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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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Precast concrete central reserve barrier installed faster than slip form barrier
Lean Project Benefits Summary
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54 days saving against projected slip form outputs. Benefits Realised £940,576.62
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
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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 M40/M42 Interchange scheme has approx. 11km of central reserve concrete barrier to construct in an 8 month construction programme. The typical approach of using slip form methodology to construct the barrier may not meet programme requirements, is reliant on delivery and installation of wet mix concrete with slower curing at lower temperatures. A Lean study is required to find the optimum solution to improve production outputs and deliver to programme
Measure
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DHS M6 J4-5 had installed concrete barrier in June 2022 using slip form methodology. The as built records were assessed. 2289m of barrier was installed in 29 shifts equating to an average installation rate of 79m per shift which includes Time Risk Allowance. During procurement for the M40-M42 Interchange central reserve concrete barrier, prices were obtained from three slip form companies and two companies offering a precast solution. This provided a comparison on costs for the different solutions
Analyse
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The prices quoted for precast were more expensive than the slip form quotations. However the precast solutions can be installed on site more quickly than the slip form. Prelim costs are high on site so time savings can offset investments. The balance was assessed that if precast was 3 weeks quicker than slip form then it offered the best value. A business case was put forward to the Alliance to progress with a precast solution from Hardstaff barriers. Slip form requires a temperature of 2 degrees Celsius and rising. There is quality risk on logistical supply of wet concrete.
Improve
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A physical rehearsal was carried out in the M40/M42 compound to measure the production output of the Hardstaff Precast barrier. This included 8m long precast concrete foundation units and an automatic drilling rig to drill and fix the barrier unit to the foundation block it was demonstrated that 12 No. barrier units (96m in total) could be fully installed in 1 hour and the drilling rig could simultaneously drill two holes in a minute. The drilling is Hand Arm Vibration (HAV) free and has a dust extraction system that removes the dust created by drilling.
Control
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The order was confirmed for Hardstaff to supply and install 10480m of precast concrete central reserve barrier. Sections 1 and 3 totalling 7850m would be installed on concrete foundations. Section 2 totalling 2630m would be drilled and fixed into asphalt. The engineering team collated as built information in the form of a master tracker and daily shift reports. The planner used this data to chart production graphs for each discipline which were regularly reviewed by the management team to make data driven decisions
Transfer
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The full installation including specials and downtime took 79 shifts equating to an average production rate of 133m per shift. The investment in Precast was validated by a saving of 54 days when compared to the projected slip form outputs for this workscope. A Direct Work Observation was carried out one nightshift to observe and verify the outputs that could be achieved. The operation was very efficient and the biggest opportunity for improvement was to extend the nightshift working window. The lessons learned from M40-M42 will be transferred onto the next scheme DHS M42 J4-7
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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