre-construction efforts, which are crucial for designing the remainder of the system. Key components include:
- Proposal and Interview: This is where you win the job.
- Concept and Schematic Design: Early in the project, you need to set parameters and assemble your pre-construction team.
- Design Development: This phase includes real-time budget and schedule updates to enable designers and plan the project with builders. Engage Superintendents and trade partners to ensure a strong start within the first 90 to 120 days on-site.
Key Components of the IPCS
In implementing the IPCS, you also need several key components:
- Team Dynamics: Build a strong team by balancing individual strengths and managing risks.
- Planning Systems: Utilize First and Last Planner systems, and incorporate Lean contracts.
- Supply Chain Management: Implement an effective procurement system, ensure prefabrication is in place, and have a logistics plan for material delivery.
- Culture: Cultivate a winning culture that prioritizes onboarding, safety, and a clean, organized work environment.
- Training: Ensure that your workforce is well-prepared through comprehensive training programs.
Importance of Implementing the Takt Production System
The Takt Production System is essential to maintaining rhythm in your project’s operations. You should have various trade partners working in synchronization, ensuring a steady flow of production.
Takt Steering and Control: When delays occur, your system must have mechanisms to redirect and recover without losing momentum.
Importance of Implementing the Last Planner System
The Last Planner System is vital for fostering collaboration among foremen and ensuring that all elements come together seamlessly.
Additionally, you need an Accountability System that includes:
- Zero Tolerance: Implement a contractor grading system and daily correction methods.
- Quality Control: Ensure quality at the source and establish a way to track team health and performance metrics (KPIs).
Overview of Integrated Production Control System
To summarize, the Integrated Production Control System encompasses:
- External Factors: The right environment for your project to thrive.
- Planning: Proper planning of the project, ensuring that all systems work together rhythmically to maintain flow.
- Collaboration: Work closely with trade partners, as they are integral to the planning cycle.
The IPCS consists of the First Planner System, Takt Production System, and Last Planner System. Remember, you cannot simply pick one and implement it in isolation; they must all work together seamlessly for effective results.
As you navigate this process, keep in mind the importance of proper planning, establishing the right rhythm, and fostering collaboration with your trade partners. If you want to dive deeper into these concepts, I encourage you to check out my upcoming book, Elevating Construction First Planners, which outlines these principles.
I’m excited to share these insights with you, and I look forward to helping you transform your projects through the Integrated Production Control System. Happy planning!
