Implementing Lean Construction Principles in Civil Infrastructure Projects: An Analytical Framework for Productivity Enhancement and Waste Elimination

The global civil construction sector faces chronic structural inefficiencies, characterized by a low task completion reliability rate (PPC of 55–60%) and stagnant labor productivity. This study proposes an integrated Lean-Transformation-Flow-Value (TFV) operational framework tailored to civil engineering projects. By synthesizing macroeconomic datasets (McKinsey Global Institute, Funcas, U.S. Bureau of Labor Statistics) through a PRISMA-guided protocol and coupling them with a Discrete-Event Simulation (DES) model of a multi-span highway viaduct, this paper evaluates the operational transition from traditional Push scheduling to a synchronized Pull-JIT system. Quantitative findings indicate that non-value-adding activities account for up to 57% of total operational time in construction, compared to 26% in manufacturing. Furthermore, while heavy civil operations achieve an isolated productivity index of 119% relative to the industry average, sub-contractor fragmentation reduces net productivity by 12%. The conceptual simulation demonstrates that stabilizing the Lookahead planning window through the Last Planner System, Takt planning, and WIP capping increases plan reliability (PPC > 80%), compresses total process Lead Time by 46.2% (from 45.0 to 24.2 days [95% CI: 22.5–25.9 days]), stabilizes workflow reliability at a mean PPC of 82.4% [95% CI: 79.8–85.1%], and reduces Work-in-Progress queue buffers by 78.5% (from 55 to 11.8 active units [95% CI: 10.4–13.2 units]). The research establishes a predictable operational baseline, mitigating multi-tiered waste propagation across civil engineering infrastructure delivery.