Work Structuring to Achieve Integrated Product–Process Design
Publication: Journal of Construction Engineering and Management
Volume 130, Issue 6
Abstract
This paper presents “work structuring,” a term used to describe the effort of integrating product and process design throughout the project development process. To illustrate current work structuring practice, we describe a case study involving the installation of door frames into walls in a prison. We analyze why various problems existed. To improve the work structuring effort, we apply the “five whys” to develop local and global fixes for the system of precast walls and door frames. The five whys is a technique to elicit alternative ways of structuring work without being constrained by contractual agreements, traditions, or trade boundaries. We discuss the importance of dimensional tolerances in construction and how these affect the handoff of work from one group of workers to the next. We argue that these constraints and tolerance management practices are so embedded that project participants can miss opportunities to better integrate product and process design. We propose shifting the focus of work structuring from maximizing local trade efficiency to improving overall performance in the delivery system of a capital project.
Get full access to this article
View all available purchase options and get full access to this article.
References
1.
Anderson, S.D. ( 1997). “Owner/contractor work structure process handbook.” Implementation Resource 111-2, Construction Industry Institute, Austin, Tex.
2.
Ballard, G. ( 1999). “Work structuring.” White Paper-5, Lean Construction Institute, Ketchum, Id., 〈http://www.leanconstruction.org/pdf/WP5-WorkStructuring.pdf〉 (12 June).
3.
Ballard, G. ( 2000). “Lean project delivery system.” White Paper-8(Revision 1), Lean Construction Institute, Ketchum, Id., 〈http://www.leanconstruction.org/pdf/WP8-LPDS.pdf〉 (23 Sept).
4.
Ballard, G., Koskela, L., Howell, G., and Zabelle, T. ( 2001). “Production system design: Work structuring revisited.” White Paper-11, Lean Construction Institute, Ketchum, Id.
5.
Champagne, A.F. ( 1997). “Project delivery systems: CM at risk, design-build, design-bid-build.” Research Summary 133-1, Construction Industry Institute, Austin, Tex.
6.
Charette, R.P., and Marshall, H.E. ( 1999). “UNIFORMAT II: Elemental classification for building specifications, cost estimating, and cost analysis.” Natl. Inst. of Standards and Technology Internal Rep.(NISTIR) No. 6389, NIST, Gaithersburg, Md.
7.
Dept. of Defense–Natl. Aeronautics and Space Administration (DOD-NASA). ( 1962). DOD and NASA guide to PERT/COST systems design, Office of Secretary of DOD and NASA, Washington, D.C.
8.
Dept. of Justice (DOJ). ( 1997). “Prison construction: keeping pace with population growth.” U.S. Department of Justice, Washington, D.C., 〈http://www.ojp.usdoj.gov/bjs/pub/press/csfcf95.pr〉 (7 Aug).
9.
Doyle, C. ( 2000a). “Where, oh where? Would-be, public-sector design/build customers say they wouldn’t rush to limited bidding.” Daily Reporter Publishing Company, Milwaukee, 〈http://dailyreporter.com/special/db/where.html〉 (Nov. 25, 2002).
10.
Doyle, C. ( 2000b). “Call me irresistible: Allure of lucrative jobs tempts contractors toward design/build gold rush.” Daily Reporter Publishing Company, Milwaukee, 〈http://www.dailyreporter.com/special/db/irresist.html〉 (Nov. 25, 2002).
11.
Engineering News Record (ENR). ( 2002). “Top 400 contractors.” Engineering News Record, New York, 〈http://enr.construction.com/people/topLists/topContractor/topCont_A-Z.asp〉 (Nov. 25).
12.
Freedman, S. ( 1996). “MNL-117-96, Division 7—Product tolerances.” Manual for quality control for plants and production of architectural precast concrete products, 3rd Ed., Precast/Prestressed Concrete Institute, Chicago, 159–166.
13.
Gil, N., Tommelein, I.D., Kirkendall, B., and Ballard, G. ( 2000). “Contribution of specialty contractor knowledge to early design.” Proc., 8th Annual Conf. Int’l. Group for Lean Constr., Univ.of Sussex, Brighton, U.K. 〈http://www.ce.berkeley.edu/~tommelein/IGLC8–GilEtAl.pdf〉 (Nov. 25, 2002).
14.
Halpin, D.W., Escalona, A.L., and Szmurlo, P.M. ( 1987). “Work packaging for project control management.” Source Document 28, Construction Industry Institute, Austin, Tex.
15.
Heizmann, J. ( 1983). “Work structuring in automated manufacturing systems exemplified by use of industrial robots for body assembly.” Design of Work in Automated Manufacturing Systems, Pergamon, Oxford, 109–114.
17.
Howell, G., and Ballard, G. ( 1999). “Design of construction operations.” White Paper-4, Lean Construction Institute, 〈http://www.leanconstruction.org/pdf/WP4-OperationsDesign.pdf〉 (Jan. 9).
16.
Howell, G., Laufer, A., and Ballard, G. (1993). “Interaction between subcycles: One key to improved methods.” J. Constr. Eng. Manage., 119(4), 714–728.
46.
Kellogg, J. C. (1971). “A profile of the future construction system.” J. Constr. Div., Am. Soc. Civ. Eng., 97(C01), 147–161.
18.
Kenrich Products. ( 2002). “Model GP-2HD hand operated grout pump: Ideal for grouting metal door frames.” Kenrich Products webpage, 〈http://www.kenrichproducts.com/ModelGP2HD.html〉 (Nov. 25).
19.
Konchar, M., and Sanvido, V. (1998). “Comparison of U.S. project delivery systems.” J. Constr. Eng. Manage., 124(6), 435–444.
20.
Koskela, L. ( 2000). “An exploration towards a production theory and its application to construction.” VTT Publication 408, VTT Building Technology, Espoo, Finland, 〈http://www.inf.vtt.fi/pdf/publications/2000/P408.pdf〉 (May 19).
21.
Laufer, A. ( 1997). “Implementable research: A prerequisite for implementation of research results.” Proc., “How do we do research to improve the engineering and construction industry” workshop, Construction Industry Institute and Natl. Science Foundation, Austin, Tex.
22.
Means, R.S. ( 1997). Building construction cost data 1997, Western Ed., R. S. Means Company, Inc., Kingston, Mass.
45.
Mechanical Contractors Association of America (MCAA). (2003). “CSI reverses course on proposed revision to Masterformat.” The MCAA National Update, 〈http://www.mcaa.org/update/archives/nu112403.cfm〉 (Nov. 24).
23.
Meredith, J. (1998). “Building operations management theory through case and field research.” J. Operations Manage., 16(4), 441–454.
24.
Midwest Construction. ( 2002). “Top design firms ranked by total billings for projects completed in Illinois, Indiana, and Wisconsin.” Midwest Construction website, McGraw–Hill, Chicago, 〈http://midwest.construction.com/people/toplists/02_TopDesignFirms.pdf〉 (Nov. 25).
25.
Milberg, C. and Tommelein, I.D. ( 2003). “Role of tolerances and process capability data in product and process design integration.” Proc., Construction Research Congress, ASCE, Reston, Va., 〈http://www.ce.berkeley.edu/~tommelein/papers/CRC03–Milberg&Tommelein-40671–011–004.pdf〉 (Oct. 12).
26.
Miles, R.S. ( 1998). “Alliance lean design/construct on a small high tech project.” Proc., 6th Annual Conf. Intl. Group for Lean Construction,http://www.ce.berkeley.edu/~tommelein/IGLC-6/Miles.pdf〉 (Nov. 25, 2002).
27.
Molenaar, K. R. and Songer, A. D. (1998). “Model for public sector design-build project selection.” J. Constr. Eng. Manage., 124(6), 467–479.
28.
Neil, J. ( 1988). “Work packaging for project control.” Publication 6-6, Construction Industry Institute, Austin, Tex.
29.
Oglesby, C.H., Parker, H.W., and Howell, G.A. ( 1989). Productivity improvement in construction, McGraw–Hill, Boston.
30.
Ohno, T. ( 1988). Toyota production system: Beyond large-scale production, Productivity Press, Portland, Ore.
44.
Paulson, B. C. (1976). “Designing to reduce construction costs.” J. Constr. Div., Am. Soc. Civ. Eng., 102(C04), 587–592.
31.
Ryan, S. ( 2000). “Options open: Would-be, public-sector design/build customers say they wouldn’t rush to limited bidding.” Daily Reporter Publishing Company, Milwaukee, 〈http://www.dailyreporter.com/special/db/options.html〉 (Nov. 25, 2002).
32.
Sanvido, V.E., and Konchar, M.D. ( 1998). “Project delivery systems: CM at risk, design-build, and design-bid-build.” Research Rep. No. 133, Construction Industry Institute, Austin, Tex.
33.
Schmenner, R.W. ( 1993). Production/operations management, 5th Ed., Prentice–Hall, Englewood Cliffs, N.J.
34.
Schultz, S. ( 2000a). “Top educators say defining design/build is allacademic.” Daily Reporter Publishing Co., Milwaukee, 〈http://www.dailyreporter.com/special/db/educate.html〉 (Nov. 25, 2002).
35.
Schultz, S. ( 2000b). “Define the following: Contractors answer afew trick questions.” Daily Reporter Publish. Co., Milwaukee, 〈http://www.dailyreporter.com/special/db/quiz.html〉 (Nov. 25, 2002).
36.
Slaughter, E. S. (1993). “Builders as sources of construction innovation.” J. Constr. Eng. Manage., 119(3), 532–549.
37.
Snow, D. ( 2000). “Design/build always demands definition: There is nothing, absolutely nothing, good about design/build.” Daily Reporter Publishing Company, Milwaukee, 〈http://www.dailyreporter.com/special/db/snow2000.html〉 (Nov. 25, 2002).
38.
Thompson, C. ( 2000). “Boldt rolled with the punches to deliver a picture-perfect prison.” Daily Reporter Publishing Company, Milwaukee, 〈http://www.dailyreporter.com/special/topjob2000/redgranite.html〉 (Nov. 25, 2002).
39.
Tommelein, I. D., and Ballard, G. ( 1997). “Coordinating specialists.” Technical Rep. No. 97-8, Constr. Engrg. Mgmt. Prog., Dept. of Civil and Environmental Engineering, Univ. of Calif., Berkeley, Calif.
40.
Tommelein, I. D., Riley, D., and Howell, G. A. (1999). “Parade game: Impact of work flow variability on trade performance.” J. Constr. Eng. Manage., 125(5), 304–310.
47.
Tommelein, I. D., Walsh, K. D., and Hershauer, J. C. ( 2003). “Improving capital projects supply chain performance.” Research Rep. PT172–11, Construction Industry Institute, Austin, Tex.
41.
Tsao, C.C. Y., Tommelein, I.D., Swanlund, E., and Howell, G.A. ( 2000a). “Case study for work structuring: Installation of metal door frames.” Proc., 8th Conf., Int. Group Lean Constr., Univ. of Sussex, Brighton, UK., 〈http://www.ce.berkeley.edu/~tommelein/IGLC8–TsaoEtAl.pdf〉 (Nov. 25, 2002).
42.
Tsao, C. C. Y., Tommelein, I. D., Swanlund, E., and Howell, G. A. ( 2000b). “Towards work structuring: Five whys applied to installation of metal door frames.” Technical Rep. No. 2000-03, Constr. Engrg. Mgmt. Prog., Dept. of Civil and Environmental Engineering, Univ. of California, Berkeley, Calif.
43.
Wilson, P.F., Dell, L.D., and Anderson, G.F. ( 1993). Root cause analysis: A tool for total quality management, ASQ Quality Press, Milwaukee.
Information & Authors
Information
Published In
Journal of Construction Engineering and Management
Volume 130 • Issue 6 • December 2004
Pages: 780 - 789
Copyright
Copyright © 2004 ASCE.
History
Published online: Nov 15, 2004
Published in print: Dec 2004
Authors
Metrics & Citations
Metrics
Citations
Download citation
If you have the appropriate software installed, you can download article citation data to the citation manager of your choice. Simply select your manager software from the list below and click Download.