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When Lean Cultures Converge to Achieve Project Success

Thursday, 10/16/2017

Rohn MacNulty: Senior Project Manager, Massachusetts Port Authority (Massport)

Jonathan McCredie: Principal, Fennick | McCredie Architecture

Michael Zeppieri: Director, Innovation Services, Skanska USA Building

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Introduction

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The Project Team

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Owner

Public Agency

Embracing Lean

Construction Manager

Mature Lean culture

Architect

First Lean project

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Massport Lean Objectives

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• Maximize project team resources and delivery of services by implementing Lean practices on capital projects when

applicable, covering all phases (program definition, design development, construction, and commissioning).

• Improve Lean leadership on projects through (a) senior management buy-in, support & participation at the program

level and (b) through Massport Project Manager and consultant/contractor team leadership at the project level.

• Provide focused training at both the Departmental level and the project specific level so that senior management and

project teams can make informed decisions on the best use of Lean tools and approaches for projects.

• Establish Lean protocols and procedures for deploying Lean on projects consistently and effectively and ensuring that

consultant and contractor contracts support implementation.

• Provide metrics so that Lean performance and Lean “value for money” can be tracked, measured, and acted on.

• Improve stakeholder engagement by involving, and demonstrating the value of, Lean practices to internal and external

stakeholders.

• Provide ongoing support of Lean implementation on projects through the provision of resources and coaching to teams,

including building internal capacity within the Department so that project managers can coach project teams.

• Perform regular periodic retrospectives to better apply lessons learned on future projects.

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LCI CONGRESS PRESENTATION STYLE GUIDEProject Overview

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South Boston Waterfront Transportation Center

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District Connector

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Of the public realm

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• Public plazas

• Public transit connections

• Pedestrian walkways

• Transportation center hub

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Stakeholder collaboration

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• Urban walkway across three separate

parcels

• Building a façade design collaboration

with adjacent developer projects

• Six separate public authorities

• Massport

• City of Boston

• State of Massachusetts

• Convention Center Authority

• Massachusetts DOT

• FAA

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Technical Challenges

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LCI CONGRESS PRESENTATION STYLE GUIDELean in Design

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Conditions of Satisfaction

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• Maintain pre-existing urban infrastructure

• Place for people

• Connect the district

• Support development

• Multi-modal hub

• Design excellence

• Inclusive public process

• Meet aggressive schedule

• Complete within budget

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Pull Planning

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• 50+ construction directives issued for key

project components at last responsible

moment

• Maximized stakeholder integration and

decision-making processes to promote

consensus and by-in

• Reduced re-work due to

design/construction proceeding ahead of

stakeholder input

• Promoted schedule acceleration when

required due to unforeseen below-grade

obstructions

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Virtual Big Room

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• Both physical and virtual

simultaneously

• Weekly meetings attended by Owner,

Construction Manager and Architect

with selected sub consultant

disciplines and trades

• Hosted by Architect during design,

shift to Construction Manager host

on-site during construction

• Mini-team break-out sessions

promoted fast and efficient testing of

complex design options

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Target Value Design

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• Project separated into components

each with their own TVD

• Prevented elements from being

compromised for cost simply because

such elements were last to be

constructed

• Provided logical guidelines for

thoughtful cost reduction decisions

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Lean Design Assist

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Design Assist – precast concrete structure

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• 50% design bid package

• Virtual big room daily worksessions

• BIM integration

• Remaining 50% design complete in

collaboration, within budget

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Design Assist – precast concrete structure

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• Integrated design of embedded

elements last responsible moment

• Phased fabrication of precast

elements to maximize time for proper

coordination with related elements by

other trades

• Fast tack schedule achieved

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Design Assist – custom metal façade system

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• 50% design bid package

• Virtual big room daily worksessions

• BIM integration

• Remaining 50% design complete in

collaboration, within budget

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Design Assist – custom metal façade system

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• Custom system requiring multiple

physical scale mock-ups

• Integrated into client and stakeholder

decision and approval process

without project delay

• As a identified Target Value Design

component, no value engineering

impacts during design assist and

fabrication

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LCI CONGRESS PRESENTATION STYLE GUIDELean Construction

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Pull Planning

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• Culture of Continuous Improvement: CM team already

trained on and familiar with Lean concepts (Lean101)

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Pull Planning

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• Preparation

• Scope the right milestone

• Communicating expectations to participants ahead

of Pull

• Printed copies of Drawings and Schedule

• Execution

• Use BIM for orientation and sequence

• Take the time to train the foremen (Block Game or

Parade of Trades)

• Make ready work – dirty laundry

• Sequence and handoffs

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Use of BIM

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Pull Planning

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• Work the room

• Facilitate, don’t orchestrate

• CM project team members

present and engaged

• Don’t let the Superintendent revert

back to Push

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Focus on Removal of Waste

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Talent

Underutilizing

people’s talents,

skills & knowledge

Waiting

People, products

or materials

waiting for the next

step in the process

Motion

Unnecessary

movements by

people, products

or materials

Defects

Rework, creating

more work or

otherwise

deviating from

what creates

customer value

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Weekend Work Over Right of Way

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• Multiple agencies

• Limited window

• Unclear sequence

• Extensive coordination

• Stakeholder confidence

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Pull Planning

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• Your foremen will surprise you

• Don’t replicate the schedule!!!

• Pull Planning is not a schedule

recovery or accelerant

• Pull Planning will help expose the

waste a schedule cannot

• Do a Plus/Delta after every Pull

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LCI CONGRESS PRESENTATION STYLE GUIDEClient Value

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SBWTC Lean Dashboard

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In the spirit of continuous improvement, we would like to remind you to complete this session’s survey in the Congress app! We look forward to receiving your feedback. Highest rated presenters will be recognized.