P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
CPMC Cathedral Hill Hospital Project
Look ahead planning at design and preconstruction“Lessons learned”
Baris Lostuvali Jessica KelleyHerreroBoldt Southland IndustriesCHH Structural Cluster CHH MEP Cluster
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Agenda• Project Background• Lean Design Principles• LPS process and look ahead planning• Future state • Q&A
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
CHH Project Background
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
CHH Project Background
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
•Extension of urban core
•Improved narrower profile
•Appropriate to Van Ness Ave. character
•Less ‘off site’ sun & view impacts
•Massing sympathetic in height
and scale to the neighborhood
•Improve downtown view
CHH Project Background
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
CHH Project Background
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
CHH Project Background
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Set Based Design– An iterative process of developing sets of solutions that satisfy cost, function and quality. – Sets of solutions are advanced until the last responsible moment
Sharing Incomplete Information Often– Willingness of team members to continuously share incomplete information. – Daily or at least weekly sharing of design and budget information. – Design and budget evolve simultaneously
Simultaneous design of Product and Process– Product and process design decisions are made simultaneously.
3D Design / Modeling, and Digital Prototyping– Use digital prototyping to integrate design and cost characteristics. – Provide widespread access to the design model as it evolves.
Lean Design Principles
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Detailed design by specialty contractors and vendors– Designers and engineers produce only those deliverables needed for
permitting and needed by specialty contractors or other suppliers for detailing.
Multidisciplinary Design Teams - Designers, Facility Users, Constructors, Major specialty contractors and suppliers are contracted early – Value based proposal process. – Specialty Contractors and Suppliers work together early in the Design Phase to
simultaneously develop the design and budget.– Multidisciplinary teams meet at least weekly.
Production Planning and Management – Production Planning and Management is applied during the Design phase
using Constraints Analysis, and Weekly Work Plans. – Design and budget production is planned and managed to emulate a
continuous flow process. – Project Based Production Management is formally applied using standard
Lean Processes and Principles
Lean Design Principles
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Information flow - a typical design process
Deliverable
Deliverable
Deliverable.
Deliverable
Deliverable
Deliverable
External Constraints
External Constraints
External Constraints
External Constraints
External Constraints
courtesy of
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Owner
Trade Partners
Architect
Engineer
General Contractor
It’s not easy:• Paper-based updates• Chasing people down• Multiple scheduling technologies• Multiple CAD softwares
People are separated by:• Being in different organizations• Using different technologies• Having different processes• Having different experiences
Information flow – Typical tools
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Information flow - Now we have the data… Great !
courtesy of
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
The right information at the right place
at the right time
Information flow - Goal
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
The Planning Scale
Project LevelActivities
Phase LevelMilestones
Phase LevelActivities
LookaheadTasks
Work PlanTasks
Learning
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Who is the Last Planner on CHH?
Cluster Leader
LastPlanner
LastPlanner
LastPlanner
LastPlanner
LastPlanner
LastPlanner
Cluster Leader
LastPlanner
LastPlanner
LastPlanner
LastPlanner
LastPlanner
LastPlanner
Cluster Leader
LastPlanner
LastPlanner
LastPlanner
LastPlanner
LastPlanner
LastPlanner
Cluster Leader
LastPlanner
LastPlanner
LastPlanner
LastPlanner
LastPlanner
LastPlanner
Production Planner
ProjectMaster
Scheduler
The Closest Management Person to the Actual Work Being Done within a Cluster Group
In Construction the Last Planner is Generally a Foreman
Last Planners will be Formally Designated and Coached
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Cluster Groups – CG Leader
IPDT – Production Planner
IDPT – Master Scheduler
The Planning Leadership
Project LevelActivities
Phase LevelMilestones
Phase LevelActivities
LookaheadTasks
Work PlanTasks
Learning
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Plan Development Detail
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Master Schedule
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Master Schedule – Primavera P6
Master Schedulewith Phases
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Master Schedule
• Primavera P6 central database.
• Web access.
• Milestones based on Senate Bill requirements, OSHPD, Owner business plan, and IPDTeam.
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Alignment Meetings
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Alignment Meeting
• Focus on next near milestones to better define the deliverables within the phases.
• For each milestone.– Identify the customer.
– Brief on each milestone.
– Clarify Conditions of Satisfaction.
– Verify Responsibilities.
• Not a discussion about sequence, or time, or dates.
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Phase Scheduling
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Phase Schedule Session
• Perform a Reverse Phase Schedule (sequence using pull methods).– Build the schedule in terms of pre-requisite work, information,
materials, tools, etc needed to complete the successor activity.
• Identify specific Constraints (constraints log).
• Use 8x5 cards while someone generating live in P6 so that there is a distributable plan by the end of the session.
• The Phase is the expanded detail within the Master Schedule
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Look ahead Plan + Weekly Work Plan
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Lookahead Schedule View – Primavera P6
6 Week Lookahead
View
Master Schedulewith Phases
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Lookahead Schedule to Lookahead Plan
6 Week Lookahead
View
View from Phase Schedule transfer to Plan
Lookahead Plan informs Phase Schedule
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Six Week Lookahead View to Lookahead Plan
• P6 to Excel.
• Filter 6 Weeks from P6 Phase Schedule to be used in the Cluster Group facilitated Excel Lookahead Plan.
• There is more detail on the Cluster Group WWP+Lookahead Plan than there will be in P6.
• The Lookahead Plan is the internal workings of the Cluster Group.
• Allows for the Cluster Groups to modify their plan freely without constantly changing or confusing the Phase Schedule.
• Production Planner with Master Scheduler compare the information.
• Color coding and Shared IDs are cues for updating the Phase Schedule.
• The Lookahead does not have to be in Excel, it is an easy format that almost anyone can comprehend.
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Weekly Work Plan + Lookahead
EXAMPL
E
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Weekly Work Plan + Lookahead
Lookahead PlanWeekly Work Plan
Pull Lookahead onto WWP
Sh
ared
ID
Co
nst
rain
ts P
rom
pt
Metrics
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Lookahead Planning Sessions
• Start with a Six Week Lookahead View taken from the Phase Schedule.
• Break week 1 and 2 of Phase Activities into Tasks that can essentially fit onto a Weekly Work Plan.
• Review weeks 3, 4, and 5 to ensure that all constraints will be removed.– screen activities for constraints (materials, information, obstacles, permissions, anything
hindering an activity from happening).
– Achieve commitments to ensure the constraint removal.
• The team only allows tasks to keep their scheduled dates if there is confidence that all constraints will be removed.
• At this point planning is a regular non-formally scheduled meeting, it is part of everyday work.
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Where are We? Constraint Log
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Phase Schedule Informed from Cluster Group Lookahead Plans
Planning Cycles….
Monday Tuesday Wednesday Thursday Friday
MEP
Structural
Equipment
Exterior
EIR
Interior
6WLA ViewDistribute
Core Group Core Group
Master Schedule Informed from Phase Schedule
Continuous Update of Planning Wall
Sustainability
Trade Coord
Technology
IntegratedPlanning
IPDTLP Meeting
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Metrics
• Percent Planned Complete (PPC)
• Tasks Anticipated (TA)
• Tasks Made Ready (TMR)
• Categories of Variance
• Tasks Repeated
• Root Cause Analysis (5 Whys)
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
IPDTeam Last Planner Meeting – almost there
• All are invited.
• Brief Briefing on Phase Schedule.
• Another forum to remove constraints.– 10 minutes each cluster group to report on current plan and
make requests, requires to be well prepared.
• Not a working session (other than 5 Why).
• Present root cause analysis (5 Why’s) from Cluster Groups that can be learned from as an IPDT.
• Focus on learning from plan failures.
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Integrated Planning Meeting
• Who attends?– Master Project Scheduler and Production Planner.
– Cluster Group facilitators (representatives from both design and construction).
• Discuss and update the Phase Schedule as it relates to current areas of focus and concern.
• Forum to release constraints.
• A live P6 working session.
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Where are We?
• Learning about how to take the detailed planning of the cluster groups to inform the master and phase schedule while recognizing the iterative ever changing nature of design.
• Not plan people to death.
• This is our future state and in the future it will look nothing like this.
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Where are We? Identify the key interdependencies between clusters
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Where are We? First Run Study
P2SL - PROJECT PRODUCTION SYSTEMS LABORATORYLast Planner Initiative – Look ahead Planning, March 06, 2009
Future state
• Traditionally, the design phases of projects suffer from:– Temporary organizations / departmental silos;– poor understanding of complexity;– inevitable iteration & rework;– unforeseen changes; &– inappropriate project management methodologies & tools
• What is working now– The right information at the right place at the right time – Better foresight thru LPS and look ahead planning– Highlight the interfaces between disciplines– Co-location is effective and powerful– Integrating the design & development processes of all participants
• What we are focusing on for future improvement– Identifying process ‘knots’ and options for unraveling them– Continuing to utilize appropriate management methodologies & tools– Using tracking metrics more to adjust current planning