Production planning, monitoring and review: comparison between the practices in an urban rail transit megaproject with the Last Planner System

Abstract

Purpose

Megaprojects are typically very expensive public-centred projects that leave little space for any mismanagement or deficient planning, which could affect the project adversely. The Last Planner™ System (LPS) is a lean construction planning and control tool that functions to reduce waste and increase performance. Given the benefits, the application of the LPS in megaprojects is still scarce, especially in Malaysia. Hence, this study aims to compare the current production planning, monitoring and review practices in a megaproject with the LPS in order to explore the possibilities of adapting the LPS to the current practices.

Design/methodology/approach

This longitudinal case-based study has first explored the current practices implemented in an infrastructure megaproject, which is an urban rapid transit (URT) project, which was then compared to the standard LPS practices. The case study has adopted several research methods such as observation, interview and document review.

Findings

Findings from the study highlight that the current production planning, monitoring and review practices in the URT project mostly differs from the standard LPS practices with only slight similarities found in the major planning phases. The comparative study, which based on five reference points through master, phase, look-ahead, weekly work plan and measure, and learning has resulted in several key elements, representative of the different planning phases, such as collaborative programming, reverse planning, reliability, dependability and continuous learning.

Practical implications

This study provides an alternative perspective to rail planners, as well as other types of project planners in considering the use of the LPS to enhance the quality of planning, monitoring and review in projects. The framework that highlights the core values and key elements for the related planning phases enables project teams with no lean background to partially adapt their current practices to the LPS with minimal disruption.

Originality/value

This study first contributes to the body of knowledge, where limited study was found comparing and contrasting current production planning practices against the LPS, particularly in rail-based megaproject. The results from the comparison are the key elements representing each of the planning phases that was rooted back to the core values (teamwork, involvement and collaboration, communication and transparency, and continuous improvement) necessary to enhance the current practices.

Citation

Belayutham, S., Mohamad Jaafar, R.N.A., Ismail, H.B. and Che Ibrahim, C.K.I. (2022), "Production planning, monitoring and review: comparison between the practices in an urban rail transit megaproject with the Last Planner System", The TQM Journal, Vol. 34 No. 3, pp. 515-533. https://doi.org/10.1108/TQM-11-2020-0282