Case study 04 · Nuclear marine works

Getting more from a 104-person lifting operation, safely

Subcontract costs were running 10% above plan, and the lifting operation was one of the largest teams on the job. We were asked to find where it could work more efficiently without affecting safety, quality or delivery. Working strictly within the client’s lifting standard, we identified up to £4.6m a year of efficiency opportunity.

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At a glance

104 people in the lifting operation

3 efficiency improvements, all within the lifting standard

£4.6m a year of efficiency opportunity identified

Three ways to make lifting more efficient, all within the client’s lifting standard: supervision organised around clear sight lines (about £1.1m a year), remote barriers for traffic control (about £0.5m a year) and lifting capacity that follows the critical path (about £3m a year); up to £4.6m a year identified

Context

The challenge

The lifting operation was around 104 people, organised into three gangs at each tunnel location across a shift pattern. Every role was set by the client’s lifting standard, which governs supervision and limits the dual roles that are normal on other sites.

Gang sizes were fixed regardless of how busy each location was. In quieter areas, skilled people spent time waiting for lifts while the critical path set the pace elsewhere.

Our approach

How we tackled it

We reviewed the lifting standard line by line, observed live operations at two tunnel locations and worked through each role with section managers. The aim was to match lifting resource to the work, and every proposal had to stay within the standard.

Supervision

The standard requires a second lift supervisor only when one cannot practicably see both the slinging and the landing. From a raised viewing point, one supervisor could see both, so supervision could be organised around clear sight lines rather than a fixed pair at every lift.

Traffic control

Marshals were already covering for each other during breaks without losing control of traffic. Remote-operated barriers, controlled by one marshal per area, would add a physical barrier around lifting areas and free marshals for other duties.

Lifting windows

One gang would follow the critical path while a second worked planned lifting windows across the quieter locations, so lifting capacity goes where the work is instead of waiting where it isn’t.

Outcome

The results

Up to £4.6m a year of efficiency opportunity identified, with no departure from the client’s lifting standard.
Around £1.1m a year from supervision, £0.5m from traffic control and £3m from planned lifting windows.
A first improvement was made straight away, worth around £257K a year.
Physical barriers proposed to strengthen traffic protection around lifting areas.
A clear, evidence-based plan the lifting team could adopt in full or in part.