Lean Construction Ireland Annual Book of Cases 2021 83 Case 23 Operating successfully for over 150 years, the bedrock of Royal BAM Group’s success has always been an understanding of our clients’ needs and a willingness to deliver innovative solutions that ensure cost savings and surpass environmental expectations. Operating across all construction sectors and throughout the complete project lifecycle, our principal activities are building contracting and civil engineering in the public, private, and PPP sectors. Other activities include facilities management, property development, and rail infrastructure. We are a member operating company (OpCo) of Royal BAM Group of the Netherlands, a stock market listed PLC answerable for performance,which has a turnover of €8 Billion and employs approx. 23,000 people worldwide.At BAM,we are building the present while creating a sustainable future for all. Miyamoto Musashi (1584–1645), was a swordsman, philosopher, strategist,writer, ronin and is considered a Kensei – a sword-saint of Japan. In his final years he authoredThe Book of Five Rings, a book on close quarter combat that has become a foundation of Japanese strategic business and manufacturing thinking. In it, Musashi advises to “… gather information from every possible source. Leave no stone unturned.Use spies, consultants, informants…Perceiving the enemy’s position allows you to defeat it…”. Today, we strive to learn from what we do and how we can continuously improve, and our enemy is a lack of timely information in the decision-making process. In August 2020, the Digital Construction Department of BAM Ireland attended its subsidiary Modular Homes Ireland (MHI) for a technical visit with a view to improving the execution of their digital processes. Since then, both companies have worked together to reduce waste and add value.Our journey began by mapping out the work process, and today we are digitally tracking that work to add greater value. Company Overview BAM IRELAND bam.com Overview & Background to the Lean Initiative Simon Tritschler Author Lean Initiative Undertaken – Lean Thinking, Tools, Techniques In August 2020, at an initial tour of the facility, BAM Ireland Digital Construction was introduced to MHI – a subsidiary of BAM Ireland – teams responsible for the design and production processes for the creation of steel panel modular houses and units.This was followed with a factory floor walk to get a better understanding of the entire production process, starting with the cold forming of the blank steel rolls into the modular panel wall frames, assembly of the units, and right up to the final wrapping of a completed module. From this initial visit, it was clear that Digital Construction could bring value and remove waste from their processes through the application of Lean methodologies and the implementation of better digital technological practices. Over the following visits, our first action was to complete a current state value steam map (VSM) so as to understand the entire production process, establish a benchmark value, and to use as a basis to build a recovery deployment plan. VSM is a snapshot of how a process is currently executed, regardless of what the ideal or perceived process state may be – it reflects what is happening out in the real world.TheVSMworks to capture the entire span and duration of a process, and to identify within the process where value has been added or lost for the client. Undertaking this process gives visibility to waste or roadblocks in the overall production process and is created through direct process observations and forthright staff interviews to understand the pain points. Over 3-4 visits we interviewed all the key personnel from each department and worked hard in the design office and on the production floor to understand the different task durations for the“first of a kind (FOK)” and“many of a kind (MOK)” events. The MHI process begins with the client need which is translated via the design teams into a viable design.Once finalised, this FOK design is reviewed by the production team, and any lessons learned from the first production run are reapplied to the design, thus improving the outcomes for the following production units (MOKs). Physical production starts with the cutting and forming of a flat roll of light gauge steel into a structural unit.These units are then moved to frame assembly where they are joined together to form the structural panels for the final unit being created. Panels are then combined to create the final modular structure, and these units move along the production line for slabbing, insulation, glazing 1st and 2nd fix, and so on, culminating in a fully-finished unit. Once all
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