IMPLEMENTATION OF LEAN METHODOLOGY IN INDIAN CONSTRUCTION

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1 International Journal of Civil Engineering and Technology (IJCIET) Volume 7, Issue 6, November-December 2016, pp , Article ID: IJCIET_07_06_071 Available online at ISSN Print: and ISSN Online: IAEME Publication IMPLEMENTATION OF LEAN METHODOLOGY IN INDIAN CONSTRUCTION P. Abhiram PG CTM Student, Department of Civil Engineering, KL University, Andhra Pradesh, India SS. Asadi Associate Dean Academic, Department of Civil Engineering, KL University, Pradesh, India A.V.S. Prasad PRO-Vice Chancellor, Department of Civil Engineering, KL University, Andhra Pradesh, India ABSTRACT Background: Indian construction industries play a vital role in economic growth of the country. But the construction industry is very much challenging because of 3D s in industrydifficult, dangerous and demanding so it lag far more years from manufacturing industries. To overcome this, Lean technique of manufacturing industry were applied to construction industry to minimize waste, inefficiency. Objective: To identify major possible waste factors in construction industry and suggesting suitable mitigation measures. Analysis: Questionnaire survey is prepared on different wastes and analysing them using Statistical Package of Social Sciences (SPSS) software and comparing the result with manual methods. Expected Findings: Manual ranking is given to highest waste producing factor of FRIEDMAN MEAN RANK Technique which is an outcome of SPSS. Improvements: With conclusions drawn we can minimize waste, cost, time and to maximize performance of construction projects. Key words: Lean Construction, Waste Minimization using Lean techniques, SPSS. Cite this Article: P. Abhiram and SS. Asadi and A.V.S. Prasad, Implementation of Lean Methodology in Indian Construction. International Journal of Civil Engineering and Technology, 7(6), 2016, pp INTRODUCTION The Indian construction industry plays a momentous role in economic growth, both directly and indirectly through the provision of buildings and organizations and it activities, for the smooth and effective functioning of commercial enterprises. Yet, the construction industry is highly challenged as 3D s industry difficult, dangerous and demanding industry. The construction industry lags far more years behind the manufacturing industry because of the several reasons. The prime reason it is being split approach rather than a mixed approach. The other reason is that the construction industry is more complex than the manufacturing industry and therefore development of technical modernization is to be implemented significantly. Lean construction is a new production methodology which will bring a radical change in the construction industry. Construction companies have improved their work effectiveness and quality of editor@iaeme.com

2 Implementation of Lean Methodology in Indian Construction work, and reduced waste and costs and increased their profits to ensure their survival in today s competitive market. This is especially more squeezing conditions under present financial crisis and economic recession [3]. As a result of growing competition in construction industry, a mixture of high quality,project speed, and low cost has become a key engineering and managerial effort[1]. Most building managers believe that many of the waste industry, overruns, delays, errors, and the possibility of inefficiency as a result, construction projects rarely end up on time, within budget, and accepted by the client on a quality level. Thus, the construction of the project management approach, lean manufacturing, lean project management, and to improve performance, including value engineering has emerged. Lean principles gradually with less effort and time to waste elimination and provide value to your approach in the construction industry has made inroads. Lean construction, as defined by the Lean Construction Institute (LCI)[1], is a production managementbased project delivery system emphasizing the reliable and speedy delivery of value. It's a new way to design and manufacturing facilities is the capital. Lean has already applied to the manufacturing industry and the construction industry has led to a major change, lean delivery changes the way the process works. Minimizing waste and maximizing the value of lean production have resulted in successfully building process. 2. METHDOLOGY 2.1. Structure of Questionnaire The questionnaire has been structured based on the three main divisions. This includes techniques used in lean construction, wastes generated in the construction industry, the stages at which wastes are produced. The questionnaire has also uploaded to Google drive in the form of Google docs so that the survey details can be collected online. Total number of respondents is Methods for Analysis of Data The questionnaires are distributed to the construction firms and the data are collected by means of online filling using Google forms from the respondents. Then the collected data are analysed by means of a manual method as well as using software methods. The manual analysis has been done by 2 manual approaches. They are: Weighted Average Method. Relative Importance Index (RII) Method. Software Analysis using SPSS (Statistical Packages of Social Sciences) Software Weighted Average Method A weighted average is defined as an average calculated by taking into account not only the frequencies of the values a variety but also any other factor such as their variance. The average weight of the observed data is the result of dividing the sum of the products of observed values, the number of times it occurs, and this other factor by the total number of observations. In order to define the relative importance of the main factors and the weight of each sub-factors the weighted average formula is used as shown in equation (1) Average weight = The wastes in the construction industry are analyzed by this method. For analysing the data, the sum of the weight of each waste is given by respondents. Weightage is shown in Figure-2.A total number of a factor is considered as the total number of listed wastes and it is 17. The total number of respondents is 103. The calculated average weight of each weight is shown in table-1. (1) editor@iaeme.com

3 P. Abhiram and SS. Asadi and A.V.S. Prasad Relative Importance Index Method (Rii) The wastes in construction industry has also been analysed by Relative Importance Index method [4]. The index is calculated by the formula shown in equation (2).!"!#$ = &' (2) ( ) Where, W is the weight given to the factors by respondents. Weightage is shown in Figure-2. A is the highest weight on the scale. N is the total number of respondents = 103. The relative important index percentage is shown in Table Analysis Using SPSS Software The analysis has been done by descriptive statistics in the SPSS (Statistical Package for Social Sciences) software [2]. In this analysis, mean, median, mode, and the standard deviation are calculated. The calculated parameters are shown in Table-3.Using Friedman mean ranking method wasted generated in construction industry has been analysed and mean ranking for respective waste generated are shown in Table-4.Depending upon the mean rank value manual ranking of wastes is given and it is shown in Table FINDINGS AND DISSCUSSIONS By comparisons of manual data result with SPSS data result we can conclude that Workers mistake rank top among wastes generated in construction industry as presented in Table-5. From the data simulation 97% of manual analysis agrees with software data analysis except the last few in this context 3 parameters whose impact is negligible. It is also found that wastes generated are mostly in operational stage and followed by material procurement and handling stages. as shown in figure-3. We know that waste cannot be eliminated but it can be minimized. From analysis data, it also found that more than 30% respondents are using lean construction techniques 40% respondents will implement in future and 26% are using if only required as shown in figure-4. It indicates that maximum professional has an idea about lean construction methods. 4. SUGGESTIONS AND SOLUTIONS From the above results of software analysis& manual calculation it has been found that the wastes generated have a great impact on construction cost, quality and time. Thus, the following solutions are recommended to minimize the wastes. Proper training for labour must be given and they must be educated about lean methodology and its techniques to reduce time, to improve quality, and to minimize waste. As we can see most of the waste is generated in operational stage this is due to ineffective work and lack of skilled labour this must be reduced. Engineers and managers must supervise the work such that there is no ineffective work or rework, due to rework materials are wasted and cost may be increased. Using lean methodology in construction field all these causes will be reduced and work efficiency will be increased and cost will be reduced as a result waste is minimized. so that waste rework is reduced. Using buffers (cost, time, capacity, space, etc.) to absorb the effort flow variability. For example, feeding buffers delay (lag) and overrun (handing over work that is not needed a specific time) in order to avoid the rights and tasks synchronized start to finish can be used editor@iaeme.com

4 Implementation of Lean Methodology in Indian Construction Equalise work resources (add or remove resources) based on workflow and work with small teams and eventually rely on the logic of tasks to adjust. Reduced variation and work less simultaneously (small chunks) small units / functions split packages of work to reduce the cycle time. Switching from one task to reduce and avoid the equipment and machinery failures. A quality policy so that no malfunction stream (i.e., stop working if necessary) is passed to the adoption. Integrating Lean Six Sigma in construction a policy framework to reduce defect where the focus is on improving Sigma enables the Rating. To attain a continuous performance and work to clean and maintain the site on a daily basis, using 5S technique s (sort, straighten, standardize, shine, and sustain) to set up the plan of the site work practices. Drag/loose task from one place/worker to another when all the resources and simultaneous tasks and preceding tasks are completed and synchronized. All work packages for the resources (material, labour, equipment, etc.), availability of the system to use less internal logistics, remove barriers, and cross-training to implement multitasking. The purpose of each job in the work package is completely ready for release (i.e., no delay, there is no shortage, no faults, etc.). Lean contributes the efficiency of construction industry. application of lean results system performance and development of project. Thus, Lean construction is required for the adoption of lean techniques to get a developmental change in construction field and to achieve the substantive flow of work. implement lean construction are recommendations minimizes wates generated in constuction industry which the sole purpose of this project. 5. RESULTED TABLES AND FIGURES Table 1 Output of Weight Average Method SL.NO Waste Generated in Construction Industry Sum of Wight of Each Waste Average Weight 1 Waste due to Improper Planning of Construction Waste due to Worker s Mistakes Waste due to delay in material supply Waste due to irregular Cash Flow Waiting due to crews interference Waiting due to Inspection Waste due to Stock Problem Waste while waiting for instruction Waste in waiting due to equipment s installation Waste due to theft or Vandalism (theft) Waste produced due to overordering & over production Waste due to wrong handling and wrong storage Waste occurred due to manufacturing defects Waste due to ordering of materials that may not meet the project requirement as explained in design documents Waste due to re-work Waste due to in-effective work (errors) Waste due to interaction between various Specialists editor@iaeme.com

5 P. Abhiram and SS. Asadi and A.V.S. Prasad Table 2 Output Data of Relative Important Index Sl. No Wastes In Construction Industry Total Weightage ( W) 1 Waste due to Improper Planning of Construction Relative Importance Index (%) Waste due to Worker s Mistakes Waste due to delay in material supply Waste due to irregular Cash Flow Waiting due to crews interference Waiting due to Inspection Waste due to Stock Problem Waste while waiting for instruction Waste in waiting due to equipment s installation Waste due to theft or Vandalism (theft) Waste produced due to overordering & over production Waste due to wrong handling and wrong storage Waste occurred due to manufacturing defects Waste due to ordering of materials that may not meet the project requirement as explained in design documents Waste due to re-work Waste due to in-effective work (errors) Waste due to interaction between various Specialists Table 3 Output as per SPSS Software Sl. No Wastes in Construction Industry Mean Standard Deviation 1 Waste due to Improper Planning of Construction Waste due to Worker s Mistakes Waste due to delay in material supply Waste due to irregular Cash Flow Waiting due to crews interference Waiting due to Inspection Waste due to Stock Problem Waste while waiting for instruction Waste in waiting due to equipment s installation Waste due to theft or Vandalism (theft) Waste produced due to overordering & over production 12 Waste due to wrong handling and wrong storage Waste occurred due to manufacturing defects editor@iaeme.com

6 Implementation of Lean Methodology in Indian Construction 14 Waste due to ordering of materials that may not meet the project requirement as explained in design documents 15 Waste due to re-work Waste due to in-effective work (errors) Waste due to interaction between various Specialists Table 4 Friedman Mean Rank Parameters Sl. No Wastes in Construction Industry Mean Rank 1 Waste due to Improper Planning of Construction Waste due to Worker s Mistakes Waste due to delay in material supply Waste due to irregular Cash Flow Waiting due to crews interference Waiting due to Inspection Waste due to Stock Problem Waste while waiting for instruction Waste in waiting due to equipment s installation Waste due to theft or Vandalism (theft) Waste produced due to overordering & over production Waste due to wrong handling and wrong storage Waste occurred due to manufacturing defects Waste due to ordering of materials that may not meet 6.92 the project requirement as explained in design documents 15 Waste due to re-work Waste due to in-effective work (errors) Waste due to interaction between various Specialists 7.64 Table 5 Manual Ranking for Each Waste Sl. No Wastes in Construction Industry Rank 1 Waste due to Worker s Mistakes 1 2 Waste due to in-effective work (errors) 2 3 Waste due to re-work 3 4 Waste due to delay in material supply 4 5 Waste due to irregular Cash Flow 5 6 Waste due to Improper Planning of Construction 6 7 Waiting due to Inspection 7 8 Waiting due to crews interference 8 9 Waste due to theft or Vandalism (theft) 9 10 Waste due to interaction between various Specialists Waste due to wrong handling and wrong storage Waste due to ordering of materials that may not meet 12 the project requirement as explained in design documents 13 Waste occurred due to manufacturing defects Waste due to Stock Problem editor@iaeme.com

7 P. Abhiram and SS. Asadi and A.V.S. Prasad 15 Waste in waiting due to equipment s installation Waste produced due to overordering & over production Waste while waiting for instruction 17 Figure 1 Methodology Flow Chart COLLECTION OF ALL POSSIBLE WASTES GENERATED IN CONSTRUCTION INDUSTRY 17 DIFFERENT WASTES ARE IDENTIFIED IN CONSTRUCTION INDUSTRY STRUCTURE OF QUESTIONNAIRE SURVEY DATA ANALYSIS 1. Waste due to Improper Planning of Construction. 2. Waste due to Worker s Mistakes. 3. Waste due to delay in material supply. 4. Waste due to irregular Cash Flow. 5. Waiting due to crew s interference. 6. Waiting due to Inspection. 7. Waste due to Stock Problem. 8. Waste while waiting for instruction. 9. Waste in waiting due to equipment s installation. 10. Waste due to theft or Vandalism (theft). 11. Waste produced due to overordering& over production. 12. Waste due to wrong handling and wrong storage 13. Waste occurred due to manufacturing defects. 14. Waste due to ordering of materials that may not meet the project requirement as explained in design documents. 15. Waste due to re-work. 16. Waste due to in-effective work (errors). 17. Waste due to interaction between various Specialists. WEIGHT AVERAGE METHOD STATISTICAL FORMULA RELATIVE IMPORTANT INDEX STATISTICAL FORMULA ANAYSIS USING SPSS SOFTWARE FINDING DESCRIPTIVE STATISTICS (MEAN, MEADIAN, MODE, STANDARD MANUAL RANKING RESULTS, SOLUTIONS, RECOMMENDATIONS, SUGGESTIONS & CONCLUSIONS editor@iaeme.com

8 Implementation of Lean Methodology in Indian Construction Weightage Given Explanation 2 Least Frequent 4 Less Frequent 6 Frequent 8 More Frequent 10 Most Frequent Figure 2 Weightage Given in Questionnaire Figure 3 Factors that cause Major waste in a project REFERENCES Figure 4 Statical data about knowledge of Lean Methodology [1] Analysis of lean construction practices at Abu Dhabi construction industry, Al-Aomar, Raid (2012) Analysis of lean construction practices at Abu Dhabi construction industry. Lean Construction Journal2012 pp [2] Study lean principle applications in construction industries, B. Dineshkumarand T. Dhivyamenaga, Indian journal of Sciencee & Technology (IJST) jan2016. [3] A Proposed Solution to the Problem of Construction Industry Overruns: Lean Construction Techniques and Linear Programming., Rohit Jindas Gade, Indian journal of Science & Technology (IJST) July editor@iaeme.com

9 P. Abhiram and SS. Asadi and A.V.S. Prasad [4] Quantification of Delay Factors Using the Relative Importance Index Method for Construction Projects in Turkey,Murat Gündüz, Yasemin Nielsen, and Mustafa Özdemir Journal of management in Engineering ASCE, APRIL [5] Remon Fayek Aziz and Sherif Mohamed Hafez (2013), Applying lean thinking in construction and performance improvement, Alexandria Engineering Journal, 52, [6] Material Waste in Building Industry: Main Causes and Prevention, Carlos T. Formoso, Lucio Soibelman, Claudia De Cesare, and Eduardo L. Isatto, ASCE-\Journal of Construction Engineering and Management, July, August [7] Shilpa Chauhan and Jagdish Kamboj, A way to Go Sustainable: Identifying Different Means & Need to Go Green in the Sector of Construction World. International Journal of Civil Engineering and Technology (IJCIET), 7(5), 2016, pp [8] Gedde Teja Pavan Kumar Reddy and B. Harish Naik, Enhancing Cost Efficiency in Construction Using Earned Value Management. International Journal of Civil Engineering and Technology (IJCIET), 7(6), 2016, pp editor@iaeme.com