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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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Improved production of Redi Rock retaining wall
Lean Project Benefits Summary
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Reduction in plant and labour costs saving £49.749.60
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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Dynamic Hard Shoulder (DHS) M6 J5-8 consists of building 2 Emergency Areas (EAs). Both EA designs contain a Redi-Rock retaining wall solution (Marshalls product) to allow the new embankment to be retained. A baseline was available from DHS M4/M5. The timeline to build Redi-Rock retaining walls on DHS M6 J5-8 and especially NEAR (National Emergency Area Retrofit) is constrained and so improvements to the baseline installation by removing any waste from the process, addressing inefficiencies in the process, enhancements to quality and for a best practice to be documented and shared will support the scheme's programme delivery dates.
Measure
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A visit to DHS M4/M5 allowed for observations on the Redi-Rock installation process to be documented and shared amongst bmJV and with the supply partner CR Civils. Production data was collated and entered into a spreadsheet. Both proposed structures are between 50m and 80m long, both 4 courses high and between 1.188m and 1.313m which is a similar size to the DHS M4/M5. The M4/M5 scheme took 12 weeks to install the retaining wall but were hampered by a 33 KV electric cable. Making an adjustment for this outlier the wall was constructed in 6 weeks which is the baseline.
Analyse
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The data revealed DHS M4/M5 took 12 weeks to lay 250 Redi-Rock blocks. Despite being constrained by an unidentified 33kv cable, even halving this timeframe did not meet programme expectations, as DHS M6 J5-8 had a duration of 4 weeks to lay 260 Redi-Rock blocks. Analysis highlighted that due to the tolerance levels of the blocks and the challenges in achieving a straight line and preventing creep it was crucial to establish a very consistent base level. Building sand was used as a base resulting in rework. The lifting arrangement for laying the blocks resulted in waiting time.
Improve
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The suggested process improvements by CR Civils were agreed by the team and implemented. Areas for improvements were: 1) Screed rails to be used for prepping the bed thus ensuring good tolerances and an accurate level bed to install to. 2) Winter 0-4mm dust to be used for screed bed, as opposed to sand, a much more predictable product during inclement weather. 3) Due to lifting points on the blocks they do not lift level, time was wasted when placing the blocks so lifting straps to be utilised along with the chain accessories, this results in the blocks lifted and placed level.
Control
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The production rate with the improvements was monitored daily and documented in a spreadsheet to allow for a comparison with DHS M4/M5. A comparison in costings exercise was undertaken to understand the financial benefits of the improvements. The process improvements enhanced the production rate so a Standard Operating Procedure (SOP) has been produced to be used in construction as well as a As built, Storyboard and an Improvement Sheet.
Transfer
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A presentation was prepared and shared at the bmJV weekly update, BAM Transport Lean forum and the bmJV NEAR Kick Off session. The improvement was also shared with NEAR M1 J16-19 in a one to one session in preparation to collaborate with their supply partners in planning construction of Redi-Rock retaining walls on their scheme.
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
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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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