Modular Construction

Project Length

• 6 Months

Objective

•   Improve Productivity & Quality

Issues to start with

•  Responsibility & Accountability

Plan to fix it

• Identify Current Issues

• Introduce task based Project Management System (Asana)

• Set up different projects by Manufacturing Discipline

• Trained Senior members of the management team on Asana.

• Coach Senior members on empowering their teams

• Introduce a weekly SLT meeting driven by Project Status in Asana

• Encourage Accountability and Responsibility

• Empower employees

Issues on the way

• Covid 19

• Remote working

• Tight Customer deadlines

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Result

• Manufacturing system defined

• System set up and managed in Asana

• Super User Identified and Trained

• Projects transferred to Client Domain.

• Training program completed for SLT

Project Length

•  15 Months

Objective

• Remove buildings at the end of the rental period in a timely manner and to budget.

• Ensure Customers are satisfied 12 month defects are resolved

Issues to start with

•  Role was being done on an adhoc basis

Plan to fix it

• Implemented and managed a programme to remove modules at the completion of hire periods.

• Overcame I&E target costs while managing a decant of 100 modules over a four-month period and multiple sites simultaneously.

• Successfully put together and agreed dilapidation costs with clients at the end of the rental Periods

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Issues on the way

• Logistics issues organising low-loaders in and out of the M25

• Had to replace an under performing Site Manager at short notice.

Result

• Decommissioned a Medical Centre in Oldbury - 25 Modules

• Decommission a Primary School in London - 44 Modules.

• Installed and fitted out two buildings for 6th Form College in Norwich. - 40 Modules

• Decommissioned a secondary school in Warrington - 12 Modules

• Resolved Issues with dissatisfied customers on 2 School Projects where 12-month defects had not been completed.

• Resolved Leaking roof issues on various buildings.

Project Length

•  20 Months

Objective

• Continue to Improve through put in factory

• Take on responsibility for transportation of Modules to Site

• Take on responsibility for Installation of Modules on Site

Issues to start with

• Transportation

• Installation Teams

• Organisation

Plan to fix it

• Setting up process for transportation

• Setting up process & Training of Installation teams

• Establishing back-office support for Installation Team

Issues on the way

• Start up issues

• Training of new procedure's processes

Result

• Delivered increases YoY, achieving up to 475 modules on time and to contract within one year.

• Slashed costs by 10% on steel frames using VA/VE, achieving £160,000 per annum in savings,

• Produced standard modules that were 15% lower than target cost.

• Reduced overtime costs by implementing a banked hour scheme

• Instrumental in significantly reducing assembly time on site through the re-engineering of high bay modules.

Project Length

•  8 Months

Objective

•  Increase production output in line with Company plan for growth

Issues to start with

• No Master Production Schedule

• Sporadic deliveries of materials

• Poor Quality

Plan to fix it

• Produce a production plan for 5 cells to meet the Contracts Department Installation Programme.

• Improve Supplier Quality

•  Negotiated JIT deliveries with all key suppliers, ensuring availability of materials to meet production plans.

• Reduced stock

Issues on the way

• Setting up 5 Production Cells in the factory

• Introducing dedicated Teams of 4

• Improving Supplier Quality

Result

• Reduced stock to less than 48 hours

• Increased production output YoY to support business growth from £15m to £35m in 2 years.

Project Length

•  4 Months

Objective

•  Ensure delayed module manufacture recovered to meet contracts installation dates

Issues to start with

• Lack of Production Planning

• No defined arears to build modules

• Poor management of resources

Plan to fix it

•  Defined the manufacturing Schedule

• Measured at specific points in the process. Plan V Actual.

• Take actions to reduce delays as and when required.

Issues on the way

• Shortage of materials

• Poor Quality/ Rework

• Training

• Standard Processes

Result

•  Turned around a 2-week delay and successfully met the contracts schedule after 6 weeks, managing workforce and resources to efficiently meet the production and on site installation plans.