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RESUMO RESUMEN
The first part of the methodology consists of a brief La primera parte de la metodología consiste en un
review of all the tools of the Last Planner System, breve repaso de todas las herramientas del
likewise the use of the collaborative planning, which Sistema Last planner, asimismo se enfatizó el uso
consists of working together with all those involved de la planificación colaborativa, la cual consiste en
during the planning of each train of activities in all trabajar de manera conjunta con todos los
the system stages. He focused primarily on the implicados durante la planificación de cada tren de
Look ahead stage in order to highlight the actividades en todas las etapas del sistema. Se
importance of the support areas and to carry out a enfocó principalmente en la etapa del Lookahead
good analysis of constraints which includes con el fin de resaltar la importancia de las áreas de
knowing both the production constraints and the soporte y de realizar un buen análisis de
support areas, including security. As a second part, restricciones el cual incluya conocer tanto las
the integration methodology proposed by Brioso restricciones de producción como de las áreas de
was taken. (2015) that allows to classify the types soporte entre ellas la de seguridad. Como segunda
of work in: Productive (that generate value), parte se tomó la metodología de integración
Contributory (those that help generate value) and propuesta por Brioso (2015) que permite clasificar
Non-contributory (not generate value) and at the los tipos de trabajos en: Productivos (que generan
same time determine under what acts and standard valor), Contributivos (los que ayudan a generar
conditions or substandard (secure or insecure) are valor) y No Contributivos (no generan valor) y a la
executed. This new classification allows to vez determinar bajo que actos y condiciones
measure simultaneously the productivity and safety estándar o sub estándar (seguros o inseguros) se
of a work to know its status true in terms of these ejecutan. Esta nueva clasificación permite medir
terms. Using the proposed methodology of the simultáneamente la productividad y seguridad de
thesis, it was evaluated, through surveys, una obra para conocer su estado real en cuanto a
photographic and video records, the initial state of estos términos. Utilizando la metodología
a local construction company that makes use of propuesta de la tesis se evaluó, mediante
Lean Construction to obtain safety indicators and encuestas, registros fotográficos y videos, el
productivity and identify opportunities for estado inicial de una empresa constructora local
improvement and corrective measures. Keywords: que hace uso del Lean Construcción para obtener
Collaborative planning, Last Planner, Lean indicadores de seguridad y productividad e
construction, productivity, security. identificar oportunidades de mejora y medidas
correctivas. Palabras clave: Planificación
, colaborativa, Last Planner, Lean construction,
productividad, seguridad
INTRODUCTION
In 2007 the country experienced economic stabilization and great growth reflected with a GDP of 9%
compared to the previous year, reaching a sum of US$109,217 million, another important point was
that inflation had stabilized which made it possible to reduce interest rates and in Consequently, it
caused greater access to credits in different modalities. Likewise, the purchasing power of the
population increased, which was determinant to generate an increase in the demand for housing. All
these factors combined to generate the well-known boom real estate.
It is in this context that many of the local real estate companies have focused their efforts on improving
the homes they offer and at the same time have found it convenient to standardize its products
because the more standard whatever is produced, fewer losses occur and more profits are made
generate.
This is how it has been seen and is seen as convenient to adopt new systems of management,
one of them being the Lean Construction philosophy and its tool the
Last Planner System. Also due to this growth the
government determined to establish norms and laws that regulate the safety of workers in each
construction site and that is why we currently have
with Standard G050 and Law 29783.
According to the Lean Construction Institute (LCI 2016), the Last Planner System has the
following tools for the entire execution of the project: The Master Plan, Pull Planning, Look ahead,
Weekly Plan and Percentage of Fulfilled Plan (PPC). For him
success in the development of the system works by measuring and improving productivity (efficiency
of the use of resources to complete a project in a time certain). To measure this term in construction
works, you can use two tools, one of them is the General Level of Activity and the other the Letter
Balance. With both it is possible to determine in percentage how many of the workers, of the work
under study, are doing productive work (that generate advance value), contributory jobs (that help
generate value) and Non-contributory (those that do not generate or help to generate value). Thus, the
work measures its productivity, it also focuses on improvement and in some cases.
It is possible to compare these percentages with international standards. Secondly,
Regarding security, there is also a method to measure in percentage how many standard and sub-
standard (safe and non-safe) acts and conditions are
happening on site.
The idea of this thesis arises based on two problems: one of them is observing that several
companies that mention making use of the Last Planner end up just using the Look head’s crafting
phase by leaving aside the rest of the tools that are necessary to use. The second problem is that
although it is true measurements are made to know the productivity and safety on site, these
measurements are made separately, giving priority to the productivity measurement and leaving safety
in the background. Must be highlight that to affirm that a job is productive it must also be safe and
Usually it is found that only productivity is being considered, not safety.
The objective of this research is to implement a methodology which contains two parts: one of
them is the use of collaborative planning throughout the Last Planner system where it is sought to
review the tools that must be used and it is recommended to execute each phase in a coordinated
manner with all the involved from contractors, executors, client and all support areas.
The second part uses the integration methodology proposed by Brioso (2015) with the
in order to unfriendly show the indices of the types of work (Productive Contributory and Non
Contributory) and under what acts and conditions -whether they are standard or substandard - are
being carried out. These found percentages can be relate to the accident rates that are recorded on
site each certain time.
The relationship of the two mentioned parts occurs when obtaining indicators
low productivity and safety is due to the fact that there is some lack in the use of the Last Planner
system and to improve these indicators is that the use of collaborative planning.
Based on this objective, it was necessary to study a real case that demonstrates the importance
of using this methodology. The analysis was based on studying two works in Metropolitan Lima to
obtain its organizational status, the use of the system Last Planner and its productivity and security
indexes all based on surveys and on-site filming.
MAIN GOAL
To raise awareness of the importance of using collaborative planning throughout the
Last Planner system especially between the production area and the support areas
in the stage of making the Lookahead. Also implement a method of evaluation for works under
construction, which allows measuring the types of works (Productive, Contributory and Non-
Contributory) and the acts and standard conditions and substandard simultaneously which will be
called Integration Methodology (Brioso 2015) in order to show that both indicators are equally
important.
Scope
This paper presents the use of the Last Planner system and a methodology of integration that allows
to measure the productivity and safety of work in the area of construction of multi-family homes.
To comply with said productivity, the resources used will be seen, such as: hand labor, materials, tools
and equipment.
The use of the Last planner system and the level of productivity and security were evaluated
of each work, for this filming was made going through the work in a randomly and recording the activity
carried out by each worker, having special importance for the acts and standard and sub-standard
conditions in which found.
a) Type of company:
For the present work, a formal company constituted in the
real estate sector, which is found with several projects in the city of
Lime. It is known that he practices the philosophy of Lean Construction.
b) Type of project:
Projects within the housing construction category were considered
multi-family
c) Project stages:
The two projects under study have a stage of structural hull, masonry and
a minimum percentage of finishes.
d) Project location:
Both projects are located in Metropolitan Lima
Table 2.1-1 Comparison between traditional production and Lean production construction (Adapted
from Alarcón Fernando, 2009)
Objetive Focus on products and services It focuses on all activities of the company
• A commission will be formed in charge of the investigation which will present a report that
must contain at least the data of the worker, the circumstances, the analysis of causes and the
actions corrective.
• A statistic of accidents and illnesses will be made occupational. In addition, a record of
diseases will be kept. professionals.
• The proposed security indices are: Monthly frequency index, monthly severity, cumulative
frequency, severity accumulated and accident rate.
Work stoppage:
In the event that inspectors verify an imminent health risk and worker safety due to non-compliance
with the standard on occupational risk prevention, they have the power to order the immediate
stoppage of tasks or even of the work. In addition to this, the company must take care of the payments
or compensation in favor of the affected workers.
Classification of constraints
For the fulfillment of the tasks it is necessary to lift all the restrictions that the production look ahead
can present, according to the glossary of the institute of Lean Construction (LCI 2016) a constraint is:
“An element or requirement that prevent starting, advancing or finishing an activity as planned.
something I know interfere with the execution of a task. It is not a predecessor item or job anymore
shown in the look ahead but if it is something that has been shown as the new customer requirement.
For example, a contract that must be issued before start a job, an architect's approval before a design
change, etc. Restrictions must be identified in the Screening Process. selection)."
In order to obtain a classification of the restrictions, the causes of non-compliance, the Serpell
(2002) classification was used.
1. Inefficiencies in the administration: In the case of handling an inadequate number of workers.
- wrong methodology
- Little experience of the staff.
- Lack of communication.
3. Poor groups and activities
- Low performance.
- Poor team planning
4. Security and human resources issues
5. Inappropriate control systems.
6. Design and planning problems.
Having these causes of non-compliance, we sought to obtain a classification of the types of
restrictions which is presented below:
TIPOS DE RESTRICCIONES
CONTROLABLES NO CONTROLABLES
Materiales Diseños
Equipo Medio Ambiente
Mano de obra Proveedores
Seguridad y Salud Subcontratos
Información Otros
Actividades Predecedoras
maintenance
vibrator X X
Apisonadoras X X X X X
Grinder X X
Drill X X
tower crane X X
Photographic records and videos were made of the works under study. The duration of the recordings
were approximately one hour.
company analysis
15 190 63.90
Project Framed 𝑚𝑚2 Helmet
brickwork
brickwork
A total of 12 surveys were carried out on: two construction residents, two field managers, two heads of
technical office, two administrators, two storekeepers, two heads of prevention and two of quality. All
the surveys can be seen in Annex 2. A The results are presented globally below.
The statistical relationship of the types of works under standard and sub-acts and conditions standard
with minor, serious and serious accidents are shown in the following boards.
a. Global:
Matrix correlation of types of work and fatal, serious and minor accidents Global
These results are global for the 4,497 workers during the 236 working days. It can be seen that during
this time 26,791 weeks of work elapsed productive under sub-standard acts and standard conditions
(TP-AS-CE)
For example, suppose a solid slab casting is divided into 4 sectors, of which they will empty 2
sectors in one day and 2 the next day. A crew is appointed in each sector of two operators and three
assistants, the emptying should last approximately 40 min. To the At the time of collecting the
information on the types of work under safety criteria, notice that Worker 1 is not wearing safety gloves
at the time of regulate (see box No. 20). Immediately he must be called to attention and compelled to
put on safety gloves. For this case it is supposed to take about 10 minutes while they admonish him,
re-induce and put on the gloves, meanwhile the emptying continues, to continue with production an
extra worker is placed (bringing him from another crew) to support Worker 2 and they can finish the
emptying in the hour stipulated.
The work of the extra worker who enters to cover the work of Worker 1 will be considered as Non-
Contributory because it generates losses in other tasks
balance sheet
The percentage of non-contributory jobs would rise because the time it takes for the worker to correct
his condition or substandard act would be considered as a time dead, speaking in purely productive
terms.
The approach is left so that future research can carry out the balance sheet with the
considerations of this thesis. However, it is expected that this method it will have more barriers or
resistance to being executed due to economic factors.
It was possible to make a brief review of the Last Planner System where its tools and the use of
each. In addition, a proposal for the implementation of the use of collaborative planning from the Pull
planning stage where identified the first production and safety constraints. Emphasis was placed on
the use of collaborative planning in the development stage of the Lookahead (Item 3.2.3) where
encourages the involvement of the support areas with the production area. It should be noted that it
studied this stage because in most works there is a tendency to give greater importance to the
production area, leaving aside the support areas, which as well its name says it, they serve to support
the progress of the work. The planner must take into He realizes that it is important that all his areas
are involved with the project. The restrictions that the planner has for the progress of the work can not
only be delegated but there must be a dialogue where each support area, contractors and foremen
can formally commit to lifting each restriction or give reasons why which could not and in turn give their
own restrictions.
That is why the importance of the use of collaborative planning where two on-site meetings to take
a schedule (Lookahead) for granted and have a good analysis of constraints. In the development of
this work it was possible to demonstrate that a constraint is usually lifted by one or more support areas
for it to be used a correct methodology for its analysis. The 3.5 format is proposed for classify the
restriction according to the type that corresponds to it (material, equipment, labor, etc.) and in turn
designate the areas responsible for lifting the restriction.
Regarding the look ahead of the support areas, it was concluded that they are important for have
positive results and make the construction process a more efficient operation. synergistic. With
support from the publications of Yoza (2011) and Rosas, Ríos, Carrera (2011) It can be said that with
the elaboration of these programs the following is achieved:
-Gives an overview of the progress of the work from all perspectives, getting to know the needs of the
same and allow the resident to monitor the progress in each area.
- Identifies everyone involved and tangibly commits the contribution of each area to carry out the
scheduled It is worth mentioning that the look heads of the support areas derive from the look ahead
of production so that everyone can have the same approach and coordination of dates. The
elaboration and presentation of these look ahead will allow the production engineer perform a better
schedule considering the constraints of your entire team and the view of each of them.
On the other hand, it is very important to mention that the maintenance look ahead of equipment
and tools is vital in order not to stop production due to lack of operability or absence of these.
Likewise, to avoid sub-standard conditions that may trigger accidents caused by poor maintenance.
In the analysis carried out on the works, it was possible to observe the organizational state of each
one and the use of the Last Planner System. It can be concluded that regarding the organizational
state they have complete support areas (four areas in total are sufficient according to Villa
Garcia,2011). Of which they consider, according to degree of importance, the area of Security in
third place and first place to Technical Office. This may be correlated with the security indicators found
such as having 46% of sub-standard acts. By the importance of constantly monitoring both productivity
and security.
Regarding the use of the Last Planner system, it was noted that they only apply the look ahead
leaving aside the rest of the tools of the Last Planner System, which causes a deficiency in terms of
the true implementation of the system and based on this problem, the importance of this research is
seen, since it makes a brief review of the LPS and also evidence how not only the use of the look
ahead is enough to affirm that the Lean construction philosophy is used. As mentioned in most of
cases the substandard acts found were due to the lack of use of gloves and safety glasses. If it were
for the reason that the company did not comply with having the EPPs necessary, then it would be
shown that some of the responsible support areas were not he did his part to get the PPEs on time.
Therefore, the importance of analyzing restrictions and look ahead of support areas.
Metodología de integración
Regarding the integration methodology (Brioso 2015) it allows us to have an approach of the types of
works of the general level of activity together with the acts and standard and substandard conditions.
The present work managed to make a list with the classification of the types of work (Productive,
Contributory, Non-Contributory), this classification makes it possible for results obtained are
comparable with other investigations.
According to what was found in the field survey, it was obtained that the general level of activity
without considering safety had 35% of productive work (TP) and for contributory jobs (TC) 39%,
however when the factor of security these percentages varied to 17% and 25% respectively.
When presenting this percentage variation, it is highlighted that a productive or contributory job
does not can be considered as such if it does not comply with safety standards, so both when
percentages of the general level of activity are found, it is important to be Insurance that meets safety
standards.
According to the security plan, audits and inspections must be carried out throughout the project
as well as having statistics on occupational accidents and illnesses.
It is recommended that internal audits can be carried out every three months, together with the
duration of the pull planning, since it is approximately at that time that the of phases (train of activities)
and therefore it would be a good moment to evaluate the productivity and security.
It is emphasized that there is no valid productivity if it is not accompanied by security, both terms
are important to manage and enforce for the success of a work.
Finally, we can conclude that it is essential that the companies that are using the Last Planner
system verify that the complete system is actually being used and not only the look ahead Plan, it is
also encouraged that they can apply the planning collaborative in order to increase their productivity
and in turn obtain a good climate because everyone would know the project, the needs and schedules
of all the areas.
Likewise, it is emphasized that safety is everyone's task and that productivity must go necessarily
accompanied by this
recommendations
- It is recommended that in order to obtain the new classification of productive jobs and insurance is
done through filming because it is more practical to film in the field and process the data in cabinet. It
is proposed that each measurement be by approximately one hour and all members of the group must
be considered construction site.
- If balance charts were made, they should consider the time it takes to worker out of a substandard
act or condition. Includes warnings and re induction.
- It is recommended to keep the database of accidents that have occurred in works in order to obtain
the statistical correlation and fatal, serious, minors with the types of work according to the new
classification.
-It is seen as convenient that in the induction and safety talks it is necessary to Mention the rights and
duties of all workers and employees under the Norm and Law that govern in our country, it is important
to create awareness in all those involved.
- Regarding the implementation of collaborative planning (In Process Planning) this must be done from
the master plan where the schedule and budget are elaborated with the interested people and those
who take decisions on the project. Likewise, in the phase plan (pull planning) it is necessary to
manage this collaborative planning technique to obtain work trains well crafted. Regarding the look
ahead stage, it is recommended that it be executed the production meeting and the project meeting
within one day. It is It is extremely important that each area attends with its own programming in order
to that it can graphically show the restrictions that it is going to lift, those that cannot be fulfilled and
point out those of your area.
- The implementation of the methodology proposed in this work (Collaborative planning and integration
methodology) require commitment by the entire team, it is recommended that the Resident be the
person who drives, be constant and consistent so that your team can adapt to the changes.
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