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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!  This case study shows the value in 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 the front lines
  • Instill a vision by planning collaboratively
  • Cultivate learning & innovation


Industrial Case Study Photos

Multi-Family Case Study

✅  No Recordable Incidents or Injuries 

✅  Structural Concrete Completed 5 Weeks Early

✅  Doubled the Expected Profit 

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

Lean Construction Consulting for Capital Projects

Put an End to Bad Construction Projects...

...the ones that end months or years late, over budget, and in costly litigation.  OPL helps deliver your project early and under budget by training your teams to apply a suite of Lean Construction principles and tools, including Last Planner System® and Project Partnering.

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