A Chamber Installations Process Improvement M60 J8 & M62 J19 £228,763 saved Katie Jones, MSM Jonathan Derrick, Mway

Objectives Talk through work study Demonstrate how I-pads are used to evaluate waste Show some footage from the day and have a go at analysing waste & some thought on waste Discussion around waste at the end

Problem MSM have 345 Chambers (inclusive of A & B chambers) to install on the It is currently taking 2 days to install 1.5 chambers. Goal To improve productivity of A-chamber installations. Problem &Goal Statement

Stakeholder Benefits MSM: Certainty of programme, improved safety and less rework Rowarth: Increased productivity = more money, improved safety and reputational benefits. Mway: Reputation, finishing programme early means they can start the next job. Less waste of materials. Client: Better value for money, cost and time savings overall on the job. Public: Less disruption to the public

Deliverables  Video of study  Work Study Analysis  Improved process  Notes from improvement workshop  Improvements  Knowledge Transfer Pack  Presentation  BCRF

Success Increased productivity from1.5 chambers in 2 days to 2 per day. Increase in value adding activity Reduction in waste

Observed Process Flow for A-Chamber Installations (to ground level) with connection onto existing CCD. Show VideoVideo

How we conducted the Study?

Day 1 Analysis

Day 2 Analysis

Summary Finding slide Day 1 : 16:10 Observed Activity Day 2: Observed Activity VA: 40minsVA: 1hr 49mins ENVA: 8hr 5minsENVA: 3hrs 48mins WASTE: 9hr 10minsWASTE: 11hrs Types of Waste TransportationForgot materials and had to return to junction 19 Rework / over productionStarted digging the hole in the incorrect place. Incorrect connector duct WaitingMaterials to be moved which were located where the next chamber hole had to be dug

Improvement Workshop Went through a quick introduction to Lean Operatives came up with a list of improvements that we tried to categorise into Lean wastes

Fishbone Diagram

Typical site layout without constraints in longitudinal direction. Example site layout with obstruction e.g. gantry. Site layout

Driving the improvements

Improvements taken forward 1.Develop new process 2.Create Site Material Interface Diagrams (SMID) 3.Get a trailer for HIAB 4.Develop Visual Management Boards 5.Looking to get Ipads for supervisors and gangs 6.Detailed Collaborative Planning with the workforce 7.Pre Cast Apron

Improvement 1: The Proposed LEAN process for Installation New Process Old Process New Process

Early Prototype Site Material Interface Diagrams

Phase 1 S.M.I.D.

Phase 2 S.M.I.D.

Improvement: Trailer for HIAB Trailer carrying ducts HIAB

Site Layout These photo’s show the new site layout and the excavation which has been left open. Unfortunately we couldn't conduct a like for like time and motion study as there was two gangs on this particular day. Excavation left open after CCD’s

Visual Management New cabin for daily briefings with whiteboard highlighted. Planning includes: - -where each are gang working -logistics -materials need at next site. Intention to get ipads for supervisor/gangs to use for pre-planning next site Inc. taking photos and annotate positions of items required.

Benefits Installing 2 chambers per day (originally 1.5 in 2 days) Teams planning collaboratively Pre Cast Aprons Combining excavation with CCD = £83, Standardised plan = £137,50.00 SMID Temporary lid £7336 Total saving £228,763

I-Pad Lean Assessment Tool App is web based Type in detail of study Show VideoVideo

Any Questions? Group discussion – Waste appears on every site and appears to be accepted: - how can we change this culture? “Thanks to Rowarth/ Mways Operatives and Supervisors for their great ideas and cooperation.” Questions and Group Discussion