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Lean Construction and Safety: Term Paper On
Lean Construction and Safety: Term Paper On
Lean Construction and Safety: Term Paper On
Lean
Abstract
Lean construction has been articulated as a tool in construction safety. Idea of lean with its basic
principles has been explained. Accidents are considered Non Value adding wastages in construction.
Application of Lean Construction principles for safety has been presented. Continuous flow and 5 S of
lean construction for safety have been elaborated. Other tools and ideas of lean construction also have
been explained.
Introduction
Lean
The Word Lean was coined by Mr. James P. Womack.
In the beginning it referred to only manufacturing industry but now it is used in all industries,
retail, construction, banking etc.
Lean Thinking is defined as a way to do more and more with less and less human effort, lesser
equipment, lesser time and lesser space.
The continuous application of lean construction leads to more and more close to provide the
ultimate customer exactly what he wants.
Inspiration for Lean
Inspiration is from Toyota Production System which revolutionized the manufacturing Industry.
Toyota Production system
It has three components
(1)Mura Smooth Flow.
(2) Muri Stress.
(3)Muda Waste.
MURA speaks of the smooth flow without any gaps/ interception in the manufacturing, from
start to finish of the product.Lean Construction speaks of no gaps between different activities and
between
different trades. The bane of the construction Industry is lack of flow.
MURI speaks of no stress to the worker, who should be assigned only work he is
capable of doing.
Lean Construction also says that work allocation should permit correct time and correct
resources for the product.
Unrealistic target, particularly with incomplete resources only results in demoralizing
atmosphere and driving down performance.
MUDA speaks of non-value adding activities (Waste which all players should
work their very best to avoid) Examples of Muda are over production, waiting, transporting ,
inappropriate processing, unnecessary inventory, unnecessary/ excessive motion, defects.
Construction abounds with such wastages.
Lean Construction
Lean construction is construction concept inspired by Japanese Lean Production system.
Koskela (2002) defined Lean Construction as a way to design production system to minimize
waste of materials, time, &effort in order to generate the maximum possible amount of value.
Lean construction is optimizing Efforts, minimizing costs & time reducing waste, creating
Value and doing what best can be done.
Any Effort, be it Cost, Materials, Machinery and any one and all activities in a project should be
optimized and that is Lean Construction.
Ambience for Lean Construction
5 S of Lean Construction
STEP 1 SEIRI or Sort
Deals with the contents of a workplace, and removes all items that are not needed there.
Lean Construction
50%
30%
Value Adding
Value Adding
50%
70%
This waste can include loss or injury of trained and experienced workers, and the resulting
disruption to progress of work, undeniably represents waste in the performance of construction.
When left uncontrolled, these factors can create disruption due to many cost related factors; such
as escalating workers compensation insurance costs, high cost of medical treatment and
rehabilitation program.
The economic losses also include indirect losses such as administrative cost, productivity losses
and low morale.
It follows, then, that safeguarding construction worker from occupational hazards would be a
natural outcome of Lean Construction ideal of waste elimination.
Saurin et al. found in their exploratory study that
(1) Some lean production concepts and methods, such as the Last Planner method, which have
been used for production planning and control, can be easily extended to safety planning.
(2) Integration of production principles into safety planning would help in overcoming the
inherent shortcomings of construction safety planning.
Continuous Improvement Program (Kaizen) and Safety
Kaizen is an essential feature of Lean Construction.
An empirical study has been done by Nahmens and Lukuma (2009) to examine relationship
between Continuous improvement (CI) Program and safety in the industrialized housing
industry.
They proposed that
(1)CI program will reduce opportunity through reduced wastes in materials, motions and process
steps) and therefore reduced safety hazards.
(2)CI program may also include safety improvement as its one category undertaken as
continuous improvement program.
In first approach, attention is paid to efforts towards continuous improvement through
reduction in waste in materials and processes.
This reduction will be reduction in material consumption and motions happened during
construction process.
This will reduce probability for accident occurrence or coming in contact with hazardous
materials.
For example by reducing the number of times a heavy object is lifted the total time to complete
the project is reduced and the risk of back injury is also reduced.
Builders with CI programs have lower accident rates. The incidence rates per worker have been
identified as 14.5 per 100 workers against the incident rates of 34.7 per 100 workers those
without lean construction.
Koskela (1993) concluded that implementation of lean construction seems to be a major fact in
the elimination of accidents.
He has identified strategies to improve construction safety through the use of lean production
systems
(1)Designing, controlling, improving engineering and construction processes to ensure
predictable material and work flow on site.
(2).Improving safety management and planning processes themselves to consider hazards and
continuous improving them.
(3).Improving safety related behaviors and minimizing unsafe acts.
According to Kelliher, such techniques have resulted in fewer accidents, more efficient
schedules, and an improvement in logistics planning.
Indian Scenario
Very few organizations have adopted lean principle in India in their policies.
It is still at institute research level especially at IIT Delhi.
One non profit organization Institute for Lean Construction Excellence, established in 2008
Mumbai is working towards improving safety.
Godrej & Boyce Mfg. co. Ltd., Mumbai has adopted lean construction as part of their policy.
However they are implementing to many safety measures along with that.
But it has been reported that number of reportable accidents in 1996-97 were 82 which reduced
to 3 in 2004-05 while Frequency rate reduced from22.73 to 1.42 in the same duration. The
Severity rate also reduced from 267.3 during same time period.
Although there has not been any study and no such data available to show relationship between
safety outcomes and lean construction, but it can be said that it was continuous improvement
program. Continuous program with team collaboration is also lean construction.
Conclusions
It can be concluded that safety measures can be implemented through application of lean
construction principles.
Continuous Flow and 5S of lean construction improves the safety in construction by reducing the
opportunities of accident occurrence.
Furthermore, other principles of lean construction such as prefabrication, 3D , 4D visualization
techniques, adoption of new material and equipment helps in safety implementation.
Last Planner System and Building Integrated Modeling are the tools of lean construction which
can be used for safety as well. They are currently being used and researchers are working to
include safety as part of these tools.
Lean principles and safety can be separate from each other. Lean is about elimination of waste
and accidents are considered as non-value adding wastes.
Lean is just not a technique but it is a thinking that requires cultural shift in organization.
Lean is about creating more values to the product, more happiness to every party involved in the
process. Safety is natural outcome of Lean construction.
REFERENCES
Technical Newsletters (2008-2013), ILCE, Mumbai, India.
Forman, M., (2013), Inertia and change: lean construction and health and safety work on
construction sites, Construction Management and Economics, 31(6).
Bagi. , R. A., Safety Control in the Construction Industry, power point slides, Godrej & Boyce
Mfg. Co. Ltd.
Ghosh, S., (2009), Intersection between Lean construction and Safety Research : A review of
the literature, proceedings of 2009 industrial Research Conference.
Salem, O., Solomon , J., Genaidy A., Luegring, M. (2005), Site Implementation and
Assessment of Lean Construction Techniques., Lean Construction Journal, 2(2).
Nahmens, I. and Ikuma, L. H. (2009). An Empirical Examination of the Relationship between
Lean Construction and Safety in the Industrialized Housing Industry. Lean Construction Journal
1-12.