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 Benchmark Socre in relation to UK construction 120.00% 100.00% 80.00% industry Japan 60.00% Average UK Demo Projects 40.00% 20.00% 0.00% e e t y y s e t y t s c s t c m t t t m u o e i l c i o i v l v c e d i f b i c t i t r a t o f c a e y y n e n S r u t t t s i D o p i i o f l l d o i i i i b t n b t n o c r c o a a r P u o u P i i t i t r t c t r c c t t c s i a i d s d a n n f e f e o s s o r r C i i p p C t t a a t t s s c c e e t t n n j j o o e e r r i i P P l l C C UK Construction Indicators 2006
Japan/United Kingdom – Economic Comparisons Comparison Economics, Building- Japan United Kingdom 29/02/08 (G and T ) Labour All In Rate (gross cost of 11.62 10.10 employment- unskilled £PH As above- Semi Skilled £PH 14.16 11.07 As above – Skilled £PH 17.96 13.50 City centre A/C offices £M2 1081 1500 Factories warehouses industrial £M2 853 550 Shopping Centres £MS 880 1400 Hotels (hi quality) £MS 2167 2300
Japan/United Kingdom – Economic Comparisons Comparison Economics, Building- Japan United Kingdom 29/02/08 (G and T ) Aggregate all grades £tonne 10 29 Sand Coarse £tonne 12 20 Plaster £tonne 203 235 Carcassing Timber £Tonne 237 310 Common Bricks 100mm £/1000 335 230 Concrete blocks £M2 6 11 Glass 6 mm £M2 8 22
Some more- overall 28% cheaper Rebar/tonne supplied to site £ tonne 322 650 Structural steel £tonne 670 750 Cement £tonne 38 105 Concrete 20N/mm2 £M3 54 85
Simple Processes: The Key is Logistics, information, materials and people first part • � of 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: 400 men briefed at 7.45am each day by PM Clock Waste streams Logistics and daily plan section Handover and company information Safety info
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 Floor Prefab in Place prefabrication yard
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: Drawing ref: Area: Checked by: Approved Date: by: Comments:
Design and Construction � Unification of the responsibility for the guarantee of quality OFD Production techniques used for design Quality Early feed forward of design to Construction Feed back of Construction technology to design Cost Effective VE by scrupulous information exchange Delivery Shortening of construction time through collaboration Safety and Tackling the technology that considers Safety and Environment Environment from the design Stage
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