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Lean Construction Case Study

​This Lean Construction case study demonstrates the benefits of applying Lean thinking and Last Planner System on a heavy industrial project.  It is one of the most frequently referenced business case studies on Lean Construction.

Lean Champions Are The Key

We help you make them!  
These case studies show the value of having the right people, 

with the right training and motivation, On Point

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Industrial Project Case Study

Lean Construction Principles and Last Planner System applied to two identical equipment foundations.

Background

  • Two identical industrial equipment foundations 
  • 100,000 cubic yards of concrete in each  
  • Built side-by-side on the same site, at the same time
  • One built traditionally with a "Go as fast as you can" mindset, the other built using Lean Construction principles and Last Planner System®

Foreman using Last Planner System for their Weekly Work Planning process

The Results

  • 17.4% Less Cost 
  • $5 Million USD Savings
  • Completed 19% Faster 
  • Peak Labor:  270 vs 420
  • 65% Better Safety 
  • 12% Higher Labor Productivity

Weekly Work Plans in action on a large concrete placement

Lessons Learned

  • Invest in developing Lean Champions
  • It's not about the tools
  • Deeply engage with supervisors
  • Instill a vision by planning collaboratively
  • Cultivate learning & innovation


Industrial Case Study Photos

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Multi-Family Residential Case Study

✅  No Recordable Incidents or Injuries 

✅  Structural Concrete Completed 5 Weeks Early

✅  Doubled the Expected Profit 

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Parking Garage Case Study: Lean vs Traditional

39% BETTER

39% BETTER

39% BETTER

Total Job Cost

43% BETTER

39% BETTER

39% BETTER

Craft Labor Costs

38% BETTER

39% BETTER

38% BETTER

GC Labor Costs

10% BETTER

10% BETTER

38% BETTER

Material Costs

33% BETTER

10% BETTER

33% BETTER

Service & Supplies Cost

52% BETTER

10% BETTER

33% BETTER

Equipment Costs

Ready to take your projects to new heights?

Look no further.  We've been coaching major commercial, industrial, and civil projects since 2001. Our track record speaks for itself.

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