CDL Brownstone

EC
Project Post-Mortem
REAPLITE INDUSTRY SDN BHD
Prepared by : Muhammad Faiz B.
Shaf

Content
1

INTRODUCTION EC BROWNSTONE

PROJECT ANALYSIS

MISTAKES OCCURED

CORRECT PRACTICES

IMPROVED PRACTICES

Objective of Post-Mortem
To identify the practices that we did
correctly, so that we can practice the same
manner/technics again in similar situations.
To identify the practices that had been done
differently, so that we can refne our
techniques in the future.
To identify the practices that we did wrong,
and to suggest alternative approaches or
safety measures that we should employ
when we face a similar problem again in
future.

INTRODUCTION EC BROWNSTONE

What is EC
Using DfMA Method
PVC component
Shear wall system

Storey

10 & 12

Unit

Modules
4436

638

Description

INTRODUCTION EC BROWNSTONE

INTRODUCTION EC BROWNSTONE

PROJECT ANALYSIS
Structural Organization
Production Factor
Production Record
Delivery Record

PROJECT ANALYSIS
Structural Organization

PROJECT ANALYSIS

Production Factor

NO. MOULD per line

Line 4 (Mahmud); 7
Line 7 (Azhari); 17

Line 6 (Khalid); 16

Line 5 (Samsuri); 26

PROJECT ANALYSIS

Production Factor

Production worker per line

4

0
6

14
8

21

Line 4

16

38

48
23

Line 5
Production

Line 6
Repair

Delivery

Line 7

PROJECT ANALYSIS

Production Record

Analysis of Production vs Month

250

200

150

100
65
50 51

88
75
72

112
97
88

209

209
195

170
158

165

204
196
153

164
155

138

129
113
111

107

62

48

119
89
60
53

51
18

0 0

174

Line 4

Line 5

22

82
58
19
0

Line 6

Line 7

13
0

PROJECT ANALYSIS

Production Record

HIGHEST CASTING RATE per line

14
Line 6; 13
12

Line 5 ; 11

10

Line 7 (Azhari); 10

8
6
4
2
0

Line 4 ; 5

PROJECT ANALYSIS

Delivery Record

Analysis of Delivery vs Month

250

206

200

202

176
150
120
110
96

100

50

159
144
131

155
153

152

130

206
176

158

152

156
127

126

113
89

48
42
40

35

32

35
16

0 0

Line 4

Line 5

8391

81

119
95
87
76
42
38
21
0

Line 6

Line 7

MISTAKES OCCURED

SUMMARY ISSUE
SITE ISSUE
NCR ISSUE
QUALITY ISSUE

MISTAKES OCCURED
NCR ISSUE

Chart Title
5

TOTAL
REJECTED
MODULES
58

1
2
3
3

4
4
6
12
18
0

10

12

14

16

18

20

MISTAKES OCCURED
SITE ISSUE

No. of issue

Hook broken; 5
Wall bulging; 15 Line 4 (Mahmud); 27

Line 7 (Azhari); 17
Line 5 (Samsuri); 10

Line 6 (Khalid); 30

TOTAL
PROBLEM
MODULES
114

MISTAKES OCCURED
SITE ISSUE

Modules delivered to site no up to

standard.

MISTAKES OCCURED
SITE ISSUE

Corrugated pipe issue

Out of dimension
Chocked

MISTAKES OCCURED
SITE ISSUE

Modules crack
Lifting procedure incorrect
Not proper leveling during storage

MISTAKES OCCURED
SITE ISSUE

Starter bar position and length

Too long or too short & Spacing

MISTAKES OCCURED
SITE ISSUE

Ceiling slab falling

Secondary casting without
any surface preparation.

MISTAKES OCCURED
SITE ISSUE

Lifting hook problem

Not tying & install properly

MISTAKES OCCURED
SITE ISSUE

Lifting hook broken

Lifting hooks position & level

MISTAKES OCCURED
SITE ISSUE

Lifting hook tear-off

No proper tying
and lapping wire
strands with
mesh.

MISTAKES OCCURED
SITE ISSUE

MISTAKES OCCURED
SITE ISSUE

Rough Concrete Surface & Out of

Dimension
No proper trowel and tying side
forms

MISTAKES OCCURED
SITE ISSUE

MISTAKES OCCURED
SITE ISSUE

Surface bulging
Mould not close properly

MISTAKES OCCURED
SITE ISSUE

Missing reinforcement
Incorrect mesh used.

MISTAKES OCCURED
SITE ISSUE

Falling of spalled concrete

caused accident at site.

MISTAKES OCCURED

SUMMARY ISSUE

Missing

Corrugated

Opening

pipe

Window

Crack

Bulging

Wall
HoneyComb

Bulging

Out

of

Dimension

Poor

Finishing

Major

Chip-Off

MISTAKES OCCURED
NCR ISSUE

Major Honeycomb
Not proper vibrate
Concrete issue

MISTAKES OCCURED
NCR ISSUE

Major Honeycomb
Not proper vibrate
Concrete issue

MISTAKES OCCURED
NCR ISSUE

Recess out of dimension

Wrong intepration of drawings
Pre-pour checking not done

MISTAKES OCCURED
NCR ISSUE

Cracks
Not proper lifting
Not proper stacking/storage

MISTAKES OCCURED
NCR ISSUE

Concrete Spalling/Chipped-off
Not handling properly

MISTAKES OCCURED
NCR ISSUE

Modules Hollowness / Half cast

Not proper vibration
Less supervision during casting

MISTAKES OCCURED
NCR ISSUE

Modules Cracked & Uneven Surface

Not fixed side form properly
Not demould properly

MISTAKES OCCURED
NCR ISSUE

Mesh Marks Appear at Surface

Not properly install spacers

MISTAKES OCCURED
NCR ISSUE

Window Bulging
Not fixed frame stoppers properly

WRONG PRACTICES
NCR ISSUE

NCR Modules

WRONG PRACTICES
QUALITY ISSUE

Mould dirty/not clean

Moulds Cleaniness
Not clean properly after casting

WRONG PRACTICES
QUALITY ISSUE

WRONG PRACTICES
QUALITY ISSUE

WRONG PRACTICES
QUALITY ISSUE

WRONG PRACTICES
QUALITY ISSUE

WRONG PRACTICES
QUALITY ISSUE

Mesh not proper stacking

WRONG PRACTICES
QUALITY ISSUE

Waste concrete and polyform

not put on waste bins

CORRECT PRACTICES

HOUSE KEEPING

CORRECT PRACTICES

DEMOULDING & TRANSPORT

CORRECT PRACTICES

MOULD CLEANESS

EFFECTIVE WORK FLOWS

CASTING
SEPARATE

INTO FEW
TEAMS

REBAR

SET-UP

Arrange items
to ensure
efficient work
flows

Productivity

FOLLOW

REBAR
SCHEDULE

MESH
CORRECT
SIZE &
LAPPING
USING

DEMOULDING
DEMOULD EARLY

MORNING
FOLLOW CUBE
STRENGTH

Eliminate
waste & time
saving

SYSTEMATIC

Maintains and
review
standards

Objective achievement
To identify the things we did right,
so that we can remember to use
again in similar situations

To note the things that had been done

more effective, so that we can refine
our techniques in the future.

To identify the things that we did

wrong, and to suggest alternative
approaches or safety measures and
avoid similar situation again in
future.

5S SYSTEM

5S is a habit and
is continually
Sustain
improved

All unneeded tools,

parts and supplies are
removed from the area
Shorting

A place for
everything and
everything is in
its place

Standardiz
e

Cleaning and
identification
methods are
consistently
applied

Set in
Order

Shine

The area is
cleaned as the
work is performed

Some 5S Examples

Before 5S

After 5S - Cleaned,
organized and drawers
labeled (less time and
frustration hunting)

5S Examples - Shine

3. Shine - The area is cleaned as the work

is performed (best) and\or there is a routine
to keep the work area clean.

THANK YOU