Lean Management Model for Construction of High-Rise Apartment Buildings
Publication: Journal of Construction Engineering and Management
Volume 133, Issue 5
Abstract
Execution of the finishing works in high-rise apartment buildings is made complex by the need to customize apartments to the varying requirements and designs of individual clients. The conventional construction planning practice of progressing upward from floor to floor breaks down in the face of the arbitrary sequence in which clients finalize their decisions. The results are long cycle times for delivery of completed apartments and corollary high levels of work in progress, budget and schedule overruns, and general dissatisfaction with the process on the part of the developer, contractor, subcontractors, and the clients. Application of lean construction principles to this problem has led to development of a management model that adopts pull scheduling, reduced batch sizes, and a degree of multiskilling. The main benefits expected are an enhanced ability to provide customized apartments, improved cash flow, and reduced apartment delivery cycle times. The model was first formulated in theory, then tested using a management simulation game and computer simulation, and subsequently, developed for practical application. This paper presents an analysis of conventional practice, the theoretical background to the lean approach, and the specific management changes proposed.
Get full access to this article
View all available purchase options and get full access to this article.
Acknowledgments
The writers gratefully acknowledge the contributions of the management and staff of Danya-Cebus Construction Ltd. This research was funded in part by the company under Grant No. 2004559.
References
Ballard, G. (2001). “Cycle time reduction in home building.” 9th Int. Group for Lean Construction, D. Chua and G. Ballard, eds., National Univ. of Singapore, Singapore, 1–9.
Ballard, G., Harper, N., and Zabelle, T. (2003). “Learning to see work flow: An application of lean concepts to precast concrete fabrication.” Eng., Constr., Archit. Manage., 10(1), 6–14.
Ballard, G., and Howell, G. A. (2003). “Lean project management.” Build. Res. Inf., 31(2), 119–133.
Bashford, H. H., Sawhney, A., Walsh, K. D., and Kot, K. (2003). “Implications of even flow production methodology for U.S. housing industry.” J. Constr. Eng. Manage., 129(3), 330–337.
Carr, R. I., and Meyer, W. L. (1974). “Planning construction of repetitive building units.” J. Constr. Div., 100(3), 403–412.
Danya-Cebus. (2004). “Survey of satisfaction with the client change process for new apartments.” Market Watch Ltd., Tel Aviv, Israel, 49.
Gann, D. M. (1996). “Construction as a manufacturing process? Similarities and differences between industrialized housing and car production in Japan.” Constr. Manage. Econom., 14(5), 437–450.
Hanna, A. S., Russell, J. S., Gotzion, T. W., and Nordheim, E. V. (1999). “Impact of change orders on labor efficiency for mechanical construction.” J. Constr. Eng. Manage., 125(3), 176–184.
Hopp, W. J., and Spearman, M. L. (1996). Factory Physics, IRWIN, Chicago.
Horman, M., Kenley, R., and Jennings, V. (1997). “A lean approach to construction: An historical case study.” 5th Annual Conf. of Int. Group for Lean Construction, Griffith Univ., Gold Coast, Australia, 63–75.
Josephson, P. E., and Hammarlund, Y. (1999). “The causes and costs of defects in construction: A study of seven building projects.” Autom. Constr., 8, 681–687.
Koushki, P. A., Al-Rashid, K., and Kartam, N. (2005). “Delays and cost increases in the construction of private residential projects in Kuwait.” Constr. Manage. Econom., 23, 285–294.
Levitt. (2006). “A town is born.” ⟨http://www.levittcorporation.com/story/index2.php⟩ (Feb. 14th, 2006).
Martinez, J. C., and Ioannou, P. G. (1999). “General-purpose systems for effective construction simulation.” J. Constr. Eng. Manage., 125(4), 265–276.
Moselhi, O., Assem, I., and El-Rayes, K. (2005). “Change orders impact on labor productivity.” J. Constr. Eng. Manage., 131(3), 354–359.
Naim, M., and Barlow, J. (2003). “An innovative supply chain strategy for customized housing.” Constr. Manage. Econom., 21, 593–602.
Ohno, T. (1988). Toyota production system: Beyond large-scale production, Productivity, Cambridge, Mass.
Peer, S. (1974). “Network analysis and construction planning.” J. Constr. Div., 100(3), 203–210.
Rosenfeld, Y., and Paciuk, M. (2000). “Characterization of apartment client change orders and their impact on construction efficiency.” Rep. No. 69.008, National Building Research Institute, Haifa, Israel, 80 (in Hebrew).
Sacks, R. (2004). “Towards a lean understanding of resource allocation in a multi-project sub-contracting environment.” 12th Annual Conf. on Lean Construction, C. T. Formoso and S. Bertelsen, eds., Lean Construction-DK, Elsinore, Denmark, 97–109.
Sacks, R., Esquenazi, A., and Goldin, M. (2007). “LEAPCON: Simulation of lean construction of high-rise apartment buildings.” J. Constr. Eng. Manage., in press.
Sacks, R., and Harel, M. (2006). “An economic game theory model of subcontractor resource allocation behavior.” Constr. Manage. Econom., 24(8), 869–881.
Sakamoto, M., Horman, M. J., and Thomas, H. R. (2002). “A study of the relationship between buffers and performance in construction.” 10th Annual Conf. of the Int. Group for Lean Construction, C. T. Formoso and G. Ballard, eds., NORIE/UFRGS, Porto Alegre-RS Brazil, Gramado, Brazil, 13.
Seppanen, O., and Aalto, E. (2005). “A case study of line-of-balance based schedule planning and control system.” 13th Conf. of Int. Group for Lean Construction, R. Kenley, ed., Univ. of New South Wales, Sydney, Australia, pp. 271–279.
Thomas, H. R., Horman, M. J., Minchin, R. E., and Chen, D. (2003). “Improving labor flow reliability for better productivity as lean construction principle.” J. Constr. Eng. Manage., 129(3), 251–261.
Thomas, H. R., Horman, M. J., de Souza, U. E. L., and Zavrski, I. (2002). “Reducing variability to improve performance as a lean construction principle.” J. Constr. Eng. Manage., 128(2), 144–154.
United States Census. (2004).“ 2002 economic census industry series reports construction.” ⟨http://www.census.gov/econ/census02/guide/INDRPT23.HTM⟩ (June 6, 2005).
Womack, J. P., and Jones, D. T. (2003). Lean thinking: Banish waste and create wealth in your corporation, Simon and Schuster, New York.
Information & Authors
Information
Published In
Copyright
© 2007 ASCE.
History
Received: Jul 8, 2005
Accepted: Nov 30, 2006
Published online: May 1, 2007
Published in print: May 2007
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.