Lean Construction Ireland Annual Book of Cases 2021 5 l f s s 2 Background The LCi Book of Cases 2022 builds on the excellent work done over the previous years to identify and share best practice of lean construction.These books have become a great asset to the construction sector and a key component of many academic courses across the country, which have incorporated lean within their curriculum. In order to continuously improve the book of cases, LCi arranged a survey to listen to the voice of the customer.All LCi corporate and individual members were surveyed, and the following are some of the key findings: • 72% of survey participants said that their company was at the early to intermediate stage of lean adoption within their organisation. • 93% agreed/ strongly agreed that the book of cases was appropriate to their organisation and provided a valuable snapshot of lean construction activity. • 92% of participants said that they read at least a few, if not all the case studies. • Suggestions for improvement included the following: the addition of an introduction section, which would provide a summary of the cases; a dedicated section on BIM/ Digital Technology; making case titles clear ; break cases into categories. Based on this feedback, a new template for the cases was developed to include a case“Title”as well as a“Summary and Lessons Learned” section. In addition, the overall book of cases has been structured to include an “Introduction Chapter” and cases have been separated into appropriate chapters to make the book easier to navigate. Summary of Chapters Chapter 1: Integrated Project Delivery In Chapter 1, an international case study of Integrated Project Delivery (IPD) is presented.Written by Amr Abdel-Azin, Senior Architect at Michigan State University, the case demonstrates the positive impact that collaborative contractual arrangements can bring to a large pavilion project, which included €1m of savings returned to the customer and the project delivered three months ahead of schedule. Chapter 2: Operational Excellence In Chapter 2, case studies which focus on lean tools and techniques used for operational excellence are presented. Coffey lean and collaborative planning is the first case. Coffey started their lean journey in 2020 and have made significant progress in relation to lean adoption.The Coffey Pillars of Lean include 6S, 8Wastes,Visual Management, StandardWork,DMAIC and the Last Planner.Duggan Brothers provide an overview of their lean journey which started in 2014.The case identifies 107 tasks for improvement through the involvement of 27 senior managers across 8 departments. The next case study is written by Hawthorn Heights, which is a company that deals with landscaping and civil engineering projects as well as the design and build of playparks etc.Through their collaboration with ATU via a cross border Fusion Project, they mapped out their supply chain process, carried out an audit using the LCi Lean Audit Tool and then optimised processes. As well as incorporating 3D design into their organisation, significant improvements were achieved in their tender success and profit margin. In Kirby’s case study, the focus was on developing a framework using DMAIC for determining the cost of quality. Fish bone diagrams and 5Whys were used for the analysis stage. Mace presented a case study utilising 5S to demonstrate the positive impact that can be made.An A3 was used to assess waste management, and the 5S and 8 waste tools were used to make significant improvement to the workplace which has improved safety, quality, productivity, and better schedule compliance. A case study was also provided by the OPW relating to their significant lift replacement programme. Instead of separate lift project initiatives, the OPW developed a Dynamic Purchasing System which was a two-stage process.This lean initiative has helped the OPW increase their lift replacement programme from 5 lifts per year to 30 lifts per year and their supervision and management costs have decreased. Chapter 3: Digitisation In Chapter 3 the use of Digitisation for productivity is the focus of the case studies.Arup provide an overview of their HIVE (Human ImmersiveVirtual Environments) which utilises advanced gaming technology to provide a virtual reality experience of projects.Among many benefits, this has helped clients gain a better appreciation of proposals.At Errigal,DMAIC and digital tools were used to develop a data driven framework to identify and eliminate inefficiencies in processes. A Mavic devise was fitted to every helmet and utilises machine learning to recognise unique movements and productivity. In addition, the Oculo device is used to generate a street view of the construction site to aid inspections, spot issues and make decisions faster. Errigal also developed phone applications (aps) to streamline staff inductions and training.As a result of these initiatives, they have seen an increase in employee morale as well as overall reductions in project costs and completion times.The John Paul Construction case study focuses on a large residential scheme called the Grange Development where they have demonstrated the benefits of using the Last Planner and the cloud-based FieldView system for achieving project milestones.Mannings Construction Group outline how they reacted to Covid to by upskilling staff in lean thinking and utilising digital solutions such as dashboards, timelapse cameras, vehicle recognition systems and the common data environment to improve overall efficiency.SISK provided a case study which demonstrates the use ofArtificial Intelligence (AI) to automatically read form data such as delivery notes and concrete cube test certs. Using the Microsoft Power Platform, they set up an automatic process for paperless form management.Through automation and digitisation, significant time is being saved and the quality of data capture has improved.Walls have provided two cases on digitisation. One case outlines the significant benefits of upgrading IT infrastructure and software to increase staff efficiency using standardised forms and flows,better communication,dynamic access to data and ultimately a better controlled environment with reduced administration and energy overheads.The other case fromWalls provides an insight into employee accessibility of BIM 3D models using Dalux BIMmobile viewer.This viewing software has eliminated waste associated with going to the workstation, checking the drawing version is correct, printing and returning to the work location. Introduction Introduction
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