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Project Summary

Lean Project Name

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Lean Project Description

Lean Project Summary

Plunge pile production improved to one pile per shift

Lean Project Benefits Summary

Reduction in traffic management. Overall saving on DHS M6 J5-10a: £132,400

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

DH6 M6 J8-10a and the SMP Alliance NEAR programme have a significant amount of plunge piles to install. This work study has been proposed due to the identification of significant waste observed during a GEMBA on the installation of plunge pile within the M6 J5-8 motorway verge during overnight closures. Each pile was being installed over 2 concurrent shifts and Lean wastes of unnecessary transport, motion, waiting and extra process had been identified.

Measure

Plunge pile as built records were available from DHS M6 J5-8. Observations were documented in the GEMBA, site diaries and time observation sheets. Value stream maps (VSMs) were produced for the current, future, and proposed states.

Analyse

Once all the data was analysed, it was agreed with the supplier that there is sufficient time within one nightshift to complete one pile installation per shift, as approximately 40% of the working window was spent on mobilisation / de-mobilisation each shift. It was agreed that an average install time of 7.5 hour could be reduced to 4.5 hours. The decision was made to target one pile in one shift given a +5-hour working widow.
The team have reduced production time to a best case of 3 hours per pile (24/04/2024), therefore risk of TM overrun is minimal

Improve

Motion / Waiting – Eliminate the use of the piling rig for general offloading, use lorry mounted crane. This would allow critical tasks to commence earlier in the shift / concurrent working.
Transport and Extra Process – Focusing on one pile one shift would halve the traffic management requirement and half the time spent mobilising / demobilising all plant and equipment (cost saving).

Control

Several sessions were held with the site team and the piling subcontractor Van Elle to understand the wastes identified and programme future install operations with an aim of one pile per shift output. Key deliverables were.
-	Lift plan for lorry mounted crane. 
-	Understanding of the programme critical steps = optimising the piling rig for key works by the site team undertaking the works.
-	Another GEMBA to be carried out.

Transfer

A presentation was prepared and shared at the bmJV weekly update. It was also shared at the BAM Transport Lean forum and the bmJV NEAR Kick Off session. 
The idea was transferred and also implemented on DHS M42 J4-7.

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

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

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Was a Departure Required?

NoYes

DAS Reference

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