Contents Lean Construction Ireland Annual Book of Cases 2020 20 Case 5 Company Overview Sisk johnsiskandson.com Overview & Background to the Lean Initiative Alan Flynn Author Figure 1. Drone Footage of Top-Out Pour on Reinforced Concrete Frame The Project Team was tasked with constructing two blocks of student accommodation (145 bedrooms) on a particularly confined site in a residential area of Cork City. There were a number of key challenges, including: • The building footprint covered the entire site to within 1m of the site boundaries, except for an open corridor between the two blocks. • Working hours were limited by a 6pm finish from Monday to Friday, with no weekend work allowed. • Project duration was only 15 months. The structural frame was in-situ concrete. Typically this work requires a generous lay-down area and routinely ends up over schedule and over budget owing to the labour intensive and linear nature of the work, as well as susceptibility to weather and logistics issues. Poor productivity rapidly escalates when labour, deliveries, and cycle times are not all perfectly aligned. The remainder of the project comprised the building envelope, external works, and the fitout of 145 student bedrooms and common areas. This element in particular would benefit from Lean techniques developed by Sisk on similar projects which involve significant repetition, getting the construction detail absolutely right, adjusting details and sequence such that each trade only visits each room once, and absolute insistence on defect-free handoffs from trade to trade. It was clear that delivering a “Lean Concrete Frame” was key to a successful project. The value of the concrete frame was 21% of the total project value, the duration was 7 months (of the overall 15), and by its nature the concrete works were entirely on the project critical path. We needed efficient delivery with high levels of productivity and with the target to deliver on time, within budget, and with zero compromise on quality or safety. John Sisk & Son Ltd. (“Sisk”) is an innovative international engineering and construction company employing over 1,300 people across its operations in Ireland, the UK, and Europe. Sisk has the track record, scale, and capacity to successfully undertake large, complex, multi-disciplinary programmes, and we are recognised by our global customers as world leaders in safe delivery. Operating since 1859, Sisk is a progressive business with long- term vision and is ranked as Ireland’s No.1 provider of construction services. Sisk’s strategy is to create value for customers, partners, and people through technical knowledge, ability, and experience: • We collaborate with our customers and supply chain to provide technical and delivery solutions in an open and can-do way to meet aligned objectives. • We offer a full range of solutions where safety, innovation, quality, efficiency, and value are integral to everything we do. • We deliver projects and programmes in key sectors such as Data and Technology, Pharmaceutical and Life Sciences, Infrastructure, Transportation, Healthcare, Commercial, Residential, Retail, Industrial, Leisure, Education, Water, and Energy.