Last Planner - Ballard

8/11/2019 Last Planner - Ballard

1/193

THE LAST PLANNER SYSTEM OF PRODUCTION CONTROL

by

HERMAN GLENN BALLARD

A thesis submitted to the F !u"ty o# E$%i$ee&i$%

o# The U$i'e&sity o# Bi&mi$%h m

#o& the de%&ee o#

DOCTOR OF PHILOSOPHY

S!hoo" o# Ci'i" E$%i$ee&i$%F !u"ty o# E$%i$ee&i$%The U$i'e&sity o# Bi&mi$%h m

M y ()))


2/193

ACKNOWLEDGEMENTS

M $y i$di'idu "s $d !om* $ies !o$t&ibuted to this &ese &!h+ To $ me #e,-

D 'id Seymou&. my thesis d'iso&

A$$e Seymou&. #o& %i'i$% me home i$ Bi&mi$%h m

D 'id Ho &e $d Pete& De s"ey. thesis e/ mi$e&s

G&e% Ho,e"". busi$ess * &t$e& $d !o0thi$1e&

L u&i 2os1e" . #o& his e/ m*"e $d i$s*i& tio$

Todd 3 be""e $d the P !i#i! Co$t& !ti$% te m #o& thei& ,i""i$%$ess to t&y $e,ide s

Leo Li$be!1 III. Ed Be!1 $d 2 thy 4o$es o# Li$be!1 Co$st&u!tio$ #o& sh &i$%o**o&tu$ity $d d t 56 o# the 7 ! ses ,e&e Li$be!1 *&o8e!ts9

No&m B &$es $d the B &$es Co$st&u!tio$ te m #o& !!ess to *&o8e!ts

I&is Tomme"ei$. e/te&$ " thesis d'iso& $d !o""e %ue t UC Be&1e"ey

4e $$e B "" &d. my ,i#e. #o& *utti$% u* ,ith me. es*e!i ""y my bse$!es #&omhome


3/193

ABSTRACT

P&o8e!t !o$t&o"s h 'e t& ditio$ ""y bee$ #o!used o$ #te&0the0# !t dete!tio$ o# ' &i $!es+

This thesis *&o*oses !o$t&o" system. the L st P" $$e& system. th t ! uses the&e "i: tio$ o# *" $s. $d thus su**"eme$ts *&o8e!t m $ %eme$t;s !o$!e&$ #o& m $ %eme$t

o# !o$t& !ts ,ith the m $ %eme$t o# *&odu!tio$+

The L st P" $$e& system h s *&e'ious"y bee$ su!!essi'e"y **"ied by #i&ms ,ith di&e!t

&es*o$sibi"ity #o& *&odu!tio$ m $ %eme$t< e+%+. s*e!i "ity !o$t& !to&s+ This thesis

e/te$ds system **"i! tio$ to those !oo&di$ ti$% s*e!i "ists. both i$ desi%$ $d

!o$st&u!tio$. th&ou%h se&ies o# ! se studies. o$e o# ,hi!h "so e/*"o&es the "imits o$

u$i" te& " im*"eme$t tio$ by s*e!i "ists+

I$ dditio$ to the e/te$ded **"i! tio$. t,o =uestio$s d&i'e this &ese &!h+ The #i&st

=uestio$ is >9 What can be done by way of tools provided and improved implementation

of the Last Planner system of production control to increase plan reliability above the

70% PPC level? P&e'ious &ese &!h &e'e "ed subst $ti " im*&o'eme$t i$ *&odu!ti'ity #o&

those ,ho im*&o'ed *" $ &e"i bi"ity to the ?)@ "e'e". !o$se=ue$t"y the&e is &e so$ to

ho*e #o& #u&the& im*&o'eme$t. *ossib"y i$ "" *eo&m $!e dime$sio$s. es*e!i ""y ,ith

**"i! tio$ !&oss $ e$ti&e *&o8e!t & the& th $ "imited to i$di'idu " s*e!i "ity #i&ms+ Th t

=uestio$ is e/*"o&ed i$ th&ee ! se studies. the " st o# ,hi!h !hie'es the )@ t &%et+

The se!o$d &ese &!h =uestio$ is 2) ow!Can Last Planner be successfully applied to

increase plan reliability durin" desi"n processes 1? Th t =uestio$ is e/*"o&ed i$ $

e/te$si'e ! se study. ,hi!h si%$i#i! $t"y !o$t&ibutes to u$de&st $di$% the desi%$ *&o!ess

#&om the *e&s*e!ti'e o# !ti'e !o$t&o". but u$#o&tu$ te"y does $ot #u""y $s,e& the

=uestio$. *&im &i"y be! use the *&o8e!t , s bo&ted *&io& to st &t o# !o$st&u!tio$+

Ho,e'e&. it is &%ued th t the L st P" $$e& system is es*e!i ""y **&o*&i te #o& desi%$

*&odu!tio$ !o$t&o" be! use o# the ' "ue0%e$e& ti$% $ tu&e o# desi%$. ,hi!h &e$de&s

i$e##e!ti'e t& ditio$ " te!h$i=ues su!h s det i"ed #&o$t e$d *" $$i$% $d !o$t&o" th&ou%h

#te&0the0# !t dete!tio$ o# ' &i $!es+

> I$ this thesis. the te&m desi%$ is used to desi%$ te both desi%$ $d e$%i$ee&i$%!ti'ities. $ot sh *i$% s* !e to estheti! !&ite&i +


4/193

Issues #o& #utu&e &ese &!h &e *&o*osed. i$!"udi$% &oot ! use $ "ysis o# *" $ # i"u&es

$d =u $ti#i! tio$ o# the be$e#its o# i$!&e sed *" $ &e"i bi"ity #o& both desi%$ $d

!o$st&u!tio$ *&o!esses+


5/193

TABLE OF CONTENTS

Tit"e P %e

A!1$o,"ed%eme$ts

Abst& !t

T b"e o# Co$te$ts

List o# Fi%u&es

List o# T b"es

P %e

>+) I$t&odu!tio$ >0>>+> Co$!e*tu " F& me,o&1 >0>>+( Assum*tio$s >06>+6 Co$t&ibutio$ to 2$o,"ed%e >07

>+ The Autho&;s Ro"e i$ the Rese &!h>07>+7 St&u!tu&e o# the Disse&t tio$ >0

(+) C&iti=ue o# P&odu!tio$ Co$t&o" (0>(+> h t is P&odu!tio$ Co$t&o" (0>

(+>+> The Me $i$% o# P&odu!tio$ (0>(+>+( The Me $i$% o# Co$t&o" (06

(+( P&o8e!t M $ %eme$t (07(+(+> The P&o8e!t M $ %eme$t Body o# 2$o,"ed%e (07(+(+( C&iti=ue o# the T& ditio$ " P&o8e!t Co$t&o" Mode" (0?

(+6 P&e'ious A**"i! tio$ o# P&odu!tio$ Co$t&o" Co$!e*ts to the AEC I$dust&y (0>((+6+> Me""es $d me"i$1 (0>((+6+( 2os1e" (0>

(+ C&ite&i #o& P&odu!tio$ Co$t&o" System (0>7

6+) Des!&i*tio$ $d Histo&y o# the L st P" $$e& System o# P&odu!tio$ Co$t&o" 60>6+> Hie& &!hi! " St&u!tu&e 60>6+( Shou"d0C $0 i""0Did 60>

6+6 P&odu!tio$ U$it Co$t&o" 6066+ o&1 F"o, Co$t&o" 607

6+ +> Co$st& i$ts A$ "ysis 606+ +( Pu""i$% 60>>6+ +6 M t!hi$% Lo d $d C * !ity 60>6+ + The L st P" $$e& System As ho"e 60>7

6+7 A B&ie# Histo&y o# the L st P" $$e& System o# P&odu!tio$ Co$t&o" 60>6+ P&e'ious A**"i! tio$s o# the L st P" $$e& System to Desi%$ 60(>


6/193

6+? E' "u tio$ o# L st P" $$e& % i$st C&ite&i #o& P&odu!tio$ Co$t&o" Systems 60(6+ Rese &!h uestio$s- >9What can be done by way of tools provided and 60(7

improved implementation of the Last Planner system of productioncontrol to increase plan reliability as measured by Percent Plan Complete?2) ow!Can Last Planner be successfully applied to increase plan reliabilitydurin" desi"n processes?

+) Rese &!h Methodo"o%y 0>+> I$t&odu!tio$ 0>

+>+> E$%i$ee&i$% M $ %eme$t s Fie"d o# Study 0>+>+( Com*eti$% E$%i$ee&i$% M $ %eme$t P & di%ms 0

+( Rese &!h Desi%$ 0+(+> Rese &!h uestio$ 0+(+( Rese &!h St& te%ies 0

+6 Rese &!h Methods 0+6+> D t Co""e!tio$ 0+6+( D t A$ "ysis $d E' "u tio$ 0>)+6+6 C se Studies 0>(

7+) C se O$e- CCSR P&o8e!t 70>7+> P&o8e!t Des!&i*tio$ $d L st P" $$e& Im*"eme$t tio$ 70>7+( PPC $d Re so$s 70(7+6 Obse&' tio$s 70>)7+ Le &$i$%s 70>>

+) C se T,o- Ne/t St %e 0>+> P&o8e!t Des!&i*tio$ $d L st P" $$e& Im*"eme$t tio$ 0>+( D t 0(

+(+> PPC $d Re so$s 0(+(+( Obse&' tio$s 07+(+6 Feedb !1 #&om * &ti!i* $ts 07

+6 The N tu&e o# the Desi%$ P&o!ess $d Im*"i! tio$s #o& P&o!ess Co$t&o" 0+ E' "u tio$ o# L st P" $$e& Im*"eme$t tio$ 0>)+7 Le &$i$%s 0>(

?+) C se Th&ee- P !i#i! Co$t& !ti$% ?0>?+> P&o8e!t Des!&i*tio$ $d L st P" $$e& Im*"eme$t tio$ ?0>?+( PPC $d Re so$s ?0(?+6 Obse&' tio$s ?0??+ Le &$i$%s ?0

+) C se Fou&- O"d Chemist&y Bui"di$% Re$o' tio$ 0>+> P&o8e!t Des!&i*tio$ $d L st P" $$e& Im*"eme$t tio$ 0>+( PPC $d Re so$s 0(+6 Obse&' tio$s 0+ Le &$i$%s 07


7/193

+) C se Fi'e- 3e$e! 0>+> P&o8e!t Des!&i*tio$ $d L st P" $$e& Im*"eme$t tio$ 0>+( PPC $d Re so$s 0>+6 Co$st& i$t A$ "ysis $d M 1e Re dy 06+ Obse&' tio$s 0+7 Le &$i$%s 0

>)+) Co$!"usio$s >)0>>)+> Summ &y o# C se Study Resu"ts >)0>>)+( Rese &!h uestio$- h t ! $ be do$e by , y o# too"s *&o'ided $d >)0(

im*&o'ed im*"eme$t tio$ o# the L st P" $$e& system o# *&odu!tio$!o$t&o" to i$!&e se *" $ &e"i bi"ity s me su&ed by Pe&!e$t P" $Com*"ete

>)+6 Rese &!h uestio$- Ho,JC $ L st P" $$e& be su!!ess#u""y **"ied to >)06i$!&e se *" $ &e"i bi"ity du&i$% desi%$ *&o!esses

>)+ Di&e!tio$s #o& Futu&e Rese &!h >)0>)+7 Co$!"usio$s >)0

G"oss &y o# Te&ms G0>

List o# Re#e&e$!es R0>

Bib"io%& *hy Bib"io0>

A**e$di/ A- Ne/t St %e 2i!1o## Meeti$% A0>

A**e$di/ B- Ne/t St %eTe"e!o$#e&e$!es B0>

A**e$di/ C- Ne/t St %e A!tio$ Items Lo% C0>

A**e$di/ D- Ne/t St %e Issues Lo% D0>

A**e$di/ E- Ne/t St %e De!isio$s Lo% E0>


8/193

LIST OF FIGURES

P %e

6+> The #o&m tio$ o# ssi%$me$ts i$ the L st P" $$e& System 60(

6+( Loo1 he d P&o!ess 60

6+6 M 1e Re dy by S!&ee$i$% $d Pu""i$% 60>>

6+ A T& ditio$ " 5Push9 P" $$i$% System 60>6

6+7 L st P" $$e&0A Pu"" System 60>

6+ The L st P" $$e& System 60>

6+? PPC 5No1i P&o8e!t9 60(6

6+ P &ti!i* $t Su&'ey 5No1i P&o8e!t9 60(6

7+> CCSR0 ee1"y PPC 707

7+( CCSR0Re so$s #o& No$!om*"etio$ 70

7+6 CCSR0PPC ,ithout & i$ 70

+> Ne/t St %e0PPC 0

?+> P !i#i! Co$t& !ti$%0PPC ?0(

?+( P !i#i! Co$t& !ti$%0Re so$s ?0?

+> O"d Chemist&y Bui"di$%0PPC 06

+( O"d Chemist&y Bui"di$%0Re so$s #o& No$!om*"etio$s 0

+> 3e$e! 0PPC 0(

+( 3e$e! 0Re so$s 0(

>)+> A!ti'ity De#i$itio$ Mode" >)0

>)+( Re so$s A$ "ysis Hie& &!hy0Di&e!ti'es >)0

>)+6 Re so$s A$ "ysis Hie& &!hy0P&e&e=uisites >)0?

>)+ Re so$s A$ "ysis Hie& &!hy0Resou&!es >)0

>)+7 Re so$s A$ "ysis Hie& &!hy0P&o!ess >)0


9/193

LIST OF TABLES

P %e

>+> Co$'e&sio$JF"o,JK "ue >0>

6+> Fu$!tio$s o# the Loo1 he d P&o!ess 60?

6+( Co$st&u!tio$ Loo1 he d S!hedu"e 60

6+6 E$%i$ee&i$% Loo1 he d S!hedu"e 60>)

6+ Co$st& i$ts A$ "ysis 60>(

7+> CCSR0 ee1"y P" $$i$% Cy!"e 706

7+( CCSR0Co$st& i$ts A$ "ysis Fo&m 70

7+6 CCSR0PPC $d Re so$s D t 707

7+ CCSR0Re so$s #o& No$!om*"etio$ 5det i"ed $d ! te%o&i:ed9 70?

+> Ne/t St %e0Re so$s #o& No$!om*"etio$ 0(

+( Ne/t St %e0PPC D t 06

+6 Ne/t St %e0Re so$s 07

?+> P !i#i! Co$t& !ti$%0PPC D t $d Re so$s ?06

+> O"d Chemist&y Bui"di$%0PPC D t 06

+> 3e$e! 0Co$st& i$t A$ "ysis Fo&m 07


10/193

Ballard 1-1 Last Planner

CHAPTER ONE: INTRODUCTION

1.0 Concept !" F#!$e%o#&

P&odu!tio$ *&o!esses ! $ be !o$!ei'ed i$ t "e st th&ee di##e&e$t , ys- >9 s *&o!ess o#

!o$'e&ti$% i$*uts to out*uts. (9 s #"o, o# m te&i "s $d i$#o&m tio$ th&ou%h time $d

s* !e. $d 69 s *&o!ess #o& %e$e& ti$% ' "ue #o& !ustome&s+ A"" th&ee !o$!e*tio$s &e

**&o*&i te $d $e!ess &y+ Ho,e'e&. the !o$'e&sio$ mode" h s bee$ domi$ $t i$ the

AEC 5 &!hite!tu& "Je$%i$ee&i$%J!o$st&u!tio$9 i$dust&y u$ti" 'e&y &e!e$t"y 52os1e" $d

Huo'i" . > ?9+

#able $ $

Con'e#()on *)e% F"o% *)e% *!" e Gene#!t)on

N!t #e o+ Con(t# ct)on

! (e#)e( o+ !ct)')t)e( %,)c,con'e#t )np t(

to o tp t(.

t,e +"o%( o+ )n+o#$!t)on- #e(o #ce( %,)c,

#e"e!(e %o#&: co$po(e/o+ con'e#()on

)n(pect)on $o')n !n/%!)t)n .

! '!" e c#e!t)np#oce(( %,)c,

/e+)ne( !n/$eet( c (to$e#

#e )#e$ent(.

M!)nP#)nc)p"e(

H)e#!#c,)c!"

/eco$po()t)on o+ !ct)')t)e(2 cont#o" !n/opt)$)3!t)on 45

!ct)')t5.

Deco$po()t)on !t

6o)nt(. E")$)n!t)on o+ %!(te 7 nnece((!#5!ct)')t)e(8 t)$e

#e/ ct)on.

E")$)n!t)on o+ '!" e"o(( 9 t,e !p

4et%een !c,)e'e/!n/ po(()4"e '!" e.

Met,o/(-P#!ct)ce(

Wo#& 4#e!&/o%n(t# ct #e c#)t)c!" p!t,

$et,o/. P"!nn)nconce#ne/ %)t, t)$)n(t!#t !n/ #e(pon()4)")t5

+o# !ct)')t)e( t,#o ,cont#!ct)n o#

!(() n)n .

Te!$ !pp#o!c, #!p)/#e/ ct)on o+

nce#t!)nt5 (,)e"/)n04!"!nc)n /eco p")n0.

P"!nn)n conce#ne/%)t, t)$)n !")t5 !n/

#e"e!(e o+ %o#&.

De'e"op$ent !n/ te(t)n0o+ en/( ! !)n(t $e!n( to/ete#$)ne #e1 )#e$ent(.P"!nn)n conce#ne/ %)t,%o#& (t# ct #e p#oce((

!n/ p!#t)c)p!t)on.

P#!ct)c!"Cont#)4 t)on

T!&)n c!#eto /o

nece((!#5t,)n (.

T!&)n c!#e t,!tt,e nnece((!#5)( /one !( ")tt"e

!( po(()4"e.

Conversion!&low!'alue 2

T!&)n c!#e t,!tc (to$e#

#e )#e$ent( !#e$et )n t,e 4e(tpo(()4"e $!nne#.


11/193

The desi%$ $d !o$st&u!tio$ o# AEC # !i"ities 5bui"di$%s. *&o!ess *" $ts. i&*o&t

te&mi$ "s. hi%h, ys. et!+9 *oses di##i!u"t m $ %eme$t *&ob"ems to ,hi!h the mode"s $d

te!h$i=ues b sed o$ the !o$'e&sio$ 'ie, h 'e *&o'e$ i$ de=u te+ T& deo##s bet,ee$

!om*eti$% desi%$ !&ite&i must be m de th&ou%hout the desi%$ *&o!ess. o#te$ ,ith

i$!om*"ete i$#o&m tio$ $d u$de& i$te$se bud%et $d s!hedu"e *&essu&e+ I$!&e si$%"y.

*&o8e!ts &e sub8e!t to u$!e&t i$ty be! use o# the * !e o# te!h$o"o%i! " !h $%e $d the

& *id shi#ti$% o# m &1et o**o&tu$ities $d !om*etito& !tio$s+

P&odu!tio$ m $ %eme$t !o$!e*ts $d te!h$i=ues b sed o$ the !o$'e&sio$ mode" h 'e

$ot *&o'e$ ! * b"e o# so"'i$% these di##i!u"t *&ob"ems+ The he &t o# the !o$'e&sio$ mode"

is the ssum*tio$ th t the ,o&1 to be do$e ! $ be di'ided i$to * &ts $d m $ %ed s i#

those * &ts ,e&e i$de*e$de$t o$e #&om $othe&+ M $ %eme$t te!h$i=ues su!h s ,o&1

b&e 1do,$ st&u!tu&es $d e &$ed ' "ue $ "ysis be"o$% to this !o$'e&sio$ mode"+ o&1

b&e 1do,$ st&u!tu&es &e d&i'e$ by s!o*i$% $d bud%et !o$!e&$s $d h 'e the ob8e!ti'es

o# i$su&i$% th t "" the ,o&1 s!o*e is i$!"uded i$ o$e o# the * &ts. i$su&i$% th t $o ,o&1

s!o*es o'e&" *. $d ""o! ti$% !osts to e !h * &t su!h th t the &o""u* yie"ds the tot " #o&

the *&o8e!t+ This di'isio$ i$to * &ts is $e!ess &y i$ o&de& to ""o! te &es*o$sibi"ity to

i$te&$ " o& e/te&$ " ,o&1 !e$te&s. ,hi!h ! $ subse=ue$t"y be !o$t&o""ed % i$st s!o*e.

bud%et. $d s!hedu"e !ommitme$ts+

This is #u$d me$t ""y !o$t& !ti$% me$t "ity. ,hi!h # !i"it tes the m $ %eme$t o#

!o$t& !ts & the& th $ the m $ %eme$t o# *&odu!tio$ o& ,o&1 #"o,+ P&odu!tio$

m $ %eme$t is the "o! " &es*o$sibi"ity o# those to ,hom the ' &ious * &ts &e ssi%$ed

o& !o$t& !ted+ I# e'e&yo$e meets thei& !o$t& !tu " ob"i% tio$s. the *&o8e!t *eo&ms

su!!ess#u""y+ U$#o&tu$ te"y. this **&o !h is the o**osite o# &obust+ he$ somethi$%

%oes ,&o$%. s it 'e&y o#te$ does. the e$ti&e st&u!tu&e is *&o$e to !o"" *se+


12/193

I# m $ %eme$t *hi"oso*hy $d too"s &e $eeded th t #u""y i$te%& te the !o$'e&sio$.

#"o,. $d ' "ue mode"s. ,e mi%ht !o$side& the *&odu!t de'e"o*me$t *&o!esses em*"oyed

by #i&ms desi%$i$% $d m $u# !tu&i$% !o$sume& *&odu!ts 5 utomobi"es. *&i$te&s.

to ste&s. et!+9+ Su!h *&o!esses h 'e de'e"o*ed *ote$ti ""y use#u" !o$!e*ts es*e!i ""y i$

the &e o# ' "ue< ide$ti#i! tio$ o# !ustome& $eeds $d t& $s" tio$ i$to e$%i$ee&i$%

s*e!i#i! tio$s 5U"&i!h $d E**i$%e& > 69+ P&odu!t de'e"o*me$t *&o!esses "so &e

st&u%%"i$% ,ith othe& issues &e"e' $t to the desi%$ o# AEC # !i"ities. i$!"udi$% desi%$

de!om*ositio$. o&% $i: tio$ " me $s #o& i$te%& tio$. et!+ 5H yes. et ". > < E**i$%e&.

et ". > )< Geb " $d E**i$%e&. > >9+

As !o$t&ibutio$ to the i$te%& tio$ o# "" th&ee mode"s. this thesis **"ies the #"o,

mode" to m $ %i$% the desi%$ $d !o$st&u!tio$ o# AEC # !i"ities+ Co$!e*tu "i:i$% the

desi%$ $d !o$st&u!tio$ *&o!ess s #"o, o# i$#o&m tio$ $d m te&i "s "e$ds itse"# to

&edu!i$% , ste by mi$imi:i$% time i$#o&m tio$ o& m te&i "s s*e$d , iti$% to be used.

time s*e$t i$s*e!ti$% i$#o&m tio$ o& m te&i "s #o& !o$#o&m $!e to &e=ui&eme$ts. time

s*e$t &e,o&1i$% i$#o&m tio$ o& m te&i "s to !hie'e !o$#o&m $!e. $d time s*e$t mo'i$%

i$#o&m tio$ o& m te&i "s #&om o$e s*e!i "ist to the $e/t+ Fu&the&. !o$!e*tu "i:i$% the

desi%$ $d !o$st&u!tio$ *&o!ess s #"o, o# i$#o&m tio$ $d m te&i "s ""o,s

!oo&di$ tio$ o# i$te&de*e$de$t #"o,s $d the i$te%& tio$ o# desi%$ ,ith su**"y $d site

!o$st&u!tio$+

1. A(( $pt)on(

Fu$d me$t " ssum*tio$s u$de&"yi$% this &ese &!h i$!"ude the #o""o,i$%-


13/193

Cu&&e$t !o$st&u!tio$ i$dust&y *&odu!tio$ m $ %eme$t thi$1i$% $d *& !ti!e is

domi$ ted by the !o$'e&sio$ mode". !o$se=ue$t"y ' "ue %e$e& tio$ $d #"o,

m $ %eme$t !o$!e*ts $d te!h$i=ues &e u$de&de'e"o*ed+

To be !o$siste$t ,ith "" th&ee mode"s. !o$'e&sio$. #"o,. $d ' "ue. *&odu!tio$

m $ %eme$t shou"d be !o$!ei'ed s h 'i$% the *u&*ose o# !&e ti$% !ustome& ' "ue

,hi"e mi$imi:i$% , ste i$ time $d !ost+ Custome& ' "ue is u$de&stood to i$!"ude

$ot o$"y the #it$ess #o& use o# the # !i"ity !o$side&ed ,ith &e% &d to #u$!tio$ "ity. but

"so ,ith &e% &d to "" othe& !&ite&i to ,hi!h the !ustome& tt !hes ' "ue. e+%+.

*&o8e!t de"i'e&y ,ithi$ time $d #o& !ost th t meets the !ustome& s m &1et $d

#i$ $!i " $eeds+

P&odu!tio$ is u$de&stood to i$!"ude both desi%$i$% $d m 1i$%+ The histo&i! "

de'e"o*me$t o# *&odu!tio$ theo&y i$ m $u# !tu&i$% h s e&&o$eous"y su%%ested th t

*&odu!tio$ is e$ti&e"y !o$!e&$ed ,ith ;m 1i$%;+6

P&odu!tio$ m $ %eme$t is !o$!ei'ed to !o$sist o# !&ite&i dete&mi$ tio$ $d ,o&1

st&u!tu&i$% i$ the *" $$i$% *h se. $d to !o$sist o# ,o&1 #"o, !o$t&o" $d

*&odu!tio$ u$it !o$t&o" i$ the e/e!utio$ o& !o$t&o" *h se+

This thesis t&e ts o$"y !o$t&o" #u$!tio$s. $ot *" $$i$% #u$!tio$s+ It does $ot t&e t the 'e&y

#i&st $d #u$d me$t " *&odu!tio$ m $ %eme$t !ti'ity< i+e+. the dete&mi$ tio$ o#

!ustome& $eeds $d thei& t& $s" tio$ i$to desi%$ !&ite&i + C&ite&i dete&mi$ tio$ be"o$%s

to the ' "ue %e$e& tio$ 'ie,+ This thesis t&e ts o$"y the #"o, 'ie,+ Simi" &"y. ,o&1

st&u!tu&i$% !ti'ities su!h s ide$ti#i! tio$. se=ue$!i$%. $d s!hedu"i$% t s1s &e "so $ot

6 The&e m y be di##e&e$!es bet,ee$ the U+S+ $d U+2+ i$ the use o# these te&ms+ He$!ethe e##o&t to be *&e!ise+ Fo& the most * &t. the theo&y o# *&odu!i$% &ti# !ts h s eme&%ed#&om e##o&ts to bette& m $ %e # !to&ies+ Mo&e &e!e$t"y. i$ some i$st $!es. the te&m

m $u# !tu&i$% h s !=ui&ed %&e te& s!o*e th $ me&e"y # !to&y *&odu!tio$+


14/193

t&e ted he&e+ The s!o*e o# this thesis is the !o$t&o" #u$!tio$s o# *&odu!tio$ u$it !o$t&o"

$d ,o&1 #"o, !o$t&o"+

1.; Cont#)4 t)on to Kno%"e/ e

This disse&t tio$ *&o*oses to m 1e the #o""o,i$% !o$t&ibutio$s to 1$o,"ed%e-

Ad *ted #&om m $u# !tu&i$%. system #o& *&odu!tio$ !o$t&o". the L st P" $$e&

system. is *&ese$ted th t e/em*"i#ies the !o$!e*t o# !o$t&o" s ! usi$% e'e$ts to

!o$#o&m to *" $. s disti$!t #&om the t& ditio$ " !o$!e*tio$ o# *&o8e!t !o$t&o" i$

te&ms o# #te&0the0# !t ' &i $!e dete!tio$+

A**&o*&i te **"i! tio$ o# the *&odu!tio$ !o$t&o" system is sho,$ to im*&o'e ,o&1

#"o, &e"i bi"ity. ,hi!h *&omises subst $ti " be$e#its i$ *&o8e!t !ost $d du& tio$

&edu!tio$+

Im*&o'eme$ts to the L st P" $$e& system o# *&odu!tio$ !o$t&o" &e de'e"o*ed $d

tested i$ se&ies o# ! se studies. &esu"ti$% i$ $e, !o$!e*ts $d te!h$i=ues+

P&o8e!t !o$t&o"s i$ the AEC i$dust&y h 'e #o!used o$ dete!ti$% ' &i $!es #&om *&o8e!t

ob8e!ti'es #o& !ost $d s!hedu"e. $d h 'e $ot di&e!t"y de "t ,ith the m $ %eme$t o#

*&odu!tio$+ The L st P" $$e& system o# *&odu!tio$ !o$t&o" h s *&o'e$ $ e##e!ti'e too"

#o& im*&o'i$% the *&odu!ti'ity o# the *&odu!tio$ u$its th t im*"eme$t its *&o!edu&es $d

te!h$i=ues 5B "" &d $d Ho,e"". > ?9+ This disse&t tio$ shi#ts the #o!us #&om the

*&odu!ti'ity o# the immedi te *&odu!tio$ u$it to the &e"i bi"ity o# ,o&1 #"o, bet,ee$

*&odu!tio$ u$its. $d "so e/te$ds **"i! tio$ o# the system to desi%$+

1.< T,e A t,o#=( Ro"e )n t,e Re(e!#c,

I+e+. #&om the mode"s $d theo&ies de'e"o*ed i$ i$dust&i " e$%i$ee&i$%


15/193

The L st P" $$e& system h s bee$ i$ de'e"o*me$t by the utho& si$!e > (+ Se'e& "

* *e&s h 'e *&e'ious"y bee$ *ub"ished by this utho& o$ the sub8e!t. the #i&st o# them i$

> 6 5B "" &d. > 69 t the #ou$di$% !o$#e&e$!e o# the I$te&$ tio$ " G&ou* #o& Le $

Co$st&u!tio$+ L st P" $$e& &ese &!h be% $ ,ith #o!us o$ im*&o'i$% the =u "ity o#

ssi%$me$ts i$ ,ee1"y ,o&1 *" $s 52o!h Re#i$e&y Mid0P" $ts P&o8e!t. > 60 79. dded

"oo1 he d *&o!ess to sh *e $d !o$t&o" ,o&1 #"o, 5PARC. > 7 < DMOS0 . > ?9.

$d e'e$tu ""y , s e/te$ded #&om !o$st&u!tio$ to desi%$ 5No1i $d He,"ett0P !1 &d .

> 9+ Du&i$% th t de'e"o*me$t. the ob8e!ti'e shi#ted #&om im*&o'i$% *&odu!ti'ity to

im*&o'i$% the &e"i bi"ity o# ,o&1 #"o,+ This &esu"ted #&om !h $%e i$ !o$!e*tu "

#& me,o&1+ The i$iti " #& me,o&1 ! me #&om the =u "ity m $ %eme$t $d *&odu!ti'ity

im*&o'eme$t i$iti ti'es th t domi$ ted !o$st&u!tio$ i$dust&y *eo&m $!e im*&o'eme$t

e##o&ts i$ the > )s+ The shi#t to ,o&1 #"o, &e"i bi"ity &e#"e!ted the utho&;s i$!&e si$%

, &e$ess o# the &e'o"utio$ i$ m $u# !tu&i$% i$s*i&ed by the Toyot P&odu!tio$ System

$d e'e$tu ""y " be"ed "e $ *&odu!tio$ . $d "so !o$t !t ,ith the thi$1i$% o# L u&i

2os1e" &e% &di$% *&odu!tio$ theo&y $d its **"i! tio$ to the !o$st&u!tio$ i$dust&y+

A 1ey met&i! o# the L st P" $$e& system is the *e&!e$t %e o# ssi%$me$ts !om*"eted

5PPC9. ,hi!h is !"e &"y de#e!t & te $d *&odu!t o# the =u "ity m $ %eme$t me$t "ity+

Gi'e$ the ob8e!ti'e o# im*&o'i$% *&odu!ti'ity. me su&eme$ts ,e&e m de o# the

&e" tio$shi* bet,ee$ the de#e!t & te o# !&e,. its PPC. $d the *&odu!ti'ity o# th t !&e,+

Not su&*&isi$%"y. su!h me su&eme$ts &e'e "ed *ositi'e !o&&e" tio$>)

+ Ho,e'e&. the

7 B "" &d $d Ho,e"". > ?B "" &d. Ho,e"". $d C ste$ 5> 9

? B "" &d $d Ho,e"". > ?2os1e" . B "" &d. $d T $hu $* 5> ?9Mi"es 5> 9

>) Fo& e/ m*"es. see the &e#e&e$!es #oot$oted *&e'ious"y+


16/193

!ti'ity #o!us !h & !te&isti! o# the *&odu!ti'ity im*&o'eme$t ;mi$d; !o$!e "ed the

im*o&t $!e o# th t !&e,;s PPC #o& the *&odu!ti'ity o# the !&e,s th t #o""o,ed it $d bui"t

u*o$ its ,o&1 *&odu!t+ E'e$ the i$t&odu!tio$ o# "oo1 he d *&o!ess , s moti' ted

i$iti ""y by the obse&' tio$ th t sim*"y shie"di$% !&e, #&om *oo& ssi%$me$ts , s

i$su##i!ie$t to o*timi:e !&e, *&odu!ti'ity+ To do so &e=ui&ed m t!hi$% "o d $d ! * !ity.

both o# ,hi!h &e=ui&ed m $ %i$% "o d o& ,o&1 #"o,+ The mo&e *o,eu" $d

#u$d me$t " o**o&tu$ity to !oo&di$ te !tio$ mo$% mu"ti*"e !&e,s , s hidde$ by the

domi$ $!e o# ,h t 2os1e" h s ! ""ed the !o$'e&sio$ mode" $d its e/!"usi'e #o!us o$

the !ti'ity s the u$it o# !o$t&o" & the& th $ ,o&1 #"o,+

P&io& to the #ou$di$% o# the Le $ Co$st&u!tio$ I$stitute 5LCI9 i$ Au%ust o# > ?>>.

the L st P" $$e& system h d e'o"'ed to &ou%h"y its !u&&e$t #o&m. ,ith !"e & !o$!e*tu "

b sis i$ *&odu!tio$ theo&y " 2os1e" $d $ e/*"i!it $d se"#0!o$s!ious ob8e!ti'e o#

m $ %i$% ,o&1 #"o,+ h t &em i$ed to be do$e , s to "e &$ ho, to im*&o'e ,o&1 #"o,

&e"i bi"ity bo'e the 67@0 7@ & $%e !ommo$"y dis!o'e&ed u* to th t time+ O$e *u&*ose

o# this disse&t tio$ is to des!&ibe ,h t , s do$e to im*&o'e ,o&1 #"o, &e"i bi"ity.

me su&ed by PPC. $d the &esu"ts !hie'ed+ Th t im*&o'i$% ,o&1 #"o, &e"i bi"ity is

be$e#i!i " h &d"y &e=ui&es &%ume$t+ Ho,e'e&. ide$ti#yi$% $d =u $ti#yi$% the s*e!i#i!

be$e#its ,i"" be m tte& #o& #utu&e &ese &!h+ The se!o$d *u&*ose o# this &ese &!h is to

e/*"o&e **"i! bi"ity o# the L st P" $$e& system to desi%$+

>>

The Le $ Co$st&u!tio$ I$stitute , s #ou$ded i$ Au%ust o# > ? s * &t$e&shi* bet,ee$ G&e%o&y A+ Ho,e"" $d G"e$$ B "" &d. dedi! ted to &ese &!h. t& i$i$% $d!o$su"ti$% i$ !o$st&u!tio$ i$dust&y *&odu!tio$ m $ %eme$t+ Subse=ue$t"y. I&isTomme"ei$ $d Todd 3 be""e h 'e be!ome * &t$e&s i$ the e$te&*&ise. "o$% ,ith M &1 Rey$o"ds. M $ %i$% Di&e!to& o# Le $ Co$st&u!tio$ I$te&$ tio$ ". b sed i$ Lo$do$+ A""the ! se studies &e*o&ted i$ this thesis ,e&e u$de&t 1e$ s &ese &!h *&o8e!ts #o& LCI. o# ,hi!h this utho& is Rese &!h Di&e!to&+ A"" ! se studies ,e&e ! &&ied out u$de& the


17/193

1.< St# ct #e o+ t,e D)((e#t!t)on

T& ditio$ " *&o8e!t !o$t&o" theo&y $d *& !ti!e is des!&ibed $d !&iti=ued i$ Ch *te&

T,o+ The L st P" $$e& System o# P&odu!tio$ Co$t&o" is *&ese$ted i$ Ch *te& Th&ee s

s tis#yi$% the &e=ui&eme$ts &e'e "ed by the !&iti=ue+ Ch *te& Fou& des!&ibes the &ese &!h

methodo"o%y used i$ the disse&t tio$ $d is #o""o,ed by Ch *te&s 7. . ?. . $d . e !h

de'oted to ! se study+ Co$!"usio$s #&om the ! se studies &e &e*o&ted i$ Ch *te& >).

#o""o,ed by %"oss &y o# te&ms. "ist o# &e#e&e$!es. bib"io%& *hy. $d $ **e$di/

!o$sisti$% o# do!ume$ts #&om the desi%$ ! se. Ne/t St %e+

di&e!tio$ o# this utho&. ,ho "so , s the *&im &y * &ti!i* $t i$ *&o8e!t e'e$ts $d the *&im &y !o""e!to& o# ! se study d t +


18/193


CHAPTER TWO: CRITI>UE OF PRODUCTIONCONTROL

.1 W,!t )( P#o/ ct)on Cont#o"?

The *u&*ose o# this !h *te& is to *&o'ide !&iti=ue o# *&odu!tio$ !o$t&o" theo&y $d

*& !ti!e+ But #i&st it is $e!ess &y to !" &i#y ,h t is me $t by *&odu!tio$ !o$t&o" +

.1.1 T,e Me!n)n o+ @P#o/ ct)on

P&odu!tio$ h s bee$ $ e/*"i!it to*i! o# study *&im &i"y i$ i$dust&i " e$%i$ee&i$%. ,hi!h

h s de "t "most e$ti&e"y ,ith o$e ty*e o# *&odu!tio$< $ me"y. m $u# !tu&i$% 5i$ the

se$se o# ;m 1i$%;9. ,ith o$"y o!! sio$ " #o& ys i$to !o$st&u!tio$. *" $t m i$te$ $!e.

bui"di$% m i$te$ $!e. %&i!u"tu&e. #o&est&y. mi$i$%. #ishi$%. et!+ Desi%$ $d e$%i$ee&i$%

h 'e i$#&e=ue$t"y bee$ !o$!ei'ed s *&odu!tio$ *&o!esses< the #o!us "most e$ti&e"y

bei$% *" !ed o$ m 1i$% thi$%s & the& th $ desi%$i$% them+

A"thou%h the me $i$% o# the te&m t its most u$i'e&s " is sy$o$ymous ,ith

m 1i$% . m $u# !tu&i$% is most !ommo$"y>( used to de$ote the m 1i$% o# m $y

!o*ies #&om si$%"e desi%$. $d !o$se=ue$t"y is *&im &i"y #o!used o$ *&odu!ts #o&

m ss m &1et. most o# those *&odu!ts bei$% mo'e b"e #&om the *" !e m $u# !tu&ed to the

*" !e o# use+ The&e &e e/!e*tio$s to the *&odu!ts bei$% mo'e b"e. "thou%h sti"" !o*ies

#&om si$%"e desi%$< e+%+. shi*s $d i&*" $es+ ithi$ the ,o&"d o# !o$st&u!tio$.

m $u# !tu&i$% i$ this se$se is **&o !hed most"y !"ose"y by ;m $u# !tu&ed housi$%;+

>( E/!e*tio$s o!!u& ,ith thi$1e&s $d ,&iti$%s &e% &di$% *&odu!t de'e"o*me$t. ,hi!h byits $ tu&e must i$te%& te desi%$i$% $d m 1i$%. t "e st i$ the se$se o# m 1i$%

*&ototy*es+


19/193


K &ious ty*es o# m 1i$% h 'e bee$ *&o*osed. mo$% them ssemb"y . the 8oi$i$% o#

* &ts i$to ,ho"e. s disti$!t #&om # b&i! ti$% . the sh *i$% o# m te&i "s+ Fo& e/ m*"e.

!o$st&u!tio$ is o#te$ ! te%o&i:ed s ty*e o# #i/ed *ositio$ m $u# !tu&i$%

5S!hme$$e&.

> 69. "o$% ,ith shi*bui"di$% $d i&*" $e ssemb"y+ I$ "" these i$st $!es o# ssemb"y.

the ssemb"ed *&odu!t e'e$tu ""y be!omes too " &%e to be mo'ed th&ou%h ssemb"y

st tio$s. so the st tio$s 5,o&1 !&e,s9 must be mo'ed th&ou%h them. ddi$% dditio$ "

!om*o$e$ts $d sub ssemb"ies u$ti" the &ti# !t 5bui"di$%. b&id%e. tu$$e". *" $t. house.

hi%h, y. et!9 is !om*"eted+

M $y *ub"i! tio$s e/ist o$ the to*i! o# *&odu!tio$ m $ %eme$t i$ m $u# !tu&i$%.

the " &%e& * &t o# ,hi!h do*t the *e&s*e!ti'e o# the i$dust&i " o& *&odu!tio$ e$%i$ee&

5Be&t& $d et ". > )< Ho** $d S*e &m $. > < Mu&&i"". > >< Ko""m $ et ". > (9+ A

subset o# this ! te%o&y !o$!e&$ themse"'es ,ith the *sy!ho"o%i! "Jso!io"o%i! " s*e!ts o#

m $u# !tu&i$% m $ %eme$t 5S!he&e&. > 9+ The de'e"o*me$t o# "te&$ ti'es to m ss

*&odu!tio$ o'e& the " st ) ye &s h s bee$ &e'o"utio$ &y+ E &"y $d i$#"ue$ti " *&odu!tio$

m $ %eme$t theo&ists i$!"ude 4 !1 Bu&bid%e 5> 6< > 9 $d + Ed, &ds Demi$%

5> 9. to me$tio$ but #e, #&om the est+ T ii!hi Oh$o 5> 9 $d Shi%eo Shi$%o

5> 9 ,e&e the *&im &y &!hite!ts o# the Toyot P&odu!tio$ System. the &!hety*e #o&

"e $ *&odu!tio$. so $ med i$ * &t to !ou$te&*ose it to m ss *&odu!tio$+ Bu&bid%e;s

%&ou$db&e 1i$% thou%ht be% $ to eme&%e i$ the > )s+ Demi$% , s i$st&ume$t " i$ the

im*"eme$t tio$ o# =u "ity m $ %eme$t $d st tisti! " =u "ity !o$t&o" !o$!e*ts $d

te!h$i=ues i$ 4 * $ #te& the ($d o&"d &+ The ,o&1 o# Oh$o $d Shi$%o , s

!o$!e$t& ted i$ the *e&iod o# the " te 7);s i$to the ?);s+ #he (achine #hat Chan"ed the

World 5 om !1 et "+. > )9 &e*o&ted the #i$di$%s o# $ i$te&$ tio$ " study o# the

utomoti'e i$dust&y $d , s #o""o,ed by Lean #hin in" 5 om !1 $d 4o$es. > 9


20/193


,hi!h *&ese$ted the *&i$!i*"es $d b si! !o$!e*ts behi$d the $e, #o&ms o#

m $u# !tu&i$% $d *&o*osed to e/te$d them to the e$ti&e e$te&*&ise+ om !1 $d 4o$es

h 'e *o*u" &i:ed $d m de mo&e e si"y !!essib"e the !o$!e*ts $d te!h$i=ues o# "e $

*&odu!tio$+

De#i$i$% *&odu!tio$ s the desi%$i$% $ d m 1i$% o# &ti# !ts ""o,s us to u$de&st $d

ho, !o$st&u!tio$ is ty*e o# *&odu!tio$ $d "so th t desi%$ is $ esse$ti " !om*o$e$t

i$ *&odu!tio$ %e$e& ""y $d i$ !o$st&u!tio$ s*e!i#i! ""y+ L u&i 2os1e" 52os1e"

> (.

> < 2os1e" $d Huo'i" > ?< 2os1e" et "+ > . > ?9 is the #o&emost *&odu!tio$

theo&ist i$ !o$st&u!tio$+ His study o# the **"i! bi"ity o# $e,"y eme&%e$t m $u# !tu&i$%

!o$!e*ts $d te!h$i=ues to the !o$st&u!tio$ i$dust&y h s d&i'e$ him b !1 to the

de'e"o*me$t o# theo&y o# *&odu!tio$ s su!h 52os1e" . > 9+

.1. T HE M EANING OF @CONTROL

The te&m !o$t&o" h s ,ide & $%e o# me $i$%s+ A!!o&di$% to the Co$!ise O/#o&d

Di!tio$ &y. its me $i$%s i$!"ude to domi$ te. !omm $d< to !he!1. 'e&i#y< to &e%u" te+ It

h s "o$% bee$ sso!i ted ,ith !!ou$ti$%+ The O"d F&e$!h contreroller - to 1ee* &o"" o#

!!ou$ts+

A!!ou$ti$% is the esse$!e o# *&o8e!t !o$t&o" theo&y. mo&e #u""y des!&ibed i$ se!tio$

(+(+( be"o, 5Die1m $$ $d Th&ush. > < P&o8e!t M $ %eme$t Body o# 2$o,"ed%e

5PMBO29. > < Ri%%s. > 9+ The esse$ti " !ti'ity is mo$ito&i$% !tu " !osts o&

s!hedu"e *eo&m $!e % i$st t &%et i$ o&de& to ide$ti#y $e% ti'e ' &i $!es+ Co&&e!ti'e

!tio$ is ob'ious"y $e!ess &y i$ o&de& to !o&&e!t su!h $e% ti'e ' &i $!es. but the

"ite& tu&e h &d"y dd&esses !o&&e!ti'e !tio$+


21/193


I$dust&i " *&o!ess !o$t&o" i$t&odu!es #eedb !1 $d #eed#o&, &d me!h $isms #o&

&e%u" ti$% *&o!ess 5Mu&&i"". > 69+ Feedb !1 is i$iti ted by !om* &iso$ o# !tu " ,ith

t &%et out*uts+ Feed#o&, &d is i$iti ted by !om* &iso$ o# !tu " ,ith t &%et i$*uts+

The &ti#i!i " i$te""i%e$!e !ommu$ity !o$t&ibutes the b" !1bo &d system o# !o$t&o". i$

,hi!h !oo&di$ tio$ o# $umbe& o# i$te&de*e$de$t s*e!i "ists is m $ %ed by &u"es #o&

t 1i$% tu&$s ;,&iti$% o$ b" !1bo &d;< i+e+. #o& !o$t&ibuti$% to thei& !o"" bo& ti'e ,o&1

5H yes0Roth. > 79+ AI dhe&e$ts h 'e bee$ i$ the #o&e#&o$t o# em*i&i! " study o#

desi%$. $d des*ite thei& te!h$o"o%i! " o&ie$t tio$. h 'e #ou$d so!i " $d o&% $i: tio$ "

issues to be o# %&e t im*o&t $!e+ Fi$%e& et " 5> 79 !o$!"ude- The so!i " *&o!ess *" ys

m 8o& &o"e i$ the &ti!u" tio$ $d &e "i: tio$ o# the *&odu!t desi%$. * &ti!u" &"y i$ " &%e

*&o8e!ts+ 5*+ 9+ Bu!!i &e""i 5> 9 &e*o&ts th t desi%$e&s s*e$d 70 )@ o# thei& time

t "1i$%. ,&iti$%. $e%oti ti$%. meeti$%. se &!hi$%. et!+ s o**osed to d& ,i$% $d

! "!u" ti$%+

P&odu!tio$ !o$t&o" theo&ists ,o&1i$% i$ m $u# !tu&i$% disti$%uish t,o *&im &y , ys

o# &e%u" ti$% ,o&1 #"o, i$ m $u# !tu&i$% systems- *ush $d *u""+ Push systems &e"e se

m te&i "s o& i$#o&m tio$ i$to system b sed o$ *&e ssi%$ed due d tes 5#&om m ste&

*&odu!tio$ s!hedu"e. #o& e/ m*"e9 #o& the *&odu!ts o# ,hi!h they &e * &ts+ Pu"" systems

&e"e se m te&i "s o& i$#o&m tio$ i$to system b sed o$ the st te o# the system 5the

mou$t o# ,o&1 i$ *&o!ess. the =u "ity o# ' i" b"e ssi%$me$ts. et!9 i$ dditio$ to due

d tes 5Ho** $d S*e &m $. > 9+ I$ # !to&y systems. *u"" m y be de&i' ti'e u"tim te"y

#&om !ustome& o&de&s+ I$ !o$st&u!tio$. *u"" is u"tim te"y de&i' ti'e #&om t &%et

!om*"etio$ d tes. but s*e!i#i! ""y **"ies to the i$te&$ " !ustome& o# e !h *&o!ess+

A**"i! bi"ity o# these !o$!e*ts to *&odu!tio$ !o$t&o" h s bee$ e/*"o&ed by this utho&

5B "" &d. > 9+


22/193


Some theo&ists 52e""y. > 9 *&o*ose th t !om*"e/. dy$ mi! systems &e &e%u" ted

$ot by $ythi$% &esemb"i$% !e$t& " mi$d. but th&ou%h the i$de*e$de$t !tio$ o#

dist&ibuted de!isio$ m 1e&s+ The #o""o,i$% e/!e&*t #&om E&i! S!he&e& s i$t&odu!tio$ to

*hop &loor Control+, *ystems Perspective i$di! tes the eme&%e$!e o# $e, !o$!e*tu "

#& me,o&1.

-#o master the challen"es of the future. there must be a chan"e inour thin in" paradi"m (anufacturin" is not deterministic/ the

problem of systems desi"n for shop floor control is no lon"er the problem of 1optimi ation3 #he reductionistic paradi"m needs tobe replaced by a holistic paradi"m of a"ile activity. dynamicbehavior. and evolutionary development 4

. P#o6ect M!n! e$ent

. .1 T HE P RO ECT M ANAGEMENT BOD OF K NOWLEDGE

The !o$st&u!tio$ i$dust&y is o&% $i:ed i$ *&o8e!ts $d !u&&e$t *&odu!tio$ theo&y $d

*& !ti!e &e he 'i"y i$#"ue$!ed by the !o$!e*ts $d te!h$i=ues o# *&o8e!t m $ %eme$t+

A!!o&di$% to PMI s , 5uide to the Pro6ect (ana"ement ody of 8nowled"e . *&o8e!t

is tem*o& &y e$de 'o& u$de&t 1e$ to *&odu!e u$i=ue *&odu!t o& se&'i!e+ The

m 1i$% 5i+e+. m $u# !tu&i$%9 o# mu"ti*"e !o*ies o# *&odu!t does $ot o!!u& th&ou%h

*&o8e!ts so u$de&stood+ This #o!us o$ *&odu!t u$i=ue$ess $d the *&o8e!t #o&m o#

o&% $i: tio$ h s domi$ ted thi$1i$% bout *&odu!tio$ o# the bui"t e$'i&o$me$t so # & s

to dis!ou& %e "e &$i$% #&om $o$0*&o8e!t i$dust&ies su!h s *&odu!t m $u# !tu&i$%

52os1e" . > (9+

A% i$ !!o&di$% to PMI 5> 9. *&o8e!t m $ %eme$t i$!"udes the m $ %eme$t o#

i$te%& tio$. s!o*e. time. !ost. =u "ity. hum $ &esou&!es. !ommu$i! tio$s. &is1. $d

*&o!u&eme$t+ A$y o& "" o# these !ou"d !o$!ei' b"y !o$!e&$ the !tu " *&odu!tio$

*&o!ess itse"#. but *e&h *s most o# "" time $d !ost+


23/193


Time m $ %eme$t is s id to !o$sist o# !ti'ity de#i$itio$. !ti'ity se=ue$!i$%. !ti'ity

du& tio$ estim ti$%. s!hedu"e de'e"o*me$t. $d s!hedu"e !o$t&o"+ The #o!us is e$ti&e"y o$

de"i'e&i$% *&o8e!t ob8e!ti'es< i$ 2os1e" s te&ms. o$ the t& $s#o&m tio$ o& !o$'e&sio$

*&o!esses 5 !ti'ities9 $d $ot o$ #"o, o& ' "ue %e$e& tio$ *&o!esses+ A!ti'ities &e to be

de#i$ed so s to # !i"it te di'isio$ o# " bo& $d subse=ue$t t& !1i$% 5 !!ou$ti$%9 o#

!o$#o&m $!e to &e=ui&eme$ts+ The&e is $o me$tio$ o# st&u!tu&i$% ,o&1 #o& #"o, o& o#

de#i$i$% !ti'ities so th t they # !i"it te the !tu " *eo&m $!e o# the ,o&1+ A!ti'ity

se=ue$!i$% ssumes th t h $do##s #&om o$e set o# s*e!i "ists to the $e/t o!!u& o$"y o$!e 9+ The ob8e!ti'e is to dete!t $e% ti'e ' &i $!es #&om t &%et. so !o&&e!ti'e

!tio$ ! $ be t 1e$+ This is =uite di##e&e$t #&om the !ti'e !o$!e*t o# !o$t&o" domi$ $t i$

m $u# !tu&i$% *&odu!tio$ !o$t&o" systems. es*e!i ""y those em*"oyi$% *u"" st& te%y. i$

,hi!h the *u&*ose o# !o$t&o" is to ! use e'e$ts to !o$#o&m to *" $+ I$ the #o""o,i$%. ,e

#u&the& e/ mi$e t& ditio$ " *&o8e!t !o$t&o"s $d thei& di##e&e$!e #&om the !o$!e*t o#

!o$t&o" i$ the L st P" $$e& system. ,hi!h is to be i$t&odu!ed i$ Ch *te& 6+

I$ t& ditio$ " *&o8e!t !o$t&o". the ob8e!ts o# !o$t&o" &e time $d &esou&!es+

Resou&!es 5" bo& hou&s. m te&i ". e=ui*me$t. i$di&e!ts9 &e *" $$ed $d !o$t&o""ed


25/193


th&ou%h !ost !o$t&o" systems. the ob8e!ti'e o# ,hi!h is *&odu!ti'ity. i+e+. e##i!ie$t use o#

&esou&!es+ A bud%et is *&e* &ed #o& e !h &esou&!e. the use o# &esou&!es is mo$ito&ed

% i$st thei& bud%ets. $d *e&iodi! #o&e! sts &e m de o# &esou&!e &e=ui&eme$ts b sed o$

the !u&&e$t st te o# the *&o8e!t+

Co$t&o""i$% time i$'o"'es *" $$i$%. s!hedu"i$%. $d mo$ito&i$%+ P" $$i$% de!ides

,h t is to be !!om*"ished $d i$ ,h t se=ue$!e+ S!hedu"i$% dete&mi$es t s1 du& tio$

$d timi$%+ Mo$ito&i$% !he!1s *&o%&ess o# t s1s % i$st the s!hedu"e $d #o&e! sts ,he$

,o&1 ,i"" be !om*"eted+ The ob8e!ti'e o# time !o$t&o" is *&odu!tio$ o& *&o%&ess. $ot

*&odu!ti'ity+

De!isio$s m de &e% &di$% bud%et $d s!hedu"e. *&odu!ti'ity $d *&odu!tio$ must

&e!o%$i:e thei& i$te&de*e$de$!e+ P&odu!ti'ity $d *&odu!tio$ &e #o&m ""y &e" ted i$

e &$ed ' "ue systems. ,hi!h *&o*ose so"utio$ to the *&ob"em th t *&o%&ess $d

e/*e$ditu&e o# &esou&!es $eed $ot !oi$!ide+ R tes o# &esou&!e !o$sum*tio$ &e

est b"ished #o& the ' &ious 1i$ds o# ,o&1 to be *eo&med o$ *&o8e!t< e+%+. +6(

e$%i$ee&i$% " bou&0hou&s *e& *i*i$% isomet&i! d& ,i$% o& >(+ " bou&0hou&s *e& *u&!h se

o&de&+ Com*"eti$% $ i$di'idu " *i*i$% isomet&i! d& ,i$% e &$s +6( " bou&0hou&s

&e% &d"ess o# the !tu " $umbe& o# hou&s !o$sumed i$ its *&odu!tio$+ P&o%&ess to, &d

*&o8e!t !om*"etio$ is t& !1ed by !!umu" ti$% the e &$ed hou&s $d !om* &i$% th t to

the tot " hou&s to be e &$ed #o& the e$ti&e *&o8e!t+ Fo& e/ m*"e. su**ose the *&o8e!t

s!hedu"e ! ""s #o& *&odu!tio$ o# >) *i*i$% isomet&i! d& ,i$%s t time t. but o$"y

d& ,i$%s h 'e bee$ *&odu!ed+ O$"y 6+ 5 / +6(9 hou&s h 'e bee$ e &$ed o# the 6+(

s!hedu"ed. so th t *o&tio$ o# the *&o8e!t is >)@ behi$d s!hedu"e 5 6+ J 6+( + )9+ Th t

is me su&e o# *&odu!tio$ % i$st s!hedu"e+


26/193


P&odu!ti'ity ! $ be =uite di##e&e$t sto&y+ Su**ose it h s t 1e$ o$"y ) hou&s to

*&odu!e the *i*i$% isomet&i! d& ,i$%s+ Si$!e 6+ hou&s ,e&e e &$ed. the

*eo&m $!e # !to& is + 7 $d the *i*i$% %&ou* is o*e& ti$% t 7@ o# its bud%et #o&

isomet&i! d& ,i$%s+ I$ this ! se. the *&o8e!t is behi$d s!hedu"e. but u$de& bud%et+

P&odu!tio$ is *oo& $d *&odu!ti'ity is %ood+

E &$ed ' "ue $ "ysis is me $s #o& !o$t&o""i$% *&o8e!ts th&ou%h *&odu!ti'ity $d

*&o%&ess+ By itse"#. it ,ou"d h 'e the desi%$ m $ %e& be"ie'e th t *&o8e!t is *eo&mi$%

,e"" i# it is e &$i$% " bo& hou&s t the bud%et u$it & te $d "so e &$i$% su##i!ie$t hou&s to

m i$t i$ s!hedu"ed e &$i$%s *" $ e/*&essed s *e&!e$t %es o# e &$ed hou&s to tot "

hou&s to be e &$ed+ The ob'ious ,e 1$ess i$ this !o$t&o" me!h $ism is th t *&o8e!ts m y

e/hibit bud%et *&odu!ti'ity $d be o$ the e &$i$%s *" $. but $ot be doi$% the &i%ht

,o&1 i$ the &i%ht , y t the &i%ht time+ A"thou%h thi$%s **e & to be o$ t& !1. the t& i$ is

desti$ed to e'e$tu ""y &u$ o## the & i"s be! use ,o&1 is bei$% *&odu!ed th t does $ot

!o$#o&m to *&odu!t =u "ity &e=ui&eme$ts o& to *&o!ess =u "ity &e=ui&eme$ts 5e+%+. out o#

se=ue$!e9+ Co$se=ue$t"y. =u "ity !o$t&o" is i$'o1ed s se* & te !o$t&o" me!h $ism.

"thou%h & &e"y i# e'e& !o$t&o""i$% % i$st the ob8e!ti'e o# e/*&essi$% !ustome& $eeds i$

e$%i$ee&i$% s*e!i#i! tio$s. but & the& !o$t&o""i$% % i$st the ob8e!ti'es o# 'oidi$%

! "!u" tio$ " $d dime$sio$ " e&&o&s+ As #o& the issue o# the timi$% o# ,o&1. it h s *&o'e$

$e!ess &y to est b"ish s!hedu"e mi"esto$es to e$#o&!e dhe&e$!e to ,o&1 se=ue$!e+

These &e & %u &d !tio$s &e #&e=ue$t"y i$e##e!ti'e % i$st the domi$ $t *&o%&ess $d

*&odu!ti'ity !o$t&o"s. ,hi!h !o$se=ue$t"y ! use m $ %e&s to th&o, the "e'e& i$ the

,&o$% di&e!tio$ be! use they mise' "u te !tu " *&o8e!t *eo&m $!e 5Ho,e"" $d

B "" &d. > 9+


27/193


o&1 B&e 1do,$ St&u!tu&e 5 BS9 is 1ey e"eme$t i$ t& ditio$ " *&o8e!t !o$t&o"s+

A BS *&o'ides #& me,o&1 #o& i$te%& ted s!hedu"e $d !ost *" $$i$% $d ""o,s #o&

mo$ito&i$% $d !o$t&o" by m $ %eme$t by est b"ishi$% the m $$e& i$ ,hi!h estim tes &e

ssi%$ed $d !osts &e !!umu" ted $d summ &i:ed+ 5*+ (>. Die1m $$ $d Th&ush.

> 9+ The ob8e!ti'e is to di'ide the ,o&1 to be do$e i$ the *&o8e!t i$to * &ts so they ! $

be mo$ito&ed $d !o$t&o""ed+ No me$tio$ is m de o# the *&odu!tio$ *&o!ess s su!h+

NB- I$!"usio$ o# the #"o, 'ie, dds $e, !&ite&i to the de!om*ositio$ *&o!ess+ Rou%h"y

s*e 1i$%. ,e , $t to b&e 1 the ,ho"e i$to * &ts so ,e ! $ mo&e e si"y *ut the * &ts b !1

to%ethe& % i$+ St&u!tu&e ,o&1 #o& #"o, $d ssemb"y. $ot o$"y #o& bud%eti$% $d

mo$ito&i$%+Q

Fu&the& de!om*ositio$ i$ the t& ditio$ " *&o!ess e'e$tu ""y de#i$es ,o&1 * !1 %es s

the sm ""est u$it+ o&1 * !1 %es o#te$ !o&&es*o$d to !o$t& !t * !1 %es o& to * y items

,ithi$ si$%"e !o$t& !t+ The domi$ $!e o# the !o$'e&sio$ 'ie, is *e&h *s best &e'e "ed

i$ the #o""o,i$% =uotes- A ,o&1 * !1 %e is !ost !e$te&+ 5*+ ?6. Nei". 4 mes M+

Construction Cost 9stimatin" for Pro6ect Control . > (9+ The BS *&o'ides the

#& me,o&1 #o& de#i$i$% the *&o8e!t #&om the to* "" the , y do,$ to its sm ""est

!om*o$e$ts $d #o& !!umu" ti$% the !osts sso!i ted ,ith e !h *ie!e+ I$ so doi$%. the

BS *&o'ides d t b se #&om ,hi!h *&ob"em &e s ! $ be ide$ti#ied. #o&e! sts m de.

$d !o&&e!ti'e !tio$ ! $ be t 1e$+ 5*+ (>. Die1m $$ $d Th&ush. > 9+ It **e &s to

be ssumed th t !osts &ise ,ithi$ th t * &t o# the *&o8e!t i$ ,hi!h they &e dete!ted+

Fu&the&. !o$t&o" is esse$ti ""y !o$t&o" o# beh 'iou&. %i'e$ the de# u"t ssum*tio$ th t

t s1sJ,o&1 * !1 %esJ!o$t& !ts ! $ be ! &&ied out+ The #"o, 'ie,. ,ith its

i$te&de*e$de$!e o# * &ts 5both s &e% &ds the ;*&odu!t; $d the *&o!ess o# m 1i$% th t

*&odu!t9. is $e%"e!ted i$ this *e&s*e!ti'e+ E=u ""y $e%"e!ted is !o$side& tio$ o# ! * bi"ity+


28/193


e &e !"e &"y de "i$% he&e ,ith ty*e o# *ush system $d the !o$t&o"s **&o*&i te to

*ush system+

Des*ite the #o!us o$ !ost $d s!hedu"e !!ou$ti$% . theo&ists &e!o%$i:e the *&im !y

o# the !o$t&o" !t itse"#+ ithout !o&&e!ti'e !tio$s *&o8e!t !o$t&o" system be!omes

me&e"y !ostJs!hedu"e &e*o&ti$% system+ 5*+ ( . Die1m $$ $d Th&ush. > 9+

Ho,e'e&. the t& ditio$ " 'ie, is th t !o$t&o" !o$sists o# !o&&e!ti$% de'i tio$s #&om *" $+

De'i tio$s &e e/*e!ted. but th t e/*e!t tio$ is $ot &ooted i$ the ide th t ' &i tio$ is

$ tu& ". but & the& th t si$ is i$e'it b"e+ Die1m $$ $d Th&ush de'ote "ess th $ t,o * %es

o# >) * %e * *e& to !o&&e!ti'e !tio$ $d *&o'ide $o mo&e d'i!e th $ to i$#o&m

m $ %e&s $d su*e&'iso&s t e'e&y "e'e" i$ the *&o8e!t bout de'i tio$s so they ! $

!o&&e!t those t&oub"e s*ots+ 5*+ ( 9+ They **e & to ssume th t ! uses o# de'i tio$ ,i""

be ** &e$t $d the **&o*&i te !o&&e!ti'e !tio$ ob'ious+ These *&ob"ems ! $ be e si"y

t& !ed to thei& sou&!e ""o,i$% e &"y dete!tio$ o# u$# 'o& b"e t&e$ds+ 5*+ 66. Die1m $$

$d Th&ush. > 9+ I# the st $d &d !o&&e!ti'e !tio$s &e i$deed T&y h &de& $d Add

mo&e me$ . th t ,ou"d be !o$siste$t ,ith the t& ditio$ " 'ie,+

Ad'o! tes o# system dy$ mi!s h 'e *&o*osed to su**"eme$t t& ditio$ " $et,o&1

$ "yses $d mode"s. ddi$% to the %&o,i$% e'ide$!e th t $et,o&1 $ "ysis o$ its

o,$ is $ot su##i!ie$t to mode" $d m $ %e the beh 'iou& o# *&o8e!ts+ 5 i""i ms et "+.

> 7. *+ >7 9+ They *&o*ose to *&o'ide dditio$ " i$#o&m tio$ to *&o8e!t m $ %e&s so

they 'oid mise' "u ti$% the st te o# the *&o8e!t $d !o$se=ue$t"y m 1i$% de!isio$s th t

! use thi$%s to %et ,o&se & the& th $ bette& 5See *+ >(7 o# Rod&i%ues. > 9+ B "" &d $d

Ho,e"" 5> 9 su%%est th t it is im*ossib"e to m 1e %ood de!isio$s bout ! uses o&

!o&&e!tio$s o# de'i tio$s. &e"yi$% o$"y o$ *&odu!ti'ity $d *&o%&ess d t . ,ithout

u$de&st $di$% ,o&1 #"o,+ O$e ! $ h &d"y 'oid !o$!"udi$% th t the t& ditio$ "

!o$t&o"


29/193


system is i$deed b sed "most e/!"usi'e"y o$ the !o$'e&sio$ o& !ti'ity 'ie, o# the

*&odu!tio$ system+

.; P#e')o ( App")c!t)on( o+ P#o/ ct)on Cont#o" Concept( to t,e AEC

In/ (t#5

A su&'ey o# the "ite& tu&e &e'e "s se'e& " *&im &y !o$t&ibuto&s to the theo&y $d *& !ti!e

o# *&odu!tio$ 5 s o**osed to *&o8e!t9 !o$t&o" i$ the !o$st&u!tio$ i$dust&y+ B "" &d $d

Ho,e"" s !o$t&ibutio$s &e des!&ibed i$ Ch *te& Th&ee+ Me""es $d me"i$1 5> 69

de'e"o*ed 'e&y simi" & "i$e o# thi$1i$% i$de*e$de$t"y. !u"mi$ ti$% i$ thei& 8oi$t PhD

thesis t De"#t U$i'e&sity. The Nethe&" $ds+ L u&i 2os1e" . Se$io& Rese &!he& t

Fi$" $d s bui"di$% &ese &!h i$stitute. KTT. is the "e di$% theo&ist i$ *&odu!tio$

m $ %eme$t i$ !o$st&u!tio$+ The U$i'e&sity o# Re di$% h s bee$ !ti'e i$ the #ie"d o#

*&odu!tio$ m $ %eme$t #o& $umbe& o# ye &s+ 4oh$ Be$$ett sConstruction

(ana"ement #&om > 7 is $ e/!e""e$t e/ m*"e o# thei& ,o&1+ Addis > ) boo1.

*tructural en"ineerin": the nature and theory of desi"n . is "so hi%h"y &e"e' $t ,o&1

#o& this &ese &!h+ A"e/ $de& L u#e& s ,o&1 o$ *&o8e!t *" $$i$% t 1es *&odu!tio$

!o$t&o" o&ie$t tio$ by 'i&tue o# its #o!us o$ u$!e&t i$ty $d ' &i bi"ity $d thei&

m $ %eme$t+ Gi'e$ the &e" ti'e obs!u&ity o# Me""es $d me"i$1 s. o$"y thei& ,o&1 is

*&ese$ted i$ det i"+ The ,o&1 o# 2os1e" is des!&ibed o$"y to the e/te$t $eeded to &emi$d

the &e de& o# his 'it " !o$t&ibutio$s+ Th t shou"d i$ $o , y be t 1e$ s $ i$di! tio$ o#

&e" ti'e im*o&t $!e o# the ' &ious !o$t&ibutio$s+

.;.1 M ELLES AND W AMELINK

I$t&odu!i$% thei& dis!ussio$ o# the theo&y o# *&odu!tio$ !o$t&o". Me""es $d me"i$1

5> 69 e/*" i$. Co$t& &y to ,h t is !ustom &y i$ the !o$st&u!tio$ i$dust&y ,e sh ""$ot


30/193


ssume. be#o&eh $d. the theo&ies i$ the #ie"d o# *&o8e!t m $ %eme$t+ P&odu!tio$

!o$t&o" i$ !o$st&u!tio$ !om* $ies h s t& ditio$ ""y bee$ imed t the !o$t&o" o#

*&o8e!ts+ Fo& Me""es $d me"i$1. *&odu!tio$ !o$t&o" !o$sists o# the !ti'ities

&e" ti$% to the d8ustme$t o# "" s*e!ts o# the *&odu!tio$ *&o!ess. so th t the

*&e!o$ditio$s i$ ,hi!h the *&odu!tio$ *&o!ess is to be e/e!uted. &e met+ D& ,i$% o$

m $u# !tu&i$% *&odu!tio$ !o$t&o". they em*h si:e- >9 Thi$1i$% i$ te&ms o# hie& &!hi! "

"e'e"s o# de!isio$< i+e+. !o$t&o" t !om* $y "e'e". # !to&y "e'e". $d *&odu!tio$ u$it "e'e".

$d (9 Thi$1i$% i$ te&ms o# de!isio$ #u$!tio$s ,ithi$ the hie& &!hi! " "e'e"s< i+e+.

%%&e% te *&odu!tio$ !o$t&o". m te&i " !oo&di$ tio$. ,o&1"o d !o$t&o". ,o&1o&de&

&e"e se. ,o&1"o d !!e*t $!e. det i"ed ,o&1o&de& s!hedu"i$%. ! * !ity ""o! tio$. $d

sho* #"oo& !o$t&o"+ The m $u# !tu&i$% mode" o$ ,hi!h they &e"y is th t o# Be&t& $d et

"+.

> )+

Me""es $d me"i$1 *&o*ose t& $s" tio$ o# the m $u# !tu&i$% mode" i$to

de!isio$ #u$!tio$s **&o*&i te to ' &ious ty*es o# !o$st&u!tio$. ide$ti#yi$% t the

# !to&y "e'e" *&o8e!t !oo&di$ tio$ 5 !hie'ed i$ * &t by $et,o&1 s!hedu"es9. mobi"is tio$

*" $$i$% 5by me $s o# si/ ,ee1s s!heme 9. $d ""o! tio$ *" $$i$% 5by me $s o# t s1

s!heme 9+

I$ dditio$ to the *&im &y !o$t&ibutio$ o# di&e!ti$% tte$tio$ to m $u# !tu&i$% theo&y

$d *& !ti!e. Me""es $d me"i$1 s ,o&1 ide$ti#ies #u$!tio$ "ities AEC i$dust&y

*&odu!tio$ !o$t&o" systems shou"d *ossess+ Thei& s*e!i#i! ob8e!ti'e , s to ssist i$ the

desi%$ o# i$#o&m tio$ systems+ Co$se=ue$t"y. they did $ot e/*"i!it"y **"y thei& mode" to

e' "u tio$ o# !u&&e$t m $ %eme$t systems $d *& !ti!e+ Ho,e'e&. the o'e&,he"mi$%"y

$e% ti'e &esu"ts o# so doi$% &e im*"i!it i$ thei& !&iti=ue o# *&o8e!t m $ %eme$t so#t, &e+

Fo& e/ m*"e. s*e 1i$% o# *&o8e!t !oo&di$ tio$. they !omme$t. it ! $ immedi te"y be


31/193


dedu!ed th t the *&o8e!t m $ %eme$t so#t, &e ' i" b"e o$ the m &1et is i$deed bout

!e&t i$ s*e!t 5,ithi$ the #& me,o&1. the de!isio$ #u$!tio$ *&o8e!t !oo&di$ tio$9+ The

othe& de!isio$ #u$!tio$s 5&esou&!e *" $$i$%. mobi"i: tio$ *" $$i$%. et!+9 &e. %e$e& ""y

s*e 1i$%. $ot &e!o%$i: b"e+ 5*+ 679+ This !&iti=ue is m de mo&e e/*"i!it"y i$ me"i$1 et

"+. > 6+

.;. K OSKELA

L u&i 2os1e" 5> 9 *&o*oses the #o""o,i$% desi%$ !&ite&i o& *&i$!i*"es #o&

*&odu!tio$ !o$t&o" system+ I$ # !t. he !" ims they &e t&ue #o& the L st P" $$e& system.

,hi!h is to be *&ese$ted i$ Ch *te& Th&ee-

The #i&st *&i$!i*"e is th t the ssi%$me$ts shou"d be sou$d &e% &di$% thei&

*&e&e=uisites+ This *&i$!i*"e h s "so bee$ ! ""ed the Com*"ete 2it by Ro$e$

5Ro$e$ > (9+ The Com*"ete 2it su%%ests th t ,o&1 shou"d $ot st &t u$ti" "" the

items &e=ui&ed #o& !om*"etio$ o# 8ob &e ' i" b"e+ Thus. this *&i$!i*"e st&i'es to

mi$imi:e ,o&1 i$ subo*tim " !o$ditio$s+

The se!o$d *&i$!i*"e is th t the &e "i: tio$ o# ssi%$me$ts is me su&ed $d

mo$ito&ed+ The &e" ted met&i!s. Pe&!e$t P" $ Com*"ete 5PPC9. is the $umbe& o#

*" $$ed !ti'ities !om*"eted. di'ided by the tot " $umbe& o# *" $$ed !ti'ities. $d

e/*&essed s *e&!e$t %e+ This #o!us o$ *" $ &e "i: tio$ dimi$ishes the &is1 o#

' &i bi"ity *&o* % tio$ to do,$st&e m #"o,s $d t s1s+

Thi&d"y. ! uses #o& $o$0&e "i: tio$ &e i$'esti% ted $d those ! uses &e &emo'ed+

Thus. i$ # !t. !o$ti$uous. i$0*&o!ess im*&o'eme$t is &e "i:ed+

The #ou&th *&i$!i*"e su%%ests m i$t i$i$% bu##e& o# t s1s ,hi!h &e sou$d #o& e !h

!&e,+ Thus. i# the ssi%$ed t s1 tu&$s out to be im*ossib"e to ! &&y out. the !&e,

! $ s,it!h to $othe& t s1+ This *&i$!i*"e is i$st&ume$t " i$ 'oidi$% "ost


32/193


*&odu!tio$ 5due to st &'i$%9 o& &edu!ed *&odu!ti'ity 5due to subo*tim "

!o$ditio$s9+

The #i#th *&i!i*"e su%%ests th t i$ "oo1 he d *" $$i$% 5,ith time ho&i:o$ o# 60

,ee1s9. the *&e&e=uisites o# u*!omi$% ssi%$me$ts &e !ti'e"y m de &e dy+ This.

i$ # !t. is *u"" system th t is i$st&ume$t " i$ e$su&i$% th t "" the *&e&e=uisites &e

' i" b"e #o& the ssi%$me$ts+ O$ the othe& h $d. it e$su&es th t too %&e t m te&i "

bu##e&s do $ot eme&%e o$ site+

.< C#)te#)! +o# ! De() n P#o/ ct)on Cont#o" S5(te$

The *&e!edi$% &e'ie, $d !&iti=ue o# the "ite& tu&e su%%ests the #o""o,i$% %uide"i$es $d

!&ite&i #o& $ e##e!ti'e desi%$ *&odu!tio$ !o$t&o" system-

'ariability must be miti"ated and remainin" variability mana"ed K &i bi"ity is 'i&tu ""y

dis&e% &ded i$ !u&&e$t !o$t&o" systems+ But the !o$st&u!tio$ i$dust&y !e&t i$"y h s its sh &e o#

' &i bi"ity- ' &i bi"ity i$ =u "ity. ' &i bi"ity i$ *&o!essi$% times. ' &i bi"ity i$ de"i'e&ies. et!+

Ne%"e!t o# ' &i bi"ity ! uses %&e te& ' &i bi"ity. $d the&e is ", ys $ sso!i ted *e$ "ty+

A!!o&di$% to Ho** $d S*e &m $ 5> 9. ' &i bi"ity &esu"ts i$ some o& "" o# the #o""o,i$%-

bu##e&i$% o# #"o,s. ,hi!h i$!&e ses "e d times $d ,o&10i$0*&o!ess

"o,e& &esou&!e uti"i: tio$

"ost th&ou%h*ut

,ssi"nments are sound re"ardin" their prere;uisites

#he reali ation of assi"nments is measured and monitored

Causes for failin" to complete planned wor are investi"ated and those causes are removed

, buffer of sound assi"nments is maintained for each crew or production unit

#he prere;uisites of upcomin" assi"nments are actively made ready

#he traditional schedule+push system is supplemented with pull techni;ues Not o$"y do *u""

systems usu ""y *eo&m bette& th $ *ush systems 5Ho** $d S*e &m $. > 9. but *u"" systems &e


33/193


es*e!i ""y $eeded i$ !o$ditio$s o# ' &i bi"ity+

Production control facilitates wor flow and value "eneration P&odu!tio$ thi$1i$% $d *& !ti!e i$

"" &e s h s #o!used *&im &i"y o$ the t s1 %o "s o# *&odu!tio$ $d $e%"e!ted #"o, $d ' "ue

5Huo'i" $d 2os1e" . > ?9+ The ob8e!t o# t& ditio$ " *&o8e!t !o$t&o" h s bee$ beh 'io&+ h t

$eeds to be !o$t&o""ed is ,o&1 #"o,+

#he pro6ect is conceived as a temporary production system The mode" #o& !o&&e!ti'e !tio$ i$

t& ditio$ " *&o8e!t !o$t&o" is !ou&se !o&&e!tio$. d& ,$ by $ "o%y #&om the * th o# 'ehi!"e bou$d

#o& s*e!i#i! desti$ tio$ ,ith t &%et &&i' " time $d s*e!i#ied s*e$di$% bud%et o& othe&,ise

"imited &esou&!es+ I# the *&o8e!t is to be !o$!ei'ed & the& s tem*o& &y *&odu!tio$ system. the

!ou&se !o&&e!tio$ mode" is & di! ""y o'e&sim*"i#ied $d i$ **&o*&i te+ The #"o, o# m te&i "s $d

i$#o&m tio$ is ,h t is to be !o$t&o""ed+ They #"o, th&ou%h 'e&y !om*"e/ $et,o&1s o# tem*o& &y $d

*e&m $e$t *&odu!tio$ systems+ Co&&e!ti'e !tio$ must be t 1e$ ,ithi$ $ u$de&st $di$% o# these

$et,o&1s $d o# the im* !t o# !h $%es i$ se=ue$!e. *&o!essi$% methodo"o%ies. bu##e& "o! tio$ $d

si:i$%. "o! " !o$t&o" st& te%ies 5e+%+. *u"" o& *ush9. et!+


34/193

Ballard 3-1 Last Planner `

CHAPTER THREE: DESCRIPTION AND HISTOR OFTHE LAST PLANNER S STEM OF PRODUCTION

CONTROL

;.1 H)e#!#c,)c!" St# ct #eAside #&om the sim*"est $d sm ""est 8obs. desi%$ $d !o$st&u!tio$ &e=ui&e *" $$i$% $d

!o$t&o" do$e by di##e&e$t *eo*"e. t di##e&e$t *" !es ,ithi$ the o&% $i: tio$. $d t

di##e&e$t times du&i$% the "i#e o# *&o8e!t+ P" $$i$% hi%h i$ the o&% $i: tio$ te$ds to

#o!us o$ %"ob " ob8e!ti'es $d !o$st& i$ts. %o'e&$i$% the e$ti&e *&o8e!t+ These ob8e!ti'es

d&i'e "o,e& "e'e" *" $$i$% *&o!esses th t s*e!i#y me $s #o& !hie'i$% those e$ds+

U"tim te"y. someo$e 5i$di'idu " o& %&ou*9 de!ides ,h t *hysi! ". s*e!i#i! ,o&1 ,i"" be

do$e tomo&&o,+ Th t ty*e o# *" $s h s bee$ ! ""ed ssi%$me$ts + They &e u$i=ue

be! use they d&i'e di&e!t ,o&1 & the& th $ the *&odu!tio$ o# othe& *" $s+ The *e&so$ o&

%&ou* th t *&odu!es ssi%$me$ts is ! ""ed the L st P" $$e& 5B "" &d $d Ho,e"" > 9+

;. S,o "/9C!n9W)""9D)/The te&m ssi%$me$ts st&esses the !ommu$i! tio$ o# &e=ui&eme$ts #&om L st P" $$e&

to desi%$ s=u d o& !o$st&u!tio$ !&e,+ But these *&odu!ts o# *" $$i$% t the *&odu!tio$

u$it "e'e" &e "so !ommitme$ts to the &est o# the o&% $i: tio$+ They s y ,h t ILL be

do$e. $d 5ho*e#u""y9 &e the &esu"t o# *" $$i$% *&o!ess th t best m t!hes ILL ,ith

SHOULD ,ithi$ the !o$st& i$ts o# CAN+


35/193

LAST PLANNERPLANNING

PROCESS


&i"ure $

SHOULD

CAN ILL

#he formation of assi"nments in the Last Planner plannin" process

U$#o&tu$ te"y. " st *" $$e& *eo&m $!e is sometimes e' "u ted s i# the&e !ou"d be $o

*ossib"e di##e&e$!e bet,ee$ SHOULD $d CAN+ h t ,i"" ,e do $e/t ,ee1

h te'e& is o$ the s!hedu"e. o& h te'e& is %e$e& ti$% the most he t+ Su*e&'iso&s

!o$side& it thei& 8ob to 1ee* *&essu&e o$ subo&di$ tes to *&odu!e des*ite obst !"es+

G& $ted th t it is $e!ess &y to o'e&!ome obst !"es. th t does $ot e/!use !&e ti$% them o&

"e 'i$% them i$ *" !e+ E&& ti! de"i'e&y o# &esou&!es su!h s i$*ut i$#o&m tio$ $d

u$*&edi!t b"e !om*"etio$ o# *&e&e=uisite ,o&1 i$' "id tes the *&esumed e=u tio$ o#

ILL ,ith SHOULD. $d =ui!1"y &esu"ts i$ the b $do$me$t o# *" $$i$% th t di&e!ts

!tu " *&odu!tio$+

F i"u&e to *&o !ti'e"y !o$t&o" t the *&odu!tio$ u$it "e'e" i$!&e ses u$!e&t i$ty $d

de*&i'es ,o&1e&s o# *" $$i$% s too" #o& sh *i$% the #utu&e+ h t is $eeded is to shi#t

the #o!us o# !o$t&o" #&om the ,o&1e&s to the #"o, o# ,o&1 th t "i$1s them to%ethe&+ The

L st P" $$e& *&odu!tio$ !o$t&o" system is *hi"oso*hy. &u"es $d *&o!edu&es. $d set

o# too"s th t # !i"iti te the im*"eme$t tio$ o# those *&o!edu&es+ Re% &di$% the

*&o!edu&es. the system h s t,o !om*o$e$ts- *&odu!tio$ u$it !o$t&o" $d ,o&1 #"o,


36/193


!o$t&o"+ The 8ob o# the #i&st is to m 1e *&o%&essi'e"y bette& ssi%$me$ts to di&e!t ,o&1e&s

th&ou%h !o$ti$uous "e &$i$% $d !o&&e!ti'e !tio$+ The #u$!tio$ o# ,o&1 #"o, !o$t&o" is

*e&h *s e'ide$t i$ its $ me to *&o !ti'e"y ! use ,o&1 to #"o, !&oss *&odu!tio$ u$its

i$ the best !hie'e b"e se=ue$!e $d & te+

;.; P#o/ ct)on Un)t Cont#o"The 1ey *eo&m $!e dime$sio$ o# *" $$i$% system t the *&odu!tio$ u$it "e'e" is its

out*ut =u "ity< i+e+ the =u "ity o# *" $s *&odu!ed by the L st P" $$e&+ The #o""o,i$% &e

some o# the !&iti! " =u "ity !h & !te&isti!s o# $ ssi%$me$t-

The ssi%$me$t is ,e"" de#i$ed+ The &i%ht se=ue$!e o# ,o&1 is se"e!ted+ The &i%ht mou$t o# ,o&1 is se"e!ted+ The ,o&1 se"e!ted is *& !ti! " o& sou$d< i+e+. ! $ be do$e+

e"" de#i$ed me $s des!&ibed su##i!ie$t"y th t it ! $ be m de &e dy $d !om*"etio$ ! $

be u$ mbi%uous"y dete&mi$ed+ The &i%ht se=ue$!e is th t se=ue$!e !o$siste$t ,ith the

i$te&$ " "o%i! o# the ,o&1 itse"#. *&o8e!t !ommitme$ts $d %o "s. $d e/e!utio$

st& te%ies+ The &i%ht mou$t is th t mou$t the *" $$e&s 8ud%e thei& *&odu!tio$ u$its

! * b"e o# !om*"eti$% #te& &e'ie, o# bud%et u$it & tes $d #te& e/ mi$i$% the s*e!i#i!

,o&1 to be do$e+ P& !ti! " me $s th t "" *&e&e=uisite ,o&1 is i$ *" !e $d "" &esou&!es

&e ' i" b"e+

The =u "ity o# #&o$t "i$e su*e&'iso&;s ssi%$me$ts m y be &e'ie,ed by su*e&io&

*&io& to issue. but su!h i$0*&o!ess i$s*e!tio$ does $ot &outi$e"y *&odu!e me su&eme$t

d t . e'e$ ,he$ !o&&e!tio$s &e $e!ess &y+ P" $$i$% system *eo&m $!e is mo&e e si"y

me su&ed i$di&e!t"y. th&ou%h the &esu"ts o# *" $ e/e!utio$+

Pe&!e$t P" $ Com*"ete 5PPC9 is the $umbe& o# *" $$ed !ti'ities !om*"eted di'ided


37/193


by the tot " $umbe& o# *" $$ed !ti'ities. e/*&essed s *e&!e$t %e+ PPC be!omes the

st $d &d % i$st ,hi!h !o$t&o" is e/e&!ised t the *&odu!tio$ u$it "e'e". bei$% de&i' ti'e

#&om $ e/t&eme"y !om*"e/ set o# di&e!ti'es- *&o8e!t s!hedu"es. e/e!utio$ st& te%ies.

bud%et u$it & tes. et!+ Gi'e$ =u "ity *" $s. hi%he& PPC !o&&es*o$ds to doi$% mo&e o# the

&i%ht ,o&1 ,ith %i'e$ &esou&!es. i+e+ to hi%he& *&odu!ti'ity $d *&o%&ess+

Pe&!e$t P" $ Com*"ete me su&es the e/te$t to ,hi!h the #&o$t "i$e su*e&'iso&;s

!ommitme$t 5 ILL9 , s &e "i:ed+ A$ "ysis o# $o$!o$#o&m $!es ! $ the$ "e d b !1 to

&oot ! uses. so im*&o'eme$t ! $ be m de i$ #utu&e *eo&m $!e+ Me su&i$%

*eo&m $!e t the L st P" $$e& "e'e" does $ot me $ you o$"y m 1e !h $%es t th t

"e'e"+ Root ! uses o# *oo& *" $ =u "ity o& # i"u&e to e/e!ute *" $$ed ,o&1 m y be #ou$d

t $y o&% $i: tio$ " "e'e". *&o!ess o& #u$!tio$+ PPC $ "ysis ! $ be!ome *o,eu"

#o! " *oi$t #o& b&e 1th&ou%h i$iti ti'es+

The #i&st thi$% $eeded is ide$ti#i! tio$ o# &e so$s ,hy *" $$ed ,o&1 , s $ot do$e.

*&e#e& b"y by #&o$t "i$e su*e&'iso&s o& the e$%i$ee&s o& !& #tsme$ di&e!t"y &es*o$sib"e #o&

*" $ e/e!utio$+ Re so$s !ou"d i$!"ude-

F u"ty di&e!ti'es o& i$#o&m tio$ *&o'ided to the L st P" $$e&< e+%+ the i$#o&m tio$system i$!o&&e!t"y i$di! ted th t i$#o&m tio$ , s ' i" b"e o& th t *&e&e=uisite,o&1 , s !om*"ete+

F i"u&e to **"y =u "ity !&ite&i to ssi%$me$ts< e+%+ too mu!h ,o&1 , s *" $$ed+ F i"u&e i$ !oo&di$ tio$ o# sh &ed &esou&!es< e+%+ " !1 o# !om*ute& o& *"otte&+ Ch $%e i$ *&io&ity< e+%+ ,o&1e&s &e ssi%$ed tem*o& &i"y to hot t s1+ Desi%$ e&&o& o& 'e$do& e&&o& dis!o'e&ed i$ the ttem*t to ! &&y out *" $$ed

!ti'ity+This *&o'ides the i$iti " d t $eeded #o& $ "ysis $d im*&o'eme$t o# PPC.

$d !o$se=ue$t"y #o& im*&o'i$% *&o8e!t *eo&m $!e+

;.< Wo#& F"o% Cont#o"He&e ,e tu&$ to the to*i! o# ,o&1 #"o, !o$t&o"< i+e+. ! usi$% ,o&1 to mo'e bet,ee$


38/193


*&odu!tio$ u$its i$ desi&ed se=ue$!e $d & te+ P&odu!tio$ U$it Co$t&o" !oo&di$ tes the

e/e!utio$ o# ,o&1 within *&odu!tio$ u$its su!h s !o$st&u!tio$ !&e,s $d desi%$ s=u ds+

o&1 F"o, Co$t&o" !oo&di$ tes the #"o, o# desi%$. su**"y. $d i$st "" tio$ throu"h

*&odu!tio$ u$its+

I$ the hie& &!hy o# *" $s $d s!hedu"es. the "oo1 he d *&o!ess h s the 8ob o# ,o&1

#"o, !o$t&o"+ Loo1 he d s!hedu"es &e !ommo$ i$ !u&&e$t i$dust&y *& !ti!e. but ty*i! ""y

*eo&m o$"y the #u$!tio$ o# hi%h"i%hti$% ,h t SHOULD be do$e i$ the $e & te&m+ I$

!o$t& st. the "oo1 he d *&o!ess ,ithi$ the L st P" $$e& system se&'es mu"ti*"e #u$!tio$s.

s "isted i$ T b"e 6+>+ These #u$!tio$s &e !!om*"ished th&ou%h ' &ious s*e!i#i!

*&o!esses. i$!"udi$% !ti'ity de#i$itio$. !o$st& i$ts $ "ysis. *u""i$% ,o&1 #&om u*st&e m

*&odu!tio$ u$its. $d m t!hi$% "o d $d ! * !ity. e !h o# ,hi!h ,i"" be dis!ussed i$ the

#o""o,i$% * %es+


39/193


&i"ure 2

PLANNING S STEM

Cu&&e$tst tus#o&e! sts

M ste& S!hedu"e

Se"e!ti$%.se=ue$!i$%. si:i$% ,o&1 ,e

thi$1 ! $ be do$e

Loo1 he d

A!tio$ to *&e'e$t&e*etiti'ee&&o&s

I$#o&m tio$

M 1e ,o&1 &e dy bys!&ee$i$%

*u""i$%

o&1 b"eB !1"o%

Se"e!ti$%.se=ue$!i$%. si:i$% ,o&1

,e 1$o,! $ be do$e

Fee1"yo&1 P" $s

Ch &tPPC

Re so$s

Resou&!es P&odu!tio$ Com*"etedFo&1

7

Last Planner *ystem with Loo ahead Process hi"hli"hted

The 'ehi!"e #o& the "oo1 he d *&o!ess is s!hedu"e o# *ote$ti " ssi%$me$ts #o& the $e/t6 to >( ,ee1s+ The $umbe& o# ,ee1s o'e& ,hi!h "oo1 he d *&o!ess e/te$ds is de!ided

b sed o$ *&o8e!t !h & !te&isti!s. the &e"i bi"ity o# the *" $$i$% system. $d the "e d times#o& !=ui&i$% i$#o&m tio$. m te&i "s. " bo&. $d e=ui*me$t+ T b"es 6+( $d 6+6 &ee/ m*"es o# !o$st&u!tio$ $d e$%i$ee&i$% "oo1 he d s!hedu"es. &es*e!ti'e"y+ The"oo1 he d s!hedu"e is $ot sim*"e d&o* out #&om the m ste& s!hedu"e+ I$deed. it is o#te$

be$e#i!i " to h 'e the te m th t is to do the ,o&1 i$ the $e/t *h se o# *&o8e!t!o""e!ti'e"y *&odu!e *h se s!hedu" e th t se&'es to !oo&di$ te !tio$s th t e/te$d

beyo$d the "oo1 he d ,i$do, 5the *e&iod o# time ,e !hoose to "oo1 he d9+


40/193

#able $

F nct)on( o+ t,e Loo&!,e!/ P#oce((

V S,!pe %o#& +"o% (e ence !n/ #!teV M!tc, %o#& +"o% !n/ c!p!c)t5V Deco$po(e $!(te# (c,e/ "e !ct)')t)e(

)nto %o#& p!c&! e( !n/ ope#!t)on(V De'e"op /et!)"e/ $et,o/( +o# e ec t)n

%o#& V M!)nt!)n ! 4!c&"o o+ #e!/5 %o#& V Up/!te !n/ #e')(e ,) ,e# "e'e" (c,e/ "e(

!( nee/e/.

&unctions of the Loo ahead ProcessP&io& to e$t&y i$to the "oo1 he d ,i$do,. m ste& s!hedu"e o& *h se s!hedu"e !ti'ities

&e e/*"oded i$to "e'e" o# det i" **&o*&i te #o& ssi%$me$t o$ ,ee1"y ,o&1 *" $s.

,hi!h ty*i! ""y yie"ds mu"ti*"e ssi%$me$ts #o& e !h !ti'ity+ The$ e !h ssi%$me$t is

sub8e!ted to !o$st& i$ts $ "ysis to dete&mi$e ,h t must be do$e i$ o&de& to m 1e it

&e dy to be e/e!uted+ The %e$e& " &u"e is to ""o, i$to the "oo1 he d ,i$do,. o& ""o,

to d' $!e #&om o$e ,ee1 to the $e/t ,ithi$ the "oo1 he d ,i$do,. o$"y !ti'ities th t

! $ be m de &e dy #o& !om*"etio$ o$ s!hedu"e+ I# the *" $$e& is $ot !o$#ide$t th t the

!o$st& i$ts ! $ be &emo'ed. the *ote$ti " ssi%$me$ts &e &et &ded to " te& d te+

Fi%u&e 6+6 is s!hem ti! o# the "oo1 he d *&o!ess. sho,i$% ,o&1 #"o,i$% th&ou%h

time #&om &i%ht to "e#t+ Pote$ti " ssi%$me$ts e$te& the "oo1 he d ,i$do, ,ee1s he d

o# s!hedu"ed e/e!utio$. the$ mo'e #o&, &d ,ee1 e !h ,ee1 u$ti" they &e ""o,ed to

e$te& i$to ,o&1 b"e b !1"o%. i$di! ti$% th t "" !o$st& i$ts h 'e bee$ &emo'ed $d th t

they &e i$ the *&o*e& se=ue$!e #o& e/e!utio$+ I# the *" $$e& ,e&e to dis!o'e&


41/193

;

!o$st& i$t 5*e&h *s desi%$ !h $%e o& !=uisitio$ o# soi"s &e*o&t9 th t !ou"d $ot be

&emo'ed i$ time. the ssi%$me$t ,ou"d $ot be ""o,ed to mo'e #o&, &d+ The ob8e!ti'e is

to m i$t i$ b !1"o% o# sou$d ,o&1. &e dy to be *eo&med. ,ith ssu& $!e th t

e'e&ythi$% i$ ,o&1 b"e b !1"o% is i$deed ,o&1 b"e+>6 ee1"y ,o&1 *" $s &e the$

#o&med #&om ,o&1 b"e b !1"o%. thus im*&o'i$% the *&odu!ti'ity o# those ,ho &e!ei'e the

ssi%$me$ts $d i$!&e si$% the &e"i bi"ity o# ,o&1 #"o, to the $e/t *&odu!tio$ u$it+

#able 2

PRO ECT: P)"o t WK LOOKAHEAD

ACTI*IT > J > 6 J ? > J ( ) J ? > J ( ? J ? ( J 6 J ? NEEDS

M T W T F S M T W T F S M T W T F S M T W T F SS! ot t ; s !&e ,

W W W W W W W W W W W W W W W CH de "i'e &s> 0 0 ? t h&u

> 0 > 6 + H d e "i'e &s > 0( ) +N CUP AHUs0> ) CH . ( H

Pu$!h. " b e ". t % AHUs / / / M t e& i "s o $ s it e

Ro $; s !&e ,

/ / / M t e& i "s o $ s it eDI St e m t o Humid i#ie &

DI St e m B"o,d o,$ / / Ch e !1 m t e &i "

DI St e m Co $d+ to !o o"e &s5 > 6 9

/ / / / / / / / / / / / / M t e& i " o $ s it e

Ch &"e s ; !&e ,

/ / / M t " d e "i'e &y > 0 0 ?( )) de % H > 0N H

( ) ) de % H > 0 B> 0 D / / / / / / / / / / Re "e s e m t "# o & > 0> 7 0?

> st #"&( ) ) d e % H%uide s $!ho &s

/ / / / / / / / / / M t e& i " o $ s it e + Nee d e st

Ri!h &d; s ! &e ,

/ / / / / Co $t &o " ' "'e s #o & d d e dKAK !o i"s

( 0N A H CH

CH i$ C0 E0G t u $ $ e"s / / / / / / / / / / / / / / / Ne e d t u $$ e "s * i$ t e d&e "e s e m t e &i "s

Mis! FCUs !o $d+ d& i$s i$ NIN. N 4N . 2 > st

/ / / / / / / / / / T 1e o # # o &d e & m t e &i "s

Pu$!h. " b e " t % / / / / / / / / / / M t e& i " o $ s it e

Construction Loo ahead *chedule $@

>6 De"ibe& te"y bui"di$% i$'e$to&ies. i$'e$to&ies o# &e dy ,o&1 i$ this ! se. m y seem!o$t& di!to&y to the %o "s o# 8ust0i$0time+ To !" &i#y. i$'e$to&ies o# "" so&t &e to bemi$imi:ed. but s "o$% s the&e is ' &i bi"ity i$ the #"o, o# m te&i "s $d i$#o&m tio$.

bu##e&s ,i"" be $eeded to bso&b th t ' &i bi"ity+ Redu!i$% ' &i bi"ity ""o,s &edu!tio$o# bu##e& i$'e$to&ies+

> The 7 ee1 Loo1 he d S!hedu"e e/!"udes the ,ee1 !o'e&ed by the ee1"y o&1 P" $. so sho,s o$"y ,ee1s+


42/193

;.


43/193


44/193

see1i$% to ! use i$te&se!tio$s i$ the #utu&e o# i$te&de*e$de$t !tio$s+

#able @

Sc#een)n A(() n$ent(: St!t ()nCon(t#!)nt(

I D A c t ) ' ) t 5 S t ! # t C o n t # ! c t e ( ) n S 4 $ ) t t ! " ( M ! t e # ) ! " ( P # e 9 R e ) ( ) t e S p ! c e E ) p $ e n t L ! 4 o # O t , e #

: 0

S m " "I $ t e & i o & "" F o &m

s L i $ e s 0 M + . 6 0 M . 6 0

2 . 0 2 + . 6 0 H

( J J

O K R F I O K O K # e 4 ! # O K O K O K N o n e

; 1 0 L & % e I$ t e & i o & ""

L i $ e L F o & m( J J

J 0 0 I$ t e & i o & S m "" "" s 6 F

$ d 6 D F o & m s ( J J

1 1 < : S m " "I $ t e & i o & "" F o &m

s L i $ e s 7 0 M + . $ d 7 0 2 + ( J J

1 J 0 E s t "" B e t , e e $ L i $ e

s ( $ d L i $ e D o u b " e U * ( J > 6 J

J : 0 I$ t e & i o & S m "" "" s 6 F

$ d 6 D D o u b " e 0 u * ( J > 6 J

1 1 <

S m ""I $ t e & i o & "" s L i$

e s 7 0 M + . $ d 7 0

2 + D o u b " e 0 u *

( J > 6 J

; : : L & % e I$ t e & i o & ""

L i $ e L D o u b " e u * ( J > J

: 0

S m ""I $ t e & i o & "" s L i$

e s 0 M + . 6 0 M . 6 0 2 . 0

2 + . 6 0 H D o u b " e 0 u *

( J > ? J

J ; I$ t e & i o & S m "" "" s 6 F

$ d 6 D S t &i *

( J > J

Constraints ,nalysis

By !o$t& st. *u""i$% ""o,s m te&i "s o& i$#o&m tio$ i$to *&odu!tio$ *&o!ess o$"y i# the

*&o!ess is ! * b"e o# doi$% th t ,o&1+ I$ ou& L st P" $$e& system. !o$#o&m $!e o#

ssi%$me$ts to =u "ity !&ite&i !o$stitute su!h !he!1 o$ ! * bi"ity+ Fu&the&. m 1i$%

ssi%$me$ts &e dy i$ the "oo1 he d *&o!ess is e/*"i!it"y $ **"i! tio$ o# *u"" te!h$i=ues+

Co$se=ue$t"y. L st P" $$e& is ty*e o# *u"" system+


45/193

PLANNING THEWORK

E ECUTINGTHE PLAN

&i"ure @

A T#!/)t)on!" 7P (,8P"!nn)n S5(te$

PRO ECTOB ECTI*ES

INFORMATION SHOULD

RESOURCES DID

, #raditional BPush) Plannin" *ystem

Ce&t i$ thi$%s h 'e "o$% bee$ *u""ed s o**osed to *ushed< e+%+. !o$!&ete+ ith its sho&t

she"# "i#e. !o$!&ete ! $$ot be o&de&ed too # & i$ d' $!e o# $eed+ Fo&tu$ te"y. the "e d

time >7 #o& !o$!&ete is sho&t. so it is usu ""y *ossib"e to , it u$ti" you 1$o, ,he$ it ,i""

be $eeded be#o&e o&de&i$% it+

Ge$e& ""y. ,i$do, o# &e"i bi"ity %&e te& th $ su**"ie& "e d time is $eeded i$

o&de& #o& *u""i$% to be most e##e!ti'e+ Othe&,ise. the *u""ed items m y $ot m t!h u* ,ith

the ,o&1 to ,hi!h they &e to be **"ied+ I$ the i$dust&y $o,. su**"ie& "e d times &e #o&

the most * &t mu!h %&e te& th $ ou& !!u& te #o&esi%ht &e% &di$% ,o&1 !om*"etio$.

he$!e

*e&h *s &e so$ #o& the i$#&e=ue$t use o# *u""i$% me!h $isms+

>7 Le d time is the time i$ d' $!e o# de"i'e&y o$e must *" !e $ o&de&+ It iso#te$ &e#e&&ed to s su**"ie& "e d time +


46/193

&i"ure

L!(t P"!nne#: A P "" S5(te$

SHOULD

CANLAST PLANNER

PLANNINGPROCESS

WILL

Last Planner: , Pull *ystem

;.


47/193

"o d $d ! * !ity &e estim ted. &e ,e ssumi$% 6)@ &esou&!e uti"i: tio$ o& )@

h t ssum*tio$s &e bei$% m de bout ' &i tio$ &ou$d 'e& %es C $ ,e

e/*e!t !tu " u$it & tes to # "" sho&t o# the 'e& %e h "# the time C"e &"y ,e $eed mu!h

mo&e !!u& te d t th $ is ty*i! ""y ' i" b"e+

h te'e& the !!u& !y o# "o d $d ! * !ity estim tes. the *" $$e& must sti"" m 1e

some d8ustme$ts+ Eithe& "o d ! $ be !h $%ed to m t!h ! * !ity. ! * !ity ! $ be

!h $%ed to m t!h "o d. o&. mo&e !ommo$"y. !ombi$ tio$ o# the t,o+ Gi'e$ the

d' $t %es o# m i$t i$i$% st b"e ,o&1 #o&!e $d 'oidi$% #&e=ue$t !h $%es. the

*&e#e&e$!e is o#te$ #o& d8usti$% "o d+ Ho,e'e&. th t ,i"" $ot be the ! se ,he$ the&e &e

*&essu&es to meet s!hedu"ed mi"esto$es o& e$d d tes+

Lo d ! $ be !h $%ed to m t!h ! * !ity by &et &di$% o& !!e"e& ti$% ,o&1 #"o,+

C * !ity ! $ be !h $%ed to m t!h "o d by &edu!i$% o& i$!&e si$% &esou&!es+ Pu""i$% he"*s

b " $!e "o d to ! * !ity be! use the PU ! $ &e=uest ,h t it $eeds $d i$ the $eeded

mou$ts+

;.


48/193

Planning theWork

Last Planner Process

Production

&i"ure D

ProjectO jective

!n"or#ation $%O&LD

CA' W!LL

(esources D!D

#he Last Planner *ystem

;. A B#)e+ H)(to#5 o+ t,e L!(t P"!nne# S5(te$ o+ P#o/ ct)on Cont#o"

The #u$!tio$s o# *&odu!tio$ m $ %eme$t systems &e *" $$i$% $d !o$t&o"+ P" $$i$%

est b"ishes %o "s $d desi&ed se=ue$!e o# e'e$ts #o& !hie'i$% %o "s+ Co$t&o" ! uses

e'e$ts to **&o/im te the desi&ed se=ue$!e. i$iti tes &e*" $$i$% ,he$ the est b"ished

se=ue$!e is eithe& $o "o$%e& #e sib"e o& $o "o$%e& desi& b"e. $d i$iti tes "e &$i$% ,he$

e'e$ts # i" to !o$#o&m to *" $ 5B "" &d. > 9+ he$ e$'i&o$me$ts &e dy$ mi! $d the

*&odu!tio$ system is u$!e&t i$ $d ' &i b"e. &e"i b"e *" $$i$% ! $$ot be *eo&med i$

det i" mu!h be#o&e the e'e$ts bei$% *" $$ed+ Co$se=ue$t"y. de!idi$% ,h t $d ho, mu!h


49/193

,o&1 is to be do$e $e/t by desi%$ s=u d o& !o$st&u!tio$ !&e, is & &e"y m tte& o#

sim*"y #o""o,i$% m ste& s!hedu"e est b"ished t the be%i$$i$% o# the *&o8e!t+ Ho, &e

su!h de!isio$s m de $d ! $ they be m de bette& These =uestio$s ,e&e the d&i'e&s o#

i$iti " &ese &!h i$ the &e o# *&odu!tio$ u$it "e'e" *" $$i$% $d !o$t&o" u$de& the tit"e o#

the L st P" $$e& System . summ &y &e*o&t o# ,hi!h is i$!"uded i$ B "" &d $d Ho,e""

5> ?9+

A 1ey e &"y #i$di$% , s th t o$"y bout h "# o# the ssi%$me$ts m de to !o$st&u!tio$

!&e,s t the be%i$$i$% o# ,ee1 ,e&e !om*"eted ,he$ *" $$ed+ E/*e&ime$ts ,e&e

*eo&med to test the hy*othesis th t # i"u&es ,e&e i$ " &%e * &t &esu"t o# " !1 o#

de=u te ,o&1 se"e!tio$ &u"es 5these mi%ht "so be ! ""ed ,o&1 &e"e se &u"es9+ u "ity

!&ite&i ,e&e *&o*osed #o& ssi%$me$ts &e% &di$% de#i$itio$. se=ue$!e. sou$d$ess. $d

si:e+ I$ dditio$. the *e&!e$t %e o# ssi%$me$ts !om*"eted , s t& !1ed 5PPC- *e&!e$t

*" $ !om*"ete9 $d &e so$s #o& $o$!om*"etio$ ,e&e ide$ti#ied. ,hi!h mou$ted to

&e=ui&eme$t th t "e &$i$% be i$!o&*o& ted i$ the !o$t&o" *&o!ess+

De#i$itio $- A&e ssi%$me$ts s*e!i#i! e$ou%h th t the &i%ht ty*e $d mou$t o# m te&i "s ! $ be !o""e!ted. ,o&1 ! $ be !oo&di$ ted ,ith othe& t& des. $dit is *ossib"e to te"" t the e$d o# the ,ee1 i# the ssi%$me$t , s !om*"eted

Sou$d$ess- A&e "" ssi%$me$ts sou$d. th t is- A&e "" m te&i "s o$ h $d Isdesi%$ !om*"ete Is *&e&e=uisite ,o&1 !om*"ete Note- Du&i$% the *" $,ee1. the #o&em $ ,i"" h 'e dditio$ " t s1s to *eo&m i$ o&de& to m 1e

ssi%$me$ts &e dy to be e/e!uted. e+%+. !oo&di$ tio$ ,ith t& des ,o&1i$% i$the s me &e . mo'eme$t o# m te&i "s to the *oi$t o# i$st "" tio$. et!+Ho,e'e&. the i$te$t is to do ,h te'e& ! $ be do$e to %et the ,o&1 &e dy

be#o&e the ,ee1 i$ ,hi!h it is to be do$e+Se=ue$! e- A&e ssi%$me$ts se"e!ted #&om those th t &e sou$d i$ the

!o$st&u!t bi"ity o&de& $eeded by the *&odu!tio$ u$it itse"# $d i$ the o&de&$eeded by !ustome& *&o!esses A&e dditio$ ". "o,e& *&io&ity ssi%$me$tside$ti#ied s ,o&1 b"e b !1"o%. i+e+. dditio$ " =u "ity t s1s ' i" b"e i$ ! se

ssi%$me$ts # i" o& *&odu!ti'ity e/!eeds e/*e!t tio$sSi: e- A&e ssi%$me$ts si:ed to the *&odu!ti'e ! * bi"ity o# e !h !&e, o&

sub!&e,. ,hi"e sti"" bei$% !hie' b"e ,ithi$ the *" $ *e&iod Does the


50/193

ssi%$me$t *&odu!e ,o&1 #o& the $e/t *&odu!tio$ u$it i$ the si:e $d#o&m t &e=ui&ed

Le &$i$ %- A&e ssi%$me$ts th t &e $ot !om*"eted ,ithi$ the ,ee1 t& !1ed $d&e so$s ide$ti#ied

As &esu"t o# **"yi$% these !&ite&i . *" $ &e"i bi"ity 5the *e&!e$t %e o#

ssi%$me$ts !om*"eted9 i$!&e sed. $d ,ith it. !&e, *&odu!ti'ity "so i$!&e sed 5B "" &d

$d Ho,e"".

> ?9> +

The use o# e/*"i!it ,o&1 se"e!tio$ &u"es $d =u "ity !&ite&i #o& ssi%$me$ts , s

te&

Last Planner - Ballard

Documents

Transcript of Last Planner - Ballard