lean concept, 5S, Pareto, efficiency


Precast industry is currently experiencing an increase in demand from consumers. Due to increasing demand, a wide variety of products, and push production systems, factories suffer from excess waste, disorganized workplaces, and unhealthy working environments, so it needs a method to overcome these problems. In overcoming this problem, research was carried out by implementing a lean concept with the concept of Seiri, Seiton, Seiso, Seiketsu, Shitsuke (5S) on the handling of waste materials that occur in the precast concrete production process. Material waste is obtained from interviews and analysis of the production cost budget assisted by the Pareto 80/20 method to determine materials that are included in the waste category. From the results of the Pareto analysis, it was found that 5 materials were wasted, namely Reinforcement Ø 13, Concrete Sand, Wire, Oil Formwork Console, and PC Strand 12.7. Then the results are re-analyzed with cause analysis based on the results of brainstorming with a quantity surveyor, two material wastages were obtained, namely wire and formwork console oil. The waste will be repaired with the seiri concept in the form of making a warehouse near the work area, so that later it will eliminate material wastage so that it can save oil. 2930-liter console formwork and 5915 kilograms of wire, with a total cost savings of IDR 123,758.060

Author Biographies

Roland Gasenda Suryaningrat, Brawijaya University

Master degree student at Construction Management,Department of Civil Engineering,Faculty of Engineering,Brawijaya University 

Indradi Wijatmiko, Brawijaya University

Vice Dean of Academic Fields,Faculty of Engineering,Brawijaya university

Yatnanta Padma Devia, Brawijaya University

Head of Master's Program,Department of Civil Engineering,Faculty of Engineering,Brawijaya university


Kurama, Yahya C., et al. "Seismic-resistant precast concrete structures: state of the art." Journal of Structural Engineering 144.4 (2018): 03118001.

Mohammed, Hussam Ali. Precast Concrete Cost Solution. Presentation presented to Al-Furat Al-Awsat Technical University-Technical Collage of Al-Mussaib-Session Presentation, Iraq, 2018.

Al Aomar, Raid A. "Applying 5S LEAN Technology: An infrastructure for continuous process improvement." (2011).

Abd Jamil, Ahmad Huzaimi, and Mohamad Syazli Fathi. "The integration of lean construction and sustainable construction: A stakeholder perspective in analyzing sustainable lean construction strategies in Malaysia." Procedia Computer Science 100 (2016): 634-643.

Posada, Juan Gregorio Arrieta. "Interacción y conexiones entre las técnicas 5s, SMED y Poka Yoke en procesos de mejoramiento continuo." Tecnura 10.20 (2007): 139-148.

Ramesh, K., V. R. Muruganantham, and N. R. Arunkumar. "5S implementation studies in biomass processing unit." International journal of innovative research in science, engineering and technology 3.4 (2014): 312-318.

Tanabe, Katsuaki. Pareto’s 80/20 rule and the Gaussian distribution. Physica A: Statistical Mechanics and its Applications, 2018, 510: 635-640.

Adegoke, B. F., et al. "The Use of 80: 20 Pareto Rule: A Guide in Testing Accuracy of Cost Estimating of Residential Buildings in Nigeria." Technology (ICONSEET) 2.43 (2017): 330-340.

Aulia, Novinda Annisa, Harimurti Harimurti, and Kartika Puspa Negara. Analisis dan Evaluasi Sisa Material Konstruksi Menggunakan Metode Pareto dan Fishbone Diagram (Studi Kasus pada Proyek Pembangunan Gedung Pascasarjana Universitas Islam Malang). Diss. Brawijaya University, 2016.

Caldera, H. T. S., Cheryl Desha, and Les Dawes. "Exploring the role of lean thinking in sustainable business practice: A systematic literature review." Journal of cleaner production 167 (2017): 1546-1565.

Vilventhan, Aneetha, V. G. Ram, and S. Sugumaran. "Value stream mapping for identification and assessment of material waste in construction: A case study." Waste Management & Research 37.8 (2019): 815-825.

Khodeir, Laila M., and Reem Othman. "Examining the interaction between lean and sustainability principles in the management process of AEC industry." Ain Shams Engineering Journal 9.4 (2018): 1627-1634.