You’re offline. This is a read only version of the page.
Skip to main content
Toggle navigation
Home
Search
Sign in
Lean Tracker Database
Case Studies
Best Practices
Collaborative Planning
Collaborative Planning Benefits
Visual Performance Management
Visual Performance Management Benefits
View Project Details
Back to Lean Tracker
Project Summary
Lean Project Name
*
*
Unique ID
*
Lean Project Description
*
*
Lean Project Summary
*
The A417 Missing Link team aimed to improve safety and confidence in high-risk activities requiring permits. Kier introduced the Permit Receiver Booklet as part of permit receiver training a simple, credit-card-sized, eight-page guide designed to help operatives verify permits effectively and challenge incomplete information. Applying Lean principles, the team used Root Cause Analysis to understand why operatives found permits daunting and often avoided questioning errors. Through collaborative planning with permit issuers and receivers, they developed a practical solution that eliminated unnecessary complexity. Standard Work was established via the booklet to create a consistent process for permit checks, while Visual Management ensured prompts were clear and easy to follow. The booklet has been successfully adopted on the A417 project and shared across Kier’s wider team, including A66 NTP and M6 Lune Gorge.
Lean Project Benefits Summary
*
The Permit Receiver Booklet improved safety engagement and confidence in high-risk activities by simplifying permit checks and standardising processes. Developed collaboratively with permit issuers and receivers, the booklet provides clear prompts for operatives, reducing uncertainty and encouraging dialogue. Adoption by operatives on the A417 scheme strengthened compliance and reduced risk without adding administrative burden. The initiative enhanced training effectiveness supported a proactive safety culture and is now being rolled out across other Kier projects, including A66 NTP and M6 Lune Gorge. This initiative demonstrates how simple, user-focused tools combined with Lean thinking can standardise processes, reduce risk, and strengthen safety culture without adding complexity.
Roads Period Efficiency Reported
RP1 2015-2020
RP2 2020-2025
RP3 2025-2030
N/A
Efficiency Value Assured
*
Efficiency Register ID
Project Cover Image
Choose File
---
Lean Construction Development Programme (LCDP) Project
Lean Construction Development Programme (LCDP) Project
No
Lean Construction Development Programme (LCDP) Project
Yes
Supplier
*
Contact Email
*
*
*
Stakeholders involved in project
*
Stakeholders Involved - Other
*
Problem Solving Strategy (DMAICT)
Define
*
On the A417 Missing Link project, operatives often found the permit-to-work process complex and daunting, leading to low confidence in reviewing permits and reluctance to challenge incomplete or incorrect information. This posed potential safety risks during high-risk activities such as ground disturbance. Kier A417 team aimed to create a simple, practical solution that would improve confidence, standardise checks, and strengthen collaboration between permit issuers and receivers without adding administrative burden.
Measure
*
The team established a baseline by reviewing Health & Safety reports and site observations, which showed that incorrect permits were causing work stoppages approximately three times per month, each lasting around 2.5 hours. This equated to an average of 7.5 hours lost monthly. In addition to time-loss data, Lean metrics were applied to quantify engagement gaps: Review Time (average time taken to check a permit, indicating inefficiency), and training effectiveness (confidence and understanding scores from post-training surveys). These measures highlighted process variation and low confidence, setting the improvement target to increase challenge rates, reduce review time, and standardise permit checks across all operatives.
Analyse
*
The team applied Lean methodologies to identify root causes and improvement opportunities. Root Cause Analysis (RCA) revealed key issues: operatives lacked confidence in challenging permits due to complex paperwork, unclear prompts, and fear of questioning authority. Voice of Customer (VoC) sessions captured feedback from operatives, confirming the need for a simple, portable tool. Collaborative Planning (CP) workshops with permit issuers and receivers helped define practical prompts and questions for each permit stage. These observations highlighted process variation, low engagement, and inefficiencies, leading to the decision to standardise checks and introduce visual aids through the Permit Receiver Booklet.
Improve
*
The team developed a credit-card-sized, eight-page Permit Receiver Booklet as an aide-memoire for operatives. It provides clear prompts and questions to verify permits, ensuring safety measures are addressed. Integrated into permit receiver training, the booklet simplified the process, improved engagement, and strengthened dialogue between teams. Adoption by over 500 personnel demonstrates its effectiveness
Control
*
The booklet is now embedded as standard practice on the A417 scheme and shared across Kier projects, including A66 NTP and M6 Lune Gorge. Continuous feedback loops, refresher training, and compliance checks maintain usability and effectiveness. This initiative supports a proactive safety culture and demonstrates scalability across major infrastructure projects.
Transfer
*
Key learnings include early engagement with operatives, co-designing practical tools, and leveraging Lean principles to eliminate complexity. Sharing the booklet and its development process across Kier projects ensures consistent application and promotes best practice in managing high-risk activities.
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?
Was a Departure Required?
No
Was a Departure Required?
Yes
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.
Loading...
Loading...
