Lean Construction and Value

Engineering for Construction

Function Analysis System Technique (FAST)

What is the problem?
How can the solution be achieved?

How ?
Why?

Function Analysis
Basic function
Secondary function

Dependent critical function

Independent supporting function
Design criteria
All the time function

Types of functions
Higher Order Functions
Basic Functions
All the Time Functions / Required Secondary Functions
Any function that is required to meet codes, standards, or
other mandatory requirements on a project

Secondary Functions
Those functions that if removed from the project, then both
the Basic and Secondary functions could still be realized

Ex: Higher order functions for Highway

Promote Economy
Access Employment
Create Jobs
Generate Revenue
Improve Livability
Encourage Development

Ex: Basic functions of Highway system

Highway

Transport People
Transport Goods
Reduce Congestion
Reduce Travel Time
Link Communities
Link Airport

Interchange

Free Flow Traffic Movement

Connect Interstates
Change Travel Direction
Manage Traffic Flow
Access Community

Ex: Basic functions of Highway system

Dedicated Lanes

Accommodate High Speed

Pass Slower Vehicles
Accommodate Varying Speed
Separate Traffic
Guide Traffic
Delineate Lanes

Median/Center Lane Accommodate Left Turn Movements

Decelerate Safely
Facilitate Access

Ex: Basic functions of Highway system

Outside Shoulder Change Tire
Decelerate Safely
Warn Vehicles (Rumble Strips)
Emergency Pullout

Basic / Secondary Functions of Drainage and Erosion Control

Dry Base

Shed Water
Extend Pavement Life
Collect Stormwater
Treat Stormwater
Prevent Flooding (of Roadway)

Ex: Other functions of Highway system

Secondary or Lower Order Functions

Construct Project
Plan Project
Obtain Approvals (Environmental, Permits)
Design Project

All The Time Functions (or Required Secondary)

Improve Safety
Enable Emergency Access
Meet Roadway Standards
Comply with Environmental Requirements

Function Analysis System Technique (FAST)

How

Why

Verb-Noun
Function

Verb-Noun
Function

Verb-Noun
Function

Verb-Noun
Function

Generating a Function Picture

Scope Line

Scope Line

Function Analysis System Technique (FAST)

Creative phase
Think deeper
Not first idea
Not design review
External or multi disciplinary

Judgement phase
Separated from creative phase
High priority for cost saving ideas
Evaluation

Benefits
Functional requirement
Reliable
Excessive original design requirement
Excessive redesign to implement
Improvement over original design
Is it used in past
Record of performance

Development phase

Develop into workable solutions

Life cycle cost
Designer to review
All technical expertise for alternatives

Make comparison design

Original and proposed design
Describe recommendations
Life cycle cost
Advantage and disadvantage of each recommendation
Implication and recommendation to implement

Value Chain
set of activities firm operating in a specific
industry performs in order to deliver a
valuable product or service for the market

Flow
Parts flow through a Value Stream
Upstream is the beginning or head of the flow
Downstream is the mouth of the flow, where the
part is pulled by the customer
Materials and parts are the parts in
manufacturing
Customers needs are the parts in service industry
Same for administration

Pull
It has become a matter of course for customers,
or users, each with a different value system, to
stand in the frontline of the marketplace and, so
to speak, pull the goods they need, in the
amount and at the time they need them.
Taiichi Ohno, Toyota Production System

Nothing is produced by the upstream

provider until the downstream customer signals
a need
Womack and Jones, Lean Thinking

Perfection

The complete elimination of all waste, so that

all activities along a value stream add value to
the product
Ideal State Map

Lean Tools

Value Stream Analysis

6S
Cells
Standard Work
Rapid Improvement Events

Value Stream Analysis

Use Value Stream Analysis as a planning tool
Break down the Value Stream in manageable
sections
Communicate the flow with maps
Information
Material

Use Value Stream Analysis to create 3 maps

Current
Ideal
Future (near time-within a year)

Develop action plan from the Future map

6S

Often confused with Lean, because you are

doing something
Second step, after Value Stream Analysis

6S

A tool to organize the workplace

SortKeep what you need, get rid of the rest

StraightenOrganize whats left
ScrubA clean workplace is more efficient
SafetyWithout our people, nothing gets done
StandardizeFind a best way and have
everyone do it that way
SustainDont let up

Cells Natural groups of parts or steps that add

value to a product
Single piece flow inside the cell
One at a time

If possible, one operator per cell

U-shaped to maximize human efficiency
Multi-skilled people required
Layout is based on the flow steps

Standard
Work
The precise
description of each work activity
specifying cycle time, takt time, the work
sequence of specific tasks, and the minimum
inventory of parts on hand to conduct the
activity
Everyone knows what they are supposed to do
at any moment in time

Rapid
Improvement
Events action, and
A seven
week cycle of preparation,
follow-up to improve one area or fix a
problem
People: work leaders, mechanics, workers,
supervisor, and a Lean Change Agent
Led by the supervisor or work leader
Guided by the Lean Change Agent

JIT
Kanban system
Pull system
Smaller lot that are better capable of providing variety for the
customer
Reduce set up time

lower costs
shorten lead
cycle time
improved quality

Features of lean production

Minimize cost of each part
No rework due to error
Decentralized decision making
Stoppage of work by worker if parts are defective

Pull WIP inventory

Lower WIP inventory
Decreased cost of design change
Less working capital