Facilitating world class construction

1
Centre for Performance Improvement in Construction
Facilitating world class construction
Vassos Chrysostomou Director
2
Improved industry performance depends on
improvements in the work processes of contracting
firms, in co-operation with clients and
professionals.... SA Government White Paper,
1999
3
The industry must replace competitive
tendering with long term relationships based on
clear measurement of performance in quality and
efficiency... Rethinking Construction
4
To manage you must measure , if you dont you
are only practicing... Jan Leschley - SKB
5
Why is the construction industry using clients
money to practice with ? Sir John Egan -BAA
6
CALIBRE
7
CALIBRE

• construction process
• 30 years experience
• all construction types
• identifying eliminating waste

8
CALIBRE

• project management toolkit
• complete supply chain
• culture fed and a culture change driver
• real time
• SA continuous improvement database

9
CALIBRE - Tools

• Resource utilisation tool
• labour and plant
• identify causes
• develop action plans
• SMARTwaste
• identification and elimination of material waste

10
CALIBRE - Tools

• BREplan
• Programme predictability
• actual progress compared with intended progress
• SEAS - Site Environment Assessment System
• working environment
• health safety

11
Adding Value by

• empowering the workforce to C.I.
• more efficient
• more productive
• more competitive
• more profitable

12
The method

• map all site processes
• identify code all tasks
• set benchmarks targets
• measure efficiency/performance
• analyse data
• feedback ask WHY

13
Mapping the process

• no new information
• suppliers method statement
• suppliers day by day programme
• project master programme
• owned by the team

14
(No Transcript)
15
(No Transcript)
16
(No Transcript)
17
Activity Codes
BK
Taking break
HS
Carrying out work related to safety
RO
Rained off - inclement weather
Not seen during observation round
A
Handling materials from stores to workplace
H1
Not working and not at the workplace
I
Not working at the workplace
N
RT
Making good or correcting completed work
Walking around site
W
18
Additional Codes

• all site personnel
• number
• trade
• skill level / experience
• all facility zones / areas
• office area /stores /stairs lift core etc
• floor by floor

19
Records

• single independent observer
• who - operative - 560 - carpenter
• what - package - 1 - substructure
• where - location - GF - ground floor - grid line
  2
• which - task - A - formwork
• how - activity - P - preparing materials

20
Analyse data

• daily - real time
• local site PC - Microsoft Access database
• with operatives/foremen/site managers
• immediate/medium/long term plans
• weekly/monthly updates - CSIR

21
(No Transcript)
22
Real Time Analysis - All Suppliers
'Real Time' analysis - Suppliers
Supplier 1
Supplier 2
Supplier 3
Supplier 4
Supplier 5
Supplier 6
-90
-60
-30
0
30
60
90
120
150
180
Man-hours
Actual
Planned
23
Real Time Analysis - Supplier X / Packages
'Real Time' Analysis - Supplier Quadro / Packages
In situ topping
Precast slabs
Steel Frame
-60
-40
-20
0
20
40
60
80
100
Man-hours
Actual
Planned
24
Real Time Analysis - Supplier X - Package In
situ topping
Shuttering
Concrete upstand
Mesh reinforcement
Pour topping
Place edge formwork
-40
-30
-20
-10
0
10
20
30
40
50
60
Man-hours
Actual
Planned
25
Real Time Analysis - Supplier X / Package In
situ topping / Task Pour topping / floor
locations
'Real Time' Analysis - Supplier Quadro / Package
'In situ topping' / Task 'Pour topping' /
floor locations
SITE
4
3
2
1
-40
-30
-20
-10
0
10
20
30
40
50
Summary
Man-hours
26
Real Time Analysis - Supplier X / Package In
situ topping / Task Pour topping
'Real Time' Analysis - Supplier Quadro / Package
'In situ topping' / Task 'Pour topping'
W
T2
SU
RT
P1
P
Not working at the workplace
N
H2
Handling materials from the compound or temporary
store to workplace
H1
F3
F1
F
C
BK
-30
-25
-20
-15
-10
-5
0
5
10
15
Summary
Man-hours
27
TRADE BENCHMARKS
Steel fixers
Steel erectors
Shopfitters
Plumber
Decorator
Heating engineer
Ground work
Glazier
General labourers
Electrician
Duct fitters
Concrete Gang
Cladder
Carpenter
Bricklayer
-60
-40
-20
0
20
40
60
80
100
Non-Productive
Productive
Productive Support
Statutory
28
Man-Hours per Week divided by productivity
O-Rourke, All Packages, All Tasks, All Activities
(10/06/96-25/03/97)
Man-hours per Week divided by productivity
Supplier Y, All Packages, All Tasks, All
Activities (10/06/96 - 25/03/97)
100
90
80
70
60
50
40
30
20
10
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
31
32
33
34
35
36
37
38
39
40
41
42
Summary
Non-Productive
Productive
Productive Support
Statutory
29
KPIs -- Benchmarks

• Performance data
• Construction costs/mhrs
• Turnover staff
• accidents / 100000 mhrs
• mhrs / man-day
• defects - repeat work mhrs / total mhrs

30
KPIs - Benchmarks

• productivity data - mhrs / m2
• plant utilisation
• SEAS - Electricity / Water / Diesel / Gas
• material wastage
• deliveries
• road kilometres / miles

31
KPIs - Benchmarks

• predictability - package / task - causes
• Site Facilities CoefficientS
• change orders
• qualifications of operatives
• as built CD - Rom

32
Defects - Repeat work mhrs / Total mhrs -
Predictability -
Site operatives NVQ index -
90
Added value time
80
70
60
50
CALIBRE
5
40
10
15
20
25
30
Non - added value time
Staff turnover
Slough Targets
Plant utilisation -
mhrs/man-day
33
Defects - Repeat work mhrs / Total mhrs -
Predictability -
Site operatives NVQ index -
90
Added value time
80
70
60
50
CALIBRE
5
40
10
15
20
25
30
Non - added value time
Staff turnover
Slough Targets
Project I
Plant utilisation -
mhrs/man-day
34
Defects - Repeat work mhrs / Total mhrs -
Predictability -
Site operatives NVQ index -
90
Added value time
80
70
60
50
CALIBRE
5
40
10
15
20
25
30
Non - added value time
Staff turnover
Slough Targets
Project I
Plant utilisation -
mhrs/man-day
Project II
35
Now

• CALIBRE - UK Construction Industry toolkit
• UK database of continuous improvement
• 30 projects in two years
• airport extension, offices, industrial units,
  m.s.c.p
• leisure facility, hotels, supermarkets, galleries
• social housing, restaurants, army facilities

36
Now

• CALIBRE - UK License - 29th September
• CALIBRE - South Africa
• CALIBRE - Singapore - 4 projects -300m
• CALIBRE - France - 6 projects - Nicolletti

37
2000

• CALIBRE - More tools - HS, noise and dust
• CALIBRE - Design and Management Process
• CALIBRE - Maintenance Process
• CALIBRE - Launch in USA
• CALIBRE - web-based toolkit - IPROS

38
Benefits - workforce

• safer working environment
• empowerment
• status - ownership and pride
• right first time
• training

39
Benefits - observers

• whole construction process
• greater understanding of causes of waste
• sponge of knowledge
• communication and management skills
• foundation training for future development

40
Benefits - contractor

• more efficient
• more productive
• more competitive
• more profitable
• real benchmarks

41
Benefits - consultants

• more efficient
• more productive
• real time feedback on design
• right first time
• real benchmarks

42
Benefits - clients

• more predictable process - planning and cashflow
• real benchmarks - selection of supply chain
• reduction on time and cost with improved quality
• more for less

43

• performance measurement
• continuous improvement
• world class

CALIBRE
44

• Bouserv.csir.co.za/calibre

CALIBRE