Lean Case Studies

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