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How can a large-scale infrastructure project overcome operational hurdles and increase its productivity by 27%?

Share IT Smart TeamExpert consultants in large-scale infrastructure projects and production optimization.
13 min read

In an international shipbuilding and road construction context, an ambitious project to build an extended-length bridge faced critical delays, planning deficiencies and a lack of effective organisational alignment. Share It Smart has intervened with an integrated strategy of optimization, digitization and streamlining of production flows, managing to generate significant improvements.

How can a large-scale infrastructure project overcome operational hurdles and increase its productivity by 27%?

The Client and General Context

Our client, a global leader in shipbuilding and road infrastructure, aimed to build a long bridge using large metal modules. The project required strict adherence to quality and efficiency standards, which was essential for its success.

Strategic Collaboration

This collaboration was crucial for delivering a safe, sustainable project meeting international standards. The combined expertise of shipbuilding excellence and world-class design ensured the highest quality outcomes.

Shipyard Partner

Responsible for manufacturing metal modules due to its expertise and high-quality infrastructure

Japanese Designer

Recognized for its advanced design and strict quality standards, ensuring module compliance with international technical requirements

Project Challenges

Significant Production Delays
First module took 3x longer than planned; working time remained nearly double the estimates
Inadequate Quality Standards
Manufactured modules failed to comply with strict designer standards and international requirements
Lack of Organizational Alignment
Significant divergences between divisions regarding targets and unclear role definitions causing decision blockages
Poor Coordination Systems
Distinct and non-aligned schedules between divisions hampering collaborative efficiency
Inefficient Time Utilization
Only 50-60% of total time was productive, resulting in significant resource waste
Absence of Visual Management
No system to track progress and escalate problems, leading to reactive rather than proactive management

Detailed Situation Analysis

The Share IT Smart and Lean Performance consulting teams conducted a comprehensive assessment, identifying critical pain points across all operational dimensions.

Project Management Issues

Fundamental structural problems affecting coordination and execution

  • โ€ขLack of a unified target model and performance indicators (KPIs)
  • โ€ขOverlapping managerial roles generating uncertainties and decision-making blockages

Planning Deficiencies

Critical gaps in scheduling and data management

  • โ€ขAbsence of a centralized scheduling system
  • โ€ขInconsistent data across divisions affecting execution consistency

Production Flow Inefficiencies

Operational bottlenecks reducing productivity

  • โ€ขHigh unproductive time due to lack of visual management system
  • โ€ขNo strategy to reduce downtime (e.g., equipment changeover optimization)

Quality and Maintenance Gaps

Process misalignment affecting output quality

  • โ€ขMaintenance process not adapted to production pace
  • โ€ขPersistent non-conformities in manufactured modules

Comprehensive Solutions Implemented

An integrated transformation approach addressing all critical areas through strategic interventions and innovative methodologies.

Managerial Alignment

Creating organizational unity through clear structures and objectives

  • โ€ขEstablishing a single unified target for all involved divisions
  • โ€ขCreating clear structure of joint meetings based on production data
  • โ€ขEscalating critical issues to higher decision-making authorities

Scheduling Optimization

Implementing advanced planning tools for resource efficiency

  • โ€ขDevelopment of scenario simulation tool for optimal resource allocation
  • โ€ขImplementation of centralized scheduling system eliminating data inconsistencies

Production Flow Streamlining

Enhancing operational efficiency through systematic improvements

  • โ€ขIntroducing visual management system to track progress and escalate issues
  • โ€ขApplying SMED process to reduce downtime and improve changeover efficiency
  • โ€ขStructuring daily meetings to resolve critical problems rapidly

Quality Assurance Enhancement

Ensuring compliance with international standards

  • โ€ขAdapting processes to meet strict quality standards
  • โ€ขImplementing rigorous quality control methods and checkpoints

Outstanding Results Achieved

27%

Productivity Increase

18%

Staff Reduction

100%

On-Time Delivery

Project completed within budget and established deadlines

Considerable financial savings generating long-term value

Sustainable performance model established for future projects

Strategic Success Factors

Integrated Approach Excellence

Demonstrated that combining operational optimization, managerial alignment, and digitalization delivers transformative results

Sustainable Performance Model

Created a replicable framework enabling consistent high performance across future projects

Quality and Efficiency Balance

Proved that strict quality standards and operational efficiency can coexist and reinforce each other

Partnership Synergy

The collaboration between Share IT Smart, Lean Performance, and client teams created exceptional value

Building the Future of Infrastructure

The bridge project demonstrates that even the most complex infrastructure challenges can be overcome through integrated operational excellence, strategic alignment, and systematic process improvement

Share IT Smart and Lean Performance delivered not just a completed project, but a sustainable operational model that continues generating value

This transformation approach is replicable across large-scale infrastructure projects, creating lasting competitive advantages for organizations committed to operational excellence

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