Lean logistics, lessons learnt from Japan Adrian Blumenthal, - - PowerPoint PPT Presentation

Lean logistics, lessons learnt from Japan

Adrian Blumenthal,

Special Projects Director, Constructing Excellence

What we found out from a product and service view

Scoping Study Results, Japanese Corporations, Compared to UK Construction Industry KPI's: Average and Demo Projects 0.00% 20.00% 40.00% 60.00% 80.00% 100.00% 120.00% C l i e n t s a t i s f a c t i

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t UK Construction Indicators 2006 Benchmark Socre in relation to UK construction industry Japan Average UK Demo Projects

Japan/United Kingdom – Economic Comparisons

1500 1081 City centre A/C offices £M2 2300 2167 Hotels (hi quality) £MS 1400 880 Shopping Centres £MS 550 853 Factories warehouses industrial £M2 13.50 17.96 As above – Skilled £PH 11.07 14.16 As above- Semi Skilled £PH 10.10 11.62 Labour All In Rate (gross cost of employment- unskilled £PH United Kingdom Japan Comparison Economics, Building- 29/02/08 (G and T )

Japan/United Kingdom – Economic Comparisons

310 237 Carcassing Timber £Tonne 22 8 Glass 6 mm £M2 11 6 Concrete blocks £M2 230 335 Common Bricks 100mm £/1000 235 203 Plaster £tonne 20 12 Sand Coarse £tonne 29 10 Aggregate all grades £tonne United Kingdom Japan Comparison Economics, Building- 29/02/08 (G and T )

85 54 Concrete 20N/mm2 £M3 105 38 Cement £tonne 750 670 Structural steel £tonne 650 322 Rebar/tonne supplied to site £ tonne

Some more- overall 28% cheaper

Simple Processes:

• The Key is Logistics, information, materials and people first part
• f the plan
• Everyone participates in Quality Management it’s the constitution
• Use PDCA cycle
• Use data and facts as the basis for planning
• Prefabricate all that you can
• Japanese process for construction: Plan, study, design, construct-

what's ours?

• Plan for early Finish!!!

Logistics of information and People The Quality Board:

Waste streams Clock Logistics and daily plan section Safety info

Handover and company information

400 men briefed at 7.45am each day by PM

Logistics of People and Info

• Achieving zero defects on all projects (visual management) and

handover process done publicly

• All problems dealt with immediately
• 7.45am presentation on daily plan to all members of the team
• 10am meetings every day to discuss next day
• Safety meetings every day to review

“hot spots” called KY!!!!

• New starters all have health check

Blood pressure monitor

Logistics of Materials On Site Prefabrication

Floor Slab and Services prefabrication yard Floor Prefab in Place

Logistics of people and materials:

Hoist on inside of building, computers log and charge all usage

Waste material and environment:

When it’s combined it’s waste, when separated it’s a resource, Japanese wide Policy

4 R’s What’s this concept of Skips!

Logistics of information:

Quality in all that we do; Promotes Health and Safety

Pragmatic View for Health and Safety

Pragmatic approach to safety

Quality checking and progress monitoring

Quality: photographic logs and quality

Quality board: photograph everything

Project: Trade: Date: Floor: Area: Drawing ref: Checked by: Approved by: Date: Comments:

Design and Construction

Cost Quality Delivery Safety and Environment Production techniques used for design Early feed forward of design to Construction Feed back of Construction technology to design Unification of the responsibility for the guarantee of quality OFD Effective VE by scrupulous information exchange Shortening of construction time through collaboration Tackling the technology that considers Safety and Environment from the design Stage