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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 A585 Earthworks Improvement Lean project focused on optimising earthwork processes by implementing collaborative planning, production control, and value stream mapping. A holistic design approach replaced individual designs, streamlining resource use and enhancing efficiency. The team utilised Stage 0 benchmarking data for strategic resource allocation and decision-making. Key improvements included reusing site materials, ensuring early stone deliveries to prevent delays and inflation, and refining layout designs for a better cut/fill balance. These actions resulted in an estimated £3 million in cost savings, reduced environmental impact, and increased stakeholder satisfaction. The project highlighted the importance of communication, sustainability, and continuous process review, offering valuable insights into resource efficiency and adaptability for future projects.
Lean Project Benefits Summary
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The Lean project delivered significant benefits, achieving an efficiency value of £2,866,741.50. Key benefits included substantial cost savings through optimised resource allocation and reduced material use. Early stone deliveries avoided potential delays and inflation, while reusing site materials minimised waste. The integrated design approach enhanced productivity and reduced environmental impact, fostering stakeholder satisfaction. Sustainable practices and improved communication strengthened project outcomes by aligning efforts towards shared goals and maintaining high safety and quality standards.
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
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 project aimed to address inefficiencies in Earthworks operations, where individual designs led to excessive resource usage and time delays. The use of articulated tippers increased output and reduced carbon impact, while optimising resource allocation by analysing cost estimates from the PCF Stage 0 Benchmark. A generic design replaced multiple schemes, holistically viewing the entire project. Dependencies included aligning haul roads and the scheme's vertical setup, minimising cutting requirements and improving the cut/fill balance. Potential impacts included minimising costs, optimising resource allocation, reducing material usage, and promoting eco-friendly practices to lower carbon footprints. Attention was needed on resource reduction strategies and maintaining quality while adopting sustainable practices. By addressing these issues, productivity improved, resources were efficiently utilised, and stakeholder satisfaction increased.
Measure
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The project involved calculating cut volumes with an assumed slope of 1:3, typically used for ground with glacial till. The estimated rate of £35 per cubic metre was applied to the cut volumes, totalling 310,149.8 cubic metres. Thus, the calculated cost for these cut volumes reached £10,855,243.00. This analysis helps identify potential budget impacts, enabling more realistic financial planning and resource allocation. Attention is required in verifying ground conditions, slope assumptions, and potential cost efficiencies to ensure project success.
Analyse
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The Lean approach utilised collaborative planning, production control, and value stream mapping to identify and eliminate waste in Earthwork processes. Observations highlighted inefficiencies caused by individual designs, leading to resource overuse. The project adopted a holistic scheme design, aligned haul roads, and streamlined vertical setups, addressing the cut slopes in glacial till conditions. These measures helped identify potential savings of £3 million in Stage 1 by reducing materials and optimising resources based on benchmarks. Strategic planning and sustainable practices were key to minimising waste, improving efficiency, and enhancing stakeholder satisfaction.
Improve
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The design team collaborated to cut costs in earthwork materials by analysing Stage 0 benchmarking data and scheme review reports. Actions included revising layout designs to optimise the cut/fill balance and adopting a holistic scheme design. These measures streamlined processes and enhanced resource efficiency, significantly reducing unnecessary materials. The positive impact yielded an estimated cost saving of £3 million, improved resource allocation, and minimised environmental impact through sustainable practices. Outcomes featured heightened stakeholder satisfaction and better project coordination, leading to enhanced safety and quality standards.
Control
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To sustain the improvements, ongoing collaboration and rigorous monitoring were implemented. The team continued using value stream mapping to identify waste and optimise efficiency. Regular reviews of processes ensured alignment with benchmarks and scheme designs. Several additional concepts were integrated and delivered on-site, resulting in a significant reduction in costs.
Transfer
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The project highlighted the importance of adaptable planning and collaboration, offering insights into efficient resource management and sustainable practices. Despite limited transferable data due to project specifics, the experience underscored effective value stream mapping and holistic scheme design. Key processes improved included aligning layout designs and using benchmarking data for informed decisions.
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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