This paper presents a study on the use of pre-stressed precast foundation piles using data collected on a building project that comprised the installation of more than 340 piles. The objective is to assess the presence of product and process variability in demand and supply, and the impact it has on precast pile delivery. Sources of variability in precasting, transportation, and installation are described. As a step towards understanding the complexity of this production system and to show how production planning decisions affect execution, this paper elaborates on two deterministic scenarios and compares those with actual data from the project. Performance of the system is analyzed on the basis of inventory vs. work completed. From the perspective of ‘lean’ thinking the paper then identifies sources of waste and suggests means to eliminate them. It also presents questions for follow-on research.
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