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Module 1: Introduction to Lean Construction Management
1-Lean-Construction-Management-Maximizing-Value-Eliminating-Waste
Principles and Philosophy of Lean Construction
History and Evolution of Lean in Construction Industry
Benefits of Lean in Buildings, Roads & Bridges Projects
Key Terminologies and Concepts (Value, Waste, Flow, Pull)
Example: Lean principles applied in a high-rise building to reduce waste
Template: Waste Identification Matrix (Tabular form showing types of wastes and mitigation strategies)
Module 2: Value Stream Mapping (VSM) in Construction Projects
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Understanding Value Stream Mapping
Creating VSM for Building Projects
VSM Application in Road Construction
VSM Application in Bridge Construction
Example: VSM of concrete pouring process in a building project
Template: VSM Template with process steps, cycle time, wait time columns
Module 3: Identifying and Eliminating Waste in Construction
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Types of Waste in Construction (TIMWOOD)
Waste Identification Techniques
Waste in Roads & Bridges Projects
Case Study: Waste Reduction in Road Resurfacing
Example: Reducing material waste in bridge girder fabrication
Template: Waste Tracking Log (Waste type, source, quantity, corrective action)
Module 4: Lean Project Planning & Scheduling
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Lean Planning Principles
Pull Planning Methodology
Creating Pull Plans for Building Projects
Pull Planning for Infrastructure Projects (Roads & Bridges)
Example: Pull planning workshop in a multi-story building
Template: Pull Planning Worksheet (Activities, responsible, start/end dates, dependencies)
Module 5: Last Planner System (LPS) Implementation
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Overview of Last Planner System
Master Scheduling
Lookahead Planning
Weekly Work Planning & PPC Measurement
Example: LPS for coordinating foundation and structural work in a bridge
Template: Weekly Work Plan with Percent Plan Complete (PPC) tracking table
Module 6: Lean Supply Chain Management
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Just-in-Time (JIT) Delivery Concepts
Vendor Collaboration & Relationship Management
Material Flow Optimization in Roads Projects
Managing Supply Chain for Bridge Components
Example: JIT material delivery for precast concrete elements
Template: Material Delivery Schedule with JIT timelines and status
Module 7: Visual Management Tools in Construction
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Importance of Visual Controls
Visual Boards for Site Management
Visual Performance Metrics & KPIs
Digital Visual Management Tools
Example: Using visual boards to track daily progress on building façade works
Template: Visual Management Board Template (Tasks, progress status, responsible person)
Module 8: Lean Quality Management
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Integrating Lean and Quality Management Systems
Defect Prevention Techniques
Quality Assurance in Roads & Bridges
Continuous Improvement through PDCA Cycle
Example: Defect tracking in bridge expansion joint installation
Template: Quality Control Checklist with defect categories and action taken
Module 9: Collaborative Contracting & Integrated Project Delivery (IPD)
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Contract Models Supporting Lean
Collaboration Between Stakeholders
IPD Case Study in Building Construction
Application of IPD in Roads and Bridges
Example: IPD model used to accelerate a bridge widening project
Template: Stakeholder Responsibility Matrix (RACI Chart)
Module 10: Lean Risk Management
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Lean Approach to Risk Identification
Risk Prioritization & Mitigation
Risk Management in Road Construction
Managing Risks in Bridge Erection
Example: Mitigating weather-related risks in road paving
Template: Risk Register with risk description, likelihood, impact, mitigation plan
Module 11: Lean Safety Management
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Lean Principles in Safety
Hazard Identification & Elimination
Safety in High-Rise Buildings
Safety Management on Roads and Bridges
Example: Safety improvement via lean methods during bridge deck concreting
Template: Safety Observation Log with corrective actions
Module 12: Lean Workforce Management and Engagement
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Workforce Optimization Using Lean
Multi-skilling and Cross-Training
Motivating Teams in Infrastructure Projects
Lean Leadership & Culture Development
Example: Cross-training laborers to reduce downtime in building MEP installation
Template: Training Matrix showing skills, training status, and gaps
Module 14: Lean Cost Management and Budget Control
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Lean Principles for Cost Control
Target Value Design (TVD)
Cost Control in Roads & Bridges
Value Engineering Examples
Example: Cost savings through prefabrication in building façade
Template: Cost Tracking Sheet with planned vs actual costs and variances
Module 15: Lean Waste Management and Sustainability
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Lean and Environmental Sustainability
Waste Segregation and Recycling on Site
Sustainable Practices in Road Construction
Bridge Construction Waste Reduction Strategies
Example: Reusing excavated material in road embankment construction
Template: Waste Segregation Log and Sustainability Performance Dashboard
Module 16: Lean Project Performance Measurement
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Key Performance Indicators (KPIs) in Lean Construction
Monitoring Project Flow Efficiency
Performance Metrics for Roads & Bridges
Continuous Improvement Using Metrics
Example: Tracking cycle times for concrete curing in bridge spans
Template: KPI Dashboard with visual charts (progress, quality, safety, costs)
Module 17: Lean Problem Solving and Continuous Improvement
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Root Cause Analysis Tools (5 Whys, Fishbone)
Kaizen Events in Construction
Applying Lean to Solve Site Issues
Improvement Case Studies
Example: Kaizen event to reduce crane idle time in building project
Template: Problem Solving Worksheet (Issue, analysis, solutions, actions)
Module 18: Lean Communication and Stakeholder Management
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Lean Communication Techniques
Managing Stakeholder Expectations
Collaborative Decision Making
Communication Tools for Construction Teams
Example: Daily huddle meetings in a bridge construction site
Template: Communication Plan Matrix (Stakeholders, message, frequency, responsibility)
Module 19: Lean Documentation and Reporting
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Lean Documentation Practices
Standardized Reporting Templates
Digital Document Management
Example: Daily progress report template used for road surfacing
Template: Standardized Daily Progress Report with sections for activities, issues, and photos
Module 20: Case Studies and Best Practices in Lean Construction
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Lean in High-Rise Building Projects
Lean Success Stories in Road Construction
Lean Applications in Bridge Projects
Example: Case study of Lean implementation reducing road construction cycle time by 20%
Template: Case Study Analysis Template (Project overview, lean tools used, outcomes)