Exploring Defects in Construction—An Experimental Study

Lean construction approach to project management incorporates the ideas of Lean thinking and lean principles to minimize waste and add value to the customers. Several firms have reported benefits through enhanced productivity by adopting Lean techniques on project sites worldwide. Some of the popular tools implemented include the last planner system and value stream mapping. While these are popular, there seems to be a dearth of studies that address the eight types of Lean wastes which include defects, overproduction, waiting, motion, unused talent, transportation, inventory, motion, and extra-processing. To this end, an experimental study was conducted across two universities wherein students from NICMAR Pune and Nottingham Trent University, UK, collaborated for a period of two months to identify different types of waste on project sites and explored strategies to minimize them. This experiment aimed to identify and mitigate Lean waste and suggests the path of moving towards zero waste in construction aligned with the United Nations goal for a sustainable development. This particular paper focuses on the ‘defects’ type of Lean waste. Using a fishbone diagram and 5-why analysis, the root cause for defects was analysed, and strategies to overcome defects were suggested. Recommendations included effective construction management including people, processes, advanced technology, and effective training and education in Lean methods and incentivizing good workmanship. The measures were tested on the project sites and validated. The findings of the study are expected to add as a stepping stone to standardize processes that can minimize waste in the construction processes.