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Project Summary
Lean Project Name
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Unique ID
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Lean Project Description
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Lean Project Summary
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Kier A417 project introduced the Inspection Theme Selector to enhance engagement in Operating Site Inspections (OSIs). This initiative sought to make inspections less daunting and more meaningful by reducing their scope, while increasing their frequency, the variety of subjects inspected, and the overall quality. Key actions included providing clear task instructions, ensuring systematic task completion, and conducting regular training sessions. The initiative successfully tripled the number of OSIs, expanded the range of inspected subjects, and garnered excellent feedback. Continuous training, feedback mechanisms, monitoring, and periodic theme updates have ensured sustained improvements. This strategy has cultivated a proactive safety culture, provided enhanced data insights, and bolstered safety performance across the business.
Lean Project Benefits Summary
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The Inspection Theme Selector on the A417 project delivered significant benefits, tripling the number of Operating Site Inspections (OSIs) and increasing the range of subjects inspected. This enhanced engagement and visibility, simplifying the inspection process and making it more accessible, especially for junior team members. It led to a more diverse range of inspections, reducing repetition and focusing on higher-risk tasks. The system fostered increased involvement from supervisors and managers, preventing inspection fatigue and promoting a proactive safety culture. The wealth of data collected provided valuable insights for targeted safety initiatives, improving overall safety performance and operational efficiency. The success of the initiative has been shared widely and adopted in other Kier Transportation contracts, including HS2, the A43, Rail, Area 13, Maple Lodge, and Northampton, demonstrating its effectiveness and scalability.
Roads Period Efficiency Reported
RP1 2015-2020
RP2 2020-2025
RP3 2025-2030
N/A
Efficiency Value Assured
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Efficiency Register ID
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Lean Construction Development Programme (LCDP) Project
Lean Construction Development Programme (LCDP) Project
No
Lean Construction Development Programme (LCDP) Project
Yes
Supplier
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Contact Email
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Stakeholders involved in project
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Stakeholders Involved - Other
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Problem Solving Strategy (DMAICT)
Define
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The Kier A417 Inspection Theme Selector Lean project addressed low engagement with Operating Site Inspections (OSIs), which were seen as daunting and time-consuming. The initiative aimed to improve safety, build stronger collaboration between Site Management and Operatives, and ensure thorough inspections. Key dependencies included clear communication, training on the Theme Selector, and support from supervisors and managers. As a result, the project aimed to increase OSI numbers, expand the range of inspection topics, and foster a proactive safety culture.
Measure
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Operating Site Inspections (OSIs) on the A417 faced engagement challenges due to being seen as daunting and time-consuming. Metrics tracked included inspection count and range of subjects covered. Previously, inspections were limited and infrequent. The Inspection Theme Selector, introduced in July 2023, increased inspection frequency by over 300% in three months and sustained this for 18 months. For example, July 2023 saw 10 OSIs (45,000+ hours worked); by July 2024, this increased to 95 OSIs (90,000+ hours). This significant increase produced valuable data to strengthen safety performance and target improvement initiatives.
Analyse
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To improve OSI engagement, Lean methods like fishbone analysis and 5S were applied to drive continuous improvement, making inspections more engaging and less daunting. 5S provided a structured way to organise inspection themes and tasks. Root cause analysis showed apprehension and literacy challenges (many operatives were overwhelmed by admin and literacy demands), inspection fatigue (repetitive, low-impact topics), and lack of engagement due to limited interaction between supervisors/operatives. The Inspection Theme Selector streamlined the process, offered clear guidance, diversified topics, and boosted engagement, promoting a more collaborative environment
Improve
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To address low OSI engagement, H&S team introduced the Inspection Theme Selector to simplify inspections, provided clear card-based instructions, and ensured supervisors/managers systemically selected tasks while relocating completed themes. These changes tripled OSIs on A417, improved inspection quality and subject range, and boosted engagement between Site Management and Operatives. The approach prevented inspection fatigue through varied topics and received strong feedback. The initiative sustained a 300% frequency increase over 18 months, broadened CDM theme coverage, delivered valuable safety insight, and fostered a proactive safety culture.
Control
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To sustain improvements from the Inspection Theme Selector, continuous training for supervisors and managers ensures effective use, while a feedback system gathers operative and management input for further improvement. Regular monitoring and reporting track inspection data to spot trends and measure progress. Themes are reviewed and updated for relevance, with workshops and meetings held to discuss outcomes and share best practice. Ongoing technical support maintains system effectiveness, with data analytics providing insight from inspection results to inform decisions.
Transfer
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The project significantly increased Operating Site Inspections (OSIs) by over 300% within three months and sustained this for 18 months, enhancing safety and collaboration. Valuable lessons include the importance of effective communication, continuous training, and diverse inspection subjects to prevent fatigue. The project addressed literacy challenges and inspection apprehension through clear instructions and structured themes. Key processes that were changed and improved include the introduction of the Inspection Theme Selector, which streamlined the inspection process, making it more organized and less daunting. Systematic task selection by supervisors and managers using cards provided clear instructions and ensured thorough and diverse inspections. Ongoing technical support and data analytics helped maintain system effectiveness and provided insights for decision-making. These changes led to a significant increase in inspection frequency and enhanced inspection quality.
What Lean Tools & Methodologies were used for your Lean Project?
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Other Project Benefits
Meeting the needs of all users
Meeting the needs of all users - Other
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Improving safety, health & wellbeing for all
Improving safety, health & wellbeing for all-Other
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Delivering better environmental outcomes
Delivering better environmental outcomes - Other
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Sustain a well-maintained and resilient network
Sustain well-maintained & resilient network- Other
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Providing fast and reliable journeys
Providing fast and reliable journeys - Other
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Achieve efficient delivery
Achieve efficient delivery - Other
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Project Detail
National Highways Directorates involved in project
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Division
Scheme Name
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Scheme PIN
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Was a Departure Required?
Was a Departure Required?
No
Was a Departure Required?
Yes
DAS Reference
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