Lean construction: Arenas of enactment, models of diffusion and the meaning of 'leanness'

The existing literature on lean construction is overwhelmingly prescriptive with little recognition of the social and politicised nature of the diffusion process. The prevailing production-engineering perspective too often assumes that organizations are unitary entities where all parties strive for the common goal of 'improved performance'. An alternative perspective is developed that considers the diffusion of lean construction across contested pluralistic arenas. Different actors mobilize different storylines to suit their own localized political agendas. Multiple storylines of lean construction continuously compete for attention with other management fashions. The conceptualization and enactment of lean construction therefore differs across contexts, often taking on different manifestations from those envisaged. However, such localized enactments of lean construction are patterned and conditioned by pre-existing social and economic structures over which individual managers have limited influence. Taking a broader view, 'leanness' can be conceptualized in terms of a quest for structural flexibility involving restructuring, downsizing and outsourcing. From this perspective, the UK construction industry can be seen to have embarked upon leaner ways of working in the mid-1970s, long before the terminology of lean thinking came into vogue. Semi-structured interviews with construction sector policy-makers provide empirical support for the view that lean construction is a multifaceted concept that defies universal definition.

The future of lean construction: a brave new world

Lean construction is considered from a human resource management (HRM) perspective. It is contended that the UK construction sector is characterised by an institutionalised regressive approach to HRM. In the face of rapidly declining recruitment rates for built environment courses, the dominant HRM philosophy of utilitarian instrumentalism does little to attract the intelligent and creative young people that the industry so badly needs. Given this broader context, there is a danger that an uncritical acceptance of lean construction will exacerbate the industry's reputation for unrewarding jobs. Construction academics have strangely ignored the extensive literature that equates lean production to a HRM regime of control, exploitation and surveillance. The emphasis of lean thinking on eliminating waste and improving efficiency makes it easy to absorb into the best practice agenda because it conforms to the existing dominant way of thinking. 'Best practice' is seemingly judged by the extent to which it serves the interests of the industry's technocratic elite. Hence it acts as a conservative force in favour of maintaining the status quo. In this respect, lean construction is the latest manifestation of a long established trend. In common with countless other improvement initiatives, the rhetoric is heavy in the machine metaphor whilst exhorting others to be more efficient. If current trends in lean construction are extrapolated into the future the ultimate destination may be uncomfortably close to Aldous Huxley's apocalyptic vision of a Brave New World. In the face of these trends, the lean construction research community pleads neutrality whilst confining its attention to the rational high ground. The future of lean construction is not yet predetermined. Many choices remain to be made. The challenge for the research community is to improve practice whilst avoiding the dehumanising tendencies of high utilitarianism.

Lean management and innovation in operational efficiency: the EGR project implemented by Pirelli Tyre Brazil in Santo André plant

O trabalho tem como objetivo avaliar e descrever analiticamente a implementação de práticas de manufatura enxuta pela Pirelli Pneus no seu complexo industrial da América Latina. Além de uma descrição estruturada e ampla dos princípios de produção de Toyota e fundamentos teóricos do Lean thinking, uma ênfase especial será dedicada ao projeto EGR (Especialistas em Gestão da Rotina), como uma ferramenta estratégica para ser usada pela empresa multinacional italiana no futuro próximo, de modo a alcançar um resultado mais eficaz e eficiente na gestão da rotina diária. Este projeto, que representa um componente significativo do Pirelli Manufacturing System (PMS) e, principalmente, voltado para supervisores e gestores de plantas, consiste principalmente em ajudar a empresa a desenvolver a capacidade empresarial para avaliar corretamente o gap potencial existente entre os resultados atuais e os esperados, para tanto entender os desvios, bem como as causas subjacentes, e melhorar continuamente o desempenho da empresa por meio da padronização de processos e redução de desperdicios. Esses objetivos podem ser perseguidos, atuando em dois meios essenciais: habilidades técnicas e comportamentais de liderança para apoiar cada equipe de projeto; uma maior eficácia na gestão de indicadores de desempenho nas diferentes unidades de fábrica, de acordo com KPIs estabelecidos no nível central pelo Head Quarter. Além disso, a investigação será focada na experiência peculiar da planta de Santo André, onde o EGR começou como piloto, com o objetivo de captar as alterações relevantes (no lado organizacional e econômico) que este projeto trouxe para a empresa, através da realização de pesquisa de campo e entrevistas, que são orientados a recolher provas, considerações e opiniões de todos os principais atores envolvidos.

Aplicação do lean six sigma na linha de produção de turbinas industriais a vapor

This work evaluates the implementation of Lean Six Sigma into the Steam Turbine’s Blades Manufacturing Process, aiming to improve productivity, quality and operational efficiency. Therefore, several tools have been applied, such as VSM, Spaghetti Diagram, Ishikawa, Pareto, DMAIC, Benchmarking and Control Charts, seeking to propose process improvements, as well as Quality Indicators creation. It was obtained a significant waste reduction throughout the process, achieving a lead time reduction of 42% and 83,41% in transport. Also, were introduced the Lean Thinking concepts, such as pull production and Continuous material flow. At the same time, it was possible to calculate the process capability and the sigma level, evaluating and proposing some improvements

Riconfigurazione delle linee di assemblaggio manuale presso una azienda produttrice di macchine per l'agricoltura: applicazione delle 5S e dei principi di Lean Production nella transizione in ottica Pull

“Lean Thinking” non è semplicemente una nuova metodologia organizzativa, ma rappresenta un nuovo modo di ragionare, teso ad accrescere la flessibilità dell’impresa attraverso un ripensamento dell’intero flusso di creazione del valore, dalla progettazione fino alla gestione degli ordini. Questo lavoro presenta i risultati che un’azienda produttrice di macchine per l’agricoltura, la Gallignani di Russi, ha ottenuto in campo logistico e produttivo, grazie all’applicazione dei principi della Lean Production.

Planejando com lean construction: diretrizes para implementação da construção enxuta em obras

Nowadays lives up in an era of tight credit caused by the global financial crisis, as occurred in the past, it is the responsibility of various sectors and segments of society find ways to reinvent itself. In this context, Lean Construction presents itself as a strong alternative production management for companies in the construction segment. Arising out of lean thinking that originated in Japan in the postwar period and has spread around the world in times of extreme scarcity with the oil crisis. In practice the Lean Construction is a philosophy that seeks to improve the process of production management, maximizing the value of the flow from the customer's perspective through the elimination of losses. And thrives in environments and cultures that consider the scarcity of resources like something natural, applying both the macroeconomic crisis as in times of prosperity. The Planning and Production Control - PCP presents itself as a fundamental building block for companies to protect themselves in the face of economic fluctuations, seeking for their survival and success in the competitive market. Motivated by the lack of discussion of the topic in the local academy, and for the identification of 93.33% of construction companies that do not make use of methodological tools for PCP in the state, this dissertation aims to study and propose the implementation of lean construction in methodology of planning projects implemented on construction sites. This characterized the management system, of the production of a construction company, pointing out the main causes of ineffectiveness related to consequent low performance of one of his ventures. In sequence, the PCP was implemented with the use of tools to serve the principles of lean construction. This being monitored through indicators that provided managers managerial view of process of actions control and production of protective mechanisms. All implementation guidelines and application of this management model, were exposed in a simplified way, practical and efficient, in order to break the resistance of new practices and old paradigms in the industry.

Princípios Lean aplicados à gestão da informação: um caso prático no departamento de custeio da ECCO

O pensamento lean, assim como os conceitos e práticas que lhe estão associados, são, hoje em dia, vistos pelas organizações como meios que promovem a busca pela excelência empresarial. A aplicação dos princípios lean ultrapassou já a barreira do domínio produtivo, conhecendo-se, cada vez mais, outros ramos de utilização, como é o caso do setor dos serviços, que tem demonstrado um potencial enorme no que diz respeito à exploração desta filosofia. No entanto, as experiências de aplicação destes princípios a outras áreas, que não a indústria de transformação, têm ainda poucos resultados concretos espelhados na literatura. Este projeto surge no sentido de contribuir para alcançar processos mais eficientes, aplicando ferramentas e metodologias da filosofia lean a processos de gestão da informação, tendo o caso prático decorrido no recém-criado Departamento de Custeio Global da ECCO. Por se tratar de um novo departamento, ergue-se a necessidade de construir e modificar ferramentas e práticas em toda a estrutura da empresa. Deste modo, o lean será utilizado como um possível caminho para promover a melhoria contínua dos vários processos, tendo em vista a obtenção de uma melhor relação entre os resultados obtidos e os recursos despendidos. Assim, serão apresentadas várias propostas de melhoria para o departamento em causa, no âmbito da gestão da informação e que, partindo de uma análise inicial baseada nos princípios lean, pretendem agregar mais valor aos processos, minimizando os desperdícios que lhes estão associados e, consequentemente, promovendo o seu melhoramento contínuo.

Ferramentas Lean na indústria corticeira

O presente projeto tem como objetivo a aplicação de ferramentas do universo Lean Thinking na indústria corticeira de forma a identificar e eliminar fontes de desperdício, criar valor e envolver a organização numa cultura de melhoria contínua focada na satisfação do cliente. A Unidade Industrial de Lamas encontra-se a passar por uma fase de mudança e carece da aplicação de ferramentas 5S, Gestão Visual, Kaizen Diário e Standard Work, contempladas no seu programa de melhoria contínua intitulado de Cork.MAIS. A aplicação das ferramentas comprovam o sucesso em termos de qualidade e eficiência operacional. Os 5S conduzem à eficiência, segurança e organização dos postos de trabalho e quando implementados despoletam de forma natural a necessidade de implementação da ferramenta Gestão Visual que acarreta inúmeros benefícios visto que visa sistemas simples e intuitivos. A ferramenta Kaizen Diário contribuiu para aumentar a comunicação entre os diferentes turnos, alinhar os colaboradores com a estratégia da Unidade Industrial de Lamas e identificar oportunidades de melhoria fomentando o trabalho em equipa. A ferramenta Standard Work contribuiu para a redução dos encravamentos dos equipamentos SVE obtendo-se um aumento de 11% do Overall Equipment Effectiveness. Realizar uma retrospetiva de todos os processos e fluxos de produção tornou-se oportuno e, para tal, recorreu-se à ferramenta Value Stream Mapping. Todo o trabalho em equipa serviria para analisar o estado atual da cadeia de valor da Unidade Industrial de Lamas no que respeita ao planeamento e fluxos de material e informação, metodologia do controlo de produto e processo e eficiência operacional. Todas as oportunidades de melhoria identificadas e implementadas acrescentam valor à cadeia da organização mas dá-se destaque às ações de melhoria implementadas no âmbito do projeto de planeamento e fluxos de informação e material. Todas as novas ferramentas implementadas contempladas no sistema pull da organização conduziram a uma redução de 11% do material em work in process e um aumento de 25% da taxa de satisfação de encomendas.

Lean universities.

This chapter examines lean implementation in higher education (HE) institutions. There is evidence of lean initiatives beginning in HE in the US in the early 2000s; there is also some evidence of business process improvement activity before this time (Moore et al., 2004; Waterbury et al., 2011). Today, many universities and other HE institutions are pursuing lean thinking.

Aplicação de ferramentas para melhorar o processo produtivo numa empresa do sector automóvel

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia Mecânica

Measuring Value in Product Development

“What is value in product development?” is the key question of this paper. The answer is critical to the creation of lean in product development. By knowing how much value is added by product development (PD) activities, decisions can be more rationally made about how to allocate resources, such as time and money. In order to apply the principles of Lean Thinking and remove waste from the product development system, value must be precisely defined. Unfortunately, value is a complex entity that is composed of many dimensions and has thus far eluded definition on a local level. For this reason, research has been initiated on “Measuring Value in Product Development.” This paper serves as an introduction to this research. It presents the current understanding of value in PD, the critical questions involved, and a specific research design to guide the development of a methodology for measuring value. Work in PD value currently focuses on either high-level perspectives on value, or detailed looks at the attributes that value might have locally in the PD process. Models that attempt to capture value in PD are reviewed. These methods, however, do not capture the depth necessary to allow for application. A methodology is needed to evaluate activities on a local level to determine the amount of value they add and their sensitivity with respect to performance, cost, time, and risk. Two conceptual tools are proposed. The first is a conceptual framework for value creation in PD, referred to here as the Value Creation Model. The second tool is the Value-Activity Map, which shows the relationships between specific activities and value attributes. These maps will allow a better understanding of the development of value in PD, will facilitate comparison of value development between separate projects, and will provide the information necessary to adapt process analysis tools (such as DSM) to consider value. The key questions that this research entails are: · What are the primary attributes of lifecycle value within PD? · How can one model the creation of value in a specific PD process? · Can a useful methodology be developed to quantify value in PD processes? · What are the tools necessary for application? · What PD metrics will be integrated with the necessary tools? The research milestones are: · Collection of value attributes and activities (September, 200) · Development of methodology of value-activity association (October, 2000) · Testing and refinement of the methodology (January, 2001) · Tool Development (March, 2001) · Present findings at July INCOSE conference (April, 2001) · Deliver thesis that captures a formalized methodology for defining value in PD (including LEM data sheets) (June, 2001) The research design aims for the development of two primary deliverables: a methodology to guide the incorporation of value, and a product development tool that will allow direct application.

Re-engineering construction: going against the grain

An overtly critical perspective on 're-engineering construction' is presented. It is contended that re-engineering is impossible to define in terms of its substantive content and is best understood as a rhetorical label. In recent years, the language of re-engineering has heavily shaped the construction research agenda. The declared goals are to lower costs and improve value for the customer. The discourse is persuasive because it reflects the ideology of the 'enterprise culture' and the associated rhetoric of customer responsiveness. Re-engineering is especially attractive to the construction industry because it reflects and reinforces the existing dominant way of thinking. The overriding tendency is to reduce organizational complexities to a mechanistic quest for efficiency. Labour is treated as a commodity. Within this context, the objectives of re-engineering become 'common sense'. Knowledge becomes subordinate to the dominant ideology of neo-liberalism. The accepted research agenda for re-engineering construction exacerbates the industry's problems and directly contributes to the casualization of the workforce. The continued adherence to machine metaphors by the construction industry's top management has directly contributed to the 'bad attitudes' and 'adversarial culture' that they repeatedly decry. Supposedly neutral topics such as pre-assembly, partnering, supply chain management and lean thinking serve only to justify the shift towards bogus labour-only subcontracting and the associated reduction of employment rights. The continued casualization of the workforce raises real questions about the industry's future capacity to deliver high-quality construction. In order to appear 'relevant' to the needs of industry, it seems that the research community is doomed to perpetuate this regressive cycle.

Adaptações do sistema de informações gerenciais para atender necessidades de empresas envolvidas com a implantação do pensamento enxuto: um estudo de caso

The management system based on lean thinking has led to significant changes in the companies that have decided to adopt it. Frequently, those changes do not create a sustainable position coherent with the good results that are obtained. Many are the causes being discussed and analyzed, not only in academia, but also by lean manufacturing institutes and companies. The existing practices related to the managerial information system and the implementation, development, and maintenance of the lean journey may be some of such causes. This dissertation emphasizes whether the changes generated by this type of management are being followed by the managerial information system. The development of such system was in many cases based on mass production, whose principles go against lean manufacturing concepts. Thus, the objective of this dissertation is to verify whether the traditional managerial information system can meet the needs of the companies that adopt lean manufacturing principles. Through a case study based on qualitative and exploratory research in an electronic equipment assembling company, the stage of the implementation of lean thinking concepts at the time of the field research was analyzed, as well as whether the metrics, financial and non financial indicators were suitable for lean principles. The aim of such study was to empirically verify if the criticism found in the existing literature was pertinent or not. The data collected through the analysis of the documentation, the interviews with managers and in loco observation was treated through the content analysis method. The main conclusion of the research is that, although the company in question is investing in training and applying lean principles in its production line and in some administrative activities, the current managerial information system does not demonstrate the specific results obtained with lean principles. However, how changes to the managerial information system will be implemented is yet to be determined. Currently, metrics and indicators aligned with lean management are being added to the managerial reports. As more lean tools are employed, mainly with the consolidation of more value streams, the company has already diagnosed the need for new indicators. The main office has started a diagnosis of measurement and control systems in a product line in one of its affiliates with the goal of studying the possibility of applying the so called lean accounting in the future.

Um estudo de caso sobre servitização e nacionalização em um fabricante de hardware elétrico

A presente dissertação tem como principais características, a pesquisa, a análise e a proposição de um modelo de reflexão que considera os fatores mais relevantes na inclusão do processo de prestação de serviços em empresas de manufatura de bens, e em particular de empresas que buscam a nacionalização de sua capacidade de fornecimento. Dentro deste conceito de transição e incorporação de serviços, que é denominado pela literatura como “servitização”, e usando como objeto de pesquisa uma empresa fabricante de hardware elétrico, verificou-se como se deu o planejamento e execução da servitização para prestação de serviços técnicos off-shore, ligados à cadeia de suprimentos do segmento de Produção de Óleo e Gás no mar. Para auxiliar o entendimento sobre o posicionamento da empresa perante serviços, servitização e nacionalização, foi necessária a revisão bibliográfica sobre Requisitos de Conteúdo Local, Gestão de Operações em Serviços, Sistemas Produto-Serviço, Servitização, e Desenvolvimento de Projeto de Produtos e Serviços. A partir da análise de documentação disponibilizada pela empresa, e a comparação desta com a literatura academica revisada, verificou-se que os modelos propostos pela literatura não contém todos os elementos necessários para aplicação direta em negócios deste tipo. Com base nesta avaliação, verifica-se quais os fatores mais relevantes para a servitização e propõe-se um modelo para reflexão. Modelo este que preenche com elementos mais específicos as lacunas que influenciam negativamente na excelência operacional e na estratégia da corporação ligada a indústria de Petróleo e Gás Off-shore.