State of Production Plan Reliability – A Case Study From India

Vishal Porwal1, Bhargav Dave2, Jose Fernandez-Solis3, Lauri J. Koskela4 & H. S. Mehta5

1Principal at InteloBuild Project Solutions (www.intelobuild.com), 505, Capt. C. S. Naidu Arcade, 10/2 Old Palasia, Indore, Madhya Pradesh-452002, India, Phone-(+91) (997) 730-8235, vporwal@intelobuild.com
2Research Fellow at Salford Centre for Research and Innovation, University of Salford, Maxwell Building, Greater Manchester, M5 4WT, UK, Phone-(+44) (161) 295-3431, b.dave@salford.ac.uk
3Assistant Professor, Department of Construction Science, College of Architecture, 3137 TAMU, Langford A 430, Texas A&M University, College Station, Texas 77843-3137, USA, Phone- (+1) (979) 458-1058, jsolis@arch.tamu.edu
4Professor of Theory Based Lean Project and Production Management, University of Salford, Maxwell Building, Greater Manchester, M5 4WT, UK, Phone- (+44) (161) 295-6378, l.j.koskela@salford.ac.uk
5Advisor to Prestige Institute of Engineering, No.74-C, Sector D, Vijay Nagar, Indore, Madhya Pradesh - 452010, India, Phone- (+91) (982) 703 9058, hsmehta17@gmail.com

Abstract

In the quest to assess the state of production plan reliability on a mid-sized residential project in India, a case study is conducted with production planning inspired by Last Planner® System of production control (LPS). The residential construction sector in India is expected to grow at more than 26% per annum till 2014. However, India does not compare favorably with other countries in the efficient execution of projects and the government has pointed out the need to enhance productivity to meet the increasing rate of economic growth with the best use of labor and resources. Variability and uncertainty in construction project production is identified as an area of improvement. In order to investigate the current state of production plan reliability on mid-sized residential construction projects, a case study is conducted on a 17-story residential project in Mumbai, India. The results indicate that initially, production plans prepared by the project team were highly unreliable with a high degree of variability, but they improved toward the end of the project. Production plan reliability measured as Percentage Plan Complete, also known as Percent Promises Complete, (PPC) varied from 25% to 100% over a period of 24 weeks. The major reasons for production plan failure were bad weather, labor unavailability, material unavailability, untimely drawings and decisions, city regulations, government compliance and unplanned holidays. A feedback loop was put in place and project participants were interviewed at the end of the project. They reported improvement in production plan reliability and indirect cost and quality benefits. This case study provides a hint to the state of production plan reliability in Indian residential construction projects. However, additional and cross sectional research on a variety of residential projects is needed to statistically validate the findings and understand the current state of production plan reliability in India.

Keywords

Last Planner® System of Production Control (LPS), Residential Construction, Production Workflow Reliability.

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Reference

Porwal, V. , Dave, B. , Fernandez-Solis, J. , Koskela, L.J. & Mehta, H.S. 2012, 'State of Production Plan Reliability – A Case Study From India' In:, Tommelein, I.D. & Pasquire, C.L., 20th Annual Conference of the International Group for Lean Construction. San Diego, USA, 18-20 Jul 2012.

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