Improving Construction Productivity by Applying the Toyota Production System (TPS)

Abstract

This research aims to enhance productivity and address labor shortages in construction by applying the Toyota Production System (TPS) to improve existing processes.
The construction industry faces various challenges, such as
a lack of skilled workers, budget and time constraints, and resource management issues, including materials, equipment, and labor. The study began with data collection through observation, interviews with managers and employees, and
the review of relevant documents. The collected data were then analyzed using Value Stream Mapping (VSM) to identify areas of waste. The overall improvements are made visible through the numerical outcomes specified.

A new process was subsequently designed and tested, utilizing TPS tools originally developed for Toyota's automotive manufacturing but adapted to the context of construction projects. Despite differences between the two industries, the adapted approach fosters systemization, reduces waste, improves productivities and resource management efficiency. The study found that the foundation pouring activity reduced its duration from 16 hours to 9.2 hours (a 42.5% reduction), while tiling decreased from 28 hours to 16.5 hours (a 41.07% reduction). Both activities showed a decrease in Takt time of over 40% and a reduction in error rates of over 70%, reflecting significantly improved resource management efficiency.