Purpose This study investigated the implementation challenges of one of lean construction’s recent tools, the Last Planner System (LPS), by exploring issues in the New Zealand construction sector to identify potential areas for improvement. To achieve this aim, the study formulated two objectives: 1) to present the challenges in LPS use; and 2) to explore solutions through using an Excel spreadsheet to facilitate LPS applications.

Design/methodology/approach The study drew primarily upon a case study approach. A fieldwork study and document analysis of a New Zealand construction project were conducted with an extensive literature review undertaken on the LPS concept.

Findings The findings revealed that, although an automated spreadsheet could be a simple and inexpensive option for using the LPS, data collection, storage and transfer into the spreadsheet could significantly influence the LPS outcomes’ reliability. Most data utilisation challenges were found to occur around the three data sets included in the Weekly Work Plan (WWP). The study presented several automation solutions which had been applied to overcome data utilisation challenges.

Originality/value Among the first of its kind in the construction industry, this study, with its first-hand account of an organisation which uses the lean paradigm, provides an in-depth insight into LPS tool implementation. The study extends the current body of knowledge through unearthing the challenges of LPS integration into construction activities and presenting efforts undertaken in a construction case project to overcome relevant issues. This adds value through enhancing the reliability of the LPS and, consequently, the effectiveness of its implementation in practical terms.