Developing optimal scaffolding erection through the integration of lean and work posture analysis

Purpose: Facility structures in liquefied natural gas (LNG) plants require tremendous amounts of scaffolding to facilitate relevant industrial operation and maintenance. As such, the productivity of scaffolding operations in turnaround maintenance (TAM) has attracted much attention in recent years. In addition, health and safety issues have been recognised as a key contributor along with productivity improvement in the LNG industry. This study aims to integrate work posture analysis into value stream mapping to achieve an optimised and balanced improvement in both productivity and health and safety. Design/methodology/approach: A case study approach is adopted to integrate lean and work posture analysis in a TAM site. The lean improvement is conducted through value stream mapping, and the work posture analysis is conducted through the Ovako Working Posture Analysis System method. A three-step optimisation strategy is then developed for achieving optimised performance in waste reduction and work posture improvement. Findings: It is found that the implementation of value stream mapping can help eliminate waste in the installation process, therefore eliminating potential health and safety risks. However, health and safety of onsite workers does not always improve as lean implementation intensifies. There is an optimised erection schedule that has the lowest health and safety risk within a waste reduction target. Originality/value: In contradiction to previous studies, which rely on qualitative assessment to identify the a positive correlation between lean and health and safety, this study reveals the distinct difference between lean attributes and health and safety attributes through a quantitative assessment and is more readily to be implemented at the site level for simultaneous improvement in lean and health and safety.