26 L EAN C ONSTRUCTION I RELAND A NNUAL B OOK OF C ASES 2018 Case 5 – Banagher Precast Concrete Banagher Precast Concrete (BPC) specialise in precast bridge beams and is the leading manufacturer and supplier of precast concrete products to the civil engineering and construction sector throughout Ireland and the UK. Precast concrete products include reinforced items such as bridge beams, columns, terrace units, walls, parapets that are used by the construction sector for large-scale buildings, viaducts, tunnels, bridges, roads, rail, marina, and stadia. Its dedicated staff of over 250 people have been committed to providing cl ients wi th a complete service, including value engineering, design, manufacture, and installation of precast concrete products for over 60 years. C O M P A N Y W E B S I T E OVERVIEW OF THE LEAN INITIATIVE LEAN INITIATIVE UNDERTAKEN – LEAN THINKING, TOOLS, TECHNIQUES https://bancrete.com/ AUTHORS Brendan Mahon Caroline Cavanagh Sean Burke Andy Brophy Implementation of Building Information Modelling (BIM) Tradi t ional ly BPC des ign a project plan from the conventional 2D drawings provided by clients, but with large-scale projects this approach has the potential to substantially increase errors as there is no clash-detection programme involved. This in turn can result in under- supply or over-supply, product discrepancies, stock- holding, and delays. Figure 1. BPC Ireland Site. BPC is Level 1 BIM compliant, and has been using the industry-recognised BIM system since 2010 – but only on projects where the contractor has required its use. It is one of the Managing Director’s key aims to attain Level 2 BIM as per new industry requirements. BIM extends beyond 3D by augmenting the three primary spatial dimensions of width, height, and depth, with time as the fourth dimension (4D) and cost as the fifth (5D). It is an intelligent system that interlinks all elements of a build to detect potential project conflicts and collisions. BIM is used from the pre-design phase onwards to drive analysis, schedules, production, logistics, and construct ion. The BIM concept envi sages vi r tual construction of a facility prior to its actual physical construction to reduce uncertainty, improve safety, work out problems, and simulate and analyse potential impacts. Figure 2. Example of BIM used on Páirc Uí Chaoimh Project. In this instance the contractor did not require the use of BACKGROUND TO THE LEAN INITIATIVE BPC star ted Lean training and implementing Lean processes in 2014 in a bid to reduce waste and drive continuous improvement (CI) within the company. BPC’s product ion facilities cover a 50-acre site with 70 gantry cranes and multiple production l ines , and thus there were many opportunities to employ Lean to ensure a safer and more efficient production plant. At the directors’ monthly Lean meeting the metrics were reviewed and the search began for Lean ideas . Al though compl icated, large-scale precast projects lend themselves to repetition of work and guaranteed volumes, and this in turn makes them ideal for the implementation of Lean to remove waste and inefficiencies. When BPC won the Pái rc Uí Chaoimh contract it was identified as an ideal project on which to implement Lean thinking and processes to reduce waste and el iminate reject ions , to dr ive efficiencies, and to ensure the delivery of best-in-class high-quality precast products in full and on time to the Client. COMPANY OVERVIEW Thi s project involved the re- development of the Páirc Uí Chaoimh Stadium in Cork, Ireland, into a 45,000 capacity GAA Stadium, and with a budget of € 80M.