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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 A417 Missing Link scheme team aimed to address congestion, emissions, and operational inefficiencies along a busy Cotswolds AONB (Area of Outstanding National Beauty) route. Kier, with Prolectric, replaced diesel generators with solar-powered solutions, including street lighting, hybrid generators, and battery storage systems. Lean tools like Value Stream Mapping, Root Cause Analysis, collaborative planning, and production control were employed to identify bottlenecks and streamline delivery. This sustainable strategy reduced carbon emissions, cut costs, improved air quality, and ensured a quieter, safer working environment. Kier’s dedication to moving away from diesel was solidified through successful trials, proving solar solutions met performance needs without compromise. The project stands as an exemplary model for environmental preservation while enhancing operational efficacy through careful supplier collaboration, extensive pre-testing, and effective Lean methodologies.
Lean Project Benefits Summary
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The Improvement project achieved over 75% carbon savings, equivalent to524,966 kg of CO2e while significantly reducing operational costs, emissions, and noise pollution. By replacing diesel generators with solar and hybrid power, the initiative cut fuel use drastically, resulting in approximately £417,196.00 in savings in the first year. Staff wellbeing improved through enhanced lighting and quieter, cleaner site conditions. The project's success supported environmental targets and showcased the scalability of solar technology across large infrastructure schemes for sustainability goals. This initiative now serves as a benchmark for future low-carbon construction projects, demonstrating substantial ecological and financial benefits while providing improved work environments and aligning with sustainability objectives effectively.
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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Kier and Prolectric collaborated to address the environmental and wildlife considerations for the A417 Missing Link project in the Cotswolds Area of Outstanding Natural Beauty (AONB). The site's ecological significance meant that traditional diesel generators and tower lighting were not ideal due to environmental concerns. Kier aimed for sustainable and cost-effective alternatives, exploring solar-powered solutions through an initial trial of Prolectric’s solar site lighting in key areas. The trial's success paved the way for a large-scale deployment of tailored solar-powered lighting solutions. The measures addressed environmental issues by enhancing operational efficiency and ecological preservation, offering both cost-effective and sustainable lighting solutions. The collaboration focused on reducing ecological disruption while maintaining project efficacy, requiring careful consideration of dependencies like technology reliability and integration into existing infrastructure.
Measure
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Initial data highlighted significant congestion, accident rates, and environmental impacts caused by the single-lane road layout and diesel generator use. Metrics, including traffic flow and incident data, pointed to delays and safety risks. The diesel generators contributed substantially to fuel consumption, emissions, poor air quality, and high operational costs. Kier began monitoring these metrics closely, aiming to reduce fuel usage and significantly cut carbon emissions across the site. Their strategy included deploying solar hybrid systems, which quickly demonstrated carbon savings exceeding 75% within months. Through detailed tracking of traffic flow, incident reports, fuel consumption, and emission levels, Kier quantified improvements and ensured sustainable progress in improving air quality and reducing costs
Analyse
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Lean methodologies such as Value Stream Mapping (VSM) and Root Cause Analysis (RCA) were crucial in addressing issues on the A417 Missing Link project. VSM identified inefficiencies in traffic flow and safety by mapping the current road network state and highlighting bottlenecks. RCA delved into the underlying causes of frequent traffic jams and accidents, revealing major contributors like poor road design and visibility. Key observations from RCA included significant delays due to the single-lane carriageway, a high incidence of serious collisions linked to inadequate visibility and road design, and high emissions from diesel generators. Collaborative planning and production control sessions further identified the need for a complete shift in how lighting and power were delivered across the project site. These methodologies and tools pinpointed areas for improvement, paving the way for sustainable solutions.
Improve
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The A417 team replaced traditional diesel generators with Prolectric’s off-grid renewable technology, including patented Solar Site Lights, Solar Street Lights on moveable blocks, and Permanent Solar Street Lights. Additionally, ProPower Solar Hybrid Generators and a ProCharge 3-Phase Solar Battery Energy Storage System were deployed. These actions resulted in significant 75% fuel and carbon savings, reducing emissions in the sensitive Cotswolds Area of Outstanding Natural Beauty (AONB). Operational costs were lowered by cutting unnecessary diesel consumption and generator maintenance. Site conditions improved by eliminating noise pollution from diesel generators, particularly in accommodation areas, and enhancing air quality. These measures aligned the project with Kier’s environmental commitments, demonstrating the practicality and financial benefits of transitioning to solar and hybrid power on large-scale infrastructure projects.
Control
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Sustained improvement for the A417 Missing Link project was ensured through remote monitoring of solar systems and expert support from Prolectric specialists. Real-time data tracking enabled efficient oversight of the solar installations, ensuring fuel consumption, emissions, and maintenance needs were minimised. This monitoring allowed for prompt adjustments and optimisation, maintaining system efficiency and sustainability. Additionally, Prolectric provided ongoing technical support, addressing any operational issues swiftly to prevent disruptions. These measures facilitated a seamless transition from diesel to solar power, enhancing cost-effectiveness and sustainability without affecting site operations. The project serves as a model for future infrastructure initiatives aiming to adopt off-grid renewable solutions for a sustainable, low-carbon construction approach, showcasing the importance of continuous monitoring and expert guidance in maintaining long-term improvements.
Transfer
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The A417 project Solar-hybrid powered Lighting successfully transitioned from diesel to renewable solar and hybrid power. Crucial learnings included conducting early trials to perfect solutions, engaging suppliers for expert input, and applying Lean methodologies like Value Stream Mapping (VSM), Root Cause Analysis (RCA), and collaborative planning to support seamless implementation. Internal sharing of setup guides, savings insights, and performance reports fostered team development. The project underscored the value of extensive testing, supplier collaboration, and Lean tools for identifying and resolving inefficiencies. For future projects, conducting thorough initial trials, maintaining strong supplier relationships, and leveraging Lean tools will optimise methodologies. Improved processes focused on tracking fuel use, emissions, and advanced power deployment, enhancing sustainability.
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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