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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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The Lodge Lane Retaining Wall improvement project, initially quoted at £3.3 million for a 400-metre wall, achieved a £750,000 saving by reducing the wall length to 300 metres. Design optimisation through adapted embankment geometry reduced material use and disposal requirements, and accelerated project completion. Lean methodologies, including Value Stream Mapping and Root Cause Analysis, identified key issues such as groundwater pressure, design constraints, and material availability. Key actions included ground investigation, collaboration with subcontractors, and rigorous checking of drawings. Continuous monitoring and planning have sustained these improvements, ensuring quality, efficiency, and stakeholder benefits.
Lean Project Benefits Summary
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The Lodge Lane retaining wall improvement project delivered multiple benefits. By reducing the wall length from 400 to 300 metres, a material cost saving of £750,000 was achieved, demonstrating the impact of design optimisation and efficient project management. Using less material lowered both costs and disposal requirements, minimising environmental impact. Optimising embankment geometry also increased the availability of fill material and improved construction efficiency, leading to a shorter project programme. Stakeholders benefit from a more sustainable approach to construction.
Roads Period Efficiency Reported
RP1 2015-2020
RP2 2020-2025
RP3 2025-2030
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Efficiency Value Assured
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£
Efficiency Register ID
Project Cover Image
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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 A585 delivery team aims to reduce the length of the Lodge Lane Wall by adapting the geometry of the embankments. The scope is to rationalise the wall length as far as geometry and design allow. Initial modelling indicates that significant savings can be achieved by reducing the wall length. This would result in cost savings, reduced material usage, and decreased disposal requirements. Additionally, shortening the wall could lead to faster project completion. Dependencies include the initial modelling results, design constraints, and stakeholder approval due to the benefits of reduced costs and shorter timelines.
Measure
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Initial modelling indicates potential for significant cost savings by reducing the wall length. However, groundwater conditions and site-specific factors may limit these benefits. A structural review is currently underway along the entire wall, with efforts to optimise and rationalise the length as much as possible within geometric and design constraints. Specific metrics and methods used include measuring the current wall length of 400 metres and targeting a reduction to 300 metres. A detailed cost analysis estimated savings by factoring in material costs, labour, and disposal fees. Quantities of materials required for construction were calculated, projecting a significant decrease in concrete and other materials required.
Analyse
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Lean tools used included Value Stream Mapping to visualise the wall construction process, and Root Cause Analysis techniques, such as the 5 Whys and Fishbone Diagram, to pinpoint underlying issues. Key observations included the potential to reduce wall length through embankment geometry adjustments, thereby increasing available fill material. However, this is influenced by groundwater pressures and final design parameters. Concerns were raised about the bending capacity of secant piled abutments and retaining walls, which may not withstand the required loads. This could necessitate additional piles, larger diameters, and extra reinforcement, thus increasing costs. Strategies to minimise the extent of the wall are being explored.
Improve
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To improve the A585 scheme Lodge Lane retaining wall, a detailed review and coordination process was undertaken, including ground investigation analysis, collaboration with subcontractors, and comprehensive WALLAP analyses to assess pile embedment, load effects, and deflections. All drawings, specifications, and reinforcement details were thoroughly checked for accuracy and compliance. Load effects from the geotechnical analysis, section capacity, and reinforcement were verified, ensuring structural integrity. Certification and documentation were then completed to meet all project standards, optimising both design efficiency and construction cost. These improvements resulted in a shorter retaining wall, more efficient use of materials, and reduced construction costs by lowering the need for additional piles and reinforcement. The Lean improvement delivered enhanced efficiency, resource savings, and maintained structural integrity, supporting overall value and effective delivery.
Control
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The Lodge Lane Retaining Wall project was initially quoted at £3.3 million for a 400-metre wall. By reducing the wall length to 300 metres, a total cost saving of £750,000 was achieved. This demonstrates the efficiency of design optimisation and effective project management in reducing costs while maintaining project quality. Collaborative planning was in place to ensure no clashes with other disciplines within the reserve work area. Regular project reviews ensured design standards were upheld and further efficiencies identified. Technical attention was given to accurate measurement, quality control, compliance with specifications, and effective communication across teams, supporting sustained cost savings and long-term project quality.
Transfer
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The Lean improvement project demonstrated that design optimisation and collaborative planning can significantly reduce costs, achieving a £750,000 saving by shortening the wall while maintaining quality. Lessons learnt include the value of early, coordinated reviews and effective communication across disciplines to identify savings and avoid rework. This Lean improvement has also been shared with the wider group through a lessons learnt document.
What Lean Tools & Methodologies were used for your Lean Project?
If Other, please specify
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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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