Lean Construction:

Construccin sin Prdidas

CLASE 15
VSM y Sustentabilidad
Agenda
Resumen clase anterior
EPA (2007) y VSM
Desperdicios ambientales
Desperdicios ambientales y 7
Mudas

Mauricio Toledo 2014 LEAN - Clase 15 2

RESUMEN
Development of Lean Model for House Construction Using Value Stream
Mapping / Yu et al. (2009)

Se busca:
Confiabilidad en el desarrollo de los procesos
Reduccin en el plazo de ejecucin de los
proyectos
Mejoras en calidad
Con la ayuda de un constructor local
(Canad) se busca un enfoque sistemtico
para analizar el estado actual y proponer
una produccin Lean.

Mauricio Toledo 2014 LEAN - Clase 15 3

RESUMEN
Caractersticas de la propuesta

1. Flujo sincronizado del tipo FIFO.

2. Nivelacin de la produccin.
3. Reorganizacin del trabajo.
4. Confiabilidad de operacin
mejorada.

Mauricio Toledo 2014 LEAN - Clase 15 4

 RESUMEN
Mapa Estado Actual Statistics:
Site Manager Workdays o/o
Total Ourabon (Average) 65.5 100%
SaJes Total CT (Average) 15.5 24% Next stage
Total LT (Average) SO.O 76%
Total Value-added Tirne 11.0 17%
Rece1ving
construcaon
file package

Cribbing

CT 2 ht CTN(3 5. 2.5) CTT(0.5. 1. 3) 6 CT,.N(3. 5)

CO 2ht C005 COO COO C00.5 COO
BT"' N(5. 4) BT z N(8. 7) BT:: N(6. 5) BT: N(6. 6) BT = N(3. 4) BT = N(5, 3) BT = N(5, 6)
Y=98% Y= 95% Y=50% Y=~ y= 95% y= 98% Y=80% y= 98%
PSSn% PSS 56% PSS 59" PSS a46% PSS 50% PSSa50% PSS 45% PSS 57%
N(8.9) N (2. 4) N(5. 5) N(5, 3) N(4. 5) N(9. 11)
05 2 35 0.5 2 1

a Customer/
Supplier
6
(:=i
lnventory

Physlcal
Flow

Manual
~

=
CT Cycle Tune
CO Changeover Tlme
=
BT Boolung Tune
Y= Yield
Elect. Panel

CT 1
COO
& Ternp.
Services
Oeep
services

CT 1
COO
services

CT,. 1
COO
Open!l!JOn ~ tnformatlOl'I PSS Perc:ent started on BT N(4. 2) BT N(5. 7) BT N(6. 10)
~ schedule
N = Nonnal d1strlbuuon y. 95'WI y,. 95" y. 95%
Push
= TrianglAat d1stnbu11on

~ arrCY>N T PSS 56% PSS = 52" PSS 47"

Data table lndicat of value- The tlme unit Is wocday

* added opefabOn unte:sss~ 1
1

Mauricio Toledo 2014 LEAN - Clase 15 5

 RESUMEN
Mapa Estado Futuro
Stte Manager Statlst!cs:
Workdays %
Total OuratJon (Average) 38 5 100%
Total CT (Average) 13 5 35%
Total LT (Average) 25.0 65%
Total Value-added Time 10.0 26%
Takt Time O 45

Rece1v1ng
construcuon file

......
package {1d)

ws

ws
!
WS
Excavat1on Footing & Weepmgt~e
1 Slake out* 1
Cnbb1ng & spray
& Oeep FIFO FIFO FIFO
services sef'Viee5'
~-2~ ~ CTN(3. 1) __ ."_..........__ CT 1
CO-U(1 2)ht COO TOM - COO COO CO O - TOM - CO O
('
- COOS
BT N(S. 2) BT Tl2 3 5~ BT T(2 3 5) BT T(2 3. 5) BT T(2. 3 5) r BT T(2. 3 5) BT T(2 3. 5)

--i
Y 100 Y 100 Y 100 Y\~ Y 1~ Y 100~ y. 100,
PSS 90.,_ PSS~ 1PSS~
4d
(1ndud;ng PSS 90' J PSS 90% 1 PSS 90% PSS 90 1
4 3 cur1ng) 3 3 3
05
1 4 0.5 2 3

lndte3l0< of va!uo-
K:snban
* oddocl oporobon
CT Cycle Time CO Changeover Timo,
Kanban Eloctronlc BT Boolung Timo Y Yield PSS
Moitonal puU
po$l 1nfonna110n Percent smrted on schedule N Nonnal

---
dlsltlbubOn. T Tnangulatdistnbubon WS
Flrst-tnfirst WO<t. standal'diz.ation TOM Tottll
Physte:)I FIFO Pullanow
out tone ~bty rnOl\1gomet1I
Fbw The time uM Is v.ori<day unleu speofied

Mauricio Toledo 2014 LEAN - Clase 15 6

RESUMEN
Value Stream Mapping in Construction: A Case Study in a Brazilian Construction
Company / Pasqualini & Zawislak (2005)

Esfuerzo sistemtico de implementacin

Lean en lugar de esfuerzo aislados.

Descripcin de adaptaciones y aplicacin

de VSM en una constructora Brasilea.

Se identificaron problemas y posibilidades

de mejoras, para transformar el flujo en ms
fluido y con menos detenciones.

Mauricio Toledo 2014 LEAN - Clase 15 7

 RESUMEN
Mapa Estado Actual
Fmal stated delrvery deadlme november/2005 ~
Weekly order (Thursday)
PCP Time programmed for masonry 5 months (about 100 workr
SUPPLIER ~- .:..- days)
~~~~~~~~~

Weekly programmmg Meebngs (Tuesday)

- Responsible en91neer.
- Mas1e1 ofwo1kmansh1p, condom1n1um
- Contractor of workmansh1p, - 9 apartments
Trame e 1 per pavement
- R$ 670 000

Weekly and datly

6<:J Oualty conrerence

1 .&
.&
Marklng i--1.11.K.!l--_....- Waillng th 1 ~
\ Elevatlon
cement ~ .-.
,J' 2 masons OlllD) ) 1 maso \ lllllO :,. 1 ma son llIID.I)

&~~ ~~r!~d" ~~:~:"~ dras ~m1n fmal stated

delrvery deadhne

F===l
~1as
8,35 days NOVEMBER
~n/m3=5/l!J7 /day ~ ~ 2005
.~secx3f,B= In

MASOHRY PER PAVEW:HT

Obs. cement:
Datly average
Obs.. Masonry:
produclton oas m~
Aferage Lead Time ofmasonry producuon perpavement 60 d:111YS
enough to produce an
Time ofvalue aggregat1on 52{J7 d:111Ys (wa1t1ng time between elevat1on and wall closing was shorter than the necessary).
average of57,07 m2 of
masonry per day

Mauricio Toledo 2014 LEAN - Clase 15 8

 RESUMEN
Mapa Estado Futuro

SUPPLIER
Weekly order (Tuesday)
~-~-
MS Prqect 1
PCP
F1n<1I st<iled dehvery decldhne november/2al5
Takl time marklng: 210,27mh\l'm~ elevatlon
19,5~n2; wal closing 590,45minlm2
Meetingsw1th customers before stages
t
that 1mply persona!1zit1on

Weekly programming Meenngs (Tuesday)

- Responsible engmeer.
Master of workmansh1p, . e ondominium"
Contractor of workmansh1p, - 9 apertments
- Tra1nee - 1 per pavement
- R$ 670 000

""V1slts by the archrtects

for better 1ntegrat1on pr0Ject-workmansh1p

y "m1niplant \j "miniptan;"

r, iil.;"~ ~~,~~ , ~,;*.;"

r-i --, e days ~--'Wabjng till..:._~ ~

~~~ { r:~:.,~l 3
~ =ii"l= \ . :2:1 ma~11~- -r.:~. '11 maso~ --

"Pulcd process"
G 2 Final stated
delrve1 y deadhne
n/m2 = 93 ,99 /day NOVEMEIER
secx2,43=3 m ~---- 1 ~ 2005
.:':' ~
MASONRY PER PAVEMENT

Obs. Masonry:
Med1um Lead lime of masonry producncn per pavement 53 77 day5
Time ofvalue aggregalion 45,71 days (walting time between elevatton and wall closing never was shorter than the necessary)

Mauricio Toledo 2014 LEAN - Clase 15 9

RESUMEN
Resultados

Flujo de produccin continuo (o casi

continuo).
Reduccin de los insumos.
Reduccin de tiempos de detencin.
Mejor rendimiento de la fuerza de
trabajo (reduccin de plazo de
ejecucin planeado).

Mauricio Toledo 2014 LEAN - Clase 15 10

The Lea11 a11d E11\Tiro11111e11t Toolkit

EPA y VSM

Mauricio Toledo 2014 LEAN - Clase 15 11

Desperdicios ambientales?
Es un uso innecesario o excesivo de recursos
o alguna substancia liberada al aire, agua
o tierra que pudiera daar la salud humana
o el medioambiente.
stos pueden ocurrir cuando las empresas
usan recursos para producir productos o
servicios (por ejemplo, la construccin de
un edificio) para sus clientes o cuando esto
clientes usan o se deshacen de estos
productos

Mauricio Toledo 2014 LEAN - Clase 15 12

Dnde buscar desperdicios
ambientales?
En casi cualquier lugar
Cuando se requiere un permiso
ambiental manejo de residuos de la
construccin, pinturas, terminaciones
metlicas, manejo de desechos
peligrosos, refrigerantes, combustibles,
etc.

Mauricio Toledo 2014 LEAN - Clase 15 13

Ejemplos de desperdicios
ambientales
Energa, agua, o insumos consumidos en exceso de lo
necesario para satisfacer las necesidades del cliente.
Contaminantes y desperdicios liberados al ambiente en
forma de emisiones de gases, descargas de aguas
residuales, desperdicios peligrosos y desechos slidos
(basura o restos desechados como despuntes,
envoltorios, etc.).
Substancias peligrosas que pueden afectar
adversamente la salud humana o el medioambiente al
ser usados en la produccin o cuando estn presentes
en productos terminados (por ejemplo, VOC,
refrigerantes, etc.).

Mauricio Toledo 2014 LEAN - Clase 15 14

Desperdicios ambientales y las
7 fuentes de Muda de Ohno
Table 1: Environmental lmpacts of Deadly Wastes
Waste Type Environmental lmpacts
Overproduction More raw materials and energy consumed in
making the unnecessary products
Extra products may spoil or become obsolete
requiring disposal
Extra hazardous materials used result in extra
emissions, waste disposal, worker exposure, etc.
lnventory More packaging to store work-in-process (WIP)
Waste from deterioration or darnage to stored WIP
More materials needed to replace damaged WIP
More energy used to heat, cool, and light inventory
space

Mauricio Toledo 2014 LEAN - Clase 15 15

Desperdicios Table 1: Environmental lmpacts of Deadly Wastes (continued)

ambientales y las 7 Waste Type Environmental lmpacts

fuentes de Muda de Transportation and

Motion
More energy use for transport

Ohno Emissions from transport

More space required for WIP movement, increasing
lighting, heating, and cooling demand and energy
consumption
More packaging required to protect components
during movement
Darnage and spills during transport
Transportation of hazardous materials requires
special shipping and packaging to prevent risk
during accidents

Defects Raw materials and energy consumed in making

detective products
Detective components require recycling or disposal
More space required for rework and repair, increas-
ing energy use for heating, cooling, and lighting

Over processi ng More parts and raw materials consumed per unit
of production
Unnecessary processing increases wastes, energy
use, and emissions

Waiting Potential material spoilage or component darnage

causing waste
Wasted energy from heating, cooling, and lightlng
during production downtime

Mauricio Toledo 2014 LEAN - Clase 15 16

Cmo aprender a ver desperdicios
ambientales en tu organizacin?
1. Agregar mtricas medioambientales a las
mtricas Lean.
2. Demostrar compromiso de la
administracin y apoyo.
3. Incluir desperdicios medioambientales en
los esfuerzos de capacitacin Lean.
4. Hacer visible los desperdicios
medioambientales y fciles de eliminar.
5. Reconocer y premiar los xitos.

Mauricio Toledo 2014 LEAN - Clase 15 17

Tipos de mtricas ambientales
Desechos/no-productos
Uso de materiales
Uso de materiales peligrosos
Uso de energa
Uso de agua
Emisiones de gases
Desechos slidos
Desechos peligrosos
Contaminacin del agua/aguas residuales
Mauricio Toledo 2014 LEAN - Clase 15 18
Incorporando consideraciones
ambientales con VSM
Usar conos para identificar procesos con
oportunidades ambientales, de salud y seguridad
(EHS)
Registrar informacin ambiental para procesos en
los VSM
Analizar el uso de materiales vs. las necesidades de
materiales en una lnea de materiales para VSM
Expandir la aplicacin de VSM a los flujos de
recursos naturales
Encontrar oportunidades LEAN-GREEN en los VSM
de estados futuros

Mauricio Toledo 2014 LEAN - Clase 15 19

LEAN-GREEN en Construccin

10 Common Manufacturing Processes With

Environmental Opportunities

1. Metal casting
2. Materials treatment
3. Metal fabrication and machining
4. Cleaning and surface preparation
5. Bonding and sealing
6. Welding
7. Metal finishing and plating
8. Painting and coatng
9. Chemical and hazardous materials management
10. Waste rnanagernent

Mauricio Toledo 2014 LEAN - Clase 15 20

 Annual Productlon Plan _____
Productlon
Control _.
....
Market Forecast
=s:::::~--~
Customer Customer
.,,
ar
A B e
Suppller Suppller ;
1 2 ..
wi
o
...;
e

:J
r+

:t 30 days ~
l'l 1 Shlpplng 1 ~
-------
Assembly &
~
=:-
Mllllng
lnspection ~
3
5 days
2 people 2 people 3 people 3 people 3::
Q)
"O
C/T = 2 mln C/T = 4 mln C/T = 7 mln C/T = 2 mln ~
C/O = 2 hr C/O = 3 hr C/O = 4 hr =
C/O 30 mln
;+
=r'
Uptlme = 74% Uptlme = 67% Uptlme = 48% Uptlme = 93% m
Haz. Waste = Haz. Waste = Haz. Waste =
::s
...o
<
5 lbs 20lbs 60 lbs :J
3
5 days 10 days 15 days 8 days 30 days ~

l
:J

_I l 1
r+

_2_mln
__ 4 mln 1 ......_7_m_l_n
1 _____,, l..____2_m_ln_
...... -
Q)

Total Lead Time= 68 days

Value Added Time = 15 mln

Mauricio Toledo 2014 LEAN - Clase 15 21

Materiales usados vs.
requeridos
Figure 4: Example "Materials Line" Showing Materials Use Versus Need

Weldlng

2 people 2 people

r---1\1201bs 151bs
L--y' Materlals Used = 135 lbs
==
Top llne:
Materlals Used
by Process
D
1------80 lbs 1 1 s lbs
--------
Bottom llne:
Materlals Added to Product
1 Materlals Needed 85 lbs
Materlals Wasted 50 lbs

Durlng the Process

Mauricio Toledo 2014 LEAN - Clase 15 22

 VSM Lnea de Materiales (U vs. R)
Productlon
Market Forecast
Annual Production Plan .....__Control ..... ~ ~=so;;::--__ 'TI
Customer Customer O:
A B
...~
e
Suppller Suppller
1 2 ..
(11

Assembly &
Mllllng Weldlng
lnspectlon
5 days
2 people 2 people 3 people 3 people

e/T = 2 mln e/T = 4 mln =

e/T 7 mln C/T = 2 mln
C/O = 2 hr C/O = 3 hr C/O = 4 hr =
C/O 30 min
Uptlme = 74% Uptlme = 67% =
Uptlme 48% Uptlme =93%
5 days 10 days 15 days 8 days 30 days

1 2 min l 1 4 min 1 1 7 min 1 1 2 min l

120 lbs 151bs 40 lbs 20 lbs
1 1 1 1 1 1 1

Mauricio Toledo 2014 LEAN - Clase 15 23

 VSM Recursos Naturales
1 Effluent 1 ~PA Reg,:ation:_
Federal Sta te

Water Water
So urce Source
1 2 Local

-o...
Extruslon Moldlng FIHlng

e
SOK gal 45K gal SK gal 150K gal SOK gal O gal ...
-
(D
::::s
~
(J>
~
30K gal 35K gal SK gal 60K gal 45K gal O gal Q)
~
(D

=
Total H20 Usage 300K Gallons Per Day
Total Need = 175K Gallons Per Day

Mauricio Toledo 2014 LEAN - Clase 15 24

 Oportunidades en VSM de Estado Futuro
'TI
Productlon ~

,
Annua' Productlon Plan L--~.:...:..:....::...:....__._
Control Market Forecast e....
__ -=s::------./ CD
,, Customer Customer ......
, ,
,,
e , ..
, A B ...
'TI
e
e
Supplier Supplier <D
1 2 ......
(/)
D)

CD

2x , ,'
, , ,'
~ L1 ~
e
CD
.......
(/)

1 Shlpplng 1 CD
Week D)
3

e..--. Milling

2 people 2 people 3 people

Assembly &
lnspectlon

3 people
s:I
'C
~
;:+
:r
m
C/T = 2 mln =
C/T 4 mln =
C/T 7 mln C/T = 2 mln
::i:::

=
(/)

C/O = 2 hr C/O 3 hr
= =
C/0 4 hr C/0 = 30 mln
Uptlme 74% = Uptlme 67% Uptime 48% = Uptime = 93%
days 10 da s 15 days 8 das
2 mln 4 mln 7 mln 2 mln
151bs 20 lbs
801bs 5 lbs 201bs 51bs

=
Lead Time 68 days Total Materlals Used < 150 lbs
Value Added Time = 15 mln =
Materlals Needed 110 lbs

Mauricio Toledo 2014 LEAN - Clase 15 25

Eventos Kaizen
Kaizen: eventos rpidos de mejoras en
los procesos. Significa mejora continua
en japons.
Actividad colectiva diseada para
eliminar desperdicios y hacer cambios
rpidos en el lugar de trabajo

Mauricio Toledo 2014 LEAN - Clase 15 26

Preguntas claves para identificar
oportunidades green-lean.

Water Use
./ How much water is used in the process and how is it used?
./ How can you reuse water and/ or reduce overall water use?
./ Can you reduce contaminants in wastewater and discharges?
Energy Use
./ How much energy is used in the process and how is it used?
./ How can you reduce overall energy use?
./ Is equipment running orare lights on when not being used?
./ Are you using efficient light bulbs?
./ Can you save energy by consolidating operations and/ or storage space?
./ Can you shift to a cleaner source of energy?

Mauricio Toledo 2014 LEAN - Clase 15 27

Preguntas claves para identificar
oportunidades green-lean. (cont.)

Chemicals and Materials Use

./ What types and quantities of chemicals/materials are used in the process?
./ How can you reduce the overall amount of chemicals and materials used?
./ Can you switch to less harmful chemicals?
./ Can you eliminate any non-value added use of chemicals or materials from
the productor process (excess packaging, unneeded painting, etc.)?
Solid Waste
./ What types and quantities of solid waste are generated by the process?
./ How can you reduce the overall amount of solid waste generated?
./ How can you reuse or recycle solid wastes?
./ Is there a local cornposting facility that the waste can be taken to?

Mauricio Toledo 2014 LEAN - Clase 15 28

Preguntas claves para identificar
oportunidades green-lean. (cont.)

Hazardous Waste
./ What types and quantities of hazardous waste are generated by the process?
./ How can you reduce the amount or toxicity of hazardous waste generated?
./ Can you better isolate and separate hazardous wastes from other wastes?
Air Emissions
./ What types and amounts of air emissions are generated by the process?
./ How can you reduce the overall amount or toxicity of air emissions?
./ How far did vehicles travel to deliver parts and supplies?

Mauricio Toledo 2014 LEAN - Clase 15 29