Bridging Theory and Practice: Evaluating Lean Construction with Lego Simulations

The construction industry faces ongoing challenges in quantifying the benefits of Lean Construction and the Last Planner System (LPS) in practical applications. To address this issue, the study examines data from 40 LEGO-based construction simulations designed to explore key parameters influencing project outcomes, including cost, waste, time, safety, defects, and Percent Plan Complete (PPC). Using statistical methods like correlation and sensitivity analyses can provide valuable insights. The research identifies cost as the most sensitive factor, while material waste management emerges as a critical driver for improving efficiency. Safety and defect reduction also significantly enhance PPC and overall project performance. By mimicking real-world construction scenarios, these simulations provide valuable insights into the practical application of lean principles. The findings highlight the effectiveness of LEGO construction simulations in bridging the gap between theoretical frameworks and on-site implementation, offering actionable recommendations for optimizing construction processes and advancing lean practices.