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Recently, our friends at Superior Mechanical were kind enough to give me a tour the new half-billion dollar Children’s Hospital expansion here Birmingham. I was interested to see how they are integrating Lean construction initiatives with their BIM work to be more efficient, and save their ultimate customer time and money.
As background, Lean is a system that seeks to streamline practices and eliminate wasted effort. The idea is to create more value with fewer resources. The system is process-oriented, with the goal of entirely eliminating excess—be it physical or in the form of time.
While Lean technology has been applied to manufacturing for several decades, Superior is using it to make them be more efficient in construction. Rodney King, their Lean Coordinator, explained the efforts.
Superior has made perfecting processes their goal. Errors are identified and the procedure is refined until mistakes evolve out. The emphasis is on the series of tasks rather than the individuals performing them, systematizing delivery.
No more creating a new mold with every project. The system becomes the skill.
Rodney gave me the example of their pre-fab shop. It was created so that many standard assemblies–like plumbing systems–can be put together in a warehouse before installing on site. The benefits are multiple:
Speed. All the tools needed are at arm’s reach. Also, with repetition, the labor becomes more time and cost efficient.
Safety. While plumbers onsite might have to work on a ladder, the tasks are at chest-level in the prefab shop.
Lower waste. Excess product that might get thrown out on the job site is set aside for another use. This is better for landfills and the bottom line.
We are evaluating lean ourselves. In fact, we’re planning a post later this week about our CFO’s visit to Basic Lean. For us, I can see the potential. While it’s not always easy to change mindsets and habits, I believe there are some wins out there in the construction industry. As Rodney said, it’s about small incremental successes over time. I agree.
Merrill Stewart is Founder and President of the Stewart Perry Company, a commercial building contractor based in Birmingham, Ala. Contact him via email