Asphalt is a black, semi-solid form of petroleum used to bind aggregate together. Asphalt’s most common use is to form smooth, durable surfaces for roads, driveways, walking paths, and parking lots. Lean and Six Sigma methods aid production and use of asphalt and paving. We’ll look at applications from Thailand, the USA, and Lebanon and finish with a video of how an asphalt plant works.


Using Lean Six Sigma and Other Continuous Improvement Methods to Improve the Asphalt Production Process: Thailand

In a case study titled “Productivity improvement of highway engineering industry by implementation of Lean Six Sigma, TPM, ECRS, and 5s: a case study of AAA Co., Ltd.” author Piyachat Burawat discusses production problems due to the asphalt process and applicable methods to improve productivity.

The case study includes:

  • Flow Process Chart of Asphalt Production Process
  • Cause and Effect Diagram for Production Delay and Poor Quality of Asphalt
  • Defined Root Causes Using Pareto Chart
  • Current and Improvement for
    • Shed for Storage Rock
    • Conveyor Belt
    • Construction Area
    • Overall Equipment Effectiveness

You can access the case study here.


Statistical Process Control Methods to Evaluate Asphalt Paving Cost Overruns: USA-Illinois

In a paper titled “Evaluating Cost Overruns of Asphalt Paving Project Using Statistical Process Control Methods” authors Khaled Nassar, Walid Nassar, and Mohamed Hegab apply control charts, pareto analysis, and cause and effect diagram to focus on reasons for cost overruns.

The paper includes:

  • Cost Overrun Classification System
  • Pareto Chart for Categories that Significantly Affect Cost Overruns
  • Cause and Effect Diagram for Cost Overruns

You can read the paper here.


Implementation of Lean Concepts in Pavement Construction: Lebanon

In an article titled “Performance-Based Specifications for Sustainable Pavements: A Lean Engineering Analysis” authors Yara Hamdar and others investigate the implementation of Lean concepts in pavement construction.

The article includes:

  • Tree Diagram of Suggested Application of Lean Concepts for Improved Pavement Performance
  • Analysis of Pavement QA/QC Methods and Specifications in Relation to Lean Concepts and Sustainability

NOTE: To access the article copy and paste the following link into your browser and click on View PDF at the upper left.


How an Asphalt Plant Works

See how an asphalt plant works in a video from Plantmix Asphalt Industry of Kentucky.

You can watch the video here.




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