“Lean” Comparison Using Process Charts of Complex Seismic Retrofit Projects

Abstract

This paper compares the delivery of two retrofit projects where seismic isolation bearings were installed. The comparison is retrospective. The design teams on these projects did not implement “lean” thinking to develop their approach, nevertheless, observed process differences are characterized using a “lean” process evaluation and optimization tool, and then gauged and rationalized from that perspective. Cross-functional process charts identify functional parties with interrelated material or information handoffs. They help to identify (un)necessary steps or complexity as measured by number of handoffs and interacting parties. Analysis of these charts shows that project value may stem from the owner integrating design development with product procurement and construction method selection. On one project, integration was made possible by structural engineers evaluating the impacts of product procurement on overall project performance, expert consultants providing construction process reviews, and experienced contractors participating in installation sequence development. This paper illustrates the value of developing a symbiotic relationship between designers and suppliers in a niche market. It stresses the need for work structuring early on in the delivery process, integrating process with product development, to improve project delivery.