Advanced Optimization Theory and Methods

Lean Thinking Through The Perspective of The Construction Industry

Engr. Ivandale C. Gundran, RChE

Master of Engineering in Chemical Engineering
Technological Institute of the Philippines

29 September 2022

MERC 113
Advanced Optimization Theory and Methods
School Year 2022-2023

Author’s Note

Correspondence concerning this article should be addressed to Engr. Ivandale C.

Gundran, RChE; MEngg student in Chemical Engineering, School of Engineering,
Technological Institute of the Philippines.
Mobile No.: (+63) 917 729 0491. E-mail: migundran@tip.edu.ph
 Advanced Optimization Theory and Methods

Lean Thinking Through The Perspective of The Construction Industry

This study was made possible through the curiosity of the Construction Industry

Institute (CII). CII is a consortium of more than 130 leading owner, engineering-

contractor, and supplier firms from both the public and private arenas based at The

University of Texas at Austin. These organizations have joined together to enhance the

business effectiveness and sustainability of the capital facility life cycle through CII

research, related initiatives, and industry alliances. A team assembled from the

consortium is tasked to take into consideration the ‘Lean Principles’ in the Engineer,

Procure, Construct [EPC] Industry.

There is no doubt now that the lean production approach has become very popular

by its ability to achieve industrial excellence for the manufacturing sector through waste

minimization, and it spreads gradually into other industries (the construction industry,

the field of health, banks…) Recently, Lean philosophy begins to be experienced in the

construction industry as an effective approach of construction projects management

aiming at reducing waste and generation value to the customer. LC encloses the

following five principles: Value, Value Stream, Flow, Pull, and Perfection. The LC

techniques and tools which are the most suitable to be applied on the construction

projects are: Just in Time (JIT), Last Planner System, Increased Visualization, First Run

Studies, Daily Huddle Meetings, The 5s Process, Fail-Safe for Quality, Standardization,

The Five Why's according to Bajjou & Chafi (2018).

I believe that the research team’s decision to to focus their investigations on the
 Advanced Optimization Theory and Methods

construction production and give relatively less attention to lean design and supply

chains was right. The dependent variables were easier to identify given the time

devoted to identifying lean principles. The team is also carrying out a series of value

steam studies to helpunderstand and characterize waste in construction production

process. Lean thinking is an approach that aims to streamline the process by reducing

waste that occurs in the production process flow. The investigation on the cause of the

waste is by using a diagram of cause and effects. Once the cause is known, efforts are

made to improve the cause of the waste that occurs. The idea of Lean CSC cost

management is to use the principles and techniques of lean thinking to improve the

effectiveness of CSC cost management, pursuing the maximum of customer

satisfaction as well as the minimum of CSC cost. In specific, by continuously eliminating

non-value added activities and getting rid of wastes in each stage across the entire

CSC, lean CSC cost management can help achieve multiple objectives of CSC

including reducing total supply chain cost, improving the effectiveness of the entire

supply chain and best satisfying more special, personalized and diversified customer

requirements, which all contribute to the enhancement of the over competence of CSC

according to M. Chaeron, R. Sentosa & A. Soepardi (2020).

This study’s focal point was to create a survey questionnaire for lean conformance

and it identified the following five topmost principles of lean construction:

Standardization, Culture/People, Continuous Improvement/Built-In Quality, Eliminate

Waste & Customer Focus.

 Advanced Optimization Theory and Methods

Standardization is one of the main features of lean construction since it adopts the

philosophy of keeping things consistent for the workers. A clean, organized, and logical

jobsite will lead to shorter cycle times and increased productivity. Standardization is a

precondition and foundation for the construction of information and it provides

necessary supports for scientific and delicacy management of commercial and e-

commerce activities. Government procurement is an important part of government

public expenditure and a major means for government economic regulation according to

H. Liang & X. Wu (2017). For me, Culture/People is concerned with Organizational

Commitment. Each employee has its specific role in the hierarchy of pecking order.

Continuous Improvement/Built-In Quality is an inevitable aspect to every human and of

course, what is a company made of? Humans, yes. To be a better version of yourself is

the bare minimum in having a progress in the corporate world. Same goes for

companies. If they want to have a better or more global reach, they have to outdo

themselves each and every time. Waste elimination is important in an industrial setting-

for me, the massive carbon emission and other obnoxious materials were accumulated

since the Industrial Revolution. As a customer, Customer Focus is a top-notch priority in

all industries. I believe that without the customers there would be no companies being

able to sell their product, above and below expectations.

To conclude, Lean Manufacturing was represented well in the questionnaire.

Deprioritization also happened to some Lean Manufacturing ideas to give way to

orthodox principles. I believe that optimization and affirmation of the said ideas can

happen in the areas that the survey has covered. Feedback from the lean community
 Advanced Optimization Theory and Methods

will be important in applying these not just to the concrete industry but also other major

business structures.
 Advanced Optimization Theory and Methods

REFERENCES

Chaeron, M., Sentosa, R., & Soepardi, A. (2020). The Implementation of the Lean
Thinking Concept for Reducing Waste: A Study Case in the Leather Tanning
Process. Department of Industrial Engineering, Universitas Pembangunan
Nasional Veteran Yogyakarta, Indonesia.
Source: https://ieeexplore.ieee.org/document/9309825/authors#authors

Bajjou, M.S., & Chafi, A. (2018). Towards implementing lean construction in the
Moroccan construction industry: Survey study. Department of Industrial
Engineering, Sidi Mohamed Ben Abdellah University Fez, Morocco. Source:
https://ieeexplore.ieee.org/document/8370556/authors#authors

Wu, X. & Liang, H. (2017). Government procurement issues and supporting role of
standardization in China. China National Institute of Standardization, Beijing,
China. Source: https://ieeexplore.ieee.org/document/7950388/authors#authors
 Advanced Optimization Theory and Methods

Lean Deployment: A Pomodoro Technique for Productivity Improvement

Engr. Ivandale C. Gundran, RChE

Master of Engineering in Chemical Engineering
Technological Institute of the Philippines

29 September 2022

MERC 113
Advanced Optimization Theory and Methods
School Year 2022-2023

Author’s Note

Correspondence concerning this article should be addressed to Engr. Ivandale C.

Gundran, RChE;
MEngg student in Chemical Engineering, School of Engineering, Technological Institute
of the
Philippines. Mobile No.: (+63) 917 729 0491. E-mail: migundran@tip.edu.ph
 Advanced Optimization Theory and Methods

Lean Deployment: A Pomodoro Technique for Productivity Improvement

Pomodoro Technique was developed by Francesco Cirillo, a CEO of XPLaps in

Germany, in the late 1980s. It is the time management method which uses a fixed block

of times to improve productivity to archive defined tasks. This idea helps to enhance

focus and concentration by reducing interruptions, including both internal and external

distractions. I believe that knowing and applying the Pomodoro technique is tantamount

to using Lean Deployment and other Work Study Methods will improve productivity.

Lean manufacturing tools are very prevalent in many industries, as evidenced by the

performance and financial boost that it gives companies. This research paper can be a

great guide to any enterprise that’s why I associated Lean Tools with the Pomodoro

Technique is that according to many researchers, using Lean Tools is the best way to

improve productivity by eliminating or reducing time consuming actions which generally

do not contribute in actual production. Manufacturing cost is greatly reduced & the

improved economics drastically increases the annual profitability of the industry.

In its simplest form, productivity is defined as a measure of outputs from a process

per unit of inputs. Productivity measurement of a system or process therefore requires

considering all that the process consumes to produce the desired outcomes.

Organizations around the globe are continuously researching the technologies and

methodologies to maximize their productivity and survive in the market. In order to put

the theoretical concept of productivity into practice, we need to develop measures of

productivity. According to Epstein, 1992, productivity has two dimensions: efficiency and

effectiveness. Efficiency refers to the level and quality of service which is obtained from
 Advanced Optimization Theory and Methods

the given number of resources. If the sector can produce a greater quantity and/or

higher quality of output with the same number of resources, it has improved its

efficiency. Effectiveness relates to the extent to which the provider meets the needs and

demands of stakeholders or customers. The stake holders of education sector are

students, faculty, community, state government, industry, and the nation-at-large

Epstein further elaborates. This broader definition by Epstein clarifies that productivity

improvement is more than mere cost-cutting. Rather it is a multi-faceted concept

strongly linked with the goals and missions of the institution.

Work Study is the most important basic technique in the Industrial Engineering

system; the purpose is to improve productivity and overall efficiency. Using Method

Study and Work Measurement (two methods of Work Study) to achieve these targets:

improving production process, production design and equipments, simplifying operation,

reducing unnecessary fatigue, using materials, equipments and manpower effectively,

improving working environment and working conditions, and finally forming operating

standards. Through Work Study, operation procedures and methods will be optimized,

fixed working hours and staff configuration will become scientific and reasonable, and

the exposure time in risk environment and operational risk will be reduced substantially

according to Lu et al., 2011.

In production scheduling, many researchers have paid attention to the “bottleneck”

problems. Constraint resource of the system determines the output capacity of the

system. From the theory of constraints, it is true that the loss of an hour in the
 Advanced Optimization Theory and Methods

bottleneck resources is the loss of an hour in the whole system. The production

scheduling in bottleneck resources will affect the output of the whole system. So if we

want to maximize the output rate, we must make best use of bottleneck resources

according to Ding et al., 2011.

Standard Work is the step-by-step method for setting a Mount Rushmore for

employees to be aware of and follow. This is to be updated every now-and-then to

ensure top-notch basis on technology, economics, and safety practices. The 5S

methodology takes its origin in Japan by the middle of 1950, in the post second great

war period, during the country's reconstruction. The period's success is accredited to

Kaoru Ishikawa, the method's developer, not said creator, having in mind the country's

previous moral education. Often approached as “commonsense” and regarded as a

low-cost and technologically independent, its implementation empowers workers

regardless of their technical knowledge. The low-cost nature of 5S implies that the

method is an adequate start in quality improvement. However, further productivity

enhancing methods are indispensable to reaching better results, considering a

continuously improved environment. This specific method was chosen because the

place that should be focusing on meeting projects and other relevant activities for the

society, although was unorganized and in some cases was making the group miss the

main ideas important for the goal. Thereby, the main objective was to organize the

workspace, optimizing resources and establishing a better co-work environment using

the 5S methodology. That being accomplished, it was expected to motivate staff and
 Advanced Optimization Theory and Methods

increase the productivity, developing more and complex projects, as the co-workspace

stimulates interdisciplinary topics and approaches according to Filho et al., 2017.

To conclude, enhancing productivity is attainable given the various tools available at

every industry’s arsenal. For every improvement to be made, it is important to be

specific on what problem is to be dealt with using the method study. After that,

Bottleneck Analysis is the proper step to use in focusing in on the problems that arose.

To find out other underlying problems, advanced time study methods should be utilized.

5S is applied to already categorized problems. Using the Lean tools stated above, much

time and resources are conserved because solutions are given to specific problems and

the tools are improved by researchers to bring success to every company that uses

them.
 Advanced Optimization Theory and Methods

REFERENCES

Ruensuk, M. (2016). An implementation to reduce internal/external interruptions in Agile

software development using pomodoro technique. Department of Information

Technology, Stamford International University, Bangkok, Thailand. Source:

https://ieeexplore.ieee.org/document/7550835/authors#authors

Iqbal, A. (2012). Productivity Measurement Issues in Education Sector of Pakistan.

Bahria University, Islamabad, Pakistan. Source:

https://ieeexplore.ieee.org/document/6387083/authors#authors

Lu, G., et al. (2011). On relation between Work Study and safe-efficient coal mine.

School of Mines, China University of Mining and Technology, Xuzhou, China.

Source: https://ieeexplore.ieee.org/document/6035387/authors#authors

Ding, W., et al. (2011). School of Energy Science and Engineering, Henan
Polytechnic University, Jiaozuo, China, Source:
https://ieeexplore.ieee.org/document/6010180/authors#authors
 Advanced Optimization Theory and Methods

Filho, W.V., et al. (2017). The benefits of a quality tool in a Student Branch:

Implementing the 5S methodology to create a new culture. Federal University

of ABC (UFABC), Santo André, Brazil. Source:

https://ieeexplore.ieee.org/document/7998408/authors#authors

Lean Production: Long-Term Effects of Organizational Change

Engr. Ivandale C. Gundran, RChE

Master of Engineering in Chemical Engineering
Technological Institute of the Philippines

29 September 2022

MERC 113
Advanced Optimization Theory and Methods
School Year 2022-2023

Author’s Note
 Advanced Optimization Theory and Methods

Correspondence concerning this article should be addressed to Engr. Ivandale C.

Gundran, RChE;
MEngg student in Chemical Engineering, School of Engineering, Technological Institute
of the
Philippines. Mobile No.: (+63) 917 729 0491. E-mail: migundran@tip.edu.ph
Lean Production: Long-Term Effects of Organizational Change

This paper is about Toyota helping Porsche to improve their operations by the

introduction and the importance of lean production. The managerial culture of Toyota

weighed a lot more than their lean tools and this was prevalent on the survey that was

conducted. Several organizations were used as a sample to determine the factors

necessary in carrying out lean principles.

Toyota is an iconic brand associated with quality and reliability. Toyota Motor

Corporation (TMC) which produces Toyota vehicles uses efficient manufacturing and

supply chain management techniques, commonly known as lean

management techniques, to create customer value according to J.K. Liker and M.

Hoseus (2008). At a strategic level, lean can be viewed as a management philosophy

aimed at reducing waste at every stage of the value chain of an organization according

to R. Shah and P.T. Ward (2007). At the turn of the 21st century, as Toyota signaled its

global presence by becoming one of the leading automobile manufacturers in the world,

the TMC recognized the need to share its values-that set Toyota apart from the others-

with its overseas facilities engaged in logistics, sales, and marketing, to sustain its

competitive position. The upshot of this was codifying Toyota's culture as what became

labelled “The Toyota Way” (TW). The TW is meant particularly for Toyota's overseas
 Advanced Optimization Theory and Methods

logistics, sales and marketing facilities, which are not exposed to Toyota's core cultural

values to the same extent as manufacturing facilities are N.P. Jayamaha et al., (2014).

The TW consists of 2 key concepts: Respect for People and Continuous Improvement.

These drive the deployment of TW in solving problems to achieve quality and process

improvement.

Lean production is the reputation given to TPS (Toyota production system) by the

international mobile experts of Massachusetts Institute of Technology after a project

called IMVP. At 1990, Mike Jones et al. published the machine that changed the

world which discussed the TPS systematically for the first time. After that the lean

production is gradually accepted and applied by more and more entrepreneurs, who try

to upgrade enterprises' competitive, through a great deal of research, the European-

American Scholars get the conclusion that lean production is the manufacturing

paragon of 21centurty. Incorporating the economy of mass production and the flexibility

of multi-varieties and small-batch production, lean production is committed to waste

reduction and pursue eliminating all the non-value-added activities. It is called the third

production model after manual production model as well as mass production model.

To upgrade competitive and take part in international competition, the companies

began to learn TPS at 80s of 20 century. In recent years, with our country's rapid

stepping into global economy, the companies of our country get broader market, but at

the same time the pressure from serious competition, cost increase and the diversity of

demands is becoming heavier and heavier. Under such circumstances, the lean

production gets unprecedented emphasis and is being applied into manufacturing and
 Advanced Optimization Theory and Methods

non-manufacturing industry. The implementation of lean production relating to many

tools and technologies, but now there is no implementation guideline or implementing

handbook, so in the process of implementation the companies have no knowledge

about the importance of respective lean tools and under this situation the experts

become the only norm. But the level of experts is uneven, the practical condition of each

company is not identical, so it is not sufficient and reasonable to rely on experts

exclusively. Obviously how to identity the rule and crucial factors of implementing lean

production successfully from the historical data has profound significance.

The participants were surveyed on their understanding, contribution, integration and

connection to the lean philosophy. Toyota’s production system philosophy was linked to

waste reduction and teamwork promotion by 9 out of 10 respondents. This supports the

background of the literature. TPS’ motto making humans the centerpiece of success is

not surprisingly favored by the surveyees. The vision & mission which laid the objectives

of the company were not heavily favoured by newer Toyota officers- they stressed more

on the right attitude towards the employees’ organizational chart. This is supported by

the employees because I believe that they are very much prioritized with these policies.

Even if the study did not make a proper chronological order in the use of lean tools, I

can be said that it generated a rather low rank for its Kaizen agenda. Companies have

to fully integrate the lean functions to fully enjoy the benefits that it brings.
 Advanced Optimization Theory and Methods

REFERENCES

Ruensuk, M. (2016). An implementation to reduce internal/external interruptions in Agile

software development using pomodoro technique. Department of Information

Technology, Stamford International University, Bangkok, Thailand. Source:

https://ieeexplore.ieee.org/document/7550835/authors#authors

Jayamaha, N.P., Grigg, N. P., & Wagner, J. P. The moderation effect of the cultural

dimension "individualism/collectivism" on Toyota Way deployment — A

global study on Toyota facilities. School of Engineering and Advanced

Technology, Massey University, Palmerston North, New Zealand Source:

https://ieeexplore.ieee.org/document/7058634/authors#authors

Shaobo, L., Chunhua W. , Hongliang, Z. Key technology analysis of implementing lean

production. School of Management, Hebei University of Engineering,

HanDan, HeBei, P. R. China. Source:

https://ieeexplore.ieee.org/document/5344259/authors#authors
 Advanced Optimization Theory and Methods

Lean Concept in the Automotive Industry

Engr. Ivandale C. Gundran, RChE

Master of Engineering in Chemical Engineering
Technological Institute of the Philippines

29 September 2022

MERC 113
Advanced Optimization Theory and Methods
School Year 2022-2023

Author’s Note
 Advanced Optimization Theory and Methods

Correspondence concerning this article should be addressed to Engr. Ivandale C.

Gundran, RChE; MEngg student in Chemical Engineering, School of Engineering,
Technological Institute of the Philippines.
Mobile No.: (+63) 917 729 0491. E-mail: migundran@tip.edu.ph
Lean Concept in the Automotive Industry

The principles of lean manufacturing, as applied in the Toyota Production System

(TPS), have been in practice by the Japanese auto industry for nearly 60 years. James

Womack and Daniel Jones argue that the defining objectives of the TPS can be

summarized into five elements: “Precisely specify value by specific product, identify the

value stream for each product, make value flow without interruptions, let the customer

pull value from the producer, and pursue perfection according to J. J. Womack in Lean

Thinking: Banish Waste and Create Wealth in Your Corporation (2003).This definition of

“lean” as given here appears to be more descriptive of a culture, rather than a specific

set of tools.

Companies have adopted lean production principles as a way to reduce costs, reduce

lead times, improve customer satisfaction, and increase productivity. The process of

becoming lean may mean transforming oneself from one's existing style of operations to

an entirely different one. Lean production is a culture and philosophy for an entire

enterprise. The process may require significant changes in the functions of the

company. Even though there are many examples of companies that have become more

competitive and successful by adopting lean production principles and practices, there

are many more examples of those who have not been as successful. Many

organizations are not clear about what does it take to become lean. To convert from
 Advanced Optimization Theory and Methods

mass production to lean, they relate lean manufacturing to kanban system, or reduction

of lot sizes from thousands to hundreds, or making a U-shaped cellular layout according

to Hallam, C.R.A et al. (2010). It may not be clearly understood by the companies

implementing lean is that kanban or pull system can be used only when it is easy to

associate part requirements with the requirements of the finished product. If it is difficult

to associate part needs and finished product requirements, then push system is better

than kanban system. Although MRP correctly calculates part requirements by precisely

associating them with the finished product requirements; but because of (1) combining

part requirements into sizable lot sizes and (2) long lead times, the association is no

longer correct thereby making a pull system impractical. The lot size and lead time

erode the close association between part requirements and the finished product

requirements. Many published articles in this area also, do not completely describe the

process of going through the gradual and painful progress towards lean manufacturing.

A number of companies have difficulty achieving even a fraction of the benefits that

studies have shown that a lean environment requires half of the hours of human effort

spent on production, one-third of the hours of human effort spent on engineering, half of

the factory space to produce the same output with a significant reduction in WIP

inventories and defect rate. Therefore, to reduce WIP, the company should concentrate

on reducing the production lead time. This is an important principle in lean production.

The techniques of lean production are geared to highlight where the lead times are

excessive and should be reduced.

Even though lean manufacturing has proven time and again to work, why are not US

companies lean? Two major reasons that have been discussed in various industrial
 Advanced Optimization Theory and Methods

forums, will be discussed next. First reason is that that lean thinking is counterintuitive

to what US management is taught. Lean manufacturing while proven, does not fit

comfortably into the business philosophies. Using economies of scale, people know that

more is better. The idea is that if you make large batches of product you have used your

equipment more efficiently and reduced the cost per piece, while the cost is not

minimized if you make small batches with time-consuming changeovers. In this

approach, the focus is on machine and operator efficiency. While in lean manufacturing

the focus is on value-added activities and the efficiency of the workflow as a whole.

More is not necessarily better. The focus is on to synchronize operations so the entire

workflow produces product that customer needs it and in the amount the customer

needs it according to Conner, B. G. in Lean Manufacturing for the Small Shop, Society

of Manufacturing Engineers (2001). In lean, the focus is on the overall system and how

the system generates value.

To conclude, with every employee’s dedication to locating the problem, lean thinking

can be used to improve the productivity, reduce the capital needed and in turn, increase

the profit of the implementing company. Even if Toyota paved the way for lean

principles and with them sharing this to their rivals, competition is still very much present

in the automotive industry.

 Advanced Optimization Theory and Methods

REFERENCES

Hallam, C. R. A., Muesel, J., Flannery, W. (2010). Analysis of the Toyota Production
System and the genesis of Six Sigma programs: An imperative for understanding
failures in technology management culture transformation in traditional manufacturing
companies. University of Texas, San Antonio, USA. Source:
https://ieeexplore.ieee.org/document/5602106/authors#authors

Narang, R.V. (2008). Some Issues to Consider in Lean Production. Indiana University-

Purdue University Fort Wayne, USA. Source:

https://ieeexplore.ieee.org/document/4580000/authors#authors
Advanced Optimization Theory and Methods