ROAD CONSTRUCTION LABOR PERFORMANCE CONTROL USING PPC, PCR AND RNC

DURING THE PANDEMIC

MG. ING. JORGE DE LA TORRE/BACH. ING. LUISA TABOADA/BACH. ING. POOL PICOY

AGENDA

1. INTRODUCTION2. METHOD3. RESULTS4. CONCLUSIONS

1. INTRODUCTION

The construction industry hasbeen critizicized and comparedto other industries due to thereduced evolution of laborperformance and the few toolsestablished to control andimprove it, which leads towastes in the processes causingcost overruns and decreasedproductivity (Bølviken andKoskela, 2016).

Figure 1. Labour productivity of on-site construction (Figure 15 in Ahmad et al., 2020)

y = -0.5458x + 99.261R² = 0.74

y = 1.3574x + 102.59R² = 0.89

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On - Site Construction Activities All Norwegian Industries

1. INTRODUCTION

This defect is more frequentin road works due to itslongitudinal nature; whichleads to a large number ofinterferences that must beidentified in a timely mannerso as not to interrupt thework flow of resources, suchas work force.

Figure 2. Road construction site

1. INTRODUCTION

Within the context of the pandemic, the lowperformance of labor has beenstrengthened, due to the nature of theexecution of its activities involving ofnumerous specialized work force teamsworking together and to the increase inworking hours spent on non-contributorytime (TNC).

Figure 3. Workmen within the context of the pandemic

1. INTRODUCTIONDue to the problem of laborperformance control in thecontext of a pandemic andthe higher incidence ofvariability in road projects,this study aims to validatethe use of PPC, PCR and RNCindicators as a mechanismfor monitoring laborperformance in roadconstruction within the newnormal.

Figure 4. Case study project

INTERFERENCES

2. METHOD

Figure 5. Flowchart of Research Process

Figure 5 represents themethodology used for thecontrol of the laborperformance of a road projectwithin the context of the newnormal using as a mechanismthe PPC and PCR indicators andRNC for decision makingoriented to continuousimprovement.

Presentación Presentación

2.1 SITUATIONAL SURVEY OF ROAD CONSTRUCTION PROJECTS

The survey was conducted among 40professionals from 16 constructioncompanies specializing in roadprojects during the new normal.

Survey results provided a situationaloverview of road works and guidedthe PPC and PCR indicators towards acontrolled labor performance withinthe context of the new normal.

Presentación21% of the respondents, according to their experience, believed that the inadequate composition and size of crews is a factor that negatively impacts labor performance.

3%

16%

17%

17%

21%

25%

0% 5% 10% 15% 20% 25%

Others

Inadequate positioning of materials

High amount of workforce turnover (hiring and firing)

Lack of project supervision

Composition and inadequate size of the working crew

Modifications during the execution of the project

Figure 6. Factor of variability of the labor performance

2.1 SITUATIONAL SURVEY OF ROAD CONSTRUCTION PROJECTS

22% of the professionalsrated Waiting orDowntime as the wastewith the greatest impacton labor performance.

Figure 7. Waste with the greatest impact on labor performance

7%

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22%

0% 5% 10% 15% 20%

Overprocessing

Excess inventory of materials

Overproduction or bottlenecks

Loss of talent

Unnecessary transport of materials

Quality defects in production

Unnecessary movement of workers

Periods of downtime and inactivity.

2.1 SITUATIONAL SURVEY OF ROAD CONSTRUCTION PROJECTS

The average Productive Time(TP), i.e., that which the timethat workers add direct valueto production of executedactivities., represents 50.45%of the activities performed atthe construction site.

Figure 8. Distribution of types of work times in road projects in the context of new normality

50.45%

28.18%

21.37%

Average TP

Average TC

Average TNC

Presentación

2.1 SITUATIONAL SURVEY OF ROAD CONSTRUCTION PROJECTS

Regarding the causes and consequencesof variability provided by road projectspecialists, they coincide in mentioningcauses attributed to external variabilityfactors.

And on the the consequences, thesecoincide in waiting, delays, lowproductivity and labor performancerates, cost overruns, and misseddeadlines.

Climate change not allow to asphalt or purpavements

Underground interference in urban areas conduce to Halt of work due to new activities which require resolution

PresentaciónIncompatibility between technical file and field reality

Not having a complete report of interferences

2.2 IDENTIFICATION OF ITEMS WITH THE GREATEST INCIDENCE

N° Item description % impact on budget

1 Rigid Pavement 34.76%

2 Granular Sub-base H=20 cm 5.66%

3 Concrete Sidewalks 4.40%

4 Pavement painting 2.99%

5 Asphalt Contraction Joint Sealing 1.50 %

6 Excavation to subgrade in Loose Material 1.20%

7 Demolition of Flexible Pavement 1.18%

Table 1. Control items

2.3 WEEKLY PLANNING MEETING

Figure 9. Weekly Planning Meeting Agenda

M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S

Executed Week Review (Week 1)

Compliance of activities

Calculate PPC

Determine RNC

Corrective actions for RNC

Calculate PCR

Labor performance curves

Corrective actions for delays in critical activities

Immediate Post Week Planning (Week 2)

Review of Lookahead 2 @ 4 restrictions

Determine executable tasks (released constraints)

Define weekly work plan 2

Submit Lookahead 3 @ 5

Constraints analysis in accordance to the Lookahead 3 @ 5

PPC: Percentage of Plan completed

RNC: Reasons for Non Compliance

PCR: Percentage of Constraint Removal

Weekly planning meeting agenda

Week 2

Week 1 Week 2 Week 3 Week 4 Week 5 Week 6

WEEK 1 PLAN

WEEK 2 PLAN

Lookahead 2 @ 4Lookahead 3 @ 5

WEEK 1 REVIEW

2.3 LABOR PERFORMANCE CURVES

This graph identifies whetherthe labor resource meets theexpected performance(input/output), according tothe budget, because if theaccumulated performance ishigher than the budgetedperformance, more man-hours (input) are being usedthan expected, whichtranslates into cost overruns.

Figure 9. Daily production report

CONTRACTUAL ITEM: Pavement painting (m) SUPPLIER:

Date: 10-oct-20 PHASE: 100

Item Unit STRETCH SIDE INITIAL PROG. FINAL PROG. WIDTH LENGTH THICKNESS QUANTITY

Pavement painting (m) m I LEFT 1+751 1+879 128 128.00

128.00

REFERENCE PHOTO:

COMMENTS:

*NOTE: This form will be filled out for each item worked on and will be cumulative.

CONTROLLER

OFFICIAL 1.0 8.0

GENERAL LABORER 6.0 8.0

FOREMAN

OPERATOR 1.0 8.0

WORK FORCE Quantity Hours

DUMP TRUCK

MATERIALS Unit Quantity

SOIL COMPACTOR

CISTERNE

MINI LOADER

MOTOR GRADER

FRONT LOADER

BACKHOE LOADER

EQUIPMENT Quantity Hours

EXCAVATOR

DAILY PRODUCTION REPORT

OBSERVATIONS

TOTAL M

INPUT

OUTPUT

3. RESULTS At lower the PPC and PCR, theperformance is higher, whichtranslates into inefficient use ofresources and cost overruns. Thisis due to the fact that, in the eventof non-compliance with therelease of constraints, theworkflow is interrupted, whichimplies greater use of man-hours.

Figure 10. PPC and PCR chart

25%

44% 43%

78%

86% 88%

25%

35% 38%

48%

60%64%

0%

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80%

100%

Week 1 Week 2 Week 3 Week 4 Week 5 Week 6

PPC Accumulated PPC

44%50%

30%

67%

75% 78%

44%48%

42%

46% 49%54%

0%

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80%

100%

Week 1 Week 2 Week 3 Week 4 Week 5 Week 6

PCR Accumulated PCR

3. RESULTS

The improvement in laborperformance begins inweek 3, at which pointthe PPC and PCR tend torise, which is explained bytimely decisions andactions regarding laborand release of constraints.

Figure 11. Labor Performance Curves

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Rigid Pavement Demolition of Flexible Pavement H=5 cm.Excavation to subgrade in Loose Material Granular Sub - base H=20 cm.Pavement painting Asphalt Contraction Joint SealingConcrete Sidewalks

3. RESULTS According RNCs identifiedduring the current healthsituation, the mostfrequent are the externalones with 42% sinceroadworks present factorsspecific to the type ofproject that can causeinterruptions in the workflow throughout itsdevelopment.

Figure 12. RNC Pareto Chart

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Management Procurement Equipment

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RNC Frequency % accumulated 80%

3. RESULTS

Table 2. Improvements in labor performance

Item description

Workmen Nr.

(a)

Labor Performance (input/output)Production speed

(output/day)

Budgeted Start

(b)

End

(c)

Start

1

b/(a × 8)

End

1

𝑐/(𝑎 × 8)

Increase

Rigid Pavement (m2) 18 0.16 0.17 0.16 848 905 7%Demolition of Flexible Pavement (m2) 6 0.19 0.02 0.01 2464 4657 89%

Excavation to subgrade in Loose Material (m3)

3 0.09 0.08 0.07 305 350 15%

Granular Sub-base H=20 cm (m2) 5 0.04 0.02 0.02 2340 2037 -13%Pavement painting (m) 8 0.64 0.62 0.20 104 320 208%

Asphalt Contraction Joint Sealing (m) 14 1.13 0.09 0.07 1287 1512 17%Concrete Sidewalks (m2) 7 0.71 1.15 0.70 49 80 63%

4. CONCLUSIONS

It was found that themonitoring of laborperformance of roadconstruction projectsthrough the PPC, PCR andRNC indicators generateda positive impact onimproving laborperformance in roadprojects developed duringthe new normal.

Specific external RNCsduring the study periodwere heavy and lighttraffic problems in thework areas, as well asinterference withresidential access anddomestic public services.

Better PPC and PCR werefound to be directly relatedto a labor performance inline with the Budget

4. CONCLUSIONS

It was found that low PPCand PCR, translates intoan inefficient laborperformance which inturn leads to higher costoverruns for the roadproject

A 24% to 64%improvement in PPCresulted in up to 67.74%improvement in the workforce performance of thepavement painting controlitem.

This study contributes toexisting knowledge andpractice, in the context ofthe pandemic, byvalidating themethodology formonitoring and optimizingthe performance of theroad construction workforce using LPS indicatorsand collecting RNCscharacteristic of the typeof work and the healthcrisis.

THANK YOU!

MG. ING. JORGE DE LA TORRE1/BACH. ING. LUISA TABOADA2/BACH. ING. POOL PICOY3

1 Magister Civil Engineer, Universidad Peruana de Ciencias Aplicadas, Lima, Peru, +51 975 355 566, pccijdel@upc.edu.pe,orcid.org/0000-0003-3596-81962 Bachelor of School of Civil Engineering, Universidad Peruana de Ciencias Aplicadas, Lima, Peru, +51 994 324 260,u201521217@upc.edu.pe, orcid.org/0000-0002-8413-50113 Bachelor of School of Civil Engineering, Universidad Peruana de Ciencias Aplicadas, Lima, Peru, +51 922 542 234,u201316815@upc.edu.pe, orcid.org/0000-0003-2372-9083