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Chương 4 - Giới thiệu về xây dựng tinh gọn (Lean construction). Chương này cung cấp một số kiến thức cơ bản về xây dựng tinh gọn như: Cấu trúc công việc (work structuring), kế hoạch nhìn trước (lookahead planning), kế hoạch hàng tuần (weekly work planning). Mời các bạn cùng tham khảo.
Gi i thi u v “xây d ng tinh n”” n Lean Construction ©2010 b i Nguy n Duy Long, Ti n S i dung “Xây d ng tinh g n” Gi i thi u u trúc công vi c (work structuring) ho ch “nhìn tr c” (lookahead planning) ho ch hàng tu n (weekly work planning) ©2010 b i Nguy n Duy Long, Ti n S Lean Construction (LC) XÂY D NG TINH G N ©2010 b i Nguy n Duy Long, Ti n S t m c a thi công xây d ng n ph m ng yên Thi t k ch dùng m t l n n ph m hi m s n xu t tr c khách hàng t mua Nhi u ngu n bi n i (variability) c sai sót s n ph m thi t qui trình cao Cơng vi c c th c hi n u ki n d i (không) t i u ©2010 b i Nguy n Duy Long, Ti n S án ang qu n lý sao? ? Xác nh yêu c u c a ch u t thi t k t c Cân i thi t k t v i gi i n v ch t l ng, ti n , ngân sách Qu n lý d án b ng cách chia nh t ng ph n vi c, c l ng th i gian yêu c u tài nguyên cho m i ph n vi c, r i a ph n vi c m t th t phù h p v i CPM Ph i h p v i vi c s d ng ti n t ng th cu c h p hàng tu n ©2010 b i Nguy n Duy Long, Ti n S án ang qu n lý sao? ? Giao hay h p ng cho m i ph n vi c, kh i công theo dõi m i ph n vi c mb o an toàn, ch t l ng, ti n chi phí Hành ng có nh ng s sai khác i chu n/tiêu chu n Chi phí có th gi m thi u b i nâng cao ng su t lao d ng; th i gian b ng cách ng t c m i ph n công vi c hay thay i trình t cơng vi c Ch t l ng an toàn t h n v i vi c giám sát ki m tra ©2010 b i Nguy n Duy Long, Ti n S th ng cung c p d án tinh g n phác thi t k c ích Tiêu chu n thi t k Thi t k t n ph m Thi t k qui trình Xác nh d án (Project Definition) Thi t k tinh g n (Lean Design) Gia công h u c n thu t chi ti t Cung p tinh g n (Lean Supply) Thay i ho c phá b n hành th p n hành b o trì t p t tinh g n (Lean Assembly) d ng (Use) Ki m Soát S n Xu t (Production Control) u Trúc Công Vi c (Work Structuring) Learning Loops Ngu n: Ballard, 2000 ©2010 b i Nguy n Duy Long, Ti n S u trúc công vi c ho t The extent of choices on the design of op erations c l a ch n cho thi t k ho t ng ng Th Timei gian Extent c lof remaining a ch n choices l i Giai n 1: C u Phasecông 1: trúc vi c Work Structuring and công tác thi design activities t k Ngu n: Lean Construction Institute, 2001 Giai n 2: Last Planner® (“Ng i Phase 2: Ho Lastch Plannernh Cu i”) ©2010 b i Nguy n Duy Long, Ti n S Nh ng hi u l m v “xây d ng tinh n” n” (LC) LC không ph i ang ph ng theo k thu t s n xu t vào thi công xây d ng LC không hi u s n xu t (production) ‘ch t o’ (‘making’) LC ang phát tri n lý thuy t s n xu t m i v i d án m t hình th c c b n c a h th ng s n xu t LC hi u s n xu t thi t k ch t o t t c t o tác (artifacts) ©2010 b i Nguy n Duy Long, Ti n S Xây D ng Tinh G n U TRÚC CƠNG VI C – WORK STRUCTURING ©2010 b i Nguy n Duy Long, Ti n S 10 th ng ho ch th ng ( y) y) nh truy n PROJECT OBJECTIVES PLANNING THE WORK INFORMATION SHOULD EXECUTING THE PLAN RESOURCES Ngu n: Lean Construction Institute, 2001 DID ©2010 b i Nguy n Duy Long, Ti n S 11 ho ch công vi c thi công hàng tu n WEEK PLAN PROJECT: Pilot ACTIVITY Gas/F.O hangers O/H "K" (48 hangers) Gas/F.O risers to O/H "K" (3 risers) 36" cond water "K" 42' 2-45 deg 1-90 deg Chiller risers (2 chillers wk.) FOREMAN: PHILLIP DATE: 9/20/96 Est Act Mon xxxx Tu xxxx Wed Thurs Fri Sat Sun Sylvano, Modesto, Terry xxxx xxxx xxxx xxxx Sylvano, Mdesto, Terry xxxx xxxx xxxx PPC Charlie, Rick, Ben xxxx xxxx xxxx No Yes Charlie, Rick, Ben Hang H/W O/H "J" (240'-14") REASON FOR VARIANCES No Owner stopped work (changing elevations) No Same as above-worked on backlog & boiler blowdown Yes xxxx xxxx xxxx xxxx xxxx xxxx xxxx xxxx xxxx xxxx Matl from shop rcvd late Thurs Grooved couplings shipped late Mark M., Mike Cooling Tower 10" tie-ins (steel) (2 towers per day) Weld out CHW pump headers "J" mezz (18) Weld out cooling towers (12 towers) xxxx xxxx Yes Steve, Chris, Mark W xxxx xxxx xxxx xxxx xxxx xxxx xxxx xxxx xxxx xxxx xxxx No xxxx xxxx xxxx xxxx xxxx Yes Yes Luke xxxx Jeff F.R.P tie-in to E.T (9 towers) 50% xxxx Eye injury Lost days welding time Firt, Packy, Tom WORKABLE BACKLOG Boiler blowdown-gas vents -rupture disks ©2010 b i Nguy n Duy Long, Ti n S 12 th ng Last Planner® Project Objectives Information Planning the Work Can SHOULD The Last Planner Inputs Ngu n: Ballard, 2000 WILL Production DID ©2010 b i Nguy n Duy Long, Ti n S 13 Các nguyên t c c a Last Planner t c k ho ch u d báo t t các d báo sai D báo xa, sai D báo chi ti t, sai Ho ch nh chi ti t h n b n n g n v i vi c th c hi n cơng vi c ó o k ho ch v i ng i s th c hi n công vi c Cùng nh n di n xóa ràng bu c c a công tác ã k ho ch o l i h a tin c y c t sai sót ©2010 b i Nguy n Duy Long, Ti n S 14 u trúc công vi c u trúc công vi c ho ch qui trình: nh, hay thi t Ho ch nh b t u v i thi t k toàn b h th ng s n xu t n thi t k t ng ho t ng riêng l Thi t k qui trình thay i t o giá tr d a s n ph m Thi t k s n ph m thay i t o giá tr d a qui trình gi m thi u lãng phí Ngun lý c a LC k t h p thi t k n ph m qui trình ©2010 b i Nguy n Duy Long, Ti n S t qu 15 a c u trúc cơng vi c Trình t t ng quát (global sequencing) t ch c/h p ng c a d án Hình tr ng c a chu i cung ng (supply chain configurations) Thi t k ho t ng “thô” (rough cut operations designs) Thi t k ho t ng chi ti t (detailed operations designs) Ti n t ng th (master schedule) ti n giai n (phase schedules) ©2010 b i Nguy n Duy Long, Ti n S 16 Ch c n ng c a ti n ng th Th hi n tính kh thi hồn thành cơng vi c th i gian s n có Phát tri n hi n th chi n l c th c hi n Xác nh c n v t t mua s m lâu (long lead items) Nh n m c (milestones) quan tr ng i ch u t bên liên quan (stakeholders) Ti n ©2010 b i Nguy n Duy Long, Ti n S 17 ©2010 b i Nguy n Duy Long, Ti n S 18 ng th Ti n Ti n ng th ©2010 b i Nguy n Duy Long, Ti n S 19 ©2010 b i Nguy n Duy Long, Ti n S 20 ng th 10 th ng Last Planner: Qui trình nhìn tr c Design Criteria Master & Phase Schedule Work Structuring Current status & forecasts Selecting, sequencing, & sizing work we think can be done Information Action to prevent repetitive errors Lookahead Selecting, Workable sequencing, Weekly Backlog & sizing work Work Plans we know can be done Make work ready by screening, pulling, & FRS Ghi chú: PPC = Percent Plan Complete: Ph n tr m k ho ch hoàn thành Completed Work Production Resources Ngu n: Ballard, 2000 Chart PPC & Reasons ©2010 b i Nguy n Duy Long, Ti n S 29 LOOKAHEAD SCHEDULE Project: Same Day Sugery Planner: Dena Deibert Week of 10-23-00 Six Week Lookahead / Constraints Analysis 10/24/04 Activity 10/31/04 11/7/04 11/14/04 11/21/04 11/28/04 Responsible Party Comments / Other M TWR F S M T WR F S M TWR F S M T WR F S M TWR F S M T WR F S Build mock-up of room 11 Boldt x xxxx Microscope vibration study SLMC/ STS Bid & award bid pack Boldt Submit-review-approve roofing shopdrwngs Langer Release updated construction documents ARC x xxxx Demolition Pour roof Boldt x xxxx Boldt 1 1 1 1 1 2 2 Expedite stone production Steel Shops: Curtainwall Support Roof detailing Phase Millwork Shop Drwngs Fabricate louvers Fabricate auto entrance doors Fabricate curtainwall Mock-up review Masonry Work Penthouse framing & decking Bid Pack Submittals Start work on patient rooms 3847 -49 Workable Backlog Fabricate AHU's / ACCU Med Gas Equip Lead-Time Demo shades at main entrance Review room numbering Ngu n: Ballard, 2000 Review with Brad x xxxx x xxxx BDI x xxxx Duwe x xxxx xx Coordinate with Ring & Du xxxx x x xxxx xxx xx x x xxxx xxxx x x xxxx xxx xx x xxx x xxx x x x x xxxx x x xxxx x xxxx xxxx x x xxxx xxx xx xxxx x Klein Dickert x x x x x xxxx x x xxxx xxx xx x x xx x xx x x xxx x xxx 5-6 week lead time - Ordered 10-19-00 x x Klein Dickert will coordinate with Mike D Shipping 11-3; Besam header to Dickert x xxx xx x xxx x xxx Waiting for framing materials-by October x x x x x xxxx x x xxxx x x xxxx xxx xx xxxx x x xxxx xxx xx x x x x Millwork; Mirror Roger needs to confirm if brick is in x x x x TBD TBD Boldt to confirm placement of AHU's Award contracts Need to coordinate with Jan Keepers Shipping: 11-13-00 Trane Delivery: 11-6-00 Squires TBD Stone was ordered 10-19-00 x xxxx x x xxxx Duwe xxx xxx Besam BDI x xxx x x Air Flow SLMC Additional submittals required x xxxx x x Duwe Precision Millwork & mirror CD's will be issued prior to this info; Isolation system will come as addendum x xxx x xxxx x ARC/ Lukes ©2010 b i Nguy n Duy Long, Ti n S 30 15 c ích c a qui trình nhìn tr c nh hình trình t m c lu ng cơng vi c Ph i ch n lu ng công vi c cơng su t Duy trì “cơng vi c t n ng” (backlog) a công vi c s n sàng Phát tri n k ho ch chi ti t v công vi c c th c hi n ©2010 b i Nguy n Duy Long, Ti n S 31 ho ch nhìn tr c Last Planner khác k ho ch nhìn tr c truy n th ng sao? ? Ti n nhìn tr c truy n th ng c dùng cung c p y t th tr c công vi c b t u th ng g n li n v i ti n t ng th chi ti t ©2010 b i Nguy n Duy Long, Ti n S 32 16 Các b tr c c qui trình nhìn Làm n (explode) cơng tác ã l p ti n thành chi ti c m c phân cơng cơng vi c, dùng mơ hình nh ngh a công tác (Activity Definition Model) nghiên c u th (First Run Studies) Sàng l c (screen) ràng bu c cho m i công vi c phân công “th i n nhìn tr c” (lookahead window) o (make) công vi c phân công s n sàng ng cách tháo d ràng bu c ©2010 b i Nguy n Duy Long, Ti n S Các b tr c 33 c qui trình nhìn Cân b ng (balance) ng t i (load) công su t (capacity) b ng cách ti n hành/trì hỗn cơng vi c ã lên ti n , t ng/gi m công su t, hay quy t nh u t thêm công su t Hi u ch nh (adjust) ti n th n u c n c (learn): o l giai n hay t ng ng c i ti n s th c hi n ©2010 b i Nguy n Duy Long, Ti n S 34 17 Ngôn ng nh d ng ng:: Mơ hình nh ngh a công vi c Ch d n Công vi c tiên quy t Qui trình t tiêu chí? t qu Tài ngun Ngu n: Ballard, 2004 Ví d mơ hình cơng vi c ©2010 b i Nguy n Duy Long, Ti n S 35 nh ngh a ©2010 b i Nguy n Duy Long, Ti n S 36 18 “Làm n ” công tác (task explosion) foundation design drawings schedule, accuracy of measureme nt Meets Criteria? LAYOUT location stakes schedule, location verification verify locations etc PILEDRIVING piles in place YES location stakes precast concrete piles access to location sequencing plan surveyor and helper, totalstation, stakes foundation crew, piledriver Ngu n: Ballard, 2004 ©2010 b i Nguy n Duy Long, Ti n S 37 Qui trình làm n Step 3- List Criteria Step - Upon Completion of Work Determine Match of Criteria to Deliverable Criteria Match Yes No Step 2-map process steps Prerequisites Engineering Process Step 1Determine Deliverable Deliverable Step 4- List Prerequisites Step 5- Determine Resources Resources Ngu n: Ballard, 2004 ©2010 b i Nguy n Duy Long, Ti n S 38 19 Mơ hình nh ngh a cơng vi c: c: Ví khe co giãn Expansion Joint Step - Upon Completion of W ork Determine Match of Criteria to Deliverable Step - List Directives Specification Section 05810 Contract Documents Contract Directives Note: T he Specifications and Contract Documents have been superseded because of the redesign Step Describe the process Prerequisite W ork Engineering Process Match Yes No Step Determine Deliverable Delevop Method of Procedure for Exterior Expansion Joints Deliverable Step - List Prerequisite W ork Step - Determine Resources Video tape of installation from Conspec Approved exterior expansion joint drawings Method of attachment Equipment and staging Superintendent plus irion workers Engineering Resources Activity Definition Model Ngu n: Ballard, 2004 ©2010 b i Nguy n Duy Long, Ti n S FRS: Ví d Bucket A Fill 45 Crane Idle 39 bê tông Place 30 Lower & Spot 30 30 30 30 Lift 30 Durations in Seconds Placing Cycle 135 Seconds Bucket A Fill Lift 45 30 Place 30 Fill Bucket B Crane 30 30 Lift 30 30 Place 30 30 Lower & Spot 45 12 12 Lift 30 Place 30 Change Hook Placing Cycle 102 Seconds Ngu n: Ballard, 2004 ©2010 b i Nguy n Duy Long, Ti n S 40 20 Xây D ng Tinh G n HO CH HÀNG TU N – WEEKLY WORK PLANNING ©2010 b i Nguy n Duy Long, Ti n S Design Criteria Work Structuring Current status & forecasts Information th ng Last Planner: K Ho ch Công Vi c Hàng Tu n Master & Phase Schedule Selecting, sequencing, & sizing work we think can be done Make work ready by screening, pulling, & FRS Action to prevent repetitive errors Lookahead Selecting, Workable sequencing, Weekly Backlog & sizing work Work Plans we know can be done Chart PPC & Reasons Production Completed Work Resources Ngu n: Ballard, 2000 41 ©2010 b i Nguy n Duy Long, Ti n S 42 21 Ch c Ch n c a Th t B i SHOULD WILL CAN ©2010 b i Nguy n Duy Long, Ti n S 43 Hình thành k ho ch cam k t SHOULD THESE TASKS NEED TO BE MADE READY ELGIBLE FOR CAN W ILL POSSIBLE WORKABLE BACKLOG Ngu n: Ballard, 2004 ©2010 b i Nguy n Duy Long, Ti n S 44 22 Ho ch Hàng Tu n PPC Project: Same Day Sugery Planner: Dena Deibert Week of 10/16/00 PPC = 69% Assignment Description Remember the Five Criteria for Release of Assignments Defined - Sound - Proper Sequence - Right Size - Able to Learn Review mock-up drywall dimensions Review microscope vibration Study Review bids - Bid Pack Review roofing shops Complete concrete haunches Releae order on limestone Re-submit curtainwall support shops Roof framing: 75% complete Submit Phase Millwork Shops Fabricate mock-up millwork Re-submit curtainwall shops & structural calcs Finalize review of louver shops Review GL-1 and GL-2 Done? PPC Analysis Responsible Party M Randy x T x W x T x F x S Y N Reasons For Variance / Comments Wardrobe dimensions changed Y David x x x x x Dena/ Brad x x x x x Y N Will aw ard next week Jose' x x x x x Y Week of Randy x x x Dena x Y Y Dick x x x x x Bob Brue x x x x x Y x Y Precision x x x x Precision x x x x Jim Leicht x x x Tony/ David x x x ARC/Jim Leight x Ngu n: Lean Construction Institute, 2001 x N Waiting for curtainw all shop drw g N Week of N x Middle of next w eek Y x Y ©2010 b i Nguy n Duy Long, Ti n S 45 c m ch t l ng c a k ho ch công vi c hàng tu n Tính xác nh (Definition) Tính y (Soundness) Tính trình t (Sequence) Kích c (Size) S h c (Learning) Ngu n: Lean Construction Institute, 2001 ©2010 b i Nguy n Duy Long, Ti n S 46 23 Bi u PPC th ng phân ph i n 100% 100% 90% 90% 80% 80% 70% 70% 60% 60% 50% 50% 40% 40% 30% 30% 20% 20% 10% 10% PPC Week Moving Average 0% 0% 12- 20- 27- 3- 10- 17- 24- 21- 28- 5- 18- 9Mar Mar Mar Apr Apr Apr Apr May May Jun Jun Jul Ngu n: Lean Construction Institute, 2001 14Jul 21Jul ©2010 b i Nguy n Duy Long, Ti n S 47 Qui T c Ti p Nh n (Entry Rules) Qui t c 1: Cho phép công tác gi nguyên ti n t ng th /giai n tr bi t khơng nên hay không th th c hi n nh ã lên ti n Qui t c 2: Cho phép cơng tác gi ngun “th i n nhìn tr c” (lookahead window) ch k ho ch viên tin r ng có th s n sàng cho thi công c lên ti n (Screening) Qui t c 3: Cho phép công tác ho ch công vi c hàng tu n ch t t c ràng bu c ã c tháo d (Shielding) ©2010 b i Nguy n Duy Long, Ti n S 48 24 Ngu n: Lean Construction Institute, 2001 ©2010 b i Nguy n Duy Long, Ti n S nh h 49 ng c a Last Planner Began making quality assignments Worse We e k ly Pro d uc t i v i t y 5 12/ 16 / 2/ 2/ 94 2/ 9/ 94 11/ 25 / 11/ 11 / 11/ 18 / 10/ 28 / 1/ 4/ 94 0/ 7/ 94 / 0/ 94 9/ 9/ 94 9/ 6/ 94 / 3/ 94 9/ 2/ 94 / 6/ 94 / 9/ 94 Ngu n: Lean Construction Institute, 2001 10/ 21 / Cu m ul a t i v e Pr od u c t i vi t y Better 10/ 14 / Pe rf orm a nce Fac t or ©2010 b i Nguy n Duy Long, Ti n S 50 25 “V t Lý Lý”” c a s n xu t: t: Variability, Lead Time, & Capacity Utilization A Capacity Utilization Ngu n: Lean Construction Institute, 2001 100% ©2010 b i Nguy n Duy Long, Ti n S Tác ng c a bi n (variability) 51 i Wait Time PPC=50% PPC=70% PPC=90% Capacity Utilization Ngu n: Lean Construction Institute, 2001 100% ©2010 b i Nguy n Duy Long, Ti n S 52 26 PPC s ng công su t (capacity utilization) Wait Time PPC=50% PPC=70% PPC=90% Target 50% 65% 80% 100% Capacity Utilization Ngu n: Lean Construction Institute, 2001 ©2010 b i Nguy n Duy Long, Ti n S Có th qu n lý s khó l bi n i 53 ng Gi m khó l ng r i làm t ng t c m b t u “che ch n” s n xu t s bi n i c a lu ng (flow variability) b ng cách ch làm nh ng công vi c “ch t l ng” (‘quality’ assignments) Qu n lý s bi n i l i v i v trí kích th c h p lý c a m t n tr cơng su t ©2010 b i Nguy n Duy Long, Ti n S 54 27 Tóm l c sốt s n xu t Gi i h n ti n mua s m lâu ngh cho ki m t ng th v i m c v t t o ti n giai n v i nhóm s th c hi n cơng vi c, tính ng c, th i gian d tr t ng minh công tác t ti n giai n vào ti n nhìn tr c tu n, sàng l c ràng bu c, ch ti n hành ràng bu c có th tháo d k p th i g ng ch t o vi c c giao ch t l Cho phép vi c c giao b t ch i Theo dõi PPC hành ho ch th t b i ng ng v i lý k ©2010 b i Nguy n Duy Long, Ti n S 55 o l ng s th c hi n d án (project performance) ARE WE ON TRACK TO ACHIEVE PROJECT OBJECTIVES? PROJECT OBJECTIVES INFORMATION INITIAL PLANNING STATUS & FORECASTS SHOULD ADJUSTING SCHEDULE CAN ADJUSTED SHOULD LAST PLANNER PLANNING PROCESS RESOURCES Ngu n: Lean Construction Institute, 2001 WILL WORK EXECUTION DID ©2010 b i Nguy n Duy Long, Ti n S 56 28 o ng th c hi n a th ng k ho ch (planning system performance) PROJECT OBJECTIVES INFORMATION INITIAL PLANNING STATUS & FORECASTS SHOULD HOW WELL DOES SHOULD MATCH ADJUSTED SHOULD ? ADJUSTING SCHEDULE ADJUSTED SHOULD CAN LAST PLANNER PLANNING PROCESS RESOURCES Ngu n: Lean Construction Institute, 2001 HOW WELL DOES ADJUSTED SHOULDMATCH WILL? WILL WORK EXECUTION HOW WELL DOES WILL MATCH DID? DID ©2010 b i Nguy n Duy Long, Ti n S 57 29 ... n Duy Long, Ti n S 46 23 Bi u PPC th ng phân ph i n 100% 100% 90% 90% 80% 80% 70% 70% 60% 60% 50% 50% 40 % 40 % 30% 30% 20% 20% 10% 10% PPC Week Moving Average 0% 0% 1 2- 2 0- 2 7- 3- 1 0- 1 7- 2 4- ... d uc t i v i t y 5 12/ 16 / 2/ 2/ 94 2/ 9/ 94 11/ 25 / 11/ 11 / 11/ 18 / 10/ 28 / 1/ 4/ 94 0/ 7/ 94 / 0/ 94 9/ 9/ 94 9/ 6/ 94 / 3/ 94 9/ 2/ 94 / 6/ 94 / 9/ 94 Ngu n: Lean Construction Institute,... n Duy Long, Ti n S 29 LOOKAHEAD SCHEDULE Project: Same Day Sugery Planner: Dena Deibert Week of 1 0-2 3-0 0 Six Week Lookahead / Constraints Analysis 10/ 24/ 04 Activity 10/31/ 04 11/7/ 04 11/ 14/ 04