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Productivity Improvement Study

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Productivity Improvement Study

  1. 1. Productivity Improvement Study <ul><li>Prepared by: Group 7 Mahendra Sutar Nirav Patel Saransh Shah Dipesh Sorathia </li></ul>CE 236 Construction Operation Analysis Successful approach improves productivity 33% 67%
  2. 2. Presentation outline <ul><li>Introduction </li></ul><ul><li>Objective </li></ul><ul><li>Process involved in concreting of slab </li></ul><ul><li>Process observed </li></ul><ul><ul><ul><li>Transit of Concrete </li></ul></ul></ul><ul><ul><ul><li>Placing, Vibrating, Spreading, and Finishing </li></ul></ul></ul><ul><li>Data Collection </li></ul><ul><li>Analysis </li></ul><ul><li>Conclusion & recommendations </li></ul>
  3. 3. Introduction <ul><li>Project: Construction of DIGITAL ART’S BUILDING </li></ul><ul><li>Location: Santa Cruz, CA </li></ul><ul><li>Owner: University of California, Santa Cruz (UCSC) </li></ul><ul><li>Total built up Area: 24,473 Sq ft. </li></ul><ul><li>Contract Value: $66,278,025 </li></ul><ul><li>Contract Type: Lump Sum </li></ul><ul><li>Sponsor: University of California, Santa Cruz </li></ul><ul><li>Project Manager: Mr. Jose Refuerzo </li></ul><ul><li>Work Start Date: January 03, 2008 </li></ul><ul><li>Expected Completion date of work: May 17, 2009 </li></ul>
  4. 4. Digital Art Building, UCSC
  5. 5. Objective Document the methods of Productivity improvement study conducted by our team on the construction of new digital art building. The technical efforts involve data gathering, analysis, and appropriate approach to implement it. Study & analysis of each of the element to determine whether the time required for any of the element could be reduced by altering the processes required to perform the element. .
  6. 6. Process involved in concreting of slab Unloading of concrete from the concrete transit truck. Pumping of concrete with the help of concrete pump to cast the slab. The foreman was responsible for testing the concrete using slump tests, filling cylinders and cubes for the stress tests before the concrete was placed in the slab. Work crews were responsible for the placing, vibrating, spreading, and finishing of concrete
  7. 7. Data Collection Issues <ul><li>Several methods were used by our team </li></ul><ul><li>1) Activity Sampling Methods </li></ul><ul><li> Field Rating </li></ul><ul><li>Productivity Rating </li></ul><ul><li>Labour-Utilization Factor </li></ul><ul><li>The 5- Minute Rating Technique </li></ul><ul><li>2) Analysis Methods </li></ul><ul><li>Work process flow diagram </li></ul><ul><li>Crew balance chart </li></ul><ul><li>Interviews </li></ul><ul><li>Questionnaires </li></ul><ul><li>Photographs </li></ul>
  8. 8. Field Rating <ul><li>The field rating is used by determining if a worker is working or not working. </li></ul><ul><li>Number of workers on job site 404 </li></ul><ul><li>Number of workers observed 353 </li></ul><ul><li>Number of workers classified as working 214 </li></ul><ul><li>Percentage working (214/353) 60.62% </li></ul><ul><li>Add for foreman and personal time (optional) 10% </li></ul><ul><li>Adjusted field-rating index 70.62% </li></ul>
  9. 9. Productivity Rating <ul><li>Productivity ratings are used to determine whether work being performed is effective, contributory or ineffective work. </li></ul>Worker Effective Contributory Idle Foreman 42% 39% 19% Labour 1 6% 41% 53% Labour 2 20% 44% 36% Labour 3 29% 31% 40% Labour 4 17% 52% 31% Total 22% 42% 36%
  10. 10. Labour-Utilization Factor Effective work + (1/4) Essential contributory work Labour-utilization factor = --------------------------------------------------------------------- Number of Total observation Labour utilization factors include essential contributory work by calculating the percentage of work by adding the number of observations of effective work to one fourth the number of observations of contributory work and dividing this sum by the total number of observations.(34% to 49%)
  11. 11. Minute Rating Technique The five-minute rating technique is not as accurate as the field-rating method. But it is an effective method for making a general work evaluation. This non-statistical method was used for quick rating of the crew during placement and spreading of concrete. Effectiveness ratio for this study was found 50% to 65%.
  12. 12. Minute Rating Technique
  13. 13. Process Chart Process charts are used in conjunction with process flow diagrams to help to clarify the movement of workers and machines when they are performing specific steps of an operation . Process chart helps to identify delays and comments are provided for clarification. New flow chart were prepared by our team, by introducing exit gate near the adjacent road and also concrete test combine with process of delivery approval and found that 22 minutes were saved in the entire process.
  14. 14. Work Flow diagram EXISTING PROPOSED
  15. 15. Comparison of flow process chart 2 Trucks 2 Trucks
  16. 16. Crew Balance Chart In this study the time taken by a worker or a machine involved in a task, is recorded and variation between cycle are evaluated to determine whether alternative processes would improve production rate or not. Crew balance chart are used when evaluating the effectiveness of worker and machine, and worker-machine combination and to demonstrate interrelationships between the activity performed by crew members.
  17. 17. Crew Balance Chart Redistribute the work of Vibrator handler to man 6 & man 7 Redistribute some of the tasks of Man 1, man 2, man 3, man 4, & man 5 Effectiveness of all the remaining 7 crew members and the overall crew effectiveness were able to be raised substantially and saving in 20 minutes. Using mechanical finisher instead of manually finishing the concrete Mechanical Concrete finishers
  18. 18. Crew balance chart for existing & proposed concreting work
  19. 19. Crew Balance Chart Existing crew effectiveness was 66% and proposed crew effectiveness is 75% and addition to this one man is reduced. Proposed Crew
  20. 20. Process involved in laying of concrete
  21. 21. Concrete spreading & finishing
  22. 22. Pouring of concrete
  23. 23. Vibrating of Concrete
  24. 24. Manually finishing of Concrete
  25. 25. Interviews & Questionnaires Project manager and engineers in charge were interviewed by the team on several occasions Responses provided information about some of the project’s issues and concerns Over all construction team was generally satisfied with the overall field condition and work environment Questions were specific to the job site and were designed to collect data such as; type of work they do, hours of work, level of satisfaction with their work, availability of materials and supplies, equipment supplied, frequency of delays, suggestions on improvement, training and instruction
  26. 26. Conclusion & Recommendation Need to use Modern construction equipments Reduction of crew members are possible without disturbing the completion time of activities Flow diagram need to change so machineries can exit the site without disturbing any other activity on site. Require to conduct time to time meetings with all crew members on the site to under stand the lower level problems of crew members. P R O D U C T I V I T Y I M P R O V E M E N T
  27. 27. Conclusion & recommendations (cont.) <ul><li>Productivity improvement is still possible, our team discussed this issue </li></ul><ul><li>with contractor. </li></ul><ul><li>Contractor uses stationary concrete pumping machinery of model no. BSA </li></ul><ul><li>1003D </li></ul><ul><li>For this pump discharge capacity is 28cum/hr. </li></ul><ul><li>Total quantity of concrete for slab is 265cum. </li></ul><ul><li>Actual time taken to finish the slab was 12hrs. </li></ul><ul><li>Theoretical time required to finish the concrete is 265/28 =9.4hrs. </li></ul><ul><li>Proposed concrete pump model HPT80,13,174RS </li></ul><ul><li>For this pump discharge capacity is 53cum/hr </li></ul><ul><li>By using proposed model time required to finish the concrete is 265/53 = </li></ul><ul><li>5hrs say 8 hrs. </li></ul><ul><li>That means concreting for slab will finish within one shift. </li></ul><ul><li>Saving of money is (crew members 35 x 4hrs x $32 = $4480) say $5000 </li></ul><ul><li>Purchasing cost for concrete finisher is around $1500 to $ 8000 </li></ul>
  28. 28. Questions