Tactical Obeyas for production control: visual management with Kaizen, Takt & LPS

Offshore wind turbine pre-assembly is a high-stakes construction environment characterised by extreme logistical complexity, crane-dependent operations, and tight vessel/weather constraints where time is the primary currency. Despite the increasing adoption of Lean Construction approaches such as the Last Planner System (LPS) and Obeya rooms, current implementations often lack the operational distinction among management levels needed for tactical production control at the site level. This paper employs a Design Science Research (DSR) approach to develop and evaluate a multi-layered Visual Management (VM) artefact. This Tactical Obeya system integrates (1) a takt production line, (2) LPS make ready, (3) an integrated deviation management layer linking safety, quality, and technical constraints to quantified flow interruptions, and (4) Kaizen layer introducing continuous improvements. The artefact shifts management emphasis from reactive output reporting toward proactive input verification and commitment-based coordination (“Reliable Promising”), enabling collective blocker removal and escalation to strategic kaizen improvement events. The theoretical analysis explains how the system reduces flow variability and enhances value delivery to the installation vessel. Initial evaluation indicates improved predictability and stability sufficient to support a reduction trajectory from a volatile 28-day average loadout cycle toward a consistent 20-day target, enabled by continuous feedback loops and structured deviation learning.