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Lean Project Summary

During the diversion planning process, United Utilities emphasised the importance of network resilience when crossing Skippool Bridge. This required a back‑up sleeve of 750mm diameter for the existing 600mm asbestos concrete main. However, the bridge deck could not accommodate two ducts of this size, and the freeboard to Main Dyke limited the potential to further strengthen the deck.

The potential impacts included compromising the structural integrity of the bridge and jeopardising the resilience of the network. Key dependencies requiring attention involved accommodating the bridge design constraints while still delivering the necessary infrastructure. The solution was to reduce the sleeve diameter to fit alongside existing assets. By achieving this balance, the project ensured network resilience while maintaining the structural integrity of Skippool Bridge, ultimately benefiting stakeholders through the delivery of a robust and reliable infrastructure solution.

Lean Project Benefits Summary

The Skippool Bridge (W1 failure recovery) project delivered significant benefits, strengthening both network resilience and structural integrity. Lean practices such as DMAIC and collaborative planning were applied to address W1 failure recovery, manage critical path issues, and control cost overruns.
The diversion was divided into four sections, with temporary connections introduced to manage complexity and prevent delays. Success was underpinned by ongoing stakeholder collaboration, regular monitoring, and flexible planning.
The project achieved estimated savings of £200,000 in site running costs and reduced the overall programme from 319 days to 195, substantially cutting lead times and ensuring efficient delivery.

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Lean Construction Development Programme (LCDP) Project

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Problem Solving Strategy (DMAICT)

Define

During the diversion planning process, United Utilities emphasised the importance of network resilience when crossing Skippool Bridge, necessitating a back-up sleeve of 750mm in diameter for the 600mm asbestos concrete main. However, the bridge deck cannot accommodate two ducts of this size, and the freeboard to Main Dyke limits the potential to further strengthen the deck. The potential impacts include compromising the structural integrity of the bridge and jeopardising the network’s resilience. The dependencies requiring attention include accommodating the bridge design constraints while delivering the necessary infrastructure and reducing the sleeve diameter to fit alongside existing assets. Achieving this will ensures network resilience while maintaining the structural integrity of Skippool Bridge, benefiting stakeholders by providing a robust and reliable infrastructure solution.

Measure

The initial design for the two bridges was scheduled for completion on 6 January 2021. However, the North Bridge required a redesign to incorporate an additional pipe bridge for United Utilities’ assets, extending the completion date to 11 November 2021, a total delay of 304 calendar days.
Accommodating these strategic assets was essential and had a significant impact on the original programme. The redesign ensured that the new pipe bridge was fully integrated without compromising the structural integrity or functionality of either bridge.
This extension reflects the inherent complexity of meeting utility requirements and highlights the challenge of balancing essential infrastructure needs with project timelines. Ultimately, the redesign delivered a resilient and functional bridge solution that satisfies all stakeholder requirements while safeguarding critical utility infrastructure.

Analyse

Kier worked closely with United Utilities to mitigate potential delays to the W1 statutory diversion. The diversion was split into four separate sections, with temporary connections implemented to maintain progress. This approach effectively managed the complexity of the diversion and allowed work to continue without significant interruption. The benefits were clear: reduced site running costs, a shortened lead time for project completion, and stronger alignment with the project’s critical path. The collaborative efforts with United Utilities ensured the delivery plan remained on track despite the challenges, ultimately supporting successful completion of the works.

Improve

Kier coordinated with United Utilities to mitigate further delays to the W1 statutory diversion by splitting the diversion into four separate sections and implementing temporary connections. These actions helped manage the complexity of the diversion and ensured work could continue without significant interruptions. The positive impact included reduced site running costs and minimised lead time for project completion. Additionally, the collaborative efforts with United Utilities supported the delivery of the plan, ensuring the project remained on track despite the challenges. These improvements and outcomes were crucial in maintaining the project’s critical path and achieving successful completion.

Control

Several measures, actions, and technical steps were implemented to ensure ongoing improvement. Continuous collaboration with United Utilities was maintained to provide support and alignment with project objectives. Regular monitoring and evaluation were carried out to track progress and quickly identify any emerging issues. Dividing the diversion into sections enabled better management and minimised delays, while temporary connections were established to maintain functionality and prevent disruption during the transition. Stakeholder engagement was prioritised to keep all parties informed and actively involved in decision-making. Together, these measures sustained the improvements and ensured the continued success of the project.

Transfer

The project provided valuable lessons in managing complex diversions and ensuring network resilience. Key insights included the benefits of continuous stakeholder collaboration, dividing large tasks into manageable phases, and utilising temporary solutions to maintain operations. Strong stakeholder engagement, regular progress monitoring, and adapting plans in response to emerging issues proved vital for success. Major process improvements were achieved by splitting the diversion into four sections, implementing temporary connections, and consistently applying Lean practices. These adjustments reduced site running costs, shortened lead times, and enabled more effective management of the project’s critical path. Together, these measures contributed to a successful outcome and enhanced the approach to future infrastructure projects.

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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

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