View Project Details

Project Summary

Lean Project Name

Unique ID

Lean Project Description

Lean Project Summary

Innovative approach to installation pile caps utilising pre-fabricated shutters

Lean Project Benefits Summary

Overall savings= £97,808.33 - £11,581.25 = £86,277.08
(National Highways Digital Efficiency Reference 4818)

Roads Period Efficiency Reported

Efficiency Value Assured

Efficiency Register ID

Image

Lean Construction Development Programme (LCDP) Project

NoYes

Supplier

Contact Email

Stakeholders involved in project

Stakeholders Involved - Other

Problem Solving Strategy (DMAICT)

Define

Prior to main works starting on site, several test piles were capped using the cardboard shutters. After having examples of cardboard shutters being damaged for water and the effort required to keep the shutter in position during concrete fill, the subcontractor L&A decided to seek alternative solutions before proceeding with the 6000 additional pile caps.

Measure

The original solution, as per typical of the process was to use cardboard shutters to contain the concrete that would be poured on top of the pile, creating a mushroom shape pile cap. This process carries a cost of over £90,000 in materials (approx. £15 per cardboard shutter) and they prove difficult to store on site due to the waxed cardboard material which are more prone to damage from rain, therefore typically require storage units erected close to the work area for storage.

Analyse

• "Waxed cardboard shutters 6050 x £15 (approx)" -£90,750.00
• "Estimated rework cost based on repositioning/damaging of cardboard from machine and or positioning (1 in 30 piles)= (6050/30*£35)
• £35 based on £15 cardboard shutter cost/damage and £20 time/machine cost"= £7,058.33
• Additional process step of removing steel shutters (observed at approx. 40 shutters removed in 30 minutes @ £50 an hour). = £3,781.25

Improve

•Pre fabricated steel shutter which are now reusable for all flared heads operation
•L&A Reinforcements designed and fabricated steel shutters to trial that could be reused on site that would fit around the pile cap for concrete pour. Not only are the shutters reusable for future piles and work, they store easily on pallets as can be stacked within each other and they are more durable for the concrete pour part of the process. There is also reduced risk of them getting damaged by the machines filling muck around the shutters to hold in to position.

Control

•Ensure quality of flared heads are consistent with design specification despite the change of method
•Monitor the number of rework compared to the old method to ensure the benefit is as per described

Transfer

•Sharing best practice
•L&A has worked in other sectors such as the HS2 where this best practice method can be shared.
•Added to NH Costain digital efficiency register
National Highways Digital Efficiency Reference 4818
•Shared across Costain

What Lean Tools & Methodologies were used for your Lean Project?

If Other, please specify

Other Project Benefits

Meeting the needs of all users

Meeting the needs of all users - Other

Improving safety, health & wellbeing for all

Improving safety, health & wellbeing for all-Other

Delivering better environmental outcomes

Delivering better environmental outcomes - Other

Sustain a well-maintained and resilient network

Sustain well-maintained & resilient network- Other

Providing fast and reliable journeys

Providing fast and reliable journeys - Other

Achieve efficient delivery

Achieve efficient delivery - Other

Project Detail

National Highways Directorates involved in project

Division

Scheme Name

Scheme PIN

Was a Departure Required?

NoYes

DAS Reference

How would you categorise your Lean project?

Uploaded Files

There are no notes to display.

You don't have permissions to view notes.

Error completing request.