LEAN CONSTRUCTION PROCEDURES (LCP®)

LEAN Root Cause Analysis

Drilling Down in LEAN - RCA

The key to any improvement is here How do we remove the LEAN waste wood from the trees?

Jidoka	Also referred to as autonomation, it is adding the human element of being able to identify problems and either stop for correction or self-correct before moving onto the next step.
Kaizen	Kaizen is a structured process to engage those closest to the process to improve both the effectiveness and efficiency of the process. Its goals are often to remove waste and add standardizatio
Poke-yoke	Mistake-proofing. A way to prevent poor quality in a process
Waste Elimination	Eliminating waste from the process is the goal of many lean tools and should be an on-going effort in itself. This comes in the form of the seven types of waste: overproduction, waiting, inventory, overprocessing, motion, transportation and defect
Yaruki	The attitude of "Can do" - everything is achievable

In order to expose the waste we must have visibility of the process performance. This can be done in several ways in construction. Consider how complex and how manty threads there are for example;

• Process Mapping
• The Main programme
• Weekly Programmes
• Procurement Schedules
• Key Performance Indicators
• 360 degree Stakeholder feed back forms
• Wastage reconcilliations
• Commercial reconcilliations
• Labour Forecast
• Plant Forecast
• Material Forecast
• Risk and opportunity analysis
• Overhead Forecast
• Bonus and incentive targets
• Best practice and Lessons learnt capture
• Performance management of the resources

The list of potential data collected on the projects performance is endless - and all of it is shouting out about areas that require your attention. The challenge for any project team is direct their focus on areas that will make EFFECTIVE changes - rather than bring limited EFFICIENCY from the LEAN Construction Procedures. By recognising that many of the causes of constraints to achieving a more effective performance are in "groups of influence" is the root to providing a way forward to making a radical reduction in waste. The results of Risk Ripple - is a good demonstration of this effect in action.

By capturing data in "groups of Influence" areas demanding focus can be more easily identified and actioned. The Root Cause analysis chart from a past project shown above demonstrates this. Over one quarter of problems caused on this site was from the lack of available resource. Does it require more labour? An "easy fix" - but would it be effective?

In this instance the Root Cause is deeper. It can be seen by exploring and recognising the Groups of Constraints.

These have their Roots in effective Programming and Preparation. Collectively they are resposible for an astonishing 73% of the CONSTRAINTS

A focus was placed on improving both the main Programme and the weekly forecast supported by process mapping and analysing KEY Critcal activity chains ahead of build. This brought a radical reduction in the more effective use of resource and eliminated the Waste caused by less than effective programming.

• Dig deeper beyond what appears to be an obvious cause.
• Recognise the GROUP of influences
• Be aware of RIPPLES within the data capture.
• Avoid the "Easy Fix" Solution