The Strategic Deployment of

Lean Construction

Presentation to LCI-Finland2nd December 2015

A £120bn Estate to be Operated, Maintained and renewed

18,000 structures, 34,000 drainage assets

4 million vehicles per day / 450,000 incidents/year

Smart Motorways

Jim O’Sullivan - Highways England

Chief Executive“We have three imperatives:

Safety - both public and workforce; we need to show inspiration,innovation and creativity in our delivery, but we also need toprioritise safety based on sound judgements.

Customer Service - we need to understand what our customersneed. With varied customers from the small car driver to the bighaulage firm, we need to change our behaviour and language tomeet these challenges.

Delivering the Road Investment Strategy - we must deliverschemes to budget.”

Road Investment Strategy

England’s largest road investment programme for a generation

Highways England’s Lean deployment strategy is a key element

Total Expenditure in the Regulated 5 year period £16bn

Capital efficiency savings of £1.212bn by 2020

“We will implement a Lean deployment strategy

that will build a culture of continuous improvement

throughout Highways England and its supply

chain to deliver increased customer value and

efficiency saving in support of the Strategic

Business Plan.”

Highways England Delivery Plan 2015-

20

The UK has a problem with construction

Productivity!

Do you?

Our Philosophy

The Client must engage with the Supply Chain to

achieve continuous improvement!

Defining Lean Thinking?

PULL

FLOW

VALUE

STREAM

CUSTOMER

VALUEUnderstanding and agreeing exactly what your customer needs

Understanding all your processes

Pulling value through the chain

Smoothing the flow

Continuing to attack wastePERFECTION

9

Is construction different from

Manufacturing?

Building a mini Building a house

Think ‘Product’

Standardise

The end to end process

Highways England Lean Deployment

HA BusinessMaintenance

Major ProjectsSMARTMotorways

ImprovementEngine

Lean Deployment Strategy

Leadership &Engagement

DevelopingCapability

Sustainability

LeanDeployment

The improvement engine

over 300 lean projects

Optimising Surfacing ProductivityThe 1000 T target

Visual Management

Collaborative Planning

Visualise the Plan

Challenge and Improve

Consider “Blockers”

Look ahead

Review

Capture Performance

Performance Management

Visual

Management

Lean Sigma

5 S

Continuous

Improvement

cells

Community

Benefits

Framework

Assessing

Maturity

Lean in

Your

business

Contracts

&

Feedback

Tracking

Lean

Projects

Knowledge

transferCollaborative

Planning

Making it all fit together!

£120m of efficiences!

0

4

Highways England Lean Maturity Assessment

Builds upon the Highways Agency Lean maturity Assessment Toolkit (HALMAT) introduced in 2011

Developed from previous HALMAT moderations in consultation with our supply chain

Clearer understanding of what needs to be done to improve Lean maturity, prioritise activity to embed Lean and deliver ongoing improvements.

HELMA has been developed on the basis of feedback we obtained during the HALMAT moderations.

Assessing Lean Maturity

Integration of Lean in Business Strategy

Lean Leadership and Engagement

Deployment Management / Lean

Infrastructure

Understanding Customer Value

Understanding of processes and value

streams

Use of methodologies and

Tools

Organisational coverage, activity

and capability

Performance Improvement /

Benefit Realisation & Delivery

Lean collaboration, climate and culture

Supplier maturity

Lean Innovation Programme

Production management - Visilean

23/03/1528

Initial planning Construction phase with VisiLean

As-designed BIM

Master plan

Import

BIM +

plan

Create detailed, task level plan

Plan phase/look-ahead/weekly work Report & analyze progress

Visualize progress in 3D

Highways (Drainage, Geometry and Pavements)

Managing Incidents

Winter Service

Structures and Restraint Systems

Risk and Knowledge Management

Commission and Statutory Process

Signs, Lighting, Signals Traffic Control

Earthworks and Geotechnics

Managing Works by Others

Routine and Cyclic Maintenance

LEAN Tools (CP, VM and CI)

Roadside features, landscaping etc.

Design Process

Lean 2011-2015

Efficiency Cost Savings

£ 250mRoad Investment

Strategy 2015-2020

Lessons Learned

Leadership at all levels is vital

Strategic deployment can be adapted to any

organization

Lean supports transformation to a continuous

improvement culture

Lean Construction is ‘factory thinking’!

“Insanity: Doing the same thing over and over

again and expecting different results.”ALBERT EINSTEIN, 1879-1955