2018Case1JonesEngineeringGroup

12 L EAN C ONSTRUCTION I RELAND A NNUAL B OOK OF C ASES 2018 Figure 5. Direct Observation of Work (summary) Direct Results of Process Improvements The streamlined processes and collaborative delivery method enabled the project to meet 100% of the scheduled construction commitments for the final peak of the project. This level of service delivery was unheard of in the first year of the project when the Lean approach was not in place. Utilising BIM from Imagery to Installation The intent from the beginning was to use BIM technology for every aspect of this project. This entailed every element of installation being computer-generated into a 3D image and then isometric drawings being produced from those 3D images. All this information was loaded and available on JEG’s own in-built project database system called “Isoserve”, including schedules and milestones. Any new revisions to design were automatically updated on Isoserve so that the latest designs were always available. When the schedule prompted it, a package was generated and distributed to the project teams. In JEG’s of f-s i te workshops , pre-fabr icat ion teams manufacture spools (pre-fabricated sections of a piping system, including for example pipe and fittings), and a complete work pack can be pre-fabricated off-site. As each spool was completed it was placed on a pipe rack with a copy of the isometric drawing, including its unique bar code, ready to go to site. When the site crews were ready, the full set of spools were loaded onto a truck and brought to site. The site crews then began the process of installing each spool in sequence, and, as they did so, they highlighted the drawing packs showing installation progress. A member of the planning department then scanned the barcodes on the highlighted drawings and this information was transferred onto Isoserve indicating how much of each work-pack was complete. Project Execution Database JEG has well-established and proven systems, procedures, processes, and tools that are applied consistently for project management functions. All JEG's projects are managed through Isoserve which ensures successful delivery and consistency of delivery of each project. For example, JEG’s “Tool Status Dashboard” details various live information on a tool such as the status of workshop fabrication, brackets installed, and pipework installed per tool. The system can be accessed from any location, either directly from the server or via an internet connection, allowing all members of the project team to have up-to-the- minute access to the latest progress information. Every spool on each isometric has a QR (quick response) code (like a bar code, but it can hold more information) which is scanned using a hand-held scanner when entering updates to increase efficiency and avoid typing errors and multiple entries. Use of Geo-Surveying Equipment Digitisation of design through BIM deliverables means that greater accuracy and precision is required throughout all stages of construction. There is a requirement for greater understanding of site conditions to maximise efficiency in all areas of the install process. Technology that is new to construction in the form of 3D Laser Scanning allows JEG to accurately understand site conditions so that all design and build projects can be precisely referenced to their actual environment. This capability can also be employed quickly, and easi ly captures any changes between “Issued For Construction” (IFC) design and the “As-Built” design, thus saving time completing the required mark-ups following construction. High precision set-out ensures that all JEG construction activities spatially adhere to design, hence minimising errors and clashes during on site construction. JEG’s geo-surveying team has perfected a process whereby they set out datums marking a grid across the entire project area. It is then easy for the install teams to accurately measure from a local datum and set up laser lines to pinpoint their starting point. Cable Spooling Machine – Just In Time (JIT) Delivery Following a survey carried out by site supervision, cable management was identified as an area for improvement and removal of waste. Specific areas to be targeted were: • Manual handling of large cable drums (Safety, Time). • Drums moved mul t iple t imes (Mot ion, Transpor t , Inventory). • Waiting & Schedule. By introducing the use of a cable spooling machine, JEG was able to improve in each of the following areas: • Reduced risk to Client project delivery. • Reliable cable spooling system. • Safer cable pulling. • Reduced inventory. • Reduced waiting, motion, and manual transport time (that is, JIT delivery). Working with the Supply Chain to Improve Efficiency – Kanban At the start of the project, JEG Electrical met with its electrical trunking manufacturer to discuss and agree where improvements could be made to streaml ine the manufacturing and supply process. One of the items that the manufacturer was concerned with was that they would not be able to store sufficient material to meet the required dates for the project. Setting up a kanban system was suggested by JEG as a means of assisting with this, and the plan was as follows: • Firstly, the amount of material in each typical work package was agreed. • Then, the dates were used from the agreed construction schedule to set up initial material orders. • Following this, a visual flag was used to warn when each material type reached an agreed minimum level. • Seeing this flag triggered manufacturing staff to order new stock. • This resulted in JIT delivery of materials, and elimination of excess inventory. The manufacturer in this case was so impressed with the results of the kanban system that it has since introduced this method across its entire operation. Last Planner® System (LPS) Use of LPS by all contractors across the project was a notable success. The fact that field supervision attended the planning sessions themselves and made their own commitments ensured that they did their best to achieve these goals. Orbital Welding Collet Kits and Local Vices – 5S To address issues related to orbital welders sharing collets between themselves for different sizes of tube, and walking to