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Project Summary

Lean Project Name

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Lean Project Description

Lean Project Summary

Earthworks balance reviewed at design stage by designer, contractor & supplier

Lean Project Benefits Summary

£4,083,680 benefits realised
10 months programme saving on embankment settlement

Roads Period Efficiency Reported

Efficiency Value Assured

Efficiency Register ID

Image

Lean Construction Development Programme (LCDP) Project

NoYes

Supplier

Contact Email

Stakeholders involved in project

Stakeholders Involved - Other

Problem Solving Strategy (DMAICT)

Define

The M54-M6 Link has a large volume of Earthworks. It is important that there is a balance of cut and fill activities to avoid either importing of material or exporting material off site. Importing and exporting material introduces additional plant movement, additional cost and additional carbon.

Measure

There were 4 Earthworks options identified:
6C starter layer – Processed material to be imported, on site material to be exported
Capping – Stone layer of processed material to be imported for underneath black top layer
Junction 11 Embankment surcharge
Detailed design overall – Import & Export
Sessions were held to understand the current position of each of the 4 improvement areas.
A spreadsheet was created to baseline area, volumes, import and export costs for the current design

Analyse

The baseline data spreadsheet was used to analyse the 4 Earthworks areas identified, VSM sessions were carried out and a SIPOC was created to understand the different customers in the Earthworks design process.
The data identified that there was a lot of material being imported to site with the original material needing to be exported. This introduces a large number of plant movement, cost of import/export and carbon into the process.

Improve

A cause and effect diagram was used to visualise the problem for the import of capping material. The proposed improvement is to use lime stabilisation to improve existing ground instead of importing material.
Value stream maps were produced for replacing imported class C material with geocomposite and the removal of surcharge requirement in Area 27. By not importing material to overload the embankment and allowing natural settlement the team have saved 10 months on the programme. 
Import and export was reduced across the whole scheme also reducing carbon.

Control

A series of one to one sessions with the BAM Agent were set up to check the values on the current and future state spreadsheets. These two spreadsheets were then presented to BAM's commercial representative to sense check and validate.

Transfer

The A3 report was generated. A PowerPoint Presentation was prepared for sharing to a wider forum.
As part of Lean Construction Development Programme (LCDP) efficiencies under National Highways Efficiency Register ID 1075

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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

Project Detail

National Highways Directorates involved in project

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Was a Departure Required?

NoYes

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