productivity improvement study

Presented ByPresented ByHarry Mills /Harry Mills / PRESENTATIONPRO PRESENTATIONPRO

Productivity Improvement StudyProductivity Improvement Study

Prepared by:Group 7

Mahendra SutarNirav Patel

Saransh ShahDipesh Sorathia

CE 236 Construction Operation Analysis

33%67%

Successful approach improves productivity


Presentation outlinePresentation outline

• Introduction

• Objective

• Process involved in concreting of slab

• Process observed• Transit of Concrete

• Placing, Vibrating, Spreading, and Finishing

• Data Collection

• Analysis

• Conclusion & recommendations


IntroductionIntroduction

• Project: Construction of DIGITAL ART’S BUILDING

• Location: Santa Cruz, CA

• Owner: University of California, Santa Cruz (UCSC)

• Total built up Area: 24,473 Sq ft.

• Contract Value: $66,278,025

• Contract Type: Lump Sum

• Sponsor: University of California, Santa Cruz

• Project Manager: Mr. Jose Refuerzo

• Work Start Date: January 03, 2008

• Expected Completion date of work: May 17, 2009


Digital Art Building, UCSCDigital Art Building, UCSC


ObjectiveObjective

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..


Process involved in concreting of slabProcess 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


Data Collection IssuesData Collection Issues

Several methods were used by our team1) Activity Sampling Methods Field Rating

Productivity RatingLabour-Utilization FactorThe 5- Minute Rating Technique

2) Analysis MethodsWork process flow diagramCrew balance chartInterviewsQuestionnairesPhotographs


Field RatingField Rating

The field rating is used by determining if a worker is working or not working.

• Number of workers on job site 404• Number of workers observed 353• Number of workers classified as working 214• Percentage working (214/353) 60.62%• Add for foreman and personal time (optional) 10%• Adjusted field-rating index 70.62%


Productivity RatingProductivity Rating

Productivity ratings are used to determine whether work being performed is effective, contributory or ineffective work.

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%

Productivity rating

22%

42%

36%

Effective

Contributory

Idle


Labour-Utilization FactorLabour-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%)


Minute Rating TechniqueMinute 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%.


Minute Rating TechniqueMinute Rating Technique

0%

10%

20%

30%

40%

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60%

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90%

Labor 1 Labor 2 Labor 3 Labor 4 Labor 5 Total

5 Minute Crew

Labor 1

Labor 2

Labor 3

Labor 4

Labor 5

Total


Process ChartProcess 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.


Work Flow diagramWork Flow diagram

EXISTING PROPOSED


Comparison of flow process chartComparison of flow process chart

2 Trucks

2 Trucks


Crew Balance ChartCrew 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.



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


Crew balance chart for existing & proposed Crew balance chart for existing & proposed concreting workconcreting work



Existing crew effectiveness was 66% and proposed crew effectiveness is 75% and addition to this one man is reduced.

Proposed Crew


Process involved in laying of concreteProcess involved in laying of concrete


Concrete spreading & finishingConcrete spreading & finishing


Pouring of concretePouring of concrete


Vibrating of ConcreteVibrating of Concrete


Manually finishing of ConcreteManually finishing of Concrete


InterviewsInterviews & & QuestionnairesQuestionnaires

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


Conclusion & RecommendationConclusion & 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.

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Conclusion & recommendations (cont.)Conclusion & recommendations (cont.)

• Productivity improvement is still possible, our team discussed this issue with contractor.• Contractor uses stationary concrete pumping machinery of model no. BSA 1003D• For this pump discharge capacity is 28cum/hr.• Total quantity of concrete for slab is 265cum.• Actual time taken to finish the slab was 12hrs.• Theoretical time required to finish the concrete is 265/28 =9.4hrs.• Proposed concrete pump model HPT80,13,174RS• For this pump discharge capacity is 53cum/hr• By using proposed model time required to finish the concrete is 265/53 = 5hrs say 8 hrs.• That means concreting for slab will finish within one shift.• Saving of money is (crew members 35 x 4hrs x $32 = $4480) say $5000• Purchasing cost for concrete finisher is around $1500 to $ 8000


QuestionsQuestions

productivity improvement study

Documents

concrete spreading

process chart process

percentage of work

work crews

ineffective work

concrete test

laying of concrete

proposed crew effectiveness