Ballast Nedam
Process optimization for the Extension of the Amaliahaven Quay Wall project
The Challenge
Ballast Nedam Infra faced significant challenges in their Vibro pile production process for the Extension of the Amaliahaven Quay Wall project in Rotterdam. The main issues centered around long lead times and inefficient production rates, with output limited to just 2.6 piles per day.
The challenges stemmed from multiple factors: excessive waiting times at the concrete plant, poor coordination between departments, and a "silo culture" that hindered effective collaboration. These inefficiencies were significantly impacting project timelines and operational costs.
Our Approach
We implemented a comprehensive design-oriented research (OGO) approach, focusing on problem exploration, diagnosis, and redesign. Through system analysis and cause-and-effect diagrams, we identified key bottlenecks and developed targeted solutions. Our methodology incorporated PDCA (Plan-Do-Check-Act) principles and Tuckman's team development model to improve both processes and team dynamics.
The Solution
We implemented a multi-faceted solution that transformed both operational processes and team dynamics, leading to significant improvements in production efficiency.
- Implementation of CONWIP control cards for better capacity management
- Appointment of a dedicated capacity coordinator between teams
- Transition to digital communication for concrete orders
- Integration of PDCA methodology for continuous improvement
- Team development through Tuckman's model to break down silos
Results & Impact
- 35% Production Increase: Improved from 2.6 to 4 piles per day on optimal production days.
- Enhanced Coordination: Significantly reduced waiting times and improved material flow management.
- Better Team Collaboration: Broke down departmental silos and established more effective communication channels.
- Cost Efficiency: Achieved substantial reduction in operational inefficiencies and associated costs.
