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Productivity Improvements in Construction Transport Operation through Lean Thinking and Systems of Systems
Publication Type:
Doctoral Thesis
Abstract
The purpose of a quarry is to extract rock material to deliver gravel and raw
material to its customers. The products can be further processed to e.g., extract
minerals such as iron or to produce cement and asphalt. These products are an
important input to the construction and maintenance of road infrastructure,
buildings, and more. The operation of quarry and road work sites is similar to
the manufacturing industry since it contains sequential processes to produce
the output product. Within the operation, there are cyclic transport activities
that in general are not synchronized and controlled in real-time towards the
overall throughput. This fact indicates a potential to increase productivity but
also points at unsolved challenges.
This thesis investigates how Lean and systems thinking combined with real
time control and optimization technologies can be used to improve productiv
ity and safety in the transport operation within quarry and road construction.
The main contributions are the identified operational improvements, its use
cases, the system design constraints, operational characteristics, and models
as well as assessed impact in productivity, energy efficiency, and safety.
The results include the development and demonstration of a method based on
Lean value stream mapping, for identifying wastes in sequential processes and
activities including mobile earthmoving machines. Operational wastes of 33%
are presented from real world operations. Related fuel savings of 42% are
measured in controlled environments. Further, the thesis presents and assesses
a system design for transport optimization purpose. A study of how wireless
communication and vehicular ad-hoc networks (VANET) can be utilized and
its performance within the quarry and road construction operation is pre
sented. The main system requirements and constraints are identified, and the
trade-offs are discussed in terms of system design with a system of systems
perspective. Energy consumption models are developed for optimization pur
poses and the key characteristics of real world operation is identified. Finally,
a prototype system has been developed and tested in controlled and operative
environments. In controlled trials, a fuel reduction of 20% for individual ma
chines was obtained using the suggested optimization technique.
Bibtex
@phdthesis{Rylander 6816,
author = {David Rylander },
title = {Productivity Improvements in Construction Transport Operation through Lean Thinking and Systems of Systems},
isbn = {978-91-7485-532-6},
month = {December},
year = {2021},
school = {M{\\"{a}}lardalen University},
url = {http://www.es.mdu.se/publications/6816-}
}