wastes in construction industry

QUESTIONNAIRE ON

WASTES IN CONSTRUCTION INDUSTRY (Responses for research / academic purposes.)

INTRODUCTION The objective of this questionnaire is to identify the various wastes and its root causes in construction industry. It is recognized that you are a professional with rich experience in construction industry. Hence, requesting you to help by filling this questionnaire. Please respond to each question honestly and accurately. All responses will be treated in absolute confidence and the responses or data would be used strictly for research or academic purposes. For any queries or suggestions, please contact Mr. Ajay Joshy Dept. of Civil Engineering, National Institute of Technology, Calicut. Email: [email protected] Mob No. 7736797731

GUIDELINES Lean construction is a different way of thinking about construction, eliminating waste and creating value for customers and end-users. Large scale construction projects suffer from different problems which directly or indirectly affect overall industry and profitability. As a result, methodologies have been developed to reduce the risk of overruns and improve project outcomes. The application of Lean to construction is based upon treating the construction site as a temporary production line and is referred to as Lean Construction. This QUESTIONNAIRE ON WASTES IN CONSTRUCTION INDUSTRY consists of Three parts.

A. GENERAL INFORMATION This is for general information of Project and Respondent B. WASTES IN CONSTRUCTION INDUSTRY The different type of wastes generated in the construction industry (Seven Nos.) has been identified from the various literatures. Explanation on Each Waste is attached in next page. Kindly rank those wastes based on your experience and related to your current project. C. IDENTIFICATION OF THE VARIOUS ROOT CAUSES IN WASTE

GENERATION The various factors or causes which lead to the generation of the respective wastes are categorized below. Kindly rate these factors based on their significance as per your opinion and experience through various projects.

EXPLANATION OF EACH WASTE Transportation Waste: This is unnecessary motion or movement of products or materials that does not directly support immediate production, such as materials being transported from one job site to another or materials being transported from job site back to the building partner. Ideally transport should be minimized for two reasons. 1. It adds time to the process during which no value added activity is being performed, and the material is exposed to handling damage. Inventory Waste: This refers to any supply (materials or goods) in excess of what is required to build the current homes under construction. Inventory includes raw materials, work-in-process and finished goods. Though not all inventory is unnecessary waste, excess inventory can quickly build-up and tie-up dollars and resources. All Inventories requires additional handling and space. Motion Waste: This term refer to the extra steps taken by people to accommodate inefficient process layout, defects, reprocessing, overproduction or excess inventory. Motion takes time and adds no value to the product or service. To move and add value is called work. To move and not add value is called motion. Waiting Waste: Also known as delay, waiting refers to the periods of inactivity that occur because a preceding activity didn’t deliver on time or finish completely. Waiting waste increases cycle time during which no value-added activity is performed. Over Processing Waste: This term generally refers to unnecessary steps in operations, such as reprocessing, double-handling, added communication and double-checking which adds no value to the product or service. Over-processing is often inserted into a process as a result of dealing with defects, overproduction or excess inventory. Over Production Waste: Overproduction occurs when operations continue after they should have stopped. It’s producing more than is needed, faster than needed or before it is needed. This results in product being produced in excess of what’s required, products being made too early, and excess inventory carrying costs. Correction (Defects) Waste: These are products, materials or services that do not meet expectation or conform to specification. Corrections and defects are anything not done correctly the first time and must be repaired, sorted, re-made or re-done, as well as materials which are scrapped due to defects.

WASTES IN CONSTRUCTION INDUSTRY ( Questionnaire ~ Responses for research / academic purposes. )

A. GENERAL INFORMATION (Please fill in the blank or tick in the box) 1. Project Name

: ................................................................................ ................................................................................

2. Project Location 3

: ................................................................................

Name of Respondent ((optional) : ................................................................................

4. Respondent Designation

: ................................................................................

5. Experience in construction filed: Less than 2 years

2-5years

6-10 years

11-15 years

above 15 years

6. Experience in the present position: Less than 2 years

2-5years

6-10 years

11-15 years

above 15 years

7. Type of employer: Project Manager

Client

Engineer

Supervisor

Main - contractor

Sub - contractor

Sub - contractor (Labour only) 8. Awareness about Lean Construction: Aware

Not Aware

1

B. WASTES IN CONSTRUCTION INDUSTRY Following are the different wastes generated in the construction industry from the various literatures. Kindly rank those wastes based on your experience and related to your current project. ( Please rank the answer that mostly suit your views as 1, 2…7 )

SL. NO.

WASTES

RANKING

1 2 3 4 5 6 7

Transportation Inventory Motion Waiting Over Processing Over Production Corrections

C) IDENTIFICATION OF THE VARIOUS ROOT CAUSES IN WASTE GENERATION The various factors or causes which lead to the generation of the respective wastes are categorized below. Kindly rate these factors based on their significance as per your opinion and experience through various projects. (i) TRANSPORTATION Rating Based on Significance Extremely significant effect - 5 Very significant effect - 4 Ranking Significant effect - 3 Slight effect - 2 No effect - 1

Sl.No.

Root Causes

1

Ineffective planning and scheduling of the project

1

2

3

4

5

2

Improper project coordination

1

2

3

4

5

3

Equipment necessary to do the job not available on time

1

2

3

4

5

Strikes called by political parties, hartals etc.

1

2

3

4

5

Labour strikes

1

2

3

4

5

4 5

2

(ii) INVENTORY Rating Based on Significance Extremely significant effect - 5 Very significant effect - 4 Ranking Significant effect - 3 Slight effect - 2 No effect - 1

Sl.No.

Root Causes

1


1

2

3

4

5

2

Lack of adequate space for storage of materials

1

2

3

4

5

3

Lack of weekly project evaluation meetings

1

2

3

4

5

4

Lack of experience of supervisor

1

2

3

4

5

5

Inadequate instructions provided by supervisor

1

2

3

4

5

6

Lack of experience of craftsmen

1

2

3

4

5

7

Lack of team spirit among craftsmen

1

2

3

4

5

Unavailability of materials in time at the workplace

1

2

3

4

5

Delay in material delivery

1

2

3

4

5

Frequent revisions of drawing / design resulting in additional work / rework

1

2

3

4

5

8 9

10

3

(iii) MOTION Rating Based on Significance Extremely significant effect - 5 Very significant effect - 4 Ranking Significant effect - 3 Slight effect - 2 No effect - 1

Sl.No.

Root Causes

1


1

2

3

4

5

2

Improper project co-ordination

1

2

3

4

5

3

Site congestion

1

2

3

4

5

4

Lack of interation among the site community

1

2

3

4

5

5

Communication problem among craftsman and supervisors

1

2

3

4

5

6

Unavailability of tools on time at the worksite

1

2

3

4

5

1

2

3

4

5

1

2

3

4

5

1

2

3

4

5

1

2

3

4

5

7

8

9

10

Equipment necessary to do the job not available on time Accidents causing hindrance to work at site Strikes called by political parties, harals etc. Frequent revisions of drawing / design resulting in additional work / rework

4

(iv) WAITING Rating Based on Significance Extremely significant effect - 5 Very significant effect - 4 Ranking Significant effect - 3 Slight effect - 2 No effect - 1

Sl.No.

Root Causes

1


1

2

3

4

5

2


1

2

3

4

5

3

Interference from other traders or other crew members

1

2

3

4

5

4

Disputes with consultants / owner causing stoppage of work

1

2

3

4

5

5

Lack of interaction among the site community

1

2

3

4

5

6


1

2

3

4

5

7

Slowness in decision making

1

2

3

4

5

8

Lack of periodic meeting among the management, site personnel and the contractors

1

2

3

4

5

9


1

2

3

4

5

10


1

2

3

4

5

11

Supervisor absenteeism

1

2

3

4

5

12


1

2

3

4

5

13

Rework due to field errors committed by craftsmen

1

2

3

4

5

5

14

Craftsmen absenteeism

1

2

3

4

5

15

Unavailability of materials in time at the workplace

1

2

3

4

5

16

Slow response on doubts arising from the drawings

1

2

3

4

5

17

Frequent revisions of drawing / design resulting in additional work / rework

1

2

3

4

5

18

Design difficult to construct

1

2

3

4

5

19

Unavailability of tools on time at the worksite

1

2

3

4

5

1

2

3

4

5

1

2

3

4

5

21

Equipment necessary to do the job not available on time Lack of maintenance of tools and plants

22

Slow equipment repair in case of breakdown

1

2

3

4

5

23

Accidents causing hindrance to work at site

1

2

3

4

5

24

Climatic changes

1

2

3

4

5

25

Strikes called by political parties, hartals etc.

1

2

3

4

5

26

Labour strikes

1

2

3

4

5

27

Poor pay

1

2

3

4

5

28

Lack of monetary incentives

1

2

3

4

5

29

Lack of workmanship

1

2

3

4

5

30

Disregard of craft worker suggestions / ideas

1

2

3

4

5

20

6

(v) OVER PROCESSING Rating Based on Significance Extremely significant effect - 5 Very significant effect - 4 Ranking Significant effect - 3 Slight effect - 2 No effect - 1

Sl.No.

Root Causes

1


1

2

3

4

5

2


1

2

3

4

5

3


1

2

3

4

5

4


1

2

3

4

5

5


1

2

3

4

5

6


1

2

3

4

5

7


1

2

3

4

5

7

(vi) OVER PRODUCTION Rating Based on Significance Extremely significant effect - 5 Very significant effect - 4 Ranking Significant effect - 3 Slight effect - 2 No effect - 1

Sl.No.

Root Causes

1


1

2

3

4

5

2


1

2

3

4

5

3

Lack of adequate space for storage of materials

1

2

3

4

5

4

Site congestion

1

2

3

4

5

5


1

2

3

4

5

6


1

2

3

4

5

7


1

2

3

4

5

8


1

2

3

4

5

9


1

2

3

4

5

10


1

2

3

4

5

8

(vii)CORRECTIONS Rating Based on Significance Extremely significant effect - 5 Very significant effect - 4 Ranking Significant effect - 3 Slight effect - 2 No effect - 1

Sl.No.

Root Causes

1


1

2

3

4

5

2

Interference from other trades or other crew members

1

2

3

4

5

3

Disputes with consultants/ owner causing stoppage of work

1

2

3

4

5

4

Lack of interaction among the site community

1

2

3

4

5

5


1

2

3

4

5

6


1

2

3

4

5

7


1

2

3

4

5

8


1

2

3

4

5

9


1

2

3

4

5

10

Supervisor absenteeism

1

2

3

4

5

11


1

2

3

4

5

1

2

3

4

5

1

2

3

4

5

12 13

Rework due to field errors committed by craftsmen Lack of Team spirit among craftsmen

9

14

Craftsmen absenteeism

1

2

3

4

5

15

Poor quality of materials

1

2

3

4

5

16

Unavailability of drawings in time at the worksite

1

2

3

4

5

17

Errors in the drawings

1

2

3

4

5

18

Slow response on doubts arising from the drawings

1

2

3

4

5

1

2

3

4

5

1

2

3

4

5

20

Frequent revisions of drawing / design resulting in additional work / rework Poor quality of tools provided / used

21

Lack of maintenance of tools and plants

1

2

3

4

5

22

Disregard of craft worker suggestions / ideas

1

2

3

4

5

19

(viii)

ADDITIONAL SUGGESTIONS & OBSERVATIONS IF ANY

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