Tese de mestrado integrado. Engenharia Civil (Construções). Universidade do Porto. Faculdade de Engenharia. 2011

Estágio realizado na Norlabor - Engenharia e Construção, SA e orientado pelo Eng.º Pedro Barros / Tese de mestrado integrado. Engenharia Industrial e Gestão. Faculdade de Engenharia. Universidade do Porto. 2010

Lean construction borrows concepts from lean manufacturing and Toyota Production System in order to eliminate waste and add value to the construction process. Manufacturing processes utilizing lean principles have matured and developed a clear understanding of the relation between lean and safety. Because lean in construction is a relatively new phenomenon, there is not a completely developed understanding of how lean practices affect safety in construction. The Lean Construction Institute and the Academic Forum for Lean Construction has recently targeted this area for focused research. Since all safety incidents imply waste in time and resources, lean and safety have a common ground in the minimization of waste. This thesis researches the common ground of lean and safety in waste minimization and proposes a framework for understanding their relationship. This thesis also critically analyzes lean and safety principles to form an insight to the relationship between lean theories as well as practices and safety issues reported in construction literature. Further, literature also revealed the safety strategies and checklists that companies typically incorporate in their program. A comparative analysis of lean and safety is employed to understand their relations in a better way. This framework establishes that lean and safety have a strong relationship in the context of construction. Future work is needed to show that lean practices indeed strongly affect safety by reducing the number of incidents.

La filosofía lean construction se inició en la década de 1990 basado en la adaptación de las teorías de producción de las grandes fábricas (Lean Production) a la industria de la construcción. Sin embargo su difusión y aplicación en el Perú es aún incipiente, está limitada a un grupo menor de empresas que apuestan por su aplicación, generando mejoras y reducciones en costos y tiempo. El presente trabajo se centra en la aplicación de la filosofía lean construction como método de planificación, ejecución y control de un proyecto de construcción desarrollado en la ciudad de Lima. A lo largo del presente trabajo se describen los principales conceptos y herramientas de la filosofía lean para poder generar una base teórica sólida que respalde la aplicación de herramientas y el análisis de resultados en los proyectos. Además, se analiza y describe de forma detallada como se aplican las herramientas más importantes de esta filosofía (Last Planner System, Sectorización, lookahead, etc.) con la finalidad de difundir la metodología de aplicación de cada herramienta y servir de guía para profesionales o empresas que busquen implementar lean construction en sus proyectos. Por otro lado se analizan las etapas del proyecto de mayor incidencia y se demuestra de manera concluyente los buenos resultados que brinda esta filosofía, buscando de esta forma alentar a que sea adoptada por más empresas del sector construcción y puedan romper el paradigma de que su aplicación genera sobre costos. Finalmente se analiza el desarrollo y performance del proyecto para poder sacar conclusiones y propuestas de mejora que puedan ser aplicadas por la empresa, y otras empresas, en la ejecución de sus próximos proyectos aplicando la metodología de mejora continua. Lean Construction philosophy began in the 1990s based on the adaptation of the theories of production of large factories (Lean Production) to the construction industry. However their dissemination and implementation in Peru is still incipient, it is limited to a smaller group of companies committed to its implementation, generating improvements and reductions in cost and time. This work focuses on the application of lean construction philosophy as a method of planning, execution and control of a construction project developed in Lima. Throughout this work the main concepts and tools of lean philosophy to generate a solid theoretical basis to support the application of tools and analysis results are described in the projects. In addition, it is analyzed and described in detail how are applied the most important tools of this philosophy (Last Planner System, sectorization, look ahead, etc.) in order to spread the methodology of application of each tool and serve as a guide for professional or companies seeking to implement lean construction projects. On the other hand are analyzed the stages of the project with the highest incidence and the good results provided by this philosophy is demonstrated conclusively , thus seeking to encourage to be adopted by companies in the construction sector and can break the paradigm that its application generates extra costs. Finally, the development and performance of the project is analyzed to draw conclusions and suggestions for improvement that can be applied by the company, and other companies, in the execution of their upcoming projects applying the methodology for continuous improvement.

This thesis integrates Lean construction (LC) with the organisational assessment method ofmaturity models (MM) and delivers an original contribution to knowledge in the form of avalidated innovative organisational framework to measure the current state of LC maturity,which is called Lean Construction Maturity Model (LCMM). This framework provides andsupports organisations towards the development of greater maturity and subsequentlyenhances the awareness and understanding of LC. The aim of this research was to enableorganisations to measure the gap between their current state and where they want to be interms of embedding LC. Accordingly, the research addressed this aim further by providingbusinesses with support and guidance in their LC maturation process in particular inmeasuring sought improvement in their journey towards greater maturity in LC. The studywas conducted as a qualitative mixed-method design in order to discover and achieve a richunderstanding of the phenomenon of LC maturity from LC key informants and best fulfil theresearch aim. Consequently, a phenomenological approach was utilised, with focus groups(FGs) as the primary study, combined with a group interview as well as individual interviewsas supplementary components. To ensure validity, three different approaches weredeployed: first the triangulation of three different methods to collect the data, second a richand thick-description, and finally the validation of the developed framework by memberchecks in the form of interviews and a FG. The major findings of this research are: thesuccessful integration of MMs and LC achieved through the development of the proposedframework, and the simplification of LC into 11 Key Attributes that explain LC in a simplerand better way than before. This framework defined a LC maturity assessment methodutilising five maturity levels, 11 Key Attributes, which have been described through 60Behaviours, Goals & Practices, and 75 Ideal Statements that more mature organisations willexemplify. Finally, the most important consequence of this work is the enabling oforganisations to obtain a systemic and holistic overview of their current state of LC maturityand providing them with support in their maturation.

Purpose: Waste and negligence in the construction industry is a way too big factor of the high costs occurring. To reduce those wastes, some companies in the manufacturing industry has started to apply Lean to get a more effectively work. Lean Construction is the construction industries counterpart and this investigation investigates what Lean Construction methods for waste management can do for small and medium-sized enterprises.The goal of this work is to analyze how small and medium-sized enterprises can work to get Lean in to the companies processes to reduce perceived wastageMethod: The methods that is used to achieve the goal and to answer the chosen questions is literature studies, interviews and participant observation.Findings: Based on the methods that is used has different factors to reduce waste been acquired. Better communication, awareness among employees, management commitment and keep the work to the time schedules is important factors for improvement.Implications: Better planning is basis for a more efficient construction process.The most important thing for small and medium-sized enterprises can think about is that expensive solutions do not need to be better than simple methods. The developed factors in this investigation can help companies that want to achieve a more efficient construction process. The reason that this investigation is theoretically based, the derived factors should be applied in real projects to see what impact they have.Limitations: The investigation is limited to small and medium-sized enterprises (SMEs) and is a case study at Brantås Bygg. The study include rework, waiting, movements and transports. The interviews are made with working managers, foremans and carpenters at Brantås Bygg. The participate observation is made at a project in the central parts of Vetlanda, Sweden.Keywords: Lean Construction, Wastes, SME, Implementation issues.

Determinar la incidencia de la Filosofía Lean Construction en la productividad de la MO de una empresa constructora de Lima Metropolitana. Determine the impact of the Lean Construction Philosophy on the productivity of the OM of a construction company in Metropolitan Lima.

Este plan de negocio se basa en que la empresa Bestcon S.A.C. mejore el flujo de procesos y eficiencia de recursos para entregar servicios personalizados al cliente, en el tiempo esperado y a un costo por debajo promedio del mercado. Para lograr esto, se plantea el uso de la metodología Lean Construction, cuyo principio fundamental es la reducción de pérdidas en las actividades de construcción y maximizar la rentabilidad del proyecto. Es importante indicar que gran parte de las pequeñas y medianas empresas utilizan la metodología tradicional para brindar sus servicios, lo cual consiste en la falta de planificación de sus actividades y únicamente entrar donde hay espacio, sin tener clara la posibilidad de optimizar sus recursos. Es así como el uso de esta metodología (Lean Construction), genera una oportunidad de negocio. Parte del estudio realizado, es determinar el grado de rivalidad de los competidores en el mercado de implementación de oficinas, es así, que se comprobó la fragmentación del mercado de implementación de oficinas, es decir, compiten muchas empresas, pero ninguna tiene gran participación en el mercado. Por este motivo, es necesario agrupar el mercado por líneas de negocio y centrarse en empresas que brinden servicios similares o iguales con una estrategia basada en costos. Los clientes potenciales serán empresas de manufactura, logística, consumo masivo, informática y telecomunicaciones, que se encuentren buscando nuevas ubicaciones para trasladar sus oficinas administrativas, mayormente en los distritos de Surco, La Molina y Magdalena del Mar.

Teniendo en cuenta la demanda actual de viviendas en el Sector A en Lima Metropolitana, así como la aplicación de diferentes metodologías en el sector construcción con el propósito de desarrollar proyectos dentro del costo, tiempo y de calidad planeados, es que se ha tomado como objeto de estudio el proyecto de construcción de un edificio de vivienda bifamiliar del sector A, con un plazo de ejecución de 6 meses, considerando un alcance de construcción hasta la etapa Casco y en la modalidad de Suma Alzada. El objetivo del presente trabajo de investigación es desarrollar un planeamiento específico para proyectos de vivienda en el sector A en un tiempo reducido para minimizar los sobrecostos y cumplir con el plazo de obra. Por tal motivo, se han identificado los problemas suscitados durante la construcción de la obra, entre los que se encuentran las incompatibilidades del proyecto, inadecuado planeamiento, cambios en el diseño, cambios de alcance y retrabajos en obra. Seguidamente se ha diagnosticado la repercusión de estos problemas en el presupuesto meta, plazo de ejecución y calidad de la edificación, para finalmente elaborar un plan de acción en donde se presenta de manera detallada el Organigrama de obra, el EDT y Cronograma de obra, Modelado y sectorización, gestión de riesgos y cambios aplicados al proyecto y por último un Diagrama de Pareto aplicado al presupuesto meta. Finalmente se realiza la evaluación del costo de implementación del plan de acción con el propósito de que se pueda ser aplicable a otras construcciones de similares características. / Taking into account the current demand for housing in Sector A in Metropolitan Lima, as well as the application of different methodologies in the construction sector with the purpose of developing projects within the planned cost, time and quality, is that it has been taken as a study object the construction project of a two-family housing building in Sector A, with an execution time of 6 months, considering a scope of construction until the Casco stage and in the modality of “Suma Alzada”. The objective of this research work is to develop a specific planning for housing projects in sector A in a reduced time to minimize cost overruns and meet the construction deadline. For this reason, the problems that have arisen during the construction of the work have been identified, among which are the incompatibilities of the project, inadequate planning, changes in design, changes in scope and rework on site. Next, the repercussion of these problems on the target budget, execution time and quality of the building was diagnosed, and finally an action plan was drawn up, in which the work organization chart, the WBS and work schedule, modeling and sectoring, risk management and changes applied to the project were presented in detail, and finally a Pareto diagram applied to the target budget. Finally, the cost of implementing the action plan is evaluated so that it can be applied to other constructions of similar characteristics. / Trabajo de investigación

This report is an evaluation on the use of Lean Construction by the contracting company Kruse Smith AS (KS). The study addresses how well the implementation of KS new Lean policy is carried out, what improvements can be made and how the policy itself can be improved. Lean is a planning methodology used by companies to increase workflow and reduce waste in a project. Lean Construction is a development of Lean to adapt to the construction industry. Kruse Smith AS is a construction company engaged in building-, construction- and real estate business. This study focuses on building projects. The survey was done by including three ongoing construction projects: Project 1 - Blocks of flats in Kristiansand Project 2 - High School in Lyngdal Project 3 - Blocks of flats in Sandnes By the results we see that the various projects interpret the policy in different ways and therefore end up with different ways of organizing and structuring the workplace. Yet we see that the basic objectives of the policy can be achieved without necessarily having to do the same. To strengthen the implementation of the policy from the corporate side, they can place the focus on monitoring the various projects, usually where most managers are not accustomed to the use of Lean. In addition, to inform everyone and to create a better knowledge of Lean they can post something about this in the Health and Safety Plan(HMS-plan) as this will be read by all. An improvement of the implementation can also be strengthened if the company puts the most experienced Lean workers with other inexperienced in the various projects. The policy itself can be strengthened by placing greater emphasis on evaluation and continuous improvement, such as entering regular meetings for this. The policy can also focus more on the removal of waste to get rid of as much as possible of unnecessary transportation, searching and waiting. The policy can be further improved by developing the company's deviation system, to include suggestions and improvments. / Dette rapporten er en undersøkelse om bruken av Lean Construction i entreprenørselskapet Kruse Smith AS. Undersøkelsen tar opp hvor godt implementeringen av Kruse Smiths nye Lean policy utføres, hvilke forbedringer som kan gjøres og hvordan selve policyen kan forbedres. Lean er en planleggings metodikk som brukes av bedriften for å øke produksjons flyten og minke sløsing i et prosjekt. Lean Construction er en videreutvikling av Lean for å tilpasse byggebransjen. Kruse Smith AS er et entreprenørselskap som driver med bygg-, anlegg- og eiendomsvirksomhet. Denne undersøkelsen tar for seg prosjekter innen bygg. Undersøkelsen ble gjort ved å inkludere tre pågående byggeprosjekt: Prosjekt 1 – Boligblokker i Kristiansand Prosjekt 2 – Ungdomsskole i Lyngdal Prosjekt 3 – Boligblokker i Sandnes Av resultatene ser man at de ulike prosjektene tolker policyen på forskjellige måter og ender derfor opp med forskjellig organisering og strukturering av arbeidsplassen. Allikevel ser man at de elementære målene i policyen kan bli nådd uten å nødvendigvis måtte gjøre det samme. For å styrke implementeringen av policyen kan det fra bedriftens side legges fokus på oppfølging av de ulike prosjektene, gjerne mest der hvor ansvarlige ikke er vant med bruken av Lean. I tillegg kan det for å informere alle og skape en bedre kjennskap til Lean legges inn noe om dette i helse, miljø og sikkerhets planen (HMS-planen) da denne skal leses av alle. Man kan også bevist plassere de mest Lean erfarne med andre uerfarne i de ulike prosjekt. Policyen kan styrkes ved å legge større fokus på evaluering og kontinuerlig forbedring ved eksempelvis å legge inn faste møter for dette, det kan også fokuseres på fjerning av sløsing slik at man kvitter seg mest mulig med unødvendig transport, leting og venting. Policyen kan i tillegg forbedres ved en videreutvikling av avviksystemet som i dag kun har fokus på uønskede hendelser og kvaliteter, til å også inkludere forbedrings forslag.