Lean management:
Lean planning in the portfolio
Construction projects in existing buildings require particularly precise planning – after all, conversions, renovations or revitalizations also take place during ongoing operations. This requires close coordination between those involved in the project. This shows that lean management can make all the difference.
The method, which originated in the automotive industry, has long since established itself as an effective tool in the construction industry. Lean Management in the Construction Industry (LMB) ensures a continuous flow of work, reduces waste and promotes open, cooperative communication. This method creates clear advantages for complex projects, such as construction in existing buildings:
Efficiency: Transparent processes make it possible to identify and optimize time buffers and unused capacities.
Cost certainty: delays and additional costs are minimized through early coordination and transparency.
Flexibility: Adjustments can be made during the course of the project without jeopardizing the entire process.
A practical example: TRUMPF GmbH + Co. KG
TRUMPF has been using lean management for years to implement larger construction projects efficiently and on schedule. One example is the completed conversion of an existing lightweight hall in Ditzingen and the addition of a new logistics building connected by a shared covered courtyard.
The high technical requirements – including clean room areas, commissioning stations for laser machines and a new technical extension – made precise coordination essential. Despite ongoing operations and a tight construction schedule, delivery and dispatch traffic had to be guaranteed smoothly. TRUMPF’s construction department called us in to support them with the use of lean management on this construction site. The Last Planner© system, a core method of lean management, was used. Experienced foremen act as knowledge carriers who contribute their expertise to the regular lean meetings. Tasks are planned, optimized and scheduled together. This approach not only creates transparency, but also strengthens trust between all those involved – a basis for successful collaboration.
Lean management in practice
The key lies in detailed and iterative planning:
- Analysis: Identification of recurring and specific requirements in the Projects.
- Planning: Work packages are jointly defined, prioritized and visualized – for example using post-its.
- Reconciliation: Regular target/actual comparisons ensure implementation and allow adjustments to be made at short notice.
- Flexibility: Time periods and processes are adapted as required in order to make optimum use of resources.
In the TRUMPF GmbH + Co KG project, areas and observation periods were flexibly adapted to meet the specific requirements. Individual areas were split up or combined as required to ensure the necessary precision. Switching from weekly to daily planning proved to be particularly crucial during the peak construction phase. This allowed the processes to be closely coordinated, the interaction between the trades to be optimized in a limited space and capacities to be used in the best possible way.
Topics such as contract award dates and construction logistics were also integrated into the lean meetings, creating a holistic overview. Thanks to the regular participation of client and user representatives, decisions could be made directly on site and delays avoided. The result: an optimized construction process with maximum efficiency and adherence to deadlines.
More than just a method
Lean management means more than just applying a method – it requires a new perspective on collaboration and processes. Instead of rigid structures, the focus is on flexibility, transparency and a cooperative approach. The success is evident in the course of the project: as soon as those involved experience the benefits, such as better communication and optimized processes, lean management becomes an indispensable part of the process. More efficient workflows, clear communication and the ability to react flexibly to challenges make the method indispensable, especially when building in existing structures. This not only saves time and money, but also promotes a partnership-based working style that ensures the success of the entire project.
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