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MEASUREMENT OF PRODUCTIVITY RATE OF DRAINAGE TRENCH
EXCAVATION USING LEAN STRATEGY
MUHAMMAD SHAHIR BIN SHAFFRUDDEEN
This project is submitted in fulfillment of the
requirements for the award of degree of
Master of Engineering (Construction Management)
Faculty of Civil Engineering
Universiti Teknologi Malaysia
JANUARY 2018
iii
DEDICATION
I dedicate my work to my family and friends. A special
feeling of gratitude to my loving parents,
whose words of encouragement and push for tenacity ring in my ears.
My sisters, who never left my side and very special to me.
I also dedicate this research to my friends,
who have supported me throughout the process.
I will always appreciate all they have done.
iv
ACKNOWLEDGMENT
Assalamualaikum. In the name of Allah the most gracious and the most merciful,
first and foremost, I would like to extend my deepest praise to Allah S. W. T who has
given me the patient, strength, determination and courage to implement this task. I
would like to express my sincere gratitude to my advisor Prof. Madya Dr Abdul
Kadir Marsono for the continuous support of my research study for his patience,
motivation, and immense knowledge. His guidance helped me in all the time of
research and writing of this thesis. I could not have imagined having a better advisor
and mentor for my research. I thank my fellow classmate in for their supports, for the
sleepless nights where they helped before deadlines, and for all the fun, we have had
in the last four years. Last but not the least, I would like to thank my family,
especially my parents and to my sister for supporting me spiritually throughout
writing this thesis and my life in general.
v
ABSTRACT
Productivity in construction industry is the ratio of output over resources that
determine the outcome of product. LEAN is the principle used by the manufacturing
industry to improve their product. This research apply the measuring productivity
principle used by the manufacturing industry on machinery to measure the
productivity of drainage civil construction activity. Hence, it aims to evaluate the
quality of the constructed drainage base on the measured productivity outcomes. In
this study, Time Cycle analysis is used to measure the productivity of a backhoe
machine used for trench excavation and the labour productivity rate to install the
drainage is also measured. Additionally, Cycle Time Tracking & Variance Analysis
model are use to analyse the data obtained. The research targets a construction of
drainage around Johor Bharu as a case study. The significant of study is to measure
the optimum productivity rate of drainage construction. The optimum productivity
rate for excavation is 3.59meters per hour with the quality of 4.2 out of 5, while the
productivity rate to install the culvert is 8 pieces per hour with the highest quality of
4 out of 5. Productivity measurement can improve the overall construction
performance in the construction.
vi
ABSTRAK
Produktiviti dalam industri pembinaan ialah nisbah output ke atas sumber yang
menentukan hasil produk. LEAN adalah prinsip yang digunakan oleh industri
perkilangan untuk meningkatkan produk mereka. Kajian ini menggunakan prinsip
produktiviti pengukuran yang digunakan oleh industri pembuatan pada mesin untuk
mengukur produktiviti aktiviti pembinaan saliran saliran. Oleh itu, ia bertujuan untuk
menilai kualiti asas saliran yang dibina pada hasil produktiviti yang diukur. Dalam
kajian ini, analisis Kitaran Masa digunakan untuk mengukur produktiviti mesin
Jentolak yang digunakan untuk penggalian parit dan kadar produktiviti buruh untuk
memasang saliran juga diukur. Di samping itu, model Pengesanan Masa & Analisis
Analisis Kitaran digunakan untuk menganalisis data yang diperolehi. Penyelidikan
ini mensasarkan pembinaan saliran di sekitar Johor Bharu sebagai kajian kes. Kajian
penting adalah untuk mengukur kadar produktiviti optimum pembinaan saliran.
Kadar produktiviti untuk penggalian adalah 3.59meter sejam dengan kualiti 4.2
daripada 5, manakala kadar pemasangan saliran pula adalah 8 biji sejam dengan
kadar kualiti 4 daripada 5. Pengukuran produktiviti dapat meningkatkan prestasi
pembinaan keseluruhan dalam pembinaan.
vii
TABLE OF CONTENTS
CHAPTER TITLE PAGE
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENT iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENTS vii
LIST OF TABLES x
LIST OF FIGURES xi
1 INTRODUCTION 1
1.1 General 1
1.2 Background Of Study 2
1.3 Problem Statement 3
1.4 Objectives and Aim 4
1.5 Scope of Study 4
1.6 Significant of Study
1.7 Research Structure
1.8 Summary
5
6
7
2 LITERATURE REVIEW 9
2.1 Introduction 9
2.2 LEAN Technique 10
2.3 LEAN and Construction Time 11
viii
2.4 LEAN Time Cycle Analysis 11
2.5 Productivity 12
2.6 Productivity and Construction Duration
2.7 Trench Drain
2.8 Trench Excavation for Drainage
2.8.1 Case 580K
2.8.2 Concrete Drain Construction
According to JKR Drainage Standard
Requirement
2.9 Labour Productivity
2.10 Productivity and Quality
2.11 Summary
13
13
14
14
18
21
22
22
3 RESEARCH METHODOLOGY 23
3.1 Introduction 23
3.2 Data Collection 23
3.3 Research Design 24
3.4 Population Sampling 25
3.5 Research Instrument
3.6 Drainage Construction
26
27
3.7 Data Analysis 35
3.8 Summary 35
4 ANALYSIS 37
4.1 Introduction 37
4.2 Data Collection 38
4.3 Project Detail 38
4.3.1 Drainage Details 39
4.4 Analysis Excavation Productivity
4.4.1Quality of Excavation
40
42
4.5 Analysis Block Drain Installation
4.5.1 Quality of Pre-Cast Culvert Block
Drain Install
46
47
ix
4.6 Project Productivity Discussion
4.6.1 Quality of Drainage Construction
Discussion
4.7 Summary of Drainage Productivity Rate and
Construction Quality Measurement
50
51
52
5 DISCUSSION AND CONCLUSION 53
5.1 Introduction 53
5.2 Research Limitation 53
5.3 Research Discussion and Conclusion 54
5.4 Conclusion 56
REFERENCES
APPENDICES
61
63
x
LIST OF TABLES
TABLE NO. TITLE PAGE
2.1
2.2
2.3
4.1
4.2
4.3
Case 580K Engine Specification
Condition of Backhoe to Operate Optimally
JKR Drainage Standard Requirement
Excavation Statistic
Excavation Quality
Pre-Cast Block Drain Installation Quality
16
16
19
41
42
47
xi
LIST OF FIGURE
FIGURE NO. TITLE PAGE
1.0
2.1
2.2
2.3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
4.1
4.2
4.3
Research Process
Backhoe model Case 580K
Case 580K Bucket
V-Shaped Block Drain Size
Excavation Activity
Material Removal
Excavation Measurement
Excavation Vertical Cut
Lean Concrete
Marking and Leveling
Material Delivered
Culvert Installation
Backfilling
Surface Drain
Plastering
Drainage Cross Section
Excavation Productivity
Pre-Cast Block Drain Installation
6
15
17
18
27
28
28
29
30
30
31
32
33
34
34
39
40
46
CHAPTER 1
INTRODUCTION
1. 1 General
According to Motwani (1995), productivity measurement in construction
industry is important for the sector to continuously improve thier performance and
compete within their sector. The practical approach to measure the productivity
within construction industry is needed to be identified. There are several model that
can be used to measure productivity in construction such as Time Cycle Analysis.
However, this research focus on LEAN strategy that currently being used in
manufacturing industry to measure their productivity. Hence, LEAN have been used
by the manufacturing sector to improve their product performance and quality. In this
project, LEAN strategy to measure productivity will be implement in construction
industry.
2
1.2 Background Of Study
According to Krugman (1994), productivity rate is the number of product can
be produce by the time given. Hence, Chia (2012), mention that productivity have
great influence on national economic growth. Measuring the construction industry
productivity will also reflect toward the measurement of the industry economic
growth itself. In construction planning and scheduling, it is necessary to know the
production rate for specific activity to estimate the period for the task completion.
LEAN thinking mostly implemented in manufacturing industry for
improvement in the industry in terms of production involving machinery.
Construction industry partially manual trade and equipment to facilitate each
construction activities. Plant and equipment require a proper management to utilize
their maximum potential and to operate according to the plan and scheduling of a
project. Thus, excavation activity involves several types of plants to facilitate the
process. The example of common plant been used for excavation activities are
excavator and backhoe. This research focus on measurement of productivity for
drainage trench excavation, involving the use of backhoe as machinery and manual
labour productivity to install the drainage pre-cast.
This research focus on the measurement of productivity rate in construction
of V-Shaped Trench Drainage activity. The activities for V-Shaped drainage
construction are identified and the productivity rate for each activity is measured.
3
1.3 Problem Statement
According to Chau (2003), researches of construction productivity have
problems in measurement and availability of data. This issues is reflect toward the
challenge of indentifying the factors affecting the level and growth of efficiency in
construction industry. Thus, according to Motwani (1995), identifying the critical
factors that influence the productivity in construction industry is a challenge. In
addition, according to Noh (2014), higher productivity rate reduce the quality of
product. This research intends to use the LEAN principle used in manufacturing
industry to measure their productivity and evaluate the quality. This process will
determine the quality of product at a certain rate. This research will measure the
productivity rate on drainage activities with specific indentified critical factors that
influence the productivity and act as constant variables.
According to Sambasivan (2006), labour and equipment related to
productivity contribute to causes of delay in construction project. Hence, according
to the research, labour and equipment was ranked 3 out of 8 categories of delay
causation in Malaysia construction industry. Hence, the quality of work and the
productivity among the workers in Malaysia, have significant impact on project
progress and efficiency. This will eventually result in delay on completion sequence,
where the successor activity will be affected and causing delay for the entire project.
4
1.4 Objectives and Aim
This study aim is to measure the productivity of drainage trench excavation.
To achieve the aim, the objectives are:
i. To measure the productivity rates of trench excavation using plant (Backhoe)
using Time Cycle Analysis
ii. To calculate the optimum manual labour productivity rates to install V-
Shaped Trench Drain using Activity Oriented formulation.
iii. To evaluate the quality of finished drainage construction base on the drainage
construction productivity rates.
1.5 Scope of Study
The research purpose is to determine the productivity rate of drainage
construction activity using LEAN principle. This research focus on the construction
of V-Shape Trench Drain activity. The activity for construction of V-Shaped
drainage is identified. Each activity will be measure its productivity rate. Hence, the
quality of the finish product will be evaluated.
The variable for productivity rate will be scope to specific resources and act
as a constant variable. The constant variable this research is plant, materials and
number of labour. In addition, each resource variable will be selected according to
common resource generally being used in Malaysia construction activity.
5
1.6 Significant of Study
Measuring the productivity within construction industry will improve the
construction process. The study aim to provide useful information regarding
construction productivity for a specific activity. The research measure the
productivity of drainage work for precast drainage. The activities measured include
the excavation process and the installation process.
The measurement for the excavation process involve the specific plant chosen
that suit the activity. Pratt (2010) mentioned the suitable machine for trench
excavation in backhoe, due to its mobility. The research measure the productivity of
a backhoe to excavate trench drain. The result can be use as standard efficiency for
backhoe to excavate trench drain.
Measuring labour productivity will determine the optimum productivity rate
for drainage installation. The productivity rate is influence by the total man-hours,
which the result will determine the standard rate of productivity to install drainage
within one hour.
Hence, this research will also clarify the problem statement on the higher the
productivity rate, the lower the quality produce. The result of productivity will then
be evaluated towards its quality. This is to measure the quality of product at a certain
productivity rate. Hence, this result can be use to improve the quality of drainage
work with respect to time taken to complete the work process.
6
1.7 Research Structure
The main purpose of this research is to measure the productivity of drainage
trench excavation and measure the quality of drainage base on the productivity rate.
In order to achieve these objectives, the activities involving construction stage for
drainage work is identified. Figure 1 shows the research process to achieve the final
objective for this research.
Figure 1.0: Research Process
Collecting data of the research will require several procedures. The first data
is regarding the first objective, to measure the productivity rates of trench excavation
using backhoe with Time Cycle Analysis, is a primary data collection. The
information gathered through measurement of backhoe excavation for specific
drainage activity on site. The data will be analyzed using SPSS.
Drainage Productivity
•LEAN Princple
Trench Excavation
•Variance Analysis
Labour Productivity
•Activity Oriented Model
Quality Assesment
•JKR Draiange Work Specification
7
Second objective also use the primary data collection method, which is to
measure the labour productivity rates to install V-Shaped Trench Drain using the
Labour Productivity Rate Activity Oriented Model formula:
The third objective is to evaluate the quality of drainage base on the drainage
construction productivity rates require the result gathered through first and second
objective. The evaluation will rated based on the standard JKR standard specification
2014.
1.8 Summary
Productivity measurement is important in construction industry to improve
their performance. Hence, it can be use as key performance indicator, measuring the
output of performance for a specific task in the industry. The problem statement is
resolved through achieving the objectives of this research.
The first objective is to determine the productivity rates of trench excavation
of a backhoe. This objective is achieve by measuring the performance of backhoe
excavating a trench on sites, thus, implanting LEAN strategy to measure the
productivity rate.
The second objective is to determine the optimum labour productivity rates to
install V-Shaped Trench Drain. This objective is achieve by measuring the total man-
hours to install the V-Shaped Trench Drain per-hour by using Activity Oriented
formula.
8
The third objective is to determine the quality of the drainage manage to
achieve through the productivity rate of both machine and labour productivity. This
objective is achieve by evaluating the quality of the final product after the installation
of V-Shaped Trench Drain completed.
61
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Performance Improvement. Structural Engineering Department, Faculty of
Engineering, Alexandria University, Egypt
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