The Last Planner System (LPS) is a collaborative process aimed at enhancing project delivery in the AEC industry. By emphasizing consistent workflow and ongoing improvement, LPS seeks to boost project predictability and efficiency. According to the Lean Construction Institute, cutting trade inconsistency from 50% to 25% can reduce the risk of project delays by a factor of six which highlights the substantial impact LPS can have on project timelines.
In this blog post, we will explore the core components of the Last Planner System, the steps for its implementation, and a comparison with alternative project management methods.
Introduction to the Last Planner System in AEC Projects
The Last Planner System (LPS) is a collaborative production planning method that involves frontline workers, known as "last planners," in the planning process. These individuals, typically foremen, supervisors, and project managers, have detailed knowledge of daily operations and are responsible for making reliable schedule commitments.
LPS is based on principles that promote collaboration among team members, aligning them with project goals and addressing potential issues before they disrupt workflow. The system includes five interconnected planning conversations:
- Milestone Planning: Aligns the team on project milestones and deadlines.
- Phase Pull Planning: Determines necessary work and sequences activities to meet milestones.
- Make-Ready Planning: Removes constraints to prepare work.
- Weekly Work Planning: Sets the plan for the upcoming week with specific task commitments.
- Learning/Improving: Involves regular reviews to enhance performance and processes.
Pull planning, a core LPS technique, bases work on demand rather than a fixed schedule, ensuring resources are available when needed to maintain production flow. LPS emphasizes removing constraints before work begins, addressing potential roadblocks to ensure all task prerequisites are met.
Key performance indicators like Percent Plan Complete (PPC) measure planning success, tracking the percentage of scheduled activities completed, and providing insights into project reliability and efficiency.
The primary objectives of LPS in AEC projects include:
- Improved Productivity: Focuses on constraint removal and reliable commitments, reducing idle time and rework.
- Waste Reduction: Aligns with lean principles to eliminate waste by using resources efficiently.
- Enhanced Workflow Reliability: Ensures task prerequisites are met, improving project control and reducing delays.
- Increased Collaboration: Fosters a collaborative environment, enhancing teamwork and continuous improvement.
- Value Maximization: Allocates resources to value-adding activities, increasing overall value for stakeholders.
Core Components of the Last Planner System
Master Scheduling establishes the project's framework by outlining major milestones and goals, aligning all stakeholders. This phase involves collaboration among architects, foremen, and site superintendents to define key project milestones and completion dates.
Phase Scheduling uses "pull planning" to determine task sequences and durations within each milestone. Teams work backward from milestone dates to detail phase requirements, typically two to three months in advance, ensuring alignment and commitment.
Lookahead Planning, or Make-Ready Planning, focuses on identifying and resolving constraints that could hinder upcoming tasks. A "look ahead plan" addresses potential obstacles like labor and material availability, ensuring smooth execution by resolving issues four to six weeks ahead.
Weekly Work Planning involves committing to tasks for the upcoming week, fostering reliability and teamwork. Teams review phase scheduling tasks and prepare a weekly work plan, clearly assigning responsibilities and deadlines to promote collaboration.
The Learning Phase, including Daily Huddles, is crucial for continuous improvement and real-time adjustments. Brief daily meetings confirm task completion and allow for necessary adjustments. Analyzing metrics like Percent Plan Complete (PPC) provides insights into progress and areas for improvement.
These components collectively enhance productivity, reduce waste, improve workflow reliability, increase collaboration, and maximize value in construction projects.
Implementing the Last Planner System in AEC Projects
Implementing the Last Planner System (LPS) in AEC projects requires a structured and collaborative approach.
Obtain Executive Buy-In and Support
Engage both formal and informal leaders within the organization to champion LPS and facilitate its adoption.
Develop a High-Level Strategy and Robust CPM Schedule
Create a high-level strategy and a robust Critical Path Method (CPM) schedule before implementing LPS. Include work sequence, continuous improvement, off-site manufacturing, and 5S standardization. The CPM schedule should inform the LPS process through feedback loops to maintain synchronized workflow.
Integrate LPS with Existing Lean Initiatives
Integrating LPS with existing lean initiatives can enhance buy-in and streamline implementation.
Implement the Core Components of LPS
Master Scheduling and Milestone Planning: Set overall project goals and major milestones. This flexible roadmap allows for adjustments as the project progresses.
Phase Scheduling and Pull Planning: Break down the master schedule into phases. Use pull planning to work backward from milestones to determine necessary activities, eliminating waste and improving efficiency.
Make-Ready Planning: Prepare planned work by removing constraints in advance, addressing potential hurdles before they impact project flow.
Weekly Work Planning: Create specific plans and make weekly commitments. This requires full collaboration to complete work as promised.
Daily Huddles: Conduct daily huddles to set expectations for each day’s work, helping teams complete more of the Weekly Work Plan and address issues promptly.
Use Visual Management Tools
Visual management tools like Kanban boards, color-coded schedules, and digital dashboards enhance communication and provide real-time project updates.
Foster a Culture of Reliable Promises
Implementing LPS requires a shift towards collaborative planning and reliable promise-making. Team members should commit to tasks they are confident they can complete, improving project reliability.
Monitor and Measure Performance
Use key performance indicators like Percent Plan Complete (PPC) to quantify project reliability and efficiency. Metrics such as task anticipation and constraint removal rate provide insights into the team’s ability to address potential issues proactively.
Continuous Improvement and Constraint Management
Use LPS meetings for continuous improvement through constraint and data analysis. This informs first-run studies, fishbone analysis workshops, and other activities. Regularly review and refine the approach using Plan-Do-Check-Act (PDCA) cycles.
Comparison of Last Planner System with Alternative Project Management Methods
The Last Planner System (LPS) is a distinctive project management approach in construction. To appreciate its strengths and weaknesses, it is essential to compare it with traditional methods like the Critical Path Method (CPM) and Gantt Charts.
Traditional Project Management Approaches
- Critical Path Method (CPM): CPM relies heavily on precise task duration estimates and struggles with the dynamic nature of construction projects. It is often rigid and not easily adaptable to changes or delays.
- Gantt Charts: Gantt Charts offer a clear visual overview but can become complex for large projects. They do not inherently promote collaboration or team commitment.
Last Planner System (LPS) vs. Traditional Methods
- Collaboration and Commitment: LPS involves frontline workers in planning, enhancing commitment and reliability. In contrast, CPM and Gantt Charts are top-down approaches that may not engage the entire team.
- Flexibility and Adaptability: LPS is flexible and adaptive, using techniques like pull planning to adjust to changing conditions. Traditional methods like CPM and Gantt Charts are more rigid and less adaptable.
- Performance Metrics: LPS uses metrics like Percent Plan Complete (PPC) to measure reliability and efficiency. Traditional methods focus more on milestones and task completion rates.
When to Choose LPS Over Other Methods
- Complex Projects: LPS is ideal for complex projects with many dependencies and strict deadlines. Its collaborative and adaptive nature manages complexities better than traditional methods.
- Dynamic Environments: Projects with frequent changes or high uncertainty are better managed with LPS, which emphasizes continuous learning and adjustment.
- Team Engagement: For projects requiring high team engagement, LPS is more suitable, ensuring all stakeholders are involved in planning and execution.
- Lean Construction: Projects aiming to implement lean principles, like reducing waste and improving efficiency, benefit more from LPS, which aligns with these principles.
Common Challenges with the Last Planner System and Tips to Overcome
Implementing the Last Planner System (LPS) often encounters significant challenges, such as communication barriers among team members. Differences in communication styles, language barriers, and the absence of a unified platform can further impede progress.
Practical Solutions:
- Standardized Communication Protocols: Establish clear protocols to align all team members, including regular daily meetings and weekly planning sessions.
- Training and Workshops: Conduct sessions to enhance communication skills and emphasize the importance of clear, timely exchanges.
- Digital Tools: Leverage digital tools for real-time communication and information sharing.
Another challenge is insufficient buy-in from stakeholders, including top management and contractors, which can hinder effective LPS implementation.
Practical Solutions:
- Top Management Support: Secure top management's commitment to LPS and its communication to all team members, integrating it into strategic goals.
- Involvement of All Stakeholders: Engage all stakeholders in planning and implementation to clarify roles and responsibilities through inclusive meetings.
- Clear Objectives and Benefits: Clearly convey LPS objectives and benefits to stakeholders, emphasizing improved project outcomes and waste reduction.
Resistance to change is common, as team members may prefer traditional methods over a collaborative, lean approach.
Practical Solutions:
- Cultural Diagnosis: Conduct a cultural assessment to identify resistance points and foster a supportive environment for open dialogue.
- Gradual Implementation: Start with small pilot projects to demonstrate LPS benefits and build team confidence.
- Leadership Team: Form a leadership team to champion the change and provide guidance during the transition.
A lack of adequate training and skills can also impede LPS implementation.
Practical Solutions:
- Comprehensive Training: Offer training programs to equip team members with necessary LPS skills, including pull planning and weekly work planning.
- Integrated Evaluation: Use evaluation processes to identify skill gaps and provide targeted training.
- Continuous Improvement: Promote a culture of continuous improvement, encouraging adaptation to new processes and tools.
Contractual and administrative issues, such as traditional contracting methods and unclear guidelines, can also pose challenges.
Practical Solutions:
- Contractual Clauses: Include clauses in contracts specifying last planners' rights and duties, aligning individual goals with project objectives.
- Standardized Guidelines: Develop standardized guidelines for consistent LPS implementation across projects.
- Administrative Support: Equip administrative staff to manage necessary conversations and negotiations, providing detailed checklists of restrictions and control indicators.
Wrapping Up
The Last Planner System (LPS) has become a transformative tool in the AEC industry, enhancing collaboration and project predictability. Implementing LPS successfully requires overcoming challenges, such as shifting from traditional project management approaches. As the industry evolves, LPS may increasingly integrate with technologies like AI to automate certain tasks and improve predictability. To leverage LPS effectively, it is crucial to understand its principles, address implementation challenges, and tailor it to the specific needs of each project.
