Case Studies of Indian companies following Lean Construction
ROADS & HIGHWAYS

Case Studies of Indian companies following Lean Construction

When HCC was constructing the two-tier Bogibeel Bridge—the country’s longest rail-cum-road bridge—placing the 125-m long fully-welded steel spans, each weighing 1,700 tonne, on the pillars embedded in the riverbed was a challenge. “On-site engineers had two choices for a more practical and economical method, either lifting the spans with floating cranes or erecting them with a launching truss,” shares Amit Uplenchwar, CEO, HCC E&C. “After weighing the pros and cons, the team came up with a third solution of pulling the steel trusses with a set of jacks and winches on the pillars. This eliminated the need to enter the river. Besides, it also ensured safer working conditions, precluded the mobilisation of a giant setup on either side of the river and accelerated the project’s pace. The strategy proved testament to the global practice of Lean construction, which is changing the way projects are executed from design to construction.”

Shapoorji Pallonji Engineering & Construction has implemented Lean for an IT park spread over 40 acre with a built-up area of 3.5 m sq ft. It required coordination among 46 contractors having more than 2,000 workers at a time. “The project was struggling with coordination issues within and among teams, and wastage of material and labour at the same time,” says SC Dixit, Executive Director, Shapoorji Pallonji Engineering & Construction. “The implementation of Lean tools such as Last Planner System (LPS) helped in coordination and streamlining communication, while Value Stream Mapping (VSM) practices helped in reducing man days and improving productivity. Further, pull-based planning ensured optimistic targets, which is further reinforced by the rest of the tools, resulting in improved productivity; and a sense of waste reduction is nurtured in the team, which resulted in improved coordination and higher percentage plan completion.”

At one of Tata Realty and Infrastructure’s recent projects in Gurugram, a large SEZ project of about 5 million sq ft, “we have implemented Lean and created a Big Room,” says Prakash Patil, Secretary General, The Institute for Lean Construction Excellence, and Vice President-Projects, Tata Realty and Infrastructure. “We are using the Last Planner (r) System (LPS), Pull Planning, BIM etc, extensively here.”

- SERAPHINA D’SOUZA

When HCC was constructing the two-tier Bogibeel Bridge—the country’s longest rail-cum-road bridge—placing the 125-m long fully-welded steel spans, each weighing 1,700 tonne, on the pillars embedded in the riverbed was a challenge. “On-site engineers had two choices for a more practical and economical method, either lifting the spans with floating cranes or erecting them with a launching truss,” shares Amit Uplenchwar, CEO, HCC E&C. “After weighing the pros and cons, the team came up with a third solution of pulling the steel trusses with a set of jacks and winches on the pillars. This eliminated the need to enter the river. Besides, it also ensured safer working conditions, precluded the mobilisation of a giant setup on either side of the river and accelerated the project’s pace. The strategy proved testament to the global practice of Lean construction, which is changing the way projects are executed from design to construction.”Shapoorji Pallonji Engineering & Construction has implemented Lean for an IT park spread over 40 acre with a built-up area of 3.5 m sq ft. It required coordination among 46 contractors having more than 2,000 workers at a time. “The project was struggling with coordination issues within and among teams, and wastage of material and labour at the same time,” says SC Dixit, Executive Director, Shapoorji Pallonji Engineering & Construction. “The implementation of Lean tools such as Last Planner System (LPS) helped in coordination and streamlining communication, while Value Stream Mapping (VSM) practices helped in reducing man days and improving productivity. Further, pull-based planning ensured optimistic targets, which is further reinforced by the rest of the tools, resulting in improved productivity; and a sense of waste reduction is nurtured in the team, which resulted in improved coordination and higher percentage plan completion.”At one of Tata Realty and Infrastructure’s recent projects in Gurugram, a large SEZ project of about 5 million sq ft, “we have implemented Lean and created a Big Room,” says Prakash Patil, Secretary General, The Institute for Lean Construction Excellence, and Vice President-Projects, Tata Realty and Infrastructure. “We are using the Last Planner (r) System (LPS), Pull Planning, BIM etc, extensively here.”- SERAPHINA D’SOUZA

Next Story
Infrastructure Transport

JNPA Becomes First Indian Port to Cross 10 Million TEU Capacity

The Jawaharlal Nehru Port Authority (JNPA), located at Uran in Navi Mumbai, has become the first port in India to achieve over 10 million TEUs (twenty-foot equivalent units) in container handling capacity.With the recent expansion, the port now operates five container terminals with a combined capacity of 10.4 million TEUs, alongside two liquid and two general cargo terminals.Handling more than half of India’s container traffic, JNPA processed 7.05 million TEUs in 2024 and has moved 15.39 million tonnes of containers and 16.64 million tonnes of total cargo in the first two months of FY 2025..

Next Story
Infrastructure Transport

Nod for Rs. 36.26 billion Expansion of Pune Metro Line 2

The Union Cabinet has approved the Rs.36.26 billion expansion of Pune Metro Line 2, adding 12.75 km of track and 13 new stations to improve east–west connectivity across the city.The project aims to link Pune’s urban core with rapidly growing suburbs, supporting the city’s rising demand for efficient and sustainable transport solutions. This expansion is part of Corridor 2 of the Pune Metro and includes two key routes: Vanaz to Chandani Chowk (Corridor 2A) and Ramwadi to Wagholi/Vitthalwadi (Corridor 2B).It will connect residential, IT, and educational hubs in areas such as Bavdhan, Koth..

Next Story
Infrastructure Transport

Assembly begins for ‘Nayak’ TBM on Thane– Borivali Twin Tunnel Project

The assembly of ‘Nayak’, the first of four Tunnel Boring Machines (TBMs) for the Thane–Borivali Twin Tube Tunnel Project, has commenced at the Thane site. Built by German firm Herrenknecht AG and deployed by Megha Engineering & Infrastructure (MEIL), the TBM marks a key milestone in Mumbai’s ambitious 11.8-km underground road corridor beneath Sanjay Gandhi National Park.The twin tunnels will reduce the Thane–Borivali travel distance by 12 km and decongest Thane Ghodbunder Road. ‘Nayak’, with a 13.2-metre diameter, is designed to bore through challenging geological conditions ..

Advertisement

Advertisement

Subscribe to Our Newsletter

Get daily newsletters around different themes from Construction world.

STAY CONNECTED

Advertisement

Advertisement

Advertisement

Advertisement

Talk to us?