https://doi.org/10.24928/2024/0219

Rigorous 2-Hour Takt Reveals Upstream Underperformance

Otto Alhava¹, Matthew O’Loughlin², Harri Haapasalo³, Jaakko Viitanen⁴ & Tomi Pitkäranta⁵

¹CTO, Flow Technologies Oy, Helsinki, Finland, [email protected], orcid.org/0000-0001-8820-0522
²Site manager, Fira Rakennus Oy, Vantaa, Finland, [email protected], orcid.org/0009-0005-1317-8355
³Professor, Department of Industrial Engineering and Management, University of Oulu, Finland, [email protected], orcid.org/0000-0001-5413-5638
⁴Project director, Fira Rakennus Oy, Vantaa, Finland, [email protected], orcid.org/0009-0006-7343-2797
⁵Head of Product, Sitedrive Oy, Helsinki, Finland, [email protected], orcid/ 0000-0003-1100-0578

Abstract

The primary purpose of this study is to demonstrate that rigorous production control requires high quality and flawlessness in the upstream production process. The research approach is a quantitative case study. One-piece flow forms the theoretical framework combined with the “sea of inventories” logic. The empirical material is collected from the case company’s renovation projects’ data, documentation, meeting minutes, and training material. The definition, modelling, and analysis of the production system are fundamental to continuous improvement in construction. Systematic analysis, documentation, quality control, and quality assurance enable fact-based improvement and control of the production system. Our study, following the logic of continuously tightening requirements for control variables in the production flow, reveals upstream underperformance and drives the elimination of the problems, thus improving efficiency. In our case, company evidence shortening the takt from 4 hours to 2 hours reveals hidden problems in upstream flow, resulting in continuous improvement in production quality. Overall, our study provides evidence of the applicability of one-piece flow in construction.

Keywords

One-piece flow, Toyota Production System, JIT, Takt

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Reference

Alhava, O. , O’Loughlin, M. , Haapasalo, H. , Viitanen, J. & Pitkäranta, T. 2024. Rigorous 2-Hour Takt Reveals Upstream Underperformance, Proceedings of the 32nd Annual Conference of the International Group for Lean Construction (IGLC 32) , 238-249. doi.org/10.24928/2024/0219

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