A Conceptual Lean-Based Framework for Improving the Environmental Performance of Ready-Mixed Concrete Production Processes

Abstract

The Ready-Mixed Concrete (RMC) industry is one of the fastest growing construction sectors and plays an important role towards infrastructure development. The RMC industry is expected to rise from INR 155-160 billion in 2009 - 2010 to INR 395 - 400 billion in 2014 – 2015 in India. The use of RMC for construction has proved to be advantageous due to its assured quality, accuracy in the mix proportion, faster construction, less workforce and improved workspace utilization. The RMC industry life cycle consists of five major phases namely manufacturing of raw materials, transportation of raw materials to batching plant, batching plant operations, delivery of concrete to site and site activities for placing and compaction. Significant amounts of resources such as materials, energy and water are used during these five phases. The transportation of raw materials and concrete is considered as one of the major sources of energy use and emissions. This study investigates the application of lean concepts for improving the environmental performance of RMC industry operations. First, the current status of RMC industry is presented. Second, a detailed study of resources used during various phases of RMC industry is summarized based on case studies carried out in Chennai. Third, lean concepts relevant for construction to minimize or eliminate non-value adding activities and wastes are discussed. Finally, this study presents a conceptual framework based on lean thinking to improve the environmental performance of RMC industry. This framework can be used to evaluate alternate RMC production scenarios and enhance the decision-making process for better production and environmental performance.