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Objectives

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  1. A Chamber Installations Process Improvement M60 J8 & M62 J19 £228,763 savedKatie Jones, MSM Jonathan Derrick, Mway

  2. Objectives Talk through work study Demonstrate how I-pads are used to evaluate waste Show some footage from the day and have a go at analysing waste & some thought on waste Discussion around waste at the end

  3. Problem &Goal Statement Problem MSM have 345 Chambers (inclusive of A & B chambers) to install on the It is currently taking 2 days to install 1.5 chambers. Goal To improve productivity of A-chamber installations.

  4. Stakeholder Benefits MSM: Certainty of programme, improved safety and less rework Rowarth: Increased productivity = more money, improved safety and reputational benefits. Mway: Reputation, finishing programme early means they can start the next job. Less waste of materials. Client: Better value for money, cost and time savings overall on the job. Public: Less disruption to the public

  5. Deliverables • Video of study • Work Study Analysis • Improved process • Notes from improvement workshop • Improvements • Knowledge Transfer Pack • Presentation • BCRF


  6. Success • Increased productivity from1.5 chambers in 2 days to 2 per day. • Increase in value adding activity • Reduction in waste

  7. Observed Process Flow for A-Chamber Installations (to ground level) with connection onto existing CCD. Show Video

  8. How we conducted the Study?

  9. Day 1 Analysis

  10. Day 1 Analysis

  11. Day 2 Analysis

  12. Day 2 Analysis

  13. Summary Finding slide

  14. Went through a quick introduction to Lean Improvement Workshop Operatives came up with a list of improvements that we tried to categorise into Lean wastes

  15. Fishbone Diagram

  16. Typical site layout without constraints in longitudinal direction. Example site layout with obstruction e.g. gantry. Site layout

  17. Driving the improvements

  18. Improvements taken forward Develop new process Create Site Material Interface Diagrams (SMID) Get a trailer for HIAB Develop Visual Management Boards Looking to get Ipads for supervisors and gangs Detailed Collaborative Planning with the workforce Pre Cast Apron

  19. Improvement 1: The Proposed LEAN process for Installation New Process Old Process New Process

  20. Early Prototype Site Material Interface Diagrams

  21. Phase 1 S.M.I.D.

  22. Phase 2 S.M.I.D.

  23. Improvement: Trailer for HIAB Trailer carrying ducts HIAB

  24. Site Layout These photo’s show the new site layout and the excavation which has been left open. Unfortunately we couldn't conduct a like for like time and motion study as there was two gangs on this particular day. Excavation left open after CCD’s

  25. New cabin for daily briefings with whiteboard highlighted. Planning includes: --where each are gang working -logistics -materials need at next site. Visual Management Intention to get ipads for supervisor/gangs to use for pre-planning next site Inc. taking photos and annotate positions of items required.

  26. Benefits • Installing 2 chambers per day (originally 1.5 in 2 days) • Teams planning collaboratively • Pre Cast Aprons • Combining excavation with CCD = £83,577.00 • Standardised plan = £137,50.00 SMID • Temporary lid £7336 Total saving £228,763

  27. I-Pad Lean Assessment Tool Show Video App is web based Type in detail of study

  28. Questions and Group Discussion Any Questions?Group discussion – Waste appears on every site and appears to be accepted: - how can we change this culture? “Thanks to Rowarth/ Mways Operatives and Supervisors for their great ideas and cooperation.”