Critical Concerns of Production Control System on Projects with Labor Constraints: Lessons from a Residential Case Study

Abstract

Labor constraints and schedule pressures are common in periods of high market growth. Such conditions can have a significant impact on project performance. However, the extent to which such conditions impact the project depends on the effectiveness of the production control system. This case study analyzes the performance problems on a large residential project with significant labor constraints. The case first describes how the combination of labor shortage, high workload, and quality problems caused extensive workflow disruptions and schedule delays. Then, the analysis discusses why the production control system (the way the work assignments are planned, coordinated, and released for execution) failed to effectively manage these problems. The case is based on data from nine single-family houses in a large residential development. To evaluate the production control system, the authors used lean construction metrics and collected detailed data on the activities completed every week, the activities that were not completed as planned for that week, and the reasons for not completion. At the completion of the units, the researchers tracked the cycle time and evaluated the effect of the production control problems on the delays. The findings illustrate that, on projects with labor constraints, it is critical that the production control system focuses on creating reliable work assignments and minimizing quality defects in order to prevent further disruptions and make the best possible utilization of the limited labor resources.