Implementation of the Last Planner System with Agile Methodologies in Wilson Sons shipyards

Project Details

Role

Project Manager

4 Budget

$20.000

Duration

6 months (2023)

Team Size

Industry

Shipbuilding

Project Objective

The project's primary objectives are to boost productivity, reduce man-hours (HH), strengthen production control, empower last-line workers, and enhance conflict management. By implementing these goals, the project aims to streamline operations, increase efficiency, foster a sense of ownership among frontline workers, and improve communication for better conflict resolution. This comprehensive approach ensures a more predictable and efficient production environment, ultimately leading to significant operational improvements.

Project Description

This systematic approach allows for the continuous monitoring and improvement of the production process. By involving last-line supervisors in planning and decision-making, the system ensures that potential issues are identified and addressed promptly, non-value-adding activities are eliminated, and the root causes of errors are thoroughly analyzed. This contributes to a smoother workflow and enhances the ability to adapt quickly to any changes or challenges.

Agile Methodology: Utilized to implement the project through iterative sprints, ensuring flexibility and continuous improvement.
Last Planner System: A collaborative planning system that empowers last-line supervisors to take an active role in the planning and execution process.
Smartsheet: A cloud-based platform for project management and collaboration, facilitating real-time updates and communication among team members.

Lessons Learned

Importance of Supervisor Involvement: Engaging last-line supervisors in planning significantly enhances the accuracy and feasibility of production plans.
Effective Communication: Clear and consistent communication channels are crucial for identifying and resolving issues promptly.
Continuous Improvement: Regularly reviewing and adjusting plans based on real-time feedback helps in maintaining project momentum and achieving goals.

Project Wins

Functional Responsibilities

As the Project Manager, I led the implementation of the Last Planner® System, ensuring the project met its objectives within the set timelines and budget. In my role as Team Leader, I coordinated cross-functional teams, fostering collaboration and clear communication to maintain project momentum.

The Last Planner® System is a structured approach to production planning and execution. It is centered around the involvement of last-line supervisors who are pivotal in ensuring that the production process runs smoothly and efficiently. Here’s a step-by-step implementation process using an agile methodology:

Sprint 1: Micro Planning and Flowchart Creation

Develop a detailed micro-planning method derived from the overall project schedule.
Create comprehensive flowcharts that outline the operation processes of the project.

Sprint 2: Monitoring Indicators Creation

Establish key performance indicators (KPIs) for monitoring, such as adherence to the schedule and man-hour (HH) consumption.

Sprint 3: Implementation of Management in Sight

Implement visual management tools that allow real-time tracking of project progress and immediate identification of any issues.

Sprint 4: PDCA (Plan-Do-Check-Act) Cycle Implementation

Integrate the PDCA cycle into the project management process to ensure continuous improvement and learning.

Enhanced Project Control: Implementation of the Last Planner System provided better oversight and management of the production process.
Improved Medium-Term Planning: The project saw significant improvements in planning accuracy and effectiveness over the medium term.
Better Collaboration and Integration: Increased collaboration and integration between different sectors of the project led to more cohesive and efficient operations.
Leadership Commitment to Efficiency: Leadership demonstrated a strong commitment to improving efficiency and productivity, focusing on reducing man-hours.
15% Reduction in HH Consumption: Achieved a significant 15% reduction in man-hour consumption in building projects, showcasing the effectiveness of the implemented system.