SlideShare a Scribd company logo
1 of 15
Download to read offline
European Students of Industrial Engineering and Management
www.estiem.org1
Decreasing Structural Frame Assembly Time
Lean Six Sigma Green Belt Project - Educational Case
Site visualizations: PES-Arkkitehdit Oy and 3Drender Oy
European Students of Industrial Engineering and Management
www.estiem.org
The Project Was Conducted As a Part of
Helsinki-Vantaa Airport Expansion
2
Site visualizations: PES-Arkkitehdit Oy and 3Drender Oy
European Students of Industrial Engineering and Management
www.estiem.org
The Goal of the Project Was to Reduce the
Leadtime of the Structural Frame Assembly
3
European Students of Industrial Engineering and Management
www.estiem.org
 A Finnish construction company is building an extension to the Helsinki-Vantaa airport. Over 300 meter
long new terminal is being built in the center of a fully functional airport.The project schedule is tight and
the process owner wants to deliver the project as soon as possible to minimize the disturbance to the
airport operations.The work phases can be roughly divided to groundwork, structural frame assembly,
facades, interior work, and HVAC.The process owner wants to focus on the frame assembly as it is on the
critical path of the project.The process improvement project is scoped in this example to the most
repeatable process step, hollow-core slab assembly.The quantity of hollow-core slabs is especially large in
this project and the estimated performance is 30 slabs per day.The project execution including all other
concrete and steel components is is scheduled to take 10 months.
 A local manufacturer provides the hollow-core slabs from Otaniemi.The manufacturer has its own logistics
and the assembly itself is done by a subcontractor specialized in structural frame assembly.The material
loading in the factory to the trucks takes approximately 30 minutes.The crane used for lifting the hollow-
core slabs on the site is provided by the main contractor.The assembly also requires two workers to install
the slabs and two workers to unload the truck. A supervisor form the subcontractor is also always present.
The site provides a logistical problem, as the trucks have to cross the airport ramp in order to get to the
site.The entry to the airport ramp is prevented if planes are moving on the ramp.
 The measurements of the slab assembly were conducted using two time-lapse cameras taking pictures with
a 1-minute interval.The cameras were positioned in two of the cranes. Crane 1 (STT1330) was close to the
actual assembly and crane 2 (STT753) was further away giving an overview.The measurements present the
time interval between two consecutive assemblies.
Project Information*
*The case is modified for educational purposes
European Students of Industrial Engineering and Management
www.estiem.org
S I P O C CTQ
Structural frame
assembly
Delivery of
materials
Lifting of
components
Fixing of
components
Delivery of
assembled
frame
Concrete
Columns
Beams
Hollow-core
slabs
Casting material
Steel
Columns
Beams
Braces
Fixings
Element suppliers
Steel supplier
Logistics
Crane & operator
Additional lifting
devices
Workers
Designers
Concrete frame
Steel frame
Frame assembly
lead time
Airport owner
Contractor
Management
and workers of
the superseding
tasks
Supplier Input Process Output Customer Key metrics
SIPOC
European Students of Industrial Engineering and Management
www.estiem.org
http://peikkousa.blogspot.fi/2016/09/peikko-frame-alternative-to-post.html
Hollow-core slab assembly
Element
manufacturer
Truck
driver
Crane
operator
Site
workers
Site
Managers
Truck drives the
elements next to
the crane
Lifting bar is
connected to
crane
Slabs are
connected to
crane
Slabs are
lifted into
place
Slabs are
aligned and
disconnected
Process repeats
until truck is
unloaded
Elements are
manufactured
and transportedLifting bar →
Process of Hollow-Core Slab Assembly
European Students of Industrial Engineering and Management
www.estiem.org
Site Layout & Logistics
A B C D E
Runway
Truck route to siteCrane
Top view of building (sections)
150 Slabs per segment
2 levels
Single truck holds 4-5 slabs
Travel time from
slab factory to site
is 30min per
direction
European Students of Industrial Engineering and Management
www.estiem.org
Data Collection
 Data was collected from video
filmed with two cameras
attached to the crane
 Start of an observation is
when previous slab is on place
European Students of Industrial Engineering and Management
www.estiem.org
756045301 50-1 5
LSL 0
Target 7
USL 15
Sample Mean 10,4144
Sample N 222
StDev(Overall) 10,1731
StDev(Within) 7,8664
Process Data
Pp 0,25
PPL 0,34
PPU 0,15
Ppk 0,15
Cpm 0,22
Cp 0,32
CPL 0,44
CPU 0,19
Cpk 0,19
Potential (Within) Capability
Overall Capability
PPM < LSL 0,00 152984,37 92766,38
PPM > USL 144144,14 326083,25 279969,23
PPM Total 144144,14 479067,62 372735,61
Observed ExpectedOverall ExpectedWithin
Performance
LSL
Target
USL
Overall
Within
2211 991 771 551 331 1 1896745231
80
60
40
20
0
Observation
IndividualValue
_
X=10,41
UB=15
LB=0
Count 1 1 1 1 1 1 21 7 1 1 3 2 2 2 1 1
Percent 2 2 2 2 2 2 436 23 6 4 4 4 2 2
Cum% 85 87 89 91 94 96 1 0036 60 66 70 74 79 81 83
Delay cause
O
ther
Truck
late
+
oth er+
w
o rkers
Truck
late
+
other+
unknow
n
Tru ck la te +
other +
B ig/sm
allsla b
Tru ck
la te
+
Big/sm
all slab
Truck
change
+
w
o rkerslate
O
the r
+truck
blocked
M
a
npow
er
Break
+
truck
late
U
n know
n/break
Truck
change
M
en
had
to
m
o ve
Big/sm
a ll slab
Truck
late
+
other
Truck
late
40
30
20
1 0
0
1 00
75
50
25
0
Count
Percent
31302932
80
60
40
20
0
Day (May)
Duration
1
1
1
1
1
1
1
11
1
1
9,48989,09259
12,3171
10,1892
11,561
Process Capability Report for Slab Assembly Duration
I Chart of Slab Assembly Duration
Pareto Chart of Delay causes Boxplot of Slab Assembly Duration By Day
14.4 % of
assemblies
are out of spec
Lot of special cause variation,
low standard variation
Low day-to-day variation
Truck scheduling
major issue
Exploratory Data Analysis (EDA)
European Students of Industrial Engineering and Management
www.estiem.org
P
Manpower Machinery Mother nature
MaterialsMeasurementMethods
Money
What causes
Delay in element
assembly ?
Weather conditions:
-Wind speed
-Fog
Crane availability
Crane operator:
unclear instructions
and multiple requests
Workers:
Wrong place, wrong time
Material delivery
Method of
measurement
Amount of data,
sample size
Quality of data
Non standardized work
Additional mobile
cranes
Material manufacturing
Insufficient
funds/unwillingness
to support
increased
schedule
Not enough space
for trucks
Unloading materials
to ground
Other tasks during
assembly
Repeatability &
Reproducibility (project business)
Faulty elements
(Size)
Airport operations &
limited space
Circled factors
were keys for
improvement!
Fishbone
European Students of Industrial Engineering and Management
www.estiem.org
Process Capability & Analysis
4137332925211713951
90
80
70
60
50
40
30
20
10
0
Observation
IndividualValue
_
X=11,56
UB=20
LB=0
1
1
I Chart of Slab Assembly Duration
Results include rows where day =2. (2.5.2017)
Manpower
Truck change
Truck late + other
Truck late
Truck late + other tasks+ workers
Truck late
Truck late
Truck late + other
Break + truck late
Truck late
Single truck
(Single Day)
Truck Arrival Interval
1 6:02
2 6:41
3 7:39
1 8:25 2:23
2 9:15 2:34
3 10:23 2:44
1 11:27 3:02
2 11:30 2:15
3 12:48 2:25
1 13:40 2:13
2 14:18 2:48
• Rotation of 3 trucks
• 2,5 hour interval
• (one truck every 50
minutes)
• 30 minutes interval
needed
Significant Special CauseVariation Within a Day
European Students of Industrial Engineering and Management
www.estiem.org
Implemented Improvements
12
Increase number of trucks
Prioritize slab assembly
• Resource efficiency vs. Flow
efficiency!
• Truck waiting costs only 50€/h
• No other work started if truck is
couple of minutes late
• 4 truck schedule is possible in theory
but 5 or 6 truck schedule is required
Layout for slab delivery (5S)
1. Truck arrives and assembly starts
2. Second truck arrives to queue
3. First truck moves away after the assembly
4. Trucks turn around and leave
Buffer inventory located next to crane
European Students of Industrial Engineering and Management
www.estiem.org
Improvement Risk Analysis
Task Potential
problem
Effect Likely cause S
E
V
O
CC
Preventive actions Contingent
actions
Triggers for
contingent
All Increase in
cycle time
Truck
queue &
waiting
Issues in
assembly
2 3 Preparatory work Unload truck to
buffer inventory
Assembly lasted
over 30 mins or
multiple trucks in
queue
All Rework Truck
queue &
waiting
Defective part,
careless
assembly
4 2 Alignment done
right the first time,
necessary
measurements
Unload truck to
buffer inventory
When need for
rework is noticed
All Buffer
inventory
full
No room
for
errors/truc
k unloading
Issues in
assembly
3 1 Assemble
elements from
buffer between
trucks when
possible
Continue
assembly to time
buffer (11.00-
13.00)
Over 6 elements in
the buffer
All No
material
available
Increase in
lead time
Error in truck
schedule/truck
s late
4 2 Load buffer at the
end of the shift
Call the supplier
for ETA →start
other tasks
Buffer empty &
truck late over 10
minutes
All Man lift
failure
Assembly
stopped
Man lift not
loaded
4 4 Make sure man
lifts are loaded on
the previous day
Use secondary
man lift
As soon as failure
occurs
European Students of Industrial Engineering and Management
www.estiem.org
Leveraged Improvements to the
Whole Structural Frame Assembly
14
Schedule fast tracking based on
measured cycle times and known
variation
The slab assembly was only a small part
of the project
Small improvements on each
type added up to significant
savings
30% reduction on planned
assembly time
Elements Columns*
Beams* Trusses*
Reliable
measurement
Standardized
work
Reduced uncertainty & risk
*Both, Concrete & Steel parts
European Students of Industrial Engineering and Management
www.estiem.org
Not a common practice in the construction industry
 Easy to find small wins as use of data is not common – Huge potential!
 Few references on how long-term improvements have succeeded
 Bottom-up initiatives are difficult (green belt) – Management support needed
Project based business
 Changing work during different work phases – measurement and implementation
needs to be fast
 Repeatability between unique projects (high sigma levels are hard to obtain)
 Use of sub-contractors makes implementation difficult
 Cost-plus pricing gives low incentives for process improvement
 Sub-contractor contract clauses are not effective to motivate for collaboration
Stagnant culture
 Change initiatives are extremely difficult without good management support
Lean Six Sigma in Construction Industry

More Related Content

What's hot

Aviation Aerospace & Defense industry TRIZ Case Studies - An Overview
Aviation Aerospace & Defense industry TRIZ Case Studies - An Overview Aviation Aerospace & Defense industry TRIZ Case Studies - An Overview
Aviation Aerospace & Defense industry TRIZ Case Studies - An Overview Richard Platt
 
Advanced Work Packaging - CCT Solutions at a Glance
Advanced Work Packaging - CCT Solutions at a GlanceAdvanced Work Packaging - CCT Solutions at a Glance
Advanced Work Packaging - CCT Solutions at a GlanceCCT International
 
058 Lean Construction (PART 2) Construction productivity
058 Lean Construction  (PART 2) Construction productivity 058 Lean Construction  (PART 2) Construction productivity
058 Lean Construction (PART 2) Construction productivity Dr Fereidoun Dejahang
 
Wel100 safety for welders presentation
Wel100 safety for welders presentationWel100 safety for welders presentation
Wel100 safety for welders presentationcccschamp
 
Development of Work at Height Competency Framework
Development of Work at Height Competency FrameworkDevelopment of Work at Height Competency Framework
Development of Work at Height Competency FrameworkGoh Chye Guan
 
Formation in robotics, the key to integration in industrial environments
Formation in robotics, the key to integration in industrial environmentsFormation in robotics, the key to integration in industrial environments
Formation in robotics, the key to integration in industrial environmentsGerman Carro Fernandez
 
Problem solving thru qc circle (1)
Problem solving thru qc circle (1)Problem solving thru qc circle (1)
Problem solving thru qc circle (1)Jitesh Gaurav
 
Modified Stage-Gate: A Product Development Process by Dr. Nader Ale Ebrahim
Modified Stage-Gate: A Product Development Process     by Dr. Nader Ale EbrahimModified Stage-Gate: A Product Development Process     by Dr. Nader Ale Ebrahim
Modified Stage-Gate: A Product Development Process by Dr. Nader Ale EbrahimNader Ale Ebrahim
 
Software or Service? That’s the question!
Software or Service? That’s the question!Software or Service? That’s the question!
Software or Service? That’s the question!Luigi Buglione
 
Imagine a World Without Isometric
Imagine a World Without IsometricImagine a World Without Isometric
Imagine a World Without IsometricCCT International
 
Om rak-sbs-2 (1)
Om rak-sbs-2 (1)Om rak-sbs-2 (1)
Om rak-sbs-2 (1)smumbahelp
 
Engineering design guildline_general_plant_cost_estimating_rev01web
Engineering design guildline_general_plant_cost_estimating_rev01webEngineering design guildline_general_plant_cost_estimating_rev01web
Engineering design guildline_general_plant_cost_estimating_rev01webGABISA DEMISIE
 
Byron Pang (LinkedIn- Oct 2014)
Byron Pang (LinkedIn- Oct 2014)Byron Pang (LinkedIn- Oct 2014)
Byron Pang (LinkedIn- Oct 2014)Byron Pang
 
Labor productivity improvement in construction projects using wbs obs integra...
Labor productivity improvement in construction projects using wbs obs integra...Labor productivity improvement in construction projects using wbs obs integra...
Labor productivity improvement in construction projects using wbs obs integra...Essam Lotffy, PMP®, CCP®
 

What's hot (16)

Aviation Aerospace & Defense industry TRIZ Case Studies - An Overview
Aviation Aerospace & Defense industry TRIZ Case Studies - An Overview Aviation Aerospace & Defense industry TRIZ Case Studies - An Overview
Aviation Aerospace & Defense industry TRIZ Case Studies - An Overview
 
Advanced Work Packaging - CCT Solutions at a Glance
Advanced Work Packaging - CCT Solutions at a GlanceAdvanced Work Packaging - CCT Solutions at a Glance
Advanced Work Packaging - CCT Solutions at a Glance
 
058 Lean Construction (PART 2) Construction productivity
058 Lean Construction  (PART 2) Construction productivity 058 Lean Construction  (PART 2) Construction productivity
058 Lean Construction (PART 2) Construction productivity
 
Wel100 safety for welders presentation
Wel100 safety for welders presentationWel100 safety for welders presentation
Wel100 safety for welders presentation
 
Development of Work at Height Competency Framework
Development of Work at Height Competency FrameworkDevelopment of Work at Height Competency Framework
Development of Work at Height Competency Framework
 
Formation in robotics, the key to integration in industrial environments
Formation in robotics, the key to integration in industrial environmentsFormation in robotics, the key to integration in industrial environments
Formation in robotics, the key to integration in industrial environments
 
Problem solving thru qc circle (1)
Problem solving thru qc circle (1)Problem solving thru qc circle (1)
Problem solving thru qc circle (1)
 
Process iceberg
Process icebergProcess iceberg
Process iceberg
 
Modified Stage-Gate: A Product Development Process by Dr. Nader Ale Ebrahim
Modified Stage-Gate: A Product Development Process     by Dr. Nader Ale EbrahimModified Stage-Gate: A Product Development Process     by Dr. Nader Ale Ebrahim
Modified Stage-Gate: A Product Development Process by Dr. Nader Ale Ebrahim
 
Software or Service? That’s the question!
Software or Service? That’s the question!Software or Service? That’s the question!
Software or Service? That’s the question!
 
Imagine a World Without Isometric
Imagine a World Without IsometricImagine a World Without Isometric
Imagine a World Without Isometric
 
Advanced Work Packaging: Applying Project Controls
Advanced Work Packaging: Applying Project ControlsAdvanced Work Packaging: Applying Project Controls
Advanced Work Packaging: Applying Project Controls
 
Om rak-sbs-2 (1)
Om rak-sbs-2 (1)Om rak-sbs-2 (1)
Om rak-sbs-2 (1)
 
Engineering design guildline_general_plant_cost_estimating_rev01web
Engineering design guildline_general_plant_cost_estimating_rev01webEngineering design guildline_general_plant_cost_estimating_rev01web
Engineering design guildline_general_plant_cost_estimating_rev01web
 
Byron Pang (LinkedIn- Oct 2014)
Byron Pang (LinkedIn- Oct 2014)Byron Pang (LinkedIn- Oct 2014)
Byron Pang (LinkedIn- Oct 2014)
 
Labor productivity improvement in construction projects using wbs obs integra...
Labor productivity improvement in construction projects using wbs obs integra...Labor productivity improvement in construction projects using wbs obs integra...
Labor productivity improvement in construction projects using wbs obs integra...
 

Similar to ESTIEM Lean Six Sigma Green Belt Project at YIT - Airport Extension

IRJET- Design and Implementation of Kitting Trolley for Just in Time Producti...
IRJET- Design and Implementation of Kitting Trolley for Just in Time Producti...IRJET- Design and Implementation of Kitting Trolley for Just in Time Producti...
IRJET- Design and Implementation of Kitting Trolley for Just in Time Producti...IRJET Journal
 
Logistics Breakout – Herman Woltjes, Shell Chemicals: “Logistics Execution”
Logistics Breakout – Herman Woltjes, Shell Chemicals: “Logistics Execution”Logistics Breakout – Herman Woltjes, Shell Chemicals: “Logistics Execution”
Logistics Breakout – Herman Woltjes, Shell Chemicals: “Logistics Execution”Elemica
 
Testing Sociotechnical Systems: Heathrow Terminal 5
Testing Sociotechnical Systems: Heathrow Terminal 5Testing Sociotechnical Systems: Heathrow Terminal 5
Testing Sociotechnical Systems: Heathrow Terminal 5John Rooksby
 
Construction Equipment Fleet Management
Construction Equipment Fleet ManagementConstruction Equipment Fleet Management
Construction Equipment Fleet ManagementIJMER
 
Material Handling System
Material Handling SystemMaterial Handling System
Material Handling Systemwombaty
 
PPM BIM summer school presentation vasudeva
PPM BIM summer school presentation vasudevaPPM BIM summer school presentation vasudeva
PPM BIM summer school presentation vasudevaNarendra Vasudeva
 
Development Of Tipper Unloading Mechanism
Development Of Tipper Unloading MechanismDevelopment Of Tipper Unloading Mechanism
Development Of Tipper Unloading MechanismIRJET Journal
 
2006 iitk-urban transportation-infrastructure
2006 iitk-urban transportation-infrastructure2006 iitk-urban transportation-infrastructure
2006 iitk-urban transportation-infrastructurePravin Kolhe
 
SUJITH RESUME (1)
SUJITH RESUME (1)SUJITH RESUME (1)
SUJITH RESUME (1)Sujith sv
 
Omar Ibrahim Ayesh - Competency Demonstration
Omar Ibrahim Ayesh - Competency DemonstrationOmar Ibrahim Ayesh - Competency Demonstration
Omar Ibrahim Ayesh - Competency Demonstrationomar ayeah
 
Plant layout optimization in crane manufacturing using CRAFT and SLP
Plant layout optimization in crane manufacturing using CRAFT and SLPPlant layout optimization in crane manufacturing using CRAFT and SLP
Plant layout optimization in crane manufacturing using CRAFT and SLPEr Harshrajsinh Kher
 
Stockley Week 22 Airport Lines Possession - Share with Pride
Stockley Week 22 Airport Lines Possession - Share with PrideStockley Week 22 Airport Lines Possession - Share with Pride
Stockley Week 22 Airport Lines Possession - Share with PrideThomas Ingrey
 
IRJET- Planning and Selection of Heavy Construction Equipments in Civil En...
IRJET- 	  Planning and Selection of Heavy Construction Equipments in Civil En...IRJET- 	  Planning and Selection of Heavy Construction Equipments in Civil En...
IRJET- Planning and Selection of Heavy Construction Equipments in Civil En...IRJET Journal
 

Similar to ESTIEM Lean Six Sigma Green Belt Project at YIT - Airport Extension (20)

CV CBK 2015 N
CV CBK 2015 NCV CBK 2015 N
CV CBK 2015 N
 
IRJET- Design and Implementation of Kitting Trolley for Just in Time Producti...
IRJET- Design and Implementation of Kitting Trolley for Just in Time Producti...IRJET- Design and Implementation of Kitting Trolley for Just in Time Producti...
IRJET- Design and Implementation of Kitting Trolley for Just in Time Producti...
 
Logistics Breakout – Herman Woltjes, Shell Chemicals: “Logistics Execution”
Logistics Breakout – Herman Woltjes, Shell Chemicals: “Logistics Execution”Logistics Breakout – Herman Woltjes, Shell Chemicals: “Logistics Execution”
Logistics Breakout – Herman Woltjes, Shell Chemicals: “Logistics Execution”
 
Ijmet 09 11_006
Ijmet 09 11_006Ijmet 09 11_006
Ijmet 09 11_006
 
Testing Sociotechnical Systems: Heathrow Terminal 5
Testing Sociotechnical Systems: Heathrow Terminal 5Testing Sociotechnical Systems: Heathrow Terminal 5
Testing Sociotechnical Systems: Heathrow Terminal 5
 
Construction Equipment Fleet Management
Construction Equipment Fleet ManagementConstruction Equipment Fleet Management
Construction Equipment Fleet Management
 
Material Handling System
Material Handling SystemMaterial Handling System
Material Handling System
 
PPM BIM summer school presentation vasudeva
PPM BIM summer school presentation vasudevaPPM BIM summer school presentation vasudeva
PPM BIM summer school presentation vasudeva
 
Development Of Tipper Unloading Mechanism
Development Of Tipper Unloading MechanismDevelopment Of Tipper Unloading Mechanism
Development Of Tipper Unloading Mechanism
 
2006 iitk-urban transportation-infrastructure
2006 iitk-urban transportation-infrastructure2006 iitk-urban transportation-infrastructure
2006 iitk-urban transportation-infrastructure
 
SUJITH RESUME (1)
SUJITH RESUME (1)SUJITH RESUME (1)
SUJITH RESUME (1)
 
CURRICULUM_VITAE_Y 2015
CURRICULUM_VITAE_Y 2015CURRICULUM_VITAE_Y 2015
CURRICULUM_VITAE_Y 2015
 
Final Pesentasi Harris April 2016
Final Pesentasi Harris April 2016Final Pesentasi Harris April 2016
Final Pesentasi Harris April 2016
 
SomkiatC
SomkiatCSomkiatC
SomkiatC
 
Eng Ahmed Afifi final CV
Eng Ahmed Afifi final CVEng Ahmed Afifi final CV
Eng Ahmed Afifi final CV
 
Omar Ibrahim Ayesh - Competency Demonstration
Omar Ibrahim Ayesh - Competency DemonstrationOmar Ibrahim Ayesh - Competency Demonstration
Omar Ibrahim Ayesh - Competency Demonstration
 
Plant layout optimization in crane manufacturing using CRAFT and SLP
Plant layout optimization in crane manufacturing using CRAFT and SLPPlant layout optimization in crane manufacturing using CRAFT and SLP
Plant layout optimization in crane manufacturing using CRAFT and SLP
 
Stockley Week 22 Airport Lines Possession - Share with Pride
Stockley Week 22 Airport Lines Possession - Share with PrideStockley Week 22 Airport Lines Possession - Share with Pride
Stockley Week 22 Airport Lines Possession - Share with Pride
 
CV_Piyapol
CV_PiyapolCV_Piyapol
CV_Piyapol
 
IRJET- Planning and Selection of Heavy Construction Equipments in Civil En...
IRJET- 	  Planning and Selection of Heavy Construction Equipments in Civil En...IRJET- 	  Planning and Selection of Heavy Construction Equipments in Civil En...
IRJET- Planning and Selection of Heavy Construction Equipments in Civil En...
 

More from ESTIEM

Certification Requirements_2023 Version_FOR PUBLICATION.pdf
Certification Requirements_2023 Version_FOR PUBLICATION.pdfCertification Requirements_2023 Version_FOR PUBLICATION.pdf
Certification Requirements_2023 Version_FOR PUBLICATION.pdfESTIEM
 
A green belt practitioners guide for quality champions publication v2021
A green belt practitioners guide for quality champions publication v2021A green belt practitioners guide for quality champions publication v2021
A green belt practitioners guide for quality champions publication v2021ESTIEM
 
Local Courses
Local CoursesLocal Courses
Local CoursesESTIEM
 
Conference Paper - The influence of Lean Six Sigma Green Belt course on Europ...
Conference Paper - The influence of Lean Six Sigma Green Belt course on Europ...Conference Paper - The influence of Lean Six Sigma Green Belt course on Europ...
Conference Paper - The influence of Lean Six Sigma Green Belt course on Europ...ESTIEM
 
Conferene Paper - A blended learning approach to lean six sigma green belt ed...
Conferene Paper - A blended learning approach to lean six sigma green belt ed...Conferene Paper - A blended learning approach to lean six sigma green belt ed...
Conferene Paper - A blended learning approach to lean six sigma green belt ed...ESTIEM
 
E-book of LSSGB Project History
E-book of LSSGB Project HistoryE-book of LSSGB Project History
E-book of LSSGB Project HistoryESTIEM
 
ESTIEM Lean Six Sigma Green Belt course - Glossary of terms
ESTIEM Lean Six Sigma Green Belt course - Glossary of termsESTIEM Lean Six Sigma Green Belt course - Glossary of terms
ESTIEM Lean Six Sigma Green Belt course - Glossary of termsESTIEM
 
04 - Risk analysis - ESTIEM Lean Six Sigma Green Belt Course
04 - Risk analysis - ESTIEM Lean Six Sigma Green Belt Course04 - Risk analysis - ESTIEM Lean Six Sigma Green Belt Course
04 - Risk analysis - ESTIEM Lean Six Sigma Green Belt CourseESTIEM
 
03 - Process mapping & Bottleneck Identification - ESTIEM Lean Six Sigma Gre...
03 - Process mapping  & Bottleneck Identification - ESTIEM Lean Six Sigma Gre...03 - Process mapping  & Bottleneck Identification - ESTIEM Lean Six Sigma Gre...
03 - Process mapping & Bottleneck Identification - ESTIEM Lean Six Sigma Gre...ESTIEM
 
02 - Exploratory Data Analysis (EDA) - ESTIEM Lean Six Sigma Green Belt Course
02 - Exploratory Data Analysis (EDA) - ESTIEM Lean Six Sigma Green Belt Course02 - Exploratory Data Analysis (EDA) - ESTIEM Lean Six Sigma Green Belt Course
02 - Exploratory Data Analysis (EDA) - ESTIEM Lean Six Sigma Green Belt CourseESTIEM
 
01 - Initiating a Lean Six Sigma Project - ESTIEM Lean Six Sigma Green Belt C...
01 - Initiating a Lean Six Sigma Project - ESTIEM Lean Six Sigma Green Belt C...01 - Initiating a Lean Six Sigma Project - ESTIEM Lean Six Sigma Green Belt C...
01 - Initiating a Lean Six Sigma Project - ESTIEM Lean Six Sigma Green Belt C...ESTIEM
 
00 - Introduction to the Course - ESTIEM Lean Six Sigma Green Belt Course
00 - Introduction to the Course - ESTIEM Lean Six Sigma Green Belt Course00 - Introduction to the Course - ESTIEM Lean Six Sigma Green Belt Course
00 - Introduction to the Course - ESTIEM Lean Six Sigma Green Belt CourseESTIEM
 
DMAIC Recap - ESTIEM Lean Six Sigma Green Belt Course
DMAIC Recap - ESTIEM Lean Six Sigma Green Belt CourseDMAIC Recap - ESTIEM Lean Six Sigma Green Belt Course
DMAIC Recap - ESTIEM Lean Six Sigma Green Belt CourseESTIEM
 
09 - Control - ESTIEM Lean Six Sigma Green Belt Course
09 - Control - ESTIEM Lean Six Sigma Green Belt Course09 - Control - ESTIEM Lean Six Sigma Green Belt Course
09 - Control - ESTIEM Lean Six Sigma Green Belt CourseESTIEM
 
08 - Improve - ESTIEM Lean Six Sigma Green Belt Course
08 - Improve - ESTIEM Lean Six Sigma Green Belt Course08 - Improve - ESTIEM Lean Six Sigma Green Belt Course
08 - Improve - ESTIEM Lean Six Sigma Green Belt CourseESTIEM
 
07 - Analysis Regression - ESTIEM Lean Six Sigma Green Belt Course
07 - Analysis Regression - ESTIEM Lean Six Sigma Green Belt Course07 - Analysis Regression - ESTIEM Lean Six Sigma Green Belt Course
07 - Analysis Regression - ESTIEM Lean Six Sigma Green Belt CourseESTIEM
 
05 - Measurement System Analaysis (MSA) - ESTIEM Lean Six Sigma Green Belt Co...
05 - Measurement System Analaysis (MSA) - ESTIEM Lean Six Sigma Green Belt Co...05 - Measurement System Analaysis (MSA) - ESTIEM Lean Six Sigma Green Belt Co...
05 - Measurement System Analaysis (MSA) - ESTIEM Lean Six Sigma Green Belt Co...ESTIEM
 

More from ESTIEM (17)

Certification Requirements_2023 Version_FOR PUBLICATION.pdf
Certification Requirements_2023 Version_FOR PUBLICATION.pdfCertification Requirements_2023 Version_FOR PUBLICATION.pdf
Certification Requirements_2023 Version_FOR PUBLICATION.pdf
 
A green belt practitioners guide for quality champions publication v2021
A green belt practitioners guide for quality champions publication v2021A green belt practitioners guide for quality champions publication v2021
A green belt practitioners guide for quality champions publication v2021
 
Local Courses
Local CoursesLocal Courses
Local Courses
 
Conference Paper - The influence of Lean Six Sigma Green Belt course on Europ...
Conference Paper - The influence of Lean Six Sigma Green Belt course on Europ...Conference Paper - The influence of Lean Six Sigma Green Belt course on Europ...
Conference Paper - The influence of Lean Six Sigma Green Belt course on Europ...
 
Conferene Paper - A blended learning approach to lean six sigma green belt ed...
Conferene Paper - A blended learning approach to lean six sigma green belt ed...Conferene Paper - A blended learning approach to lean six sigma green belt ed...
Conferene Paper - A blended learning approach to lean six sigma green belt ed...
 
E-book of LSSGB Project History
E-book of LSSGB Project HistoryE-book of LSSGB Project History
E-book of LSSGB Project History
 
ESTIEM Lean Six Sigma Green Belt course - Glossary of terms
ESTIEM Lean Six Sigma Green Belt course - Glossary of termsESTIEM Lean Six Sigma Green Belt course - Glossary of terms
ESTIEM Lean Six Sigma Green Belt course - Glossary of terms
 
04 - Risk analysis - ESTIEM Lean Six Sigma Green Belt Course
04 - Risk analysis - ESTIEM Lean Six Sigma Green Belt Course04 - Risk analysis - ESTIEM Lean Six Sigma Green Belt Course
04 - Risk analysis - ESTIEM Lean Six Sigma Green Belt Course
 
03 - Process mapping & Bottleneck Identification - ESTIEM Lean Six Sigma Gre...
03 - Process mapping  & Bottleneck Identification - ESTIEM Lean Six Sigma Gre...03 - Process mapping  & Bottleneck Identification - ESTIEM Lean Six Sigma Gre...
03 - Process mapping & Bottleneck Identification - ESTIEM Lean Six Sigma Gre...
 
02 - Exploratory Data Analysis (EDA) - ESTIEM Lean Six Sigma Green Belt Course
02 - Exploratory Data Analysis (EDA) - ESTIEM Lean Six Sigma Green Belt Course02 - Exploratory Data Analysis (EDA) - ESTIEM Lean Six Sigma Green Belt Course
02 - Exploratory Data Analysis (EDA) - ESTIEM Lean Six Sigma Green Belt Course
 
01 - Initiating a Lean Six Sigma Project - ESTIEM Lean Six Sigma Green Belt C...
01 - Initiating a Lean Six Sigma Project - ESTIEM Lean Six Sigma Green Belt C...01 - Initiating a Lean Six Sigma Project - ESTIEM Lean Six Sigma Green Belt C...
01 - Initiating a Lean Six Sigma Project - ESTIEM Lean Six Sigma Green Belt C...
 
00 - Introduction to the Course - ESTIEM Lean Six Sigma Green Belt Course
00 - Introduction to the Course - ESTIEM Lean Six Sigma Green Belt Course00 - Introduction to the Course - ESTIEM Lean Six Sigma Green Belt Course
00 - Introduction to the Course - ESTIEM Lean Six Sigma Green Belt Course
 
DMAIC Recap - ESTIEM Lean Six Sigma Green Belt Course
DMAIC Recap - ESTIEM Lean Six Sigma Green Belt CourseDMAIC Recap - ESTIEM Lean Six Sigma Green Belt Course
DMAIC Recap - ESTIEM Lean Six Sigma Green Belt Course
 
09 - Control - ESTIEM Lean Six Sigma Green Belt Course
09 - Control - ESTIEM Lean Six Sigma Green Belt Course09 - Control - ESTIEM Lean Six Sigma Green Belt Course
09 - Control - ESTIEM Lean Six Sigma Green Belt Course
 
08 - Improve - ESTIEM Lean Six Sigma Green Belt Course
08 - Improve - ESTIEM Lean Six Sigma Green Belt Course08 - Improve - ESTIEM Lean Six Sigma Green Belt Course
08 - Improve - ESTIEM Lean Six Sigma Green Belt Course
 
07 - Analysis Regression - ESTIEM Lean Six Sigma Green Belt Course
07 - Analysis Regression - ESTIEM Lean Six Sigma Green Belt Course07 - Analysis Regression - ESTIEM Lean Six Sigma Green Belt Course
07 - Analysis Regression - ESTIEM Lean Six Sigma Green Belt Course
 
05 - Measurement System Analaysis (MSA) - ESTIEM Lean Six Sigma Green Belt Co...
05 - Measurement System Analaysis (MSA) - ESTIEM Lean Six Sigma Green Belt Co...05 - Measurement System Analaysis (MSA) - ESTIEM Lean Six Sigma Green Belt Co...
05 - Measurement System Analaysis (MSA) - ESTIEM Lean Six Sigma Green Belt Co...
 

Recently uploaded

Detection&Tracking - Thermal imaging object detection and tracking
Detection&Tracking - Thermal imaging object detection and trackingDetection&Tracking - Thermal imaging object detection and tracking
Detection&Tracking - Thermal imaging object detection and trackinghadarpinhas1
 
Structural Integrity Assessment Standards in Nigeria by Engr Nimot Muili
Structural Integrity Assessment Standards in Nigeria by Engr Nimot MuiliStructural Integrity Assessment Standards in Nigeria by Engr Nimot Muili
Structural Integrity Assessment Standards in Nigeria by Engr Nimot MuiliNimot Muili
 
Introduction to Machine Learning Part1.pptx
Introduction to Machine Learning Part1.pptxIntroduction to Machine Learning Part1.pptx
Introduction to Machine Learning Part1.pptxPavan Mohan Neelamraju
 
Overview of IS 16700:2023 (by priyansh verma)
Overview of IS 16700:2023 (by priyansh verma)Overview of IS 16700:2023 (by priyansh verma)
Overview of IS 16700:2023 (by priyansh verma)Priyansh
 
Introduction to Artificial Intelligence: Intelligent Agents, State Space Sear...
Introduction to Artificial Intelligence: Intelligent Agents, State Space Sear...Introduction to Artificial Intelligence: Intelligent Agents, State Space Sear...
Introduction to Artificial Intelligence: Intelligent Agents, State Space Sear...shreenathji26
 
Module-1-(Building Acoustics) Noise Control (Unit-3). pdf
Module-1-(Building Acoustics) Noise Control (Unit-3). pdfModule-1-(Building Acoustics) Noise Control (Unit-3). pdf
Module-1-(Building Acoustics) Noise Control (Unit-3). pdfManish Kumar
 
Guardians of E-Commerce: Harnessing NLP and Machine Learning Approaches for A...
Guardians of E-Commerce: Harnessing NLP and Machine Learning Approaches for A...Guardians of E-Commerce: Harnessing NLP and Machine Learning Approaches for A...
Guardians of E-Commerce: Harnessing NLP and Machine Learning Approaches for A...IJAEMSJORNAL
 
The Satellite applications in telecommunication
The Satellite applications in telecommunicationThe Satellite applications in telecommunication
The Satellite applications in telecommunicationnovrain7111
 
22CYT12 & Chemistry for Computer Systems_Unit-II-Corrosion & its Control Meth...
22CYT12 & Chemistry for Computer Systems_Unit-II-Corrosion & its Control Meth...22CYT12 & Chemistry for Computer Systems_Unit-II-Corrosion & its Control Meth...
22CYT12 & Chemistry for Computer Systems_Unit-II-Corrosion & its Control Meth...KrishnaveniKrishnara1
 
Defining the Clouds for entriprises.pptx
Defining the Clouds for entriprises.pptxDefining the Clouds for entriprises.pptx
Defining the Clouds for entriprises.pptxAshwiniTodkar4
 
Uk-NO1 Black Magic Specialist In Lahore Black magic In Pakistan Kala Ilam Exp...
Uk-NO1 Black Magic Specialist In Lahore Black magic In Pakistan Kala Ilam Exp...Uk-NO1 Black Magic Specialist In Lahore Black magic In Pakistan Kala Ilam Exp...
Uk-NO1 Black Magic Specialist In Lahore Black magic In Pakistan Kala Ilam Exp...Amil baba
 
Substation Automation SCADA and Gateway Solutions by BRH
Substation Automation SCADA and Gateway Solutions by BRHSubstation Automation SCADA and Gateway Solutions by BRH
Substation Automation SCADA and Gateway Solutions by BRHbirinder2
 
SOFTWARE ESTIMATION COCOMO AND FP CALCULATION
SOFTWARE ESTIMATION COCOMO AND FP CALCULATIONSOFTWARE ESTIMATION COCOMO AND FP CALCULATION
SOFTWARE ESTIMATION COCOMO AND FP CALCULATIONSneha Padhiar
 
Curve setting (Basic Mine Surveying)_MI10412MI.pptx
Curve setting (Basic Mine Surveying)_MI10412MI.pptxCurve setting (Basic Mine Surveying)_MI10412MI.pptx
Curve setting (Basic Mine Surveying)_MI10412MI.pptxRomil Mishra
 
Road Development plans of India-Transportation Engineering
Road Development plans of India-Transportation EngineeringRoad Development plans of India-Transportation Engineering
Road Development plans of India-Transportation EngineeringSayli Madhale
 
CS 3251 Programming in c all unit notes pdf
CS 3251 Programming in c all unit notes pdfCS 3251 Programming in c all unit notes pdf
CS 3251 Programming in c all unit notes pdfBalamuruganV28
 
Ergodomus - LOD 400 Production Drawings Exampes - Copy.pdf
Ergodomus - LOD 400 Production Drawings Exampes - Copy.pdfErgodomus - LOD 400 Production Drawings Exampes - Copy.pdf
Ergodomus - LOD 400 Production Drawings Exampes - Copy.pdfgestioneergodomus
 
Livre Implementing_Six_Sigma_and_Lean_A_prac([Ron_Basu]_).pdf
Livre Implementing_Six_Sigma_and_Lean_A_prac([Ron_Basu]_).pdfLivre Implementing_Six_Sigma_and_Lean_A_prac([Ron_Basu]_).pdf
Livre Implementing_Six_Sigma_and_Lean_A_prac([Ron_Basu]_).pdfsaad175691
 
A brief look at visionOS - How to develop app on Apple's Vision Pro
A brief look at visionOS - How to develop app on Apple's Vision ProA brief look at visionOS - How to develop app on Apple's Vision Pro
A brief look at visionOS - How to develop app on Apple's Vision ProRay Yuan Liu
 
Chapter 9 Mechanical Injection Systems.pdf
Chapter 9 Mechanical Injection Systems.pdfChapter 9 Mechanical Injection Systems.pdf
Chapter 9 Mechanical Injection Systems.pdfFaizanAhmed396943
 

Recently uploaded (20)

Detection&Tracking - Thermal imaging object detection and tracking
Detection&Tracking - Thermal imaging object detection and trackingDetection&Tracking - Thermal imaging object detection and tracking
Detection&Tracking - Thermal imaging object detection and tracking
 
Structural Integrity Assessment Standards in Nigeria by Engr Nimot Muili
Structural Integrity Assessment Standards in Nigeria by Engr Nimot MuiliStructural Integrity Assessment Standards in Nigeria by Engr Nimot Muili
Structural Integrity Assessment Standards in Nigeria by Engr Nimot Muili
 
Introduction to Machine Learning Part1.pptx
Introduction to Machine Learning Part1.pptxIntroduction to Machine Learning Part1.pptx
Introduction to Machine Learning Part1.pptx
 
Overview of IS 16700:2023 (by priyansh verma)
Overview of IS 16700:2023 (by priyansh verma)Overview of IS 16700:2023 (by priyansh verma)
Overview of IS 16700:2023 (by priyansh verma)
 
Introduction to Artificial Intelligence: Intelligent Agents, State Space Sear...
Introduction to Artificial Intelligence: Intelligent Agents, State Space Sear...Introduction to Artificial Intelligence: Intelligent Agents, State Space Sear...
Introduction to Artificial Intelligence: Intelligent Agents, State Space Sear...
 
Module-1-(Building Acoustics) Noise Control (Unit-3). pdf
Module-1-(Building Acoustics) Noise Control (Unit-3). pdfModule-1-(Building Acoustics) Noise Control (Unit-3). pdf
Module-1-(Building Acoustics) Noise Control (Unit-3). pdf
 
Guardians of E-Commerce: Harnessing NLP and Machine Learning Approaches for A...
Guardians of E-Commerce: Harnessing NLP and Machine Learning Approaches for A...Guardians of E-Commerce: Harnessing NLP and Machine Learning Approaches for A...
Guardians of E-Commerce: Harnessing NLP and Machine Learning Approaches for A...
 
The Satellite applications in telecommunication
The Satellite applications in telecommunicationThe Satellite applications in telecommunication
The Satellite applications in telecommunication
 
22CYT12 & Chemistry for Computer Systems_Unit-II-Corrosion & its Control Meth...
22CYT12 & Chemistry for Computer Systems_Unit-II-Corrosion & its Control Meth...22CYT12 & Chemistry for Computer Systems_Unit-II-Corrosion & its Control Meth...
22CYT12 & Chemistry for Computer Systems_Unit-II-Corrosion & its Control Meth...
 
Defining the Clouds for entriprises.pptx
Defining the Clouds for entriprises.pptxDefining the Clouds for entriprises.pptx
Defining the Clouds for entriprises.pptx
 
Uk-NO1 Black Magic Specialist In Lahore Black magic In Pakistan Kala Ilam Exp...
Uk-NO1 Black Magic Specialist In Lahore Black magic In Pakistan Kala Ilam Exp...Uk-NO1 Black Magic Specialist In Lahore Black magic In Pakistan Kala Ilam Exp...
Uk-NO1 Black Magic Specialist In Lahore Black magic In Pakistan Kala Ilam Exp...
 
Substation Automation SCADA and Gateway Solutions by BRH
Substation Automation SCADA and Gateway Solutions by BRHSubstation Automation SCADA and Gateway Solutions by BRH
Substation Automation SCADA and Gateway Solutions by BRH
 
SOFTWARE ESTIMATION COCOMO AND FP CALCULATION
SOFTWARE ESTIMATION COCOMO AND FP CALCULATIONSOFTWARE ESTIMATION COCOMO AND FP CALCULATION
SOFTWARE ESTIMATION COCOMO AND FP CALCULATION
 
Curve setting (Basic Mine Surveying)_MI10412MI.pptx
Curve setting (Basic Mine Surveying)_MI10412MI.pptxCurve setting (Basic Mine Surveying)_MI10412MI.pptx
Curve setting (Basic Mine Surveying)_MI10412MI.pptx
 
Road Development plans of India-Transportation Engineering
Road Development plans of India-Transportation EngineeringRoad Development plans of India-Transportation Engineering
Road Development plans of India-Transportation Engineering
 
CS 3251 Programming in c all unit notes pdf
CS 3251 Programming in c all unit notes pdfCS 3251 Programming in c all unit notes pdf
CS 3251 Programming in c all unit notes pdf
 
Ergodomus - LOD 400 Production Drawings Exampes - Copy.pdf
Ergodomus - LOD 400 Production Drawings Exampes - Copy.pdfErgodomus - LOD 400 Production Drawings Exampes - Copy.pdf
Ergodomus - LOD 400 Production Drawings Exampes - Copy.pdf
 
Livre Implementing_Six_Sigma_and_Lean_A_prac([Ron_Basu]_).pdf
Livre Implementing_Six_Sigma_and_Lean_A_prac([Ron_Basu]_).pdfLivre Implementing_Six_Sigma_and_Lean_A_prac([Ron_Basu]_).pdf
Livre Implementing_Six_Sigma_and_Lean_A_prac([Ron_Basu]_).pdf
 
A brief look at visionOS - How to develop app on Apple's Vision Pro
A brief look at visionOS - How to develop app on Apple's Vision ProA brief look at visionOS - How to develop app on Apple's Vision Pro
A brief look at visionOS - How to develop app on Apple's Vision Pro
 
Chapter 9 Mechanical Injection Systems.pdf
Chapter 9 Mechanical Injection Systems.pdfChapter 9 Mechanical Injection Systems.pdf
Chapter 9 Mechanical Injection Systems.pdf
 

ESTIEM Lean Six Sigma Green Belt Project at YIT - Airport Extension

  • 1. European Students of Industrial Engineering and Management www.estiem.org1 Decreasing Structural Frame Assembly Time Lean Six Sigma Green Belt Project - Educational Case Site visualizations: PES-Arkkitehdit Oy and 3Drender Oy
  • 2. European Students of Industrial Engineering and Management www.estiem.org The Project Was Conducted As a Part of Helsinki-Vantaa Airport Expansion 2 Site visualizations: PES-Arkkitehdit Oy and 3Drender Oy
  • 3. European Students of Industrial Engineering and Management www.estiem.org The Goal of the Project Was to Reduce the Leadtime of the Structural Frame Assembly 3
  • 4. European Students of Industrial Engineering and Management www.estiem.org  A Finnish construction company is building an extension to the Helsinki-Vantaa airport. Over 300 meter long new terminal is being built in the center of a fully functional airport.The project schedule is tight and the process owner wants to deliver the project as soon as possible to minimize the disturbance to the airport operations.The work phases can be roughly divided to groundwork, structural frame assembly, facades, interior work, and HVAC.The process owner wants to focus on the frame assembly as it is on the critical path of the project.The process improvement project is scoped in this example to the most repeatable process step, hollow-core slab assembly.The quantity of hollow-core slabs is especially large in this project and the estimated performance is 30 slabs per day.The project execution including all other concrete and steel components is is scheduled to take 10 months.  A local manufacturer provides the hollow-core slabs from Otaniemi.The manufacturer has its own logistics and the assembly itself is done by a subcontractor specialized in structural frame assembly.The material loading in the factory to the trucks takes approximately 30 minutes.The crane used for lifting the hollow- core slabs on the site is provided by the main contractor.The assembly also requires two workers to install the slabs and two workers to unload the truck. A supervisor form the subcontractor is also always present. The site provides a logistical problem, as the trucks have to cross the airport ramp in order to get to the site.The entry to the airport ramp is prevented if planes are moving on the ramp.  The measurements of the slab assembly were conducted using two time-lapse cameras taking pictures with a 1-minute interval.The cameras were positioned in two of the cranes. Crane 1 (STT1330) was close to the actual assembly and crane 2 (STT753) was further away giving an overview.The measurements present the time interval between two consecutive assemblies. Project Information* *The case is modified for educational purposes
  • 5. European Students of Industrial Engineering and Management www.estiem.org S I P O C CTQ Structural frame assembly Delivery of materials Lifting of components Fixing of components Delivery of assembled frame Concrete Columns Beams Hollow-core slabs Casting material Steel Columns Beams Braces Fixings Element suppliers Steel supplier Logistics Crane & operator Additional lifting devices Workers Designers Concrete frame Steel frame Frame assembly lead time Airport owner Contractor Management and workers of the superseding tasks Supplier Input Process Output Customer Key metrics SIPOC
  • 6. European Students of Industrial Engineering and Management www.estiem.org http://peikkousa.blogspot.fi/2016/09/peikko-frame-alternative-to-post.html Hollow-core slab assembly Element manufacturer Truck driver Crane operator Site workers Site Managers Truck drives the elements next to the crane Lifting bar is connected to crane Slabs are connected to crane Slabs are lifted into place Slabs are aligned and disconnected Process repeats until truck is unloaded Elements are manufactured and transportedLifting bar → Process of Hollow-Core Slab Assembly
  • 7. European Students of Industrial Engineering and Management www.estiem.org Site Layout & Logistics A B C D E Runway Truck route to siteCrane Top view of building (sections) 150 Slabs per segment 2 levels Single truck holds 4-5 slabs Travel time from slab factory to site is 30min per direction
  • 8. European Students of Industrial Engineering and Management www.estiem.org Data Collection  Data was collected from video filmed with two cameras attached to the crane  Start of an observation is when previous slab is on place
  • 9. European Students of Industrial Engineering and Management www.estiem.org 756045301 50-1 5 LSL 0 Target 7 USL 15 Sample Mean 10,4144 Sample N 222 StDev(Overall) 10,1731 StDev(Within) 7,8664 Process Data Pp 0,25 PPL 0,34 PPU 0,15 Ppk 0,15 Cpm 0,22 Cp 0,32 CPL 0,44 CPU 0,19 Cpk 0,19 Potential (Within) Capability Overall Capability PPM < LSL 0,00 152984,37 92766,38 PPM > USL 144144,14 326083,25 279969,23 PPM Total 144144,14 479067,62 372735,61 Observed ExpectedOverall ExpectedWithin Performance LSL Target USL Overall Within 2211 991 771 551 331 1 1896745231 80 60 40 20 0 Observation IndividualValue _ X=10,41 UB=15 LB=0 Count 1 1 1 1 1 1 21 7 1 1 3 2 2 2 1 1 Percent 2 2 2 2 2 2 436 23 6 4 4 4 2 2 Cum% 85 87 89 91 94 96 1 0036 60 66 70 74 79 81 83 Delay cause O ther Truck late + oth er+ w o rkers Truck late + other+ unknow n Tru ck la te + other + B ig/sm allsla b Tru ck la te + Big/sm all slab Truck change + w o rkerslate O the r +truck blocked M a npow er Break + truck late U n know n/break Truck change M en had to m o ve Big/sm a ll slab Truck late + other Truck late 40 30 20 1 0 0 1 00 75 50 25 0 Count Percent 31302932 80 60 40 20 0 Day (May) Duration 1 1 1 1 1 1 1 11 1 1 9,48989,09259 12,3171 10,1892 11,561 Process Capability Report for Slab Assembly Duration I Chart of Slab Assembly Duration Pareto Chart of Delay causes Boxplot of Slab Assembly Duration By Day 14.4 % of assemblies are out of spec Lot of special cause variation, low standard variation Low day-to-day variation Truck scheduling major issue Exploratory Data Analysis (EDA)
  • 10. European Students of Industrial Engineering and Management www.estiem.org P Manpower Machinery Mother nature MaterialsMeasurementMethods Money What causes Delay in element assembly ? Weather conditions: -Wind speed -Fog Crane availability Crane operator: unclear instructions and multiple requests Workers: Wrong place, wrong time Material delivery Method of measurement Amount of data, sample size Quality of data Non standardized work Additional mobile cranes Material manufacturing Insufficient funds/unwillingness to support increased schedule Not enough space for trucks Unloading materials to ground Other tasks during assembly Repeatability & Reproducibility (project business) Faulty elements (Size) Airport operations & limited space Circled factors were keys for improvement! Fishbone
  • 11. European Students of Industrial Engineering and Management www.estiem.org Process Capability & Analysis 4137332925211713951 90 80 70 60 50 40 30 20 10 0 Observation IndividualValue _ X=11,56 UB=20 LB=0 1 1 I Chart of Slab Assembly Duration Results include rows where day =2. (2.5.2017) Manpower Truck change Truck late + other Truck late Truck late + other tasks+ workers Truck late Truck late Truck late + other Break + truck late Truck late Single truck (Single Day) Truck Arrival Interval 1 6:02 2 6:41 3 7:39 1 8:25 2:23 2 9:15 2:34 3 10:23 2:44 1 11:27 3:02 2 11:30 2:15 3 12:48 2:25 1 13:40 2:13 2 14:18 2:48 • Rotation of 3 trucks • 2,5 hour interval • (one truck every 50 minutes) • 30 minutes interval needed Significant Special CauseVariation Within a Day
  • 12. European Students of Industrial Engineering and Management www.estiem.org Implemented Improvements 12 Increase number of trucks Prioritize slab assembly • Resource efficiency vs. Flow efficiency! • Truck waiting costs only 50€/h • No other work started if truck is couple of minutes late • 4 truck schedule is possible in theory but 5 or 6 truck schedule is required Layout for slab delivery (5S) 1. Truck arrives and assembly starts 2. Second truck arrives to queue 3. First truck moves away after the assembly 4. Trucks turn around and leave Buffer inventory located next to crane
  • 13. European Students of Industrial Engineering and Management www.estiem.org Improvement Risk Analysis Task Potential problem Effect Likely cause S E V O CC Preventive actions Contingent actions Triggers for contingent All Increase in cycle time Truck queue & waiting Issues in assembly 2 3 Preparatory work Unload truck to buffer inventory Assembly lasted over 30 mins or multiple trucks in queue All Rework Truck queue & waiting Defective part, careless assembly 4 2 Alignment done right the first time, necessary measurements Unload truck to buffer inventory When need for rework is noticed All Buffer inventory full No room for errors/truc k unloading Issues in assembly 3 1 Assemble elements from buffer between trucks when possible Continue assembly to time buffer (11.00- 13.00) Over 6 elements in the buffer All No material available Increase in lead time Error in truck schedule/truck s late 4 2 Load buffer at the end of the shift Call the supplier for ETA →start other tasks Buffer empty & truck late over 10 minutes All Man lift failure Assembly stopped Man lift not loaded 4 4 Make sure man lifts are loaded on the previous day Use secondary man lift As soon as failure occurs
  • 14. European Students of Industrial Engineering and Management www.estiem.org Leveraged Improvements to the Whole Structural Frame Assembly 14 Schedule fast tracking based on measured cycle times and known variation The slab assembly was only a small part of the project Small improvements on each type added up to significant savings 30% reduction on planned assembly time Elements Columns* Beams* Trusses* Reliable measurement Standardized work Reduced uncertainty & risk *Both, Concrete & Steel parts
  • 15. European Students of Industrial Engineering and Management www.estiem.org Not a common practice in the construction industry  Easy to find small wins as use of data is not common – Huge potential!  Few references on how long-term improvements have succeeded  Bottom-up initiatives are difficult (green belt) – Management support needed Project based business  Changing work during different work phases – measurement and implementation needs to be fast  Repeatability between unique projects (high sigma levels are hard to obtain)  Use of sub-contractors makes implementation difficult  Cost-plus pricing gives low incentives for process improvement  Sub-contractor contract clauses are not effective to motivate for collaboration Stagnant culture  Change initiatives are extremely difficult without good management support Lean Six Sigma in Construction Industry