Aspirations and Achievements in Lean Construction in India

Prof. N.Raghavan FNAE, FICE(UK), FIE(I)

Indian Institute of Technology Madras, India Director, Institute for Lean Construction Excellence

1 October 23-24, LIPS Doha, Qatar

Construction & the Economy -India Indian economy marching from $2.7 tn to $5 tn in 6Yrs; 7% GDP Growth

2

Industry highly fragmented;

Too many unorganised players;

Intense Competition

Constn Industry: 11% of GDP-- $500bn annual-6.4% Growth; $80bn Govt. Investment in Infrastructure

Project Management Paradigms a’ la India Often informal and ad hoc– bar charts, Excel charts; PMI systems also used in places

3

PLANNING

• Less organised generally

• Planning is more number-based, reactive and review oriented

• The larger companies are becoming more Digital; Prima Vera/ MS Projects popular with them;

• Lean is still nascent; sporadic

Lean India Highlights

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ILCC 2015 ILCC 2017 ILCC 2019

LIPS 2019 IGLC 2018

Institute for Lean Construction Excellence, Founded 2008;

Apex Body spreading Lean; 9 major construction Co.s as Charter members

Several Seminars/ Workshops

National & International Conferences

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• Highly competitive environment; pressure for quick realisation of tangible gains Tools!

• Clients still not focussed on Lean & its benefits

• First: Lean Culture, or, Lean Tools? Tools chosen: Easier to implement, more tangible, low-hanging fruits, more suitable to prevailing PM scenarios

58

14

75

56 69

39

75 84

95

78 89 90

60

83

27

85 76

88 78 80

88 90 81 86 83

92 88

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3rd

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1st W

eek

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eek

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eek

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June July August September October November December

Average Weekly PPC % PPC Chart

Before

After

Tools

Implemented at Sites

LPS/CPS

Work Sampling

Waste Eliminati

on

LBMS

Cycle Time

Optimization

Value Stream

Mapping

Root cause Analysis Waste Elimination

Value Stream Mapping

5S

Work Sampling

f

The Indian Lean Smorgasbord

The Indian Lean Smorgasbord (Contd.)

• Not many educational institutions teach Constn Mgmt, let alone Lean.

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IIT Madras developing teaching & instructional material using an web/video/You Tube-based Distance Education system-National Programme for Technology Enhanced Learning.

The Effective Lean Training Programmes

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2015, 2018

9 Sites, 9 month long; carefully designed; Quite Successful

The Sites

Contact Programmes, Webinars, Site Visits, Zoom reviews, Review of Reports on specific formats,……

Timeline of the Programme

June July Aug Sept Oct Nov Dec Feb Jan

Initial Training

Programme

Mid Term

Review

Webinars & Skype Reviews

Closure/ Feedback

Skype/ Site Reviews by IITM Team

2013 2014

3 days 2 days 2 days 2 days 8

Awards - Relative Standings of Each Project

Last

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em

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ased

Project 1 Project 2 Project 3 Project 4 Project 5 Project 6 Project 7 Project 8

Total Jul-19

Rat

ing

100

80

60

40

20

0

1st – MMRC L&T

2nd – UG1 Metro AFCONS

3rd – WWTP L&T

Plus Delta for Lean India

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• All Conferences well attended; 40-50 Papers & Posters; more

colleges started teaching Lean • IITM has developed a Lean Maturity Rating System (presented

in IGLCs); certification programme under developemnt • IITM has developed an open source, Excel-based LPSTM

Simulation Software (Presented in IGLCs) - COLPLASE • Site-based training system well developed now • Two projects have been done on Alliance contracting model

• Inculcation of widespread Lean Culture, still elusive!

Quo Vadis, Lean India?!

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• Efforts are on to get some client organisations, generally in the Public Sector, to accept Lean

practices and insist on the same in their projects.

• For sustained practices, a strongly developed Lean Culture is required. Since developing a new Culture is top driven and needs complex paradigm shifts, this requires sustained efforts over time!

• All said and done, India is on the Lean Journey and is sure to progress quite well in the coming years!

Namaste