IGLC16 Manchester

Waste Elimination of
IGLC 16
Mucking Process of a
Petroleum Storage
Tunnel through the LEAN
CONSTRUCTION
Value Stream Analysis

Seokjin Choi
Tae H. Ku
Dong H. Yeo
Seung H. Han

16th International Conference of the

International Group for Lean Construction 16th International Conference of the International Group for Lean Construction
July 16th - 18th 2008, Manchester, United Kingdom July 16th - 18th 2008, Manchester, United Kingdom
 Production System Design
IGLC 16

Value
Defining
Cycle time
Reduction
Value Adding Activities
None Value Adding activities
Systematic
None Value Added Process
but Necessary
Simplification
None Value Added and Unnecessary

16th International Conference of the International Group for Lean Construction

July 16th - 18th 2008, Manchester, United Kingdom
 Value Analysis Methods
IGLC 16

 Preliminary method: Flow Process Chart

- Simple, but effective for indentifying activity’s value
- Finds activity types, value types and working time
- Easy to make, easy to understand

 The main method: Value Stream Analysis

- Current State Mapping → Future State Mapping
- Visually described by many figures and symbols
- Easy to understand the process flows and value stream

16th International Conference of the International Group for Lean Construction

July 16th - 18th 2008, Manchester, United Kingdom
 A Case Project
IGLC 16

1650 barrels 30m

5.2km 18m

16th International Conference of the International Group for Lean Construction

July 16th - 18th 2008, Manchester, United Kingdom
 Loader-and-backhoe-work
IGLC 16

Queuing

Waiting

16th International Conference of the International Group for Lean Construction

July 16th - 18th 2008, Manchester, United Kingdom
 Backhoe-only-work
IGLC 16

Queuing

Waiting

16th International Conference of the International Group for Lean Construction

July 16th - 18th 2008, Manchester, United Kingdom
 Flow Process Charts
IGLC 16

Loader-and-Backhoe-work Backhoe-only-work
Working Time Working Time
Activity Activity type Value type Activity Flow Value
(Hr:Min) (Hr:Min)

Sum of each activity`s

Loader’s entry
Clearing debris
▶
●
00:06
00:12
⇒
□ Sum of each activity`s
Backhoe’s entry
Clearing debris
▶
●
00:15
00:25
⇒
□
⇒
working time working time
Dump trucks’ entry ▶ 00:35 Dump trucks’ entry ▶ 00:12 ⇒
1st loading by loader ● 01:41 ○ Loading by backhoe ● 03:46 ○
Loader Waits for next work ▼ 02:38 ⇒ Scaling by backhoe ● 00:45 □

31:35 □
35:58
▶
Carrying mucks to storage yard 16:27 Backhoe waits ▼ 00:36 ⇒
Dumping mucks ● 00:08 ○ Carrying mucks and returning ▶ 18:45 ⇒
Dump trucks wait ▼ 01:23 ⇒ Dumping mucks ● 00:09 ○
Backhoe waits ▼ 00:16 ⇒ Dump trucks wait ▼ 10:45 ⇒
Backhoe’s entry
Scaling by backhoe VAA - 02:09
▶
●
00:05
00:45
⇒
□
Inspection of digging distance
The sum of each activity
VAA - 03:55
■ 00:20
35:58
□
10
Loader waits ▼ 00:50 ⇒
Dump trucks wait
Loader’s re-entry
NVAA - 29:26
▼
▶
02:35
00:03
⇒
⇒
VAA
NVAA NVAA - 32:0303:55
32:03
2
8
Dump trucks’ re-entry ▶ 00:32 ⇒ Actual total working time 06:35
nd
2 loading by loader ● 00:14 ○
Loader waits ▼ 00:17 ⇒
Carrying mucks ▶ 01:12 □
Dumping mucks ● 00:01 ○
Dump trucks wait ▼ 00:15 ⇒
Backhoe waits ▼ 00:34 ⇒
Backhoe’s re-entry ▶ 00:04 ⇒

Actual total working time

Final loading by backhoe
Carrying mucks
●
▶
00:05
00:11
○
□ Actual total working time
Dumping mucks ● 00:00 ○
06:34
Dump truck waits
Backhoe waits
▼
▼
00:06
00:00
⇒
⇒
06:35
Inspection of digging distance ■ 00:20 □
The sum of each activity 31:35 28
VAA 02:09 6
NVAA 29:26 22
Actual total working time 06:34

16th International Conference of the International Group for Lean Construction

July 16th - 18th 2008, Manchester, United Kingdom
 VSM: Current state
IGLC 16

Preparation stage 1st Handling stage

Loader’ s Clearing Dump trucks’ 1st loading Carrying

Dumping
entry debris entry by loader mucks

VAA
Preparation Muck Handling Stage 101 min (loading)
NVAA

VAA
Stage
6 min 12 min
(Value Added)
2 min (waiting) 156 min (waiting)

NVAA 16 min (waiting)

VAA 8 min (dumping)
NVAA 2 min 979 min (carrying and returning) + 83 min (waiting)

Scaling stage 2nd Handling stage

Loader and
Backhoe’ s 2nd loading Carrying

Scailing
Scaling dump trucks’ Dumping
entry re-entry by loader mucks

Muck Handling Stage

VAA
Stage 14 min (loading)
NVAA 50 min (waiting) 3 min
(Value Added) 17 min (waiting)
VAA
NVAA (Non-VA)
5 min 45 min 3 min (waiting) 31 min (waiting)
VAA 1 min (dumping)
NVAA 155 min (waiting) 32 min 72 min (carrying and returning) + 15 min (waiting)

Finishing stage

Backhoe’ s Final loading

Inspection
re-entry by backhoe

VAA
NVAA
Finishing Stage Loader

VAA 5 min
Backhoe
NVAA 4 min
VAA 0 min (dumping) Dump
NVAA 6 min 11 min (carrying) trucks

16th International Conference of the International Group for Lean Construction

July 16th - 18th 2008, Manchester, United Kingdom
 Improvement Plan
IGLC 16

Owner’s representative

Superintendant

Inspector

Subcontractor

16th International Conference of the International Group for Lean Construction

July 16th - 18th 2008, Manchester, United Kingdom
 VSM: Future state
IGLC 16

Preparation stage Handling and scaling stage

Loader’ s
entry
Clearing
debris
Dump trucks’
entry MuckLoading
Handling
loader
by
Stage Dumping
Carrying
mucks

Supervisor’ s
Preparation direction
Scailing Stage
Backhoe’ s
Scaling
Stage
entry

VAA 115 min (loading)

NVAA 6 min 12 min 2 min (waiting) 173 min (waiting)
VAA
NVAA 5 min 45 min
VAA 9 min (dumping)
NVAA 2 min 1051 min (carrying and returning) + 98 min (waiting)

Finishing stage

Final loading
Inspection
by backhoe

VAA
NVAA
Finishing Stage Loader

VAA 5 min
Backhoe
NVAA

VAA 0 min (dumping) Dump

NVAA 11 min (carrying) trucks

16th International Conference of the International Group for Lean Construction

July 16th - 18th 2008, Manchester, United Kingdom
 Applying to the Actual Site
IGLC 16

Cycle Equipment Cost Improvement

time cost saving rate
Current state 394 min $1682.38 - -
Improvement plan 333 min $1421.91 $260.47 15.48%
Actual application 356 min $1520.12 $162.26 9.64%

16th International Conference of the International Group for Lean Construction

July 16th - 18th 2008, Manchester, United Kingdom
 Conclusion
IGLC 16

 Developed the improvement plan by comparing basic

work process with occasional work process
 Developed the improvement plan by considering the
concept of space with field managers and engineers
 With applying the future state map to the actual site,
simplified and improved the process

 A simulation model which concerns the reliability of the

process is now being developed to find optimal balances
between equipments.

16th International Conference of the International Group for Lean Construction

July 16th - 18th 2008, Manchester, United Kingdom
 IGLC16 Manchester
IGLC 16
THANK YOU
for listening LEAN
CONSTRUCTION

16th International Conference of the

International Group for Lean Construction 16th International Conference of the International Group for Lean Construction
July 16th - 18th 2008, Manchester, United Kingdom July 16th - 18th 2008, Manchester, United Kingdom