Kirby Lean Brochure Intel_v11

THELEANEFFECT

At Kirby, we believe that Lean is the future of the construction industry not only in Ireland, butthroughout the world. For this reason, Lean practices and processes have become critical componentsof Kirby project delivery. We are pleased to say that our culture is strongly driven by innovation,efficiency, waste elimination and meeting our client needs at minimum cost each and every time. Thisbrochure depicts how Kirby have embraced Lean Initiatives on recent Intel projects:• Site Induction Training • EHS• BIM • Mobile Technology• Off-site Fabrication • Training and Coaching• Trades Recognition • ECI/IPD• Off-site StorageSite Induction Training• Kirby were the first organisation to successfully apply online training which assisted in reducing standard safety and quality site induction by 66 %• Kirby also through elimination of waste reduced in-house mandatory harness, ladder and manual handling safety programmes by 80%: • 8 hours saved for 400+ inductions • Saving to trainers time • Electronic scheduling and tracking of training records

BIM • Kirby, through its project BIM team, developed a 3-D model to allow multi-discipline co-ordination of services, ensuring the on-site installation was “right first time”. From this model, Kirby produced fabrication and installation drawings to highest standards for the onsite team, generating savings through increased efficiencies on site • The following benefits were achieved as a result of BIM: • BIM software allowed engineers to liaise with on-site install teams to ensure constructability issues were avoided. This enabled the BIM detailers to produce a constructible model and aided the site team with containment install • IFF documentation generated by BIM was sent directly to the fabrication workshop to start the manufacturing process. Each containment system was labelled within the model, tagged in the workshop and delivered to site • Install drawings referencing the tagged containment runs were issued to the site team ensuring an accurate install • All containment was tracked from model creation to site install, enabling efficient tracking by the quality team • 50000 M+ of containment installed to project tolerance rate

Off-Site Fabrication • Kirby built a site-specific manufacturing facility for TI which allowed fabrication of containment systems to stringent tolerances. Once QA checks were completed these containment systems were shipped to site for immediate installation.   • The following benefits were achieved from a construction aspect: • Experienced fabrication team worked in a designated facility with all required materials to hand. This reduced logistics and geographical challenges which in turn increased productivity • Reduced personnel numbers working in congested areas e.g. the sub fab areas reduced the risk of EHS incidences • Reduction in the amount of construction materials stored on site, particularly in congested areas such as Fab & Sub-Fab • Materials were requested as required on site, thus reducing inventoryTrades Recognition • Development and successful implementation of the following schemes: • Idea suggestion which encourages all employees to detail new and improved methods of construction • Internal awards for selected ideas • Supervision nominated high performing employees and or Sub Contractors per geographical area or system • Monthly draws for all nominated employees and Sub Contractors • Primary benefits of these schemes: • 930,000+ incident and injury free man hours • Achieved all SL1/SL2 and project milestone dates • Lowest SOR rate

Off-Site Storage • Kirby engaged the services of a local logistics company to manage all construction material deliveries to site, eliminating waste labour activities such as double handling. • Utilising off-site storage resulted in the following benefits: • Minimising the amount of materials stored on site • Scheduling of delivery times to reduce unnecessary congestion on site • Correct quantities of materials ordered for specific tasks therefore reducing waste • All purchased materials were directed to off-site facility to eliminate any direct shipping to site

EHS • Kirby excelled in the area of Environmental Health & Safety through implementing the most up to date EHS methodologies. Success in this area is due to experienced EHS Advisors working in each designated site team. As a result of this the following were achieved: • A world-class accident & incident record for 930,000+ man hrs worked on site • 11 Safety crew of the month awards • 7 Individuals awarded for their dedication to safety • Overall Contractor of the Project for a number of months • Site PM inducted to the HERO & LEGENDS hall of fameMobile Technology • Kirby were the first organisation to introduce and use “tablets in the field” to successfully aid construction. Tablets allow the team to gain access to live registers with the latest drawings, 3D models and schedules. The provision of tablets also allows greater mobility to the management team through having access to relevant email, calendar and contact details “on the go” • The use of tablets in the field had the following primary benefits: • Substantial Direct Indirect cost savings • Teams can red line drawings and save directly to the cloud • SMWBA walks, QA checks and testing certificates completed “on the go” • Demonstration of live design information inclusive of latest changes during system walk-downs

Training and Coaching • Kirby developed a training and coaching program to enhance the site construction team’s methodologies by introducing new concepts and strategies. The following practices were implemented: • Kirby engaged the services of consultants and former Intel construction managers to coach and mentor our construction team • Kirby provided training programs on the principles of LEAN to develop the mind-set of the core on-site teams • Bi-monthly meetings to co-ordinate planning between departments and share constructability concepts • Research into Intel’s core values gave the site team a valuable insight into the workings of Intel and how to partner with them effectively to ensure that standards such as quality and EHS were maintained and exceeded • Continuous lessons learned program implementation to ensure any corrective actions are implementedECI/IPD • Early Contractor Involvement is a key principle of Integrated Project Delivery. The application of this principle in a collaborative environment enabled the following primary achievements: • Identification and resolution of constructability issues (through the integration of design and construction teams) prior to any impact on productivity during the construction phase • Development, adoption and implementation of a schedule driven productivity dashboard • Other benefits of IPD principles application: • Submittal and approval of alternative materials and suppliers • Clear definition of constructible scope • Reduction in quantity of RFI’s during the construction phase

LIMERICK DUBLIN GALWAYRaheen Business Park White Swan Business Park Monivea RoadRaheen South Circular Road BallybaneLimerick Dublin GalwayIreland Ireland IrelandT: +353 61 226 060 T: +353 1 454 0411 T: +353 91 752 860F: +353 61 226 061 F: +353 1 454 7589 F: +353 91 752 862E: [email protected] E: [email protected] E: [email protected] GLASGOW LONDONSuite 402 Chadwick House Unit 43 Grovewood Business Profile WestBirchwood Park Centre 950 Great West RoadWarrington Road, Warrington Strathclyde Business Park Brentford, TW8 9ESWA3 6AE United Kingdom Bellshill, Lanarkshire United KingdomT: +44 1616 672 360 ML4 3NQ Scotland T: +44 20 8232 7510E: [email protected] T: +44 1698 841 228 F: +44 20 8232 7511 F: +44 1698 571 249 E: [email protected] E: [email protected] 5A www.kirbygroup.com1831 DiegemBrusselsBelgiumT: +32 28 928 055M: +353 86 803 5847E: [email protected]