Metal Construction News, January 2021

GUEST COLUMN The tenets of lean manufacturing are inherent in the metal building systems industry though it is not commonly understood how widely and effectively the manufacturers employ such efficiencies Understanding why metal building manufacturing has long been a leading force in the application of both lean manufacturing and construction practices can help those within the field to better articulate the value and professionalism inherent in the industry However the industry has much to learn about lean management practices and how to streamline activities and behavior to improve employee engagement and bottom line performance Lean principles were originally popularized by Toyota in the 1930s In the spirit of the concepts foundational premise of continuous improvement these principles have been adapted to accommodate 21st century manufacturing processes and have been retooled to address the circumstances and diverse manufacturing practices relevant to different types of industrial businesses An Inherently Lean Industry Lean manufacturing principles are foundational to metal building production and have allowed the industry to gain substantial ground in the low rise non residential market Consider these findings Metal buildings generate about 6 in scrap material and even that is typically reused or recycled The materials are fully recyclable multi recyclable generate a very low carbon footprint and the waste steel accumulated during fabrication is generally recycled Metal building manufacturers who embrace lean concepts are able to deliver high quality custom designed and manufactured products at competitive prices and with superior lead times that can improve profit margins Metal building design and construction processes are more efficient than conventional construction by some 25 Job site waste is minimal because the primary building components are manufactured in a One metal building company experienced a 78 improvement in engineering lead time by implementing a process that held all areas accountable throughout design review and fabrication quality controlled factory setting so all parts come to the site at the exact size needed However lean manufacturing and lean management are two very different elements of the greater metal building story Lean Management Concepts Lead to Hefty Savings Manufacturers of metal building systems continue to benefit by building their manufacturing policies and procedures on a lean management framework Eliminating waste the non valueadded components in any process is foundational to their business activities Most understand that unless a management process has gone through lean principle analyses multiple times it contains some element of waste When done correctly lean management activities can create huge improvements in efficiency cycle time productivity inventory management material cost management and scrap reduction all leading to lower costs and improved competitiveness And lean management principles can enhance how a Implementing Lean Management Principles in the Metal Building Industry Can Result in Bottom Line Improvements Lean Manufacturing and AC472 Accreditation Two Concepts with Interwoven Goals The concepts of lean construction tie directly to the International Accreditation Services AC472 accreditation program Accreditation for Metal Building Systems Inspection This quality assurance program is designed specifically for manufacturers of metal building systems and mandates detailed quality control requirements that must be independently inspected at least annually for a company to retain its accreditation AC472 addresses quality management system elements such as personnel requirements product traceability process control and various administrative and technical expectations that are essential for code officials to deem IAS accredited entities as approved fabricators By Tony Bouquot general manager Metal Building Manufacturers Association Metal building manufacturers and all companies who supply products to them can benefit from posting metrics on display boards in each department to instill accountability and ownership for daily decisions and influence cross functional cooperation www metalconstruct ionnews com 14 METAL CONSTRUCTION NEWS January 2021