APPLICATION OF LEAN CONSTRUCTION IN SANDCRETE BLOCK PRODUCTION

APPLICATION OF LEAN CONSTRUCTION IN SANDCRETE BLOCK PRODUCTION

(A CASE STUDY OF MINNA, NIGER STATE)

ABSTRACT

This research was carried out to evaluate application of lean construction in sandcrete block production with the specific objective of minimizing waste during the production process. To achieve the set objective the research was done through the use of journals, personal observation, oral interview and structural questionnaires to ascertain sources and causes of waste generated in sandcrete block production, extent of practice of lean construction in block industries, basic lean tools that are applicable in sandcrete block production, factors acting as challenges to the implementation of lean construction in sandcrete block production and measures to overcome the challenges. From the data collected it was found that labour, time and materials are the possible resources wasted during sandcrete block production. These wastes were caused mainly by poor planning and scheduling, poor coordination and inappropriate/misuse of materials. From the research the basic lean tools applicable to sandcrete block production are just in time and last planner system. Based on the analysis of the available data the major challenges to application of lean construction in sandcrete block production are high level of illiteracy and corruption in block industry. This study also recommend that team work, timely delivery of materials and establishing proactive measure to prevent defective production should be encouraged in sandcrete block production.

CHAPTER ONE
INTRODUCTION
1.1 BACKGROUND OF STUDY
Researchers have shown that the construction industry is influenced by multiple wastes, overruns, delays, mistakes, and inefficiency. As a result of these, construction projects are not always finished on time or within budget, and at a quality level acceptable by the customer (FMI/CMAA, 2005). Since it has become essential for construction companies to increase work effectiveness, reduce cost, improve the quality of work, reduce waste, and increase profit so as to survive in today’s competitive market. The combination of project speed, low cost and high quality has become a key engineering and managerial effort in addressing the growing competition in the construction business. There are several project management approaches including lean construction which emerged to improve construction performance.

Lean construction is a production management based project delivery system which emphasizes on speedy and reliable delivery of value (LCI, 2012). In general lean construction has the goal of better meeting customer needs while using less of everything. But unlike current practice, lean construction relies on production management principles. The result is a new project delivery system that can be applied to any kind of construction but it is particularly suited for complex, uncertain, and quick projects (Gregory et al., 1999).

Lean construction as defined by Ballard (2004) “is an added value by removing or eliminating waste, being responsive to change, focusing on quality, and enhancing the effectiveness of the workforce. Typically, 95% of all lead time are non–value added”. Ballard and Howell (2004) defined lean construction as “a temporary production strategy that helps indelivering the product with minimum waste and maximum value”. Whereas Lean Construction Institute (2003) defines lean construction as, “a production management approach to project delivery. Lean production management has caused a lot of revolution in manufacturing design, assembly and supply.

From research perspectives, reviewed literature showed that lean construction efforts have been focused on proposing and applying lean methods and tools in the various sectors of construction industry. However, few or no researcher actually addressed how to evaluate the impact of lean practices on the quality, speed, and cost of sandcrete block production.

Sandcrete block is a composite material made of cement, sand and water, molded into different sizes (Barry 1969). Sandcrete block is widely used as walling unit in Nigeria and other countries like Ghana. The production process of sandcrete block is characterized by construction waste such as: low productivity, poor co-ordination, bad reputation, high accident rates, insufficient quality and overruns in cost, defect and schedule etc (Yahia, 2004). The quality of blocks produced as well as waste in its production however, differs from one industry to another due to the different methods employed in the production hence the need to apply lean thinking in its production.

1.2 STATEMENT OF PROBLEM
Most of the sandcrete block production projects are characterized by construction waste such as low productivity, defect, large variability and low performance and thus wasting time, money and other resources (FMI/CMAA, 2005). In this project, the expected benefits of using lean tools in block industry in order to reduce or eliminate waste and eventually satisfy customer needs was investigated.

1.3 NEED FOR STUDY
A lot of work has being carried out on lean construction practice in construction industry (Ballard, G. 2004, Howell G.A.and Koskela, L. (2000), Forbes L. and Ahmed S. 2004 etc) no work exists on application of lean construction to sandcrete block production, hence the need for study. The study is also needed to reduce waste in sandcrete block production which will consequently, improve the quality of sandcrete block in Nigeria for better housing delivery.

1.4 AIM AND OBJECTIVES
The aim of this research is to evaluate the applicable lean construction tools in sandcrete block production with a view to ascertain whether it would be a means of reducing waste in sandcrete block production.

The specific objectives are:
i. To identify the various wastes in the production of sandcrete blocks.

ii. To determine the causes of those wastes in the production of sandcrete blocks.

iii. To evaluate the basic lean tools applicable in production of sandcrete blocks.

iv. To determine the challenges of the application of lean construction to block industries in Minna.

1.5 METHODOLOGY
The methods that were used in undertaking this study consist of three stages:

1. Review of relevant literatures on lean construction, lean tools and sandcrete block.

2. The use of questionnaire, personal observation and oral interview to determine the waste and causes of waste generated during sandcrete block production process.

3. The use of oral interview and questionnaires to determine the basic lean tools applicable in sandcrete block production so as to reduce waste generated.

1.6 SCOPE AND LIMITATION
This study is based on how lean construction practice can be applied to the production of sandcrete block. The limitations to this research include:

High level of illiteracy among workers in block industry: This serve as barrier to communication during the process of collecting information.

Fears of disclosing commercial confidentiality: this also serve as barrier to collection of information.