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Productivity Transformation at Hinkley Point C

Images courtesy of EDF Energy

The Problem
The Hinkley Point C project in Somerset is the first new nuclear power station built in the UK in over two decades, representing a cornerstone in the nation'stransition to low-carbon energy.
This ambitious endeavour will provide reliable power to six million homes but comes with significant buildability, political, and performance challenges. The project's scale and complexity require an unprecedented level of coordination across a vast supply chain, massive workforce capability development, and careful balancing of production and productivity outputs against challenging environmental and regulatory requirements. Before Tactical Edge's involvement in the project, Main Civils Works consistently struggled to meet their projected volumes and faced significant issues with costs, schedules, and productivity outcomes.
I’ve enjoyed working with Tactical Edge enormously and know you had a tremendous impact on the project. I have very fond memories of our early starts with the teams and think the work you did with the frontline leadership is world leading.
Ben Ring
Project Director
An experienced consultancy with a great work ethic who built an immediate rapport with the client by demonstrating specialist knowledge, innovative ideas, and best practices, as well as a professional service delivering exceptional results.
Craig Wilkinson
Managing Director
The Solution
INTEGRATED PRODUCTIVITY IMPROVEMENT
To overcome legacy conflicts and drive productivity at Hinkley Point C, an integrated productivity strategy was developed and successfully implemented between NNB and BYLOR, covering £7 billion worth of scope
across seven platforms. This strategy fostered collaboration and alignment through innovative
initiatives such as Visual Performance and Production Control, enabling short interval learning and rapid improvement at local leadership level, and Rebar Preassembly Packaging, streamlining rebar material handling and installation. Crane optimisation ensured efficient lifting operations, while the
transformation of Non-Conformance Reporting (NCR) improved issue resolution times. Additionally, turbo-charging prefabrication methods reduced on-site complexity, and a strong focus on quality culture embedded excellence across all activities. The strategy resolved historical conflicts and set a new
benchmark for integrated delivery in large-scale construction projects.
The 7 Pillars of the Integrated Productivity Strategy
Make Ready Planning Production Control Rebar Assembly Packaging Crane Optimisation
NCR Resolution Rebar Enhancement One Quality Culture
Impact on Performance
RECORD BREAKING PRODUCTION
The integrated productivity strategy delivered significant productivity and production performance improvements at Hinkley Point C, achieving 15 of 16 major milestones and fostering unprecedented collaboration between NNB, Joint Design Office, BYLOR and other Tier 1 contractors to create shared risk
and reward outcomes. The project realised a 9% productivity improvement, with record-breaking volumes of concrete and rebar successfully delivered across approximately 40 buildings. The "right first time" metric increased by 2%, reflecting the enhanced focus on quality and efficiency. Lessons learned were shared with the mechanical, electrical and HVAC alliance, further embedding best practices and strengthening cross-discipline collaboration. Moreover, the strategy established a robust improvement culture and a scalable framework, paving the way for even higher performance levels in future project phases.

 
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