Optimising Surfacing ProductivityThe 1000 T target

Andrew Bradshaw, Kier Strategic HighwaysCharlotte Foster, Highways England

Problem Statement:•Highways England (HE) has the following challenges: Deliver large quantities of re-surfacing works across the network •Maintaining 97% lane availability at any point in time. •Increasing customer satisfaction•Creating 20% efficiency savings

The current rate of resurfacing for one standard shift with one gang of operatives has shown to be on average 240 tonnes per night. To meet the above targets there is a need to increase the productivity rates.

Problem Statements

D M A I C T

Project Methodology

Define

• Select the opportunity• Project planning• What does customer

want?

Measure• Map the process• How much does it cost?• Ask the team

Analyse• Where is the value and

waste?• What are the root causes?• What are the costs of waste?

D M A I C T

Improve • What are the possible solutions?

• Which ones have the greatest impact?

• Which ones are the easiest to implement?

• Will they work

Control•Implement actions

•Rewrite procedures

•Train Staff

•Measure impact – visual methods

•Manage change

TransferTake learning to other relevant areas

Project Methodology

D M A I C T

Purpose

Measures of SuccessDeliverables

Stakeholders & Benefits

Project Outline (Quad of Aims)

D M A I C T

Purpose:

Project Outline (Quad of Aims)

• To optimise the surfacing outputs per shift and establish conditions for future schemes to enable a permanent increase in resurfacing productivity.

• A specific objective for the project is to ultimately enable the laying of 1000 Tonnes of blacktop with one gang within one shift.

• The project should include the challenging of the current working window times and identifying, challenging and ultimately removing constraints to enable the above targets.

D M A I C T

Stakeholders and Benefits:

Project Outline (Quad of Aims)

• Road Users – cost reduction (economy of scale), reduced duration of road works and fewer closures

• HA/ Service Provider – Less complaints received for long running road works

• EMH and other collaboration partners – Increased profitability

• Improved quality – fewer transverse joints

D M A I C T

Deliverables:

Project Outline (Quad of Aims)

• Process map for improved process and guidance on how to implement.

• Guidance on how to identify suitable conditions.• Table/calculation clarifying possible level of

surfacing relating to specific working window times• Knowledge transfer pack / report to support sharing

the learning and continuous improvement.

D M A I C T

Success Criteria:

Project Outline (Quad of Aims)

• 1000 tonne resurfacing done in one shift with one gang• Increased repeated rate of surfacing per shift per gang

compared to current rate (where 1000 Tonne is not achievable)

• Reduced unit rates• Reduced amount of road works on the network

compared to if this project had not taken place• Implementation as Business As Usual

D M A I C T

1. Why does it take nearly half an hour from close of motorway to start planing ?2. Paver idle – Awaiting material – Why are we waiting ?3. Off site nearly 1.5 hours before we need to be – can we extend paving further and get off later?4. Are the working windows in line with contractually acceptable delay times – can they be increased?

Top critical areas of Non Value Added

D M A I C

Current state – What were the issues

Shift Time22.00 23.00 00.00 01.00 02.00 03.00 04.00 05.00 06.00 07.00

22.08 Access workingarea for surfacing

Planing 22.37 – 00.54

Paving 00.17 – 02.28

Cleaning and preparation

White Lining -

3.00

Rolling

Remove TM 4.15-4.39

Curing 1 hour +

Material Call Off

1

2

3

Paving Time [hrs]

Theoretical Working Window [hrs]

4

Working Time [hrs]

4

Issue – Why do we only pave for 33% of the available working time?– Can we increase this?

298 T Laid2Hrs 11 Mins paved

T D M A I C T

D M A I C

The outcome – 1024 T ! 21.03 Access workingarea for surfacing

Planing 21.30- 02.45

Paving 22.15 – 05.05

Cleaning and preparation

White Lining 02.30 - 06.46

Rolling – 05.25

Remove TM – 07.39

Curing 1 hour +

Material Call Off

Original work - Paver active for 33% of working time1000 T work – Paver active for 64% of working time

Working Time [hrs]

Paving Time [hrs]

Shift Time / Working Window [hrs]

22.00 00.00 02.00 04.00 08.0006.0020.00

Shift Duration (staggered): Theoretical Working Window 20.00-09.00: Actual Work (TM on – TM off) 21.03-07.39: Tonnage laid:Paving duration 22.15-05.05:

Data:

10 Hours13 Hours

10 Hr 36 Mins1024 T

6 Hr 50 Mins

Average hourly tonnage laid:Total meters laid:Paving time of full working time

- 6 Hr 50 Mins out of 10 Hrs 36 Mins

149 T2700 m

64%

Statistics (@ 45 mm thin surfacing):

T

Set-Up & De-mob Constraints times:Fixed time required before and after planing on ALL schemes (type A)

Constraints – constant at this type of work irrespective of the working window:Before paving:Finalising TM 15 minutesMobilisation of planer: 30 minutesPlaning head start: 45 minutes

After paving:Rolling: 30 minutesCooling: 75 minutesTM Removal: 30 minutes

Total Necessary Non-paving time: 3 Hrs 45 Mins

Standard for ALL future worksUp front prior to paving start

1 Hr 30 Mins

Standard for ALL future worksPost paving before road opens

2 Hr 15 Mins

D M A I C

Non-Paving but essential time within each shift

T

New theoretical laying capability in any (type A) shift

1 Hr 30 Minutes:Pre-constraints (TM /

Mobilising / Planing head-start)

Paving

Paving Time [Y Hours]

Start up Finish

2 Hr 15 Minutes:Post-constraints (Rolling /

Curing / TM removal)

Theoretical Paving Calculation:Working Window duration X HoursLess Start up / Finishing fixed times 3 Hr 45 Minutes

= Theoretical working window: Y Hours

Expected laying rate 130 Tonnes / Hour

Theoretical possible blacktop output: Y Hours x 130 Tonnes / Hour

Working Window – X Hours

D M A I C T

D M A I C

Original paving output – 2 Hrs 11 Mins (@ 137T per Hour) = 298TPaving rate average (from analysis of 6 months data) 130T per Hour (approximately = planing rate)New theoretical paving time 23.30 – 03.45: 4 Hr 15 MinsNew theoretical output 130T per Hour x 4 Hrs 15 Mins = 552T

Analysis:

Theoretical laying capability in 8 hr shift

Shift Time [hrs]22.00 23.00 00.00 01.00 02.00 03.00 04.00 05.00 06.00

Planing 22.45 – 03.00

Paving 23.30 – 3.45

Cleaning and preparation

White Lining – 4.30

Rolling – finish 4.15 Remove TM 5.30 – 6.00

Curing 4.15-5.30

Material Call Off at 21.00

Paving Time 4 Hrs 15 Mins (Theoretical in 8 Hrs)

Finalise TM 22.00 – 22.15

Mobilising plant 22.15 – 22.45

Fixed pre-paving time 1Hr 30 Mins

Fixed post-paving time 2 Hr 15 Mins

Original Paver Utilisation (8 hour shift - based on actual Working Window): 33%New Theoretical Paver Utilisation (8 hour shift – based on full working window utilisation): 53%

T

Amount of blacktop laid per shift.

Average laid per night on M5 J6-9 SB (Phase 2) works: 404 Tonnes per gang per night

Base line Avg: 240 Tonnes per gang per night SB Uplift to Base Line: 68%Nights of site visit: 300 Tonnes per gang per night SB Uplift to night visit: 35%NB (Phase 1) Avg: 344 Tonnes per gang per night SB Uplift to NB: 17%

D M A I C T

BenefitsStakeholder Benefit

Road Users Cost Reduction

Road User Schemes delivered 33% quicker – shorter duration of roadworks, 33% reduction in number of closures / fewer interventions / less disruption

Road User Improved quality through reduction in the number of joints

Road User/Tax payer More work delivered with the same resource - Management, Paving gangs and machines, Trucks, Aggregate plant – reduced unit cost (by 9% compared to reference scheme)

Supply chain Greater profitability – better resource utilisation

RCC Fewer interventions means fewer phone calls per night for signs setting

HE / Service Provider Possibly less HAILs / Customer complaints with less disruption

D M A I C T

D M A I C T

20.50 Road Closed

Milling 1 21.19-

Paving 22.43-01.17

Cleaning and preparation

Working Time [hrs]

Paving Time [hrs]

Working Window [hrs]

22.00 00.00 02.00 04.00 06.0020.00

Paving

MillingMilling 2 21.25-

Milling 3 21.30-0043

Paving 00.38-02.55

1 1

1 1

1 1

2

23

4

5 5

6

05.04-05.20

White Lining

Curing 1 hour +

Rolling

7

Area 7 Resurfacing Efficiency Work

Area 7 Resurfacing Efficiency Work

Increase in output from Eastbound to Westbound: 20% per shift

EB

Outputs significantly reduced in 7 out of 48 shifts due to plant breakdown (15%)

D M A I C T

Best DesignDonna JamesJason GlassonJames Burdall

Collaborate&

ContractShah Ahmed

Jon Cole

BuildAndy Rowley

Charlotte FosterDarren Checksfield

Asset MngtDonna JamesJason GlassonJames Burdall

Actions

Program

me

Value Mngt / EngProcess

Longer scheme lengthsSupply Chain involvementCollaborative PlanningPackage with MP schemesDevelop contingency sites for winter to avoid lost shiftsUltra thin /thin in summer, deeper inlays winter

Revise pavement spec.,Larger scheme size,Measures for designer performance / plan qualityUse PSV grade as location dictates rather than defaultInclude supply chain expertise

Programme visibility – certainty of funding leading to lower unit costPayment / incentivisationConsider Regional Civils contract rather than CM pavements

Roll out Pavement OptimisationPossessionsLean optimise working windowsLean logistics-quarry map, supply constraintsDevelop Industry Engagement Plan (inc Engagement Council work)Develop supervisor / operative skillsOptimise source of supplyReview risk appetite – early batching start upWider / echelon pavingReview working patterns to maximise working timeSafe areas for parking to reduce (un)loading

Warranty incentivisationReview life of HRA / thin surfacingFeedback to need decisions Use industry expertise to upskill asset condition modelling inc. deterioration.

Communication of efficiency ideas

Capture efficiencies and report

(Paul DoneyMartin Bolt)

£600 million 6 sub groupsestablished

taking ownership

Steering group challenges•How will we know whether we are on track?•Who do we report to & how often?

Created by: Paul DoneyDate: 24/8/15Version: 1.0

£600million 6 Sub-groups

established taking

ownership

D M A I C T