Skip to main content
Log in

Verification of lean construction benefits through simulation modeling: A case study of bricklaying process

  • Construction Management
  • Published:
KSCE Journal of Civil Engineering Aims and scope

Abstract

The construction industry includes a large number of specialized areas and disciplines, most of which are based on cyclical processes during the construction phase. With the introduction of the lean construction concept, researchers have begun to apply lean principles to construction processes. The research described in this paper applies lean principles to a construction operation using computer simulation. Simulation makes it possible to evaluate the effects of implementing lean principles into construction processes prior to real world application. A case study of the bricklaying process was conducted to quantify and evaluate the results of applying lean principles. Data required for constructing the simulation model were gathered from the construction site through work and time study techniques. Preliminary results show improvement opportunities exist in the bricklaying process due to a high share of non value-adding work. The results of lean principles implementation also reveal that lean principles can enhance the performance of the bricklaying process through more than 40% productivity improvement.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Similar content being viewed by others

References

  • Abbasian-Hosseini, S.A., Nikakhtar, A., and Ghoddousi, P. (2012). “Flow production of construction processes through implementing lean construction principles and simulation.” IACSIT International Journal of Engineering and Technology, Vol. 4, No. 4, pp. 475–479.

    Article  Google Scholar 

  • Abdel-Razek, R. H., Abd Elshakour, H., and Abdel-Hamid, M. (2007). “Labor productivity: Benchmarking and variability in Egyptian projects.” International Journal of Project Management, Vol. 25, No. 2, pp. 189–197.

    Article  Google Scholar 

  • Agbulos, A. and AbouRizk, S. M. (2003). “An application of lean concepts and simulation for drainage operations maintenance crews.” 2003 Winter Simulation Conference New Orleans USA, pp. 1534–1540.

    Google Scholar 

  • Alkoc, E. and Erbatur, F. (1997). “Productivity improvement in concreting operations through simulation models.” Building Research and Information, Vol. 25, No. 2, pp. 82–91.

    Article  Google Scholar 

  • Al-Sudairi, A., Diekmann, J., Songer, A., and Hyman, B. (1999). “Simulation of construction processes: Traditional practices versus lean principles.” 7th Annual Conference of International Group for Lean Construction, Berkeley, CA, USA, pp. 39–50.

    Google Scholar 

  • Al-Sudairi, A. A. (2007). “Evaluating the effect of construction process characteristics to the applicability of lean principles.” Construction Innovation: Information, Process, Management, Vol. 7. No. 1, pp. 99–121.

    Article  Google Scholar 

  • Altiok, T. and Melamed, B. (2007). Simulation modeling and analysis with ARENA, Elsevier.

    Google Scholar 

  • Ballard, G. and Howell, G. (1994). “Implementing lean construction: Stabilizing work flow.” 2nd Annual Conference on Lean Construction, Santiago, Chile, pp. 1–10.

    Google Scholar 

  • Choi, J. (2011). “Quantifying the effects of interference for an alternative method of construction productivity estimation.” KSCE Journal of Civil Engineering, Vol. 15, No. 5, pp. 761–769.

    Article  Google Scholar 

  • Christian, J. and Hachey, D. (1995). “Effects of delay times on production rates in construction.” Journal of Construction Engineering and Management, Vol. 121, No. 1, pp. 20–26.

    Article  Google Scholar 

  • Dunlop, P. and Smith, S. D. (2004). “Planning, estimation and productivity in the lean concrete pour.” Engineering, Construction and Architectural Management, Vol. 11, No. 1, pp. 55–64.

    Article  Google Scholar 

  • Farrar, J. M., AbouRizk, S. M., and Mao, X. (2004). “Generic implementation of lean concepts in simulation models.” Lean Construction Journal, Vol. 1, No. 1, pp. 1–23.

    Google Scholar 

  • Hajjar, D. and AbouRizk, S. (1999). “SIMPHONY: An environment for building special purpose construction simulation tools.” 1999 Winter Simulation Conference, Phoenix, AZ, U.S.A, pp. 998–1006.

    Google Scholar 

  • Halpin, D. W. (1977). “CYCLONE-method for modeling job site processes.” Journal of Construction Division, Vol. 103, No. 3, pp. 489–499.

    Google Scholar 

  • Halpin, D. W. and Kueckmann, M. (2002). “Lean construction and simulation.” 2002 Winter Simulation Conference, San Diego, USA, pp. 1697–1703.

    Google Scholar 

  • Halpin, D. W. and Martinez, L. H. (1999). “Real world application of construction process simulation.” 1999 Winter Simulation Conference, Phoenix, AZ, USA pp. 956–962.

    Google Scholar 

  • Hassan, M. M. and Gruber, S. (2008). “Simulation of concrete paving operations on Interstate-74.” Journal of Construction Engineering and Management, Vol. 134, No. 1, pp. 2–9.

    Article  Google Scholar 

  • Koskela, L. (1993). “Lean production in construction.” 1st Workshop on Lean Construction, Espoo, Finland, pp. 47–54.

    Google Scholar 

  • Koskela, L. (2000). An exploration towards a production theory and its application to construction, VTT Publications Espoo, Finland.

    Google Scholar 

  • Krupka, D. C., Heim, J. A., and Compton, W. D. (1992). “Time as a primary system metric in manufacturing systems: Foundations of world-class practice.” National Academy Press, Washington D.C., pp. 166–172.

    Google Scholar 

  • Kvam, P. H. and Vidakovic, B. (2007). Nonparametric statistics with applications to science and engineering, John Wiley.

    Book  MATH  Google Scholar 

  • Larsson, R. (2008). “Simulation of construction operations applied to in situ concrete frameworks.” 16th Annual Conference of International Group of Lean Construction, Manchester, U.K., pp. 143–154.

    Google Scholar 

  • Law, A. M. and Kelton, W. D. (2000). Simulation modeling and analysis, 3rd Edition, McGraw-Hill New York, N.Y.

    Google Scholar 

  • Mao, X. and Zhang, X. (2008). “Construction process reengineering by integrating lean principles and computer simulation techniques.” Journal of Construction Engineering and Management, Vol. 134, No. 5, pp. 371–381.

    Article  Google Scholar 

  • Martinez, J. and Ioannou, P. G. (1994). “General purpose simulation with stroboscope.” 1994 Winter Simulation Conference, Piscataway, N.J., pp. 1159–1166.

    Google Scholar 

  • Park, H. S. (2006). “Conceptual framework of construction productivity estimation.” KSCE Journal of Civil Engineering, Vol. 10, No. 5, pp. 311–317.

    Article  Google Scholar 

  • Picard, Hans E. (2000). “Industrial construction efficiency and productivity.” 2nd World Congress on Cost Engineering, Project Management & Quantity Surveying, Calgary, Canada.

    Google Scholar 

  • Sacks, R. and Goldin, M. (2007), “Lean management model for construction of high-rise apartment buildings.” Journal of Construction Engineering and Management, Vol. 133, No. 5, pp. 374–384.

    Article  Google Scholar 

  • Senaratne, S. and Wijesiri, D. (2008), “Lean construction as a strategic option: Testing its suitability and acceptability in Sri Lanka.” Lean Construction Journal, pp. 34–48.

    Google Scholar 

  • Shi, J. (1999). “Activity-Based Construction (ABC) modeling and simulation method.” Journal of Construction Engineering and Management, Vol. 125, No. 5, pp. 354–360.

    Article  Google Scholar 

  • Takus, D. A. and Profozich, D. M. (1997). “ARENA software tutorial.” 1997 Winter Simulation Conference, Piscataway, N.J., pp. 541–544.

    Google Scholar 

  • Thomas, H. R., Guevara, J. M., and Gustenhoven, C. T. (1984). “Improving productivity estimates by work sampling.” Journal of Construction Engineering and Management, Vol. 110, No. 2, pp. 178–188.

    Article  Google Scholar 

  • Thomas, H. R., Horman, M. J., Lemes de Souza, U. E., and Završki, I. (2002). “Reducing variability to improve performance as a lean construction principle.” Journal of Construction Engineering and Management, Vol. 128, No. 2, pp. 144–154.

    Article  Google Scholar 

  • Tommelein, I. (1997). “Models of lean construction processes: Example of pipe-spool materials management.” Construction Congress V, Minneapolis, MN, pp. 405–13.

    Google Scholar 

  • Tommelein, I. D. (1998). “Pull-driven scheduling for pipe-spool installation: Simulation of lean construction technique.” Journal of Construction Engineering and Management, Vol. 124, No. 4, pp. 279–288.

    Article  Google Scholar 

  • Tommelein, I. D. and Odeh, A. M. (1994). “Knowledge-based assembly of simulation networks using construction designs, plans, and methods.” 1994 Winter Simulation Conference, New York, pp. 1145–1158.

    Google Scholar 

  • Wang, S. and Halpin, D. W. (2004). “Simulation experiment for improving construction processes.” 2004 Winter Simulation Conference, Washington, D. C., USA, pp. 1252–1259.

    Google Scholar 

  • Wang, P., Mohamed, Y., Abourizk, S. M., and Rawa, A. R. T. (2009). “Flow production of pipe spool fabrication: simulation to support implementation of lean technique.” Journal of Construction Engineering and Management, Vol. 135, No. 10, pp. 1027–1038.

    Article  Google Scholar 

  • Womack, J. P. and Jones, D. T. (1996). Lean thinking: Banish waste and create wealth in your corporation, Free Press Business London.

    Google Scholar 

  • Yeh, Y. and Schmeiser, B. (2000). “Simulation output analysis via dynamic batch means.” 2000 Winter Simulation Conference, Orlando FL, pp. 637–645.

    Google Scholar 

  • Zhang, H., Tam, C. M., and Li, H. (2005). “Activity object-oriented simulation strategy for modeling construction operations.” Journal of Computing in Civil Engineering, Vol. 19, No. 3, pp. 313–322.

    Article  MATH  Google Scholar 

  • Zhao, Y. and Chua, D. K. H. (2003). “Relationship between productivity and non value-adding activities.” 11th Annual Conference of International Group of Lean Construction, Virginia, USA.

    Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to S. Alireza Abbasian-Hosseini.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Abbasian-Hosseini, S.A., Nikakhtar, A. & Ghoddousi, P. Verification of lean construction benefits through simulation modeling: A case study of bricklaying process. KSCE J Civ Eng 18, 1248–1260 (2014). https://doi.org/10.1007/s12205-014-0305-9

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12205-014-0305-9

Keywords

Navigation