Construction projects are notoriously unpredictable. Despite meticulous planning, unforeseen issues and dynamic site conditions often derail even the most well-intentioned schedules. To navigate this reality, effective on-site control mechanisms are essential. The Last Planner System (LPS) paired with visual management techniques—specifically, short-term planning boards—offer a collaborative and transparent way to manage work in lean construction. These systems don’t just create plans; they enable teams to control and adapt them in real-time.
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The Need for Visual Control
Traditional project management often relies on static schedules and top-down directives. However, construction thrives on flexibility and immediate response. Site conditions change, materials arrive late, and unexpected clashes occur. Without a system that allows for rapid assessment and adjustment, projects quickly fall behind. This is where visual boards become invaluable. They move control to the people working on the ground, where it can be most effective.
How Visual Boards Work
Visual management boards, such as those used on the London Underground project, provide a clear, shared understanding of the work ahead. These boards typically feature columns representing project areas (locations) and time periods (days, shifts, weeks) for a three-week lookahead. Contractors use color-coded cards to record their activities, including work area, date, manpower, and duration.
The color coding aligns with the master schedule (e.g., blue for concrete, red for electrical), making it easy to identify dependencies and potential conflicts. Each day, the construction manager reviews progress, flipping completed activity cards to reveal a green back. Incomplete tasks remain visible, prompting immediate replanning.
Beyond activity cards, contractors also use cards to flag issues requiring management attention. This proactive communication ensures that problems are addressed before they escalate.
The Evolution of Control
Initially, these boards often fill up with “issue cards” as teams learn to identify and communicate challenges. Over time, as contractors improve their planning, the boards become cleaner, with most issues appearing in the third week. This progression maximizes the time available for problem-solving.
The ultimate goal is for contractors to self-manage their activities, proactively identifying and resolving issues before they impact the schedule.
Benefits of Visual Control
Implementing visual management boards delivers several key advantages:
- Increased Coordination: Shared visibility promotes dialogue between contractors.
- Facilitated Control: The board acts as a central point for tracking progress.
- Proactive Problem Solving: Issues are flagged early, allowing for timely intervention.
- Reduced Conflicts: Visualizing dependencies minimizes clashes between work crews.
- Improved Quality: Proactive problem-solving reduces errors and rework.
In essence, these boards foster a culture of preventive thinking, where teams anticipate and resolve issues before they disrupt the project.
Effective visual control isn’t just about tracking progress; it’s about empowering teams to adapt, collaborate, and deliver projects on time and within budget. By shifting control to the frontline, construction organizations can overcome the inherent unpredictability of the industry and achieve more reliable outcomes
