FAST DIAGRAMMING MADE EASY: STRAIGHTFORWARD TECHNIQUES FOR YOUR HIGHWAY PROJECT Presented at the 2013 AASHTO Value Engineering Peer Exchange Workshop, Minneapolis, Minnesota, July 9 – July 12, 2013 By: Paul Johnson, CVS-Life, CH2M HILL

Abstract FAST diagramming is embraced by some, and dreaded by others. It can be such an effective tool (and is required in your VE report), but it can easily drain a half day or more from the limited time of a fast-paced VE study. How does a VE team make fast work of FAST, to adequately model the functions of a project, and still make it an informative and interesting exercise for the team? This presentation will provide participants in highway VE studies with an effective technique for quickly constructing a FAST diagram from the list of functions generated by the VE team. This paper, and accompanying presentation is geared for beginning to intermediate VE practitioners. Set the pens and yellow stickies aside and learn how to drive a FAST diagram that your District Engineer will love.

Introduction to FAST Diagramming FAST stands for “Function Analysis System Technique” which is a critically important step in the Value Engineering (VE) process. I will start with why FAST is important to VE, followed by a discussion of “Function Analysis,” and then I will address the “System Technique” part. FAST is a critically important step in the Value Engineering process. I like to introduce VE to team members with the Value Equation, V = F/C, where “V” equals “Value” from the owner’s perspective, “F” stands for “Function” meaning the functional requirements of the project, and “C” means “Cost.” If a highway department (owner) is looking for value from a VE study, it can be obtained in a couple of ways. One way is to increase a project’s functionality (the numerator of the Value Equation) while keeping cost (the denominator) roughly the same. If a VE team suggests a geometric enhancement to an interchange and its ramps, in order to improve traffic flow to and from an interchange and a community’s roadway network for approximately the same cost as compared to the base design, then functionality (the equation’s numerator) increases, and so does value from the highway department’s perspective. Another way to improve value would be to suggest a less expensive but just as effective way to retain earth and reduce right-of-way cost, such as a mechanically stabilized earth (MSE) wall compared to a cast-in-place concrete wall, or a sloped embankment requiring a greater right-ofway footprint. The MSE wall (if properly designed and built) will generally accomplish the function at a lower cost, thus reducing the denominator of the Value Equation. The numerator of the equation (Function) remains the same, because the earth is retained as required. Since the

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denominator is smaller, Value increases in the owner’s eyes. The owner can take that savings and utilize it in some other manner such as applying the savings to an under-funded priority on the current project, directing it to another high priority project, or just by delivering the current project at a lower cost. Function Analysis breaks down a project’s components into its functional requirements, using verb-noun definitions, such as “Improve Economy” (a Higher Order function), “Transport People,” and “Transport Goods” (both Basic Functions), and “Retain Earth” (a required Secondary Function), and many other functions, which are further explained later in this paper. These functions can then be linked in terms of “How-Why” relationships on a FAST diagram, which effectively models the functional requirements of the project. With the VE team’s group process of identifying the functions of the project, and linking those functions together in a FAST diagram, the VE team can then brainstorm alternative ways of accomplishing the functions. For example, a VE team may brainstorm a less costly way to meet the secondary function of “Retain Earth” which could involve constructing an MSE wall, as compared to the base design approach of a more expensive cast-in-place concrete retaining wall. Later in the Analysis phase of the VE study, this MSE wall idea may receive a “pass for development” rating by the VE team, and then be fully evaluated in the Development phase of the VE study, then presented to the owner and design team along with other VE proposals at the conclusion of the VE study. Ultimately, the VE proposal may be accepted with the MSE wall concept incorporated into the design where it is found to be acceptable for use by the owner and design team. Thus, Functional Analysis and FAST diagramming are critical elements of the VE process. Many highway departments assign staff not involved in the project design to participate on VE studies for reasons of objectivity. This paper and accompanying presentation is intended as an introduction to FAST diagramming for those highway department VE team members who are new to the VE process. When it comes time for Functional Analysis and FAST diagramming, the writer is hopeful that this paper will help those VE team members newer to the VE process to be confident and effective participants in the Functional Analysis and FAST diagramming phase of the VE study, thus serving as a springboard to creative idea development for the project.

Brief History of FAST Larry Miles is credited as the founder of Value Engineering, in 1945 when he was an engineer with General Electric. He formulated a process called Value Engineering (VE) as a methodology to improve the manufacturing process during World War II. This involved producing manufactured products for the war effort in a shorter timeframe often with limited resources. Continuing through 1952 Larry Miles developed and improved Function Analysis as a part of the VE process. VE became a popular process, particularly in manufacturing. The Society of American Value Engineers was founded in 1959. Parallel to VE’s use in manufacturing, VE was adopted by the US Army Corps of Engineers for use in evaluating infrastructure/construction projects beginning in 19064. In that same year Charles Bytheway from Salt Lake City, Utah is credited with creating the Function Analysis System Technique (FAST) diagramming tool. He linked functions together using logical “HowWhy” relationships, onto what he called a FAST diagram.

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Highway departments adopted VE for their projects beginning in 1970. Use of VE on all public infrastructure projects became public law in 1996. According to AASHTO guidelines adopted in 2012, VE is required on bridge projects over $40 million in estimated project cost, and on highway projects over $50 million in estimated project costs. VE has been required on highway projects since the early 1970’s, but prior to 2012 the dollar value of projects for which VE was required was smaller.

Why FAST Diagramming is Important to Highway Projects FAST diagramming is very important to highway projects (and projects in general), because when a team thoroughly understands a project’s functional requirements, including understanding which functions are critical and which are supporting, that team (a VE team) can creatively find ways to accomplish those functions at a lower cost. A VE study, when properly facilitated, will explore ways to save money while respecting a project’s functional requirements. A VE study thus will never become a rudimentary cost reduction exercise because by definition, a project’s functional requirements must be met. The VE team will explore all feasible ways of accomplishing the required functions at the lowest reasonable cost.

Examples of FAST Diagrams for Highway Projects Four examples of FAST Diagrams prepared by CH2M HILL for highway projects are illustrated as follows, and in the accompanying presentation. Comments follow each o f the diagrams concerning which tool was used in the diagram’s development (Power Point or Visio), and other features of the diagrams which may be of interest to prospective VE team members for highway projects.

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FAST Diagram: Elgin O’Hare 2011 Value Planning

Figure 1 – FAST Diagram for Elgin O’Hare Western Access Project, 2011 Value Planning Study. (FAST Diagram created using Power Point.) When creating the above FAST Diagram (Figure 1) for the Elgin O’Hare Western Access Project in Chicago in 2011, the VE team (called the “Value Planning” or “VP” team in this case) decided to show several function paths within the diagram for major components of this $3.5 billion project. These components include: • • • • •

Overall Project System Interchanges Service Interchanges Elgin O’Hare Expressway West Bypass (the north-south freeway link immediately west of the Elgin O’Hare airport)

Note that the Higher Order functions (the societal reasons of “Why” the project is being done) are shown to the left of the left scope line. The Basic Functions are shown between the scope lines and are linked in terms of their “How-Why” relationships, with “Why” questions being answered to the left of each function, and “How” questions being answered to the right of each

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function. Supporting secondary (or minor) functions in this case are shown to the right of the right scope line. All-The-Time Functions are shown at the top of the diagram. The VE/VP team generated numerous additional basic and secondary functions not shown on the diagram. Note that in FAST diagramming, it is not critical to display every function generated during the Function Analysis phase of the VE/VP study. Rather, only the most important functions that satisfy the How-Why relationships describing the functional requirements of the project, at an appropriate level of abstraction, should be displayed.

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Function Analysis System Technique (FAST) Diagram Elgin O’Hare Western Access Project All the Time Functions HOW?

See VE Report for Additional Basic and Secondary Functions of the Project

Improve Safety

Improve Incident Management

Develop Community Support

Enhance Funding Capability

Control Environmental Impact

Comply with RPZ

Promote Green Alternatives

Reduce Future Operations Costs

Improve Air Quality

Complete Community Outreach

OVERALL PROJECT Reduce Travel Time

Re-Distribute Regional Travel Demand

Reduce Congestion

SYSTEM INTERCHANGES Improve Regional Mobility

Reduce Congestion

Promote Economy

SERVICE INTERCHANGES Encourage Development

Access Employment Centers, Highways, Interchanges

Generate Revenue

Reduce Outof-Direction Travel

Provide Local Access (to/ from Freeway)

Link Communities Link Airport

Allow Free Flow Traffic Movement

Connect Freeways, Expressways, Tollways

Change Direction of Travel

Connect Limited Access Facilities Construct Project

Manage Traffic Flow

Design Project

Transition Speeds

Obtain Environmental Approval

ELGIN-O’HARE EXPRESSWAY Reduce Congestion Along Parallel Routes

WEST BYPASS WHEN?

Reduce Outof Direction Travel

WHY?

Transport People and Goods

Link Communities Connect Communities to O’Hare

Manage Traffic Flow Transition Speeds

Improve EastWest Mobility

Connect to Other Freeways

Connect I-90 to Elgin O’Hare and New EOWA (N Leg)

Provide Separation to Elk Grove (N Leg)

Connect I-294 to Elgin O’Hare and New EOWA (S Leg)

Provide Connectivity Over Railroad (S Leg)

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Figure 2 – FAST Diagram for Elgin O’Hare Western Access Project, Year 2013 Value Engineering Study. (FAST Diagram created using Visio.) Because it is such a large project (approximately $3.5 billion) a second VE study was held in 2013 for the Elgin O’Hare Western Access Project in Chicago. (See Figure 2 FAST diagram above.) In this case, the FAST diagram was created in Visio instead of Power Point. The majority of the VE team members were different from the team member roster from the 2011 VP study. The VE Facilitator (the writer of this paper who facilitated both the 2011 and 2013 studies) allowed the 2013 VE team to generate functions independently of the 2011 team’s list, but then cross-checked the 2011 list for validity. The same project components were utilized as headings in the FAST diagram, and the Basic, Higher Order, All-The-Time, and Secondary functions were similar compared to the 2011 FAST diagram. The FAST diagram from the 2013 study (Figure 2) was prepared using Visio. In the writer’s opinion, Visio allows greater flexibility and neatness (straighter lines), compared to Power Point (Figure 1), when constructing the FAST diagram. Visio can easily produce a very professional looking diagram. However, Visio is a powerful flow charting tool that is expensive and may not be as common of a software program available to highway department employees on VE studies. If Visio is available, it’s a great tool for FAST diagramming. Power Point seems to be more readily available, and also produces a good diagram rather easily. Power Point can be a bit clumsy in inserting straight lines between boxes, using Power Point’s draw tool.

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FAST Diagram: Arches National Park Roadway Improvements

Figure 3 – FAST Diagram for Arches National Park Roadway Improvements. This FAST diagram (Figure 3) for Arches National Park Roadway Improvements describes a project that is much smaller in dollar volume compared to the Chicago project depicted in Figures 1 and 2. This VE study was staffed entirely with FHWA Central Federal Lands Highway Division (CFLHD) technical staff. A CVS Coach (the writer of this paper) served as overall coach of several concurrent studies staffed by FHWA-CFLHD teams. This FAST diagram was constructed using Power Point. The Arches FAST diagram illustrates several Basic Functions (green boxes), this time without a listing of major components as headings. “Rehabilitate Road,” why? In order to “Improve Pavement,” why? In order to “Support Vehicles – Buses and Autos,” why? In order to satisfy the higher order functions of “Access Park” and “Improve Recreational Opportunities.” A second critical functional path can be seen in this diagram: “Improve Pavement,” why? In order to “Carry Traffic” and when you do that you “Widen Road,” why? In order to “Accommodate Visitors,” why? In order to satisfy the higher order functions.

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The Basic Function “Improve Pavement” is worthy of note in this study. The VE team, through the Information Phase, understood that an increasing level of buses is being used at this National Park in order to transport visitors to several scenic overlooks along the route. The wheel loads from the buses are much greater compared to wheel loads from automobiles. As a result, the pavement is deteriorating rapidly, due to the increased forces transferring through the pavement, particularly at the scenic overlooks where buses decelerate, stop, and accelerate, in order to load and unload visitors. The pavement design in the current project is being strengthened in order to “Improve Pavement” and “Support Vehicles – buses and autos,” and thus to support the Higher Order functions of “Access Park” and “Improve Recreational Opportunities.” In this FAST diagram numerous Secondary Functions (yellow boxes) are illustrated. The VE team thought that when the Basic Function of “Improve Pavement” occurs, then other Secondary Functions would occur, including: “Improve Structural Section,” “Stabilize Base,” “Prevent Rutting,” and “Improve Drainage.” To the right of the right scope line are additional Secondary Functions, including: “Construct Project,” “Stage Construction,” “Permit Project,” “Design Project,” and “Determine Optimal Design.” These Secondary Functions address the “How” answer as to how the Basic Functions and other Secondary Functions of the project (functions illustrated between the scope lines) will be implemented.

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FAST Diagram: US-89, Thayne-Alpine Junction (Etna North), SW Wyoming, Star Valley, near Jackson

Figure 4 – FAST Diagram for US-89, Thayne-Alpine Junction (Etna North), SW Wyoming, Star Valley, near Jackson, WY. This FAST Diagram (Figure 4) for a US-89 improvement project near Jackson, Wyoming depicts a project that will widen an existing 2-lane highway, into a 5-lane section. The new section will provide 2 lanes in each direction, with a center lane allowing left turns onto numerous residential driveways and small arterials intersecting the highway. In this case the VE team broke down the project into the following components for functional analysis, depicted on the FAST diagram: • • • • •

Highway Mainline Dedicated Lanes Median (Center) Lane Outside Shoulders Drainage and Erosion Control

The Basic Functions describing each of the essential components listed above allowed the VE team to fully understand the purpose and need of the components including the unique median

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in this case. The median serves to not only divide opposing traffic along the highway, but to allow vehicles to accelerate and decelerate while making left turns off of the highway into driveways and other minor intersecting arterial streets. The median also provides for vehicles turning left out of properties along the highway to merge with high speed traffic on the highway. The VE team quickly understood that due to limited space, topography, and cost, that frontage roads leading to controlled highway access points would not be an option in this area. Generation of the Basic Functions helped the VE team quickly understand that the widened highway will allow peak traffic during winter ski season and summer recreational access to access resort and scenic areas sooner, and allow quicker access to and from the employment center in the valley down the road from the ski resort, thus having a beneficial effect on tourism and the overall economy for the state of Wyoming. The Basic Functions shown on the FAST diagram support the Higher Order functions to the left of the scope line. In this case the VE team decided that “Transport People” and “Transport Goods” are Higher Order instead of Basic Functions. However, these functions still support other Higher Order “Societal” functions including: “Link Destinations” (the ski resort up the hill), “Access Employment Center” (the ski resort with the rural employment center approximately 30 miles below in the valley), and “Promote Economy” (meaning maintain and increase a local employment base). Although the VE study for the project depicted in Figure 4 was held at final design (not an ideal time to implement a VE study) the DOT still accepted several hundred thousand dollars in VE cost saving proposals, which more than paid for the cost of the VE study and resulted in “Value” from the perspective of the DOT.

Lists of Common Functions Several important distinctions regarding Higher Order, Basic, Secondary, and All-The-Time Functions are described as follows. Higher Order Functions: These are the societal reasons of “Why” a project is being done. They appear to the left of the left scope line of a FAST diagram. The reasons “How” the Higher Order Functions are satisfied are addressed by the Basic and Secondary Functions, depicted to the right, between the scope lines. Basic Functions: These identify the primary reasons of How and Why a project is being done. They appear between the scope lines of a FAST diagram. These are the functions that the design team should be addressing in the project’s design, and which the VE team may have some influence over in terms of finding other economical ways of satisfying those functions within the context of alternative design approaches. Secondary Functions: These are secondary, but very necessary functions that support the Basic Functions of a project. For example, a common secondary function “Collect Stormwater” is not the reason that a highway project is undertaken. The functions of “Transport People” and “Transport Goods” are typical Basic Functions of why a highway project is undertaken. “Collect Stormwater” is a necessary, but secondary function in support of these Basic Functions.

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A VE team should strive to address less expensive ways of solving both basic and secondary functions. Cost-to-Worth ratios (not the immediate subject of this paper) are used in the VE process to identify functions devoting what may be too much money to satisfy the function. Often such functions can be satisfied at a lower cost, and thus become targets during brainstorming. For example, on one recent highway VE study, the drainage engineer on the study felt that another valid method of calculating flow through existing culverts under the highway would show that the supplemental culverts would not be necessary in order to prevent over-topping of the rural highway in a 50 year storm event. This VE proposal was accepted resulting in nearly $1 million in cost savings. The highway department and its engineers are confident that the function “Drain Stormwater” will be fully satisfied with the acceptance of the VE proposal, and that the roadway will not be over-topped with water during anything less than a 50-year storm event. On another recent highway VE study, the construction engineering VE team member from the highway department explored a different phasing method for bridge widening that would keep two lanes of traffic operational during construction, but would not require a temporary bridge to be constructed adjacent to the permanent bridge. This VE proposal is anticipated to be accepted for an approximate savings of $1 million. The function of “Maintain Traffic” will still be fully satisfied, but for $1 million less than it would otherwise cost. All-The-Time Functions: These include “Improve Safety,” “Protect Workers,” “Reduce Maintenance Cost,” “Maintain Traffic.” All-The-Time Functions are commonly shown in a box labeled as such at the top of a FAST diagram. They describe functions that must be addressed all the way through a project’s design and execution. All-The-Time Functions can be linked, but typically are not linked in terms of their “How-Why” relationships with other functions.

Tools for FAST Diagramming One common tool for FAST diagramming that requires the least level of technology is with the use of yellow stickies and a wall or white board. After the functional analysis phase during which time the VE team identifies the functions, those functions are written on yellow stickies, typically with black felt markers for legibility. The yellow stickies are then arranged on the wall or white board by the VE team members who work and re-work, the diagram until the functional relationships are understood and validated. The diagram is photographed, then translated later into electronic format using software preferred by the writer or technical editor. Another tool is for the VE Facilitator or Recorder to project their laptop’s image on a screen or wall, for all VE team members to be able to focus on as notes are typed using Word software. As the VE team brainstorms functions for each component of the project, the VE Facilitator or Recorder are typing them in as fast as they are stated. Then each function is identified through group discussion as either “H” for Higher Order, “B” for Basic, “S” for Secondary, or “A” for All-the-Time.” The VE Facilitator then guides the VE team through construction of the FAST diagram on the live image display, using Power Point or Visio. Functions are placed on the diagram, then arranged according to their “How-“Why” relationships, until the diagram is complete. As stated previously, it is not necessary to place every function on the diagram, but it is important

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to make sure the logical ties between the functions work. Sometimes new functions are discussed and documented during construction of the FAST diagram, in which case these new functions are also added to the initial list in Word.

Typical Functions for Highway Projects Typical functions for highway projects generated on studies facilitated by the writer are identified below. Most often the VE teams who have generated these functions were comprised of team members from the highway department as well as several consultant team members. Higher Order Functions (the reasons “Why” a highway project is being done, but not within the scope lines): –

Promote Economy

–

Access Employment

–

Create Jobs

–

Generate Revenue

–

Improve Livability

–

Encourage Development

Basic Functions of a Highway Project –

Transport People

–

Transport Goods

–

Reduce Congestion

–

Reduce Travel Time

–

Link Communities

–

Link Airport

Basic Functions of an Interchange –

Free Flow Traffic Movement

–

Connect Interstates

–

Change Travel Direction

–

Manage Traffic Flow

–

Access Community

Basic Functions of Dedicated Lanes –

Accommodate High Speed

–

Pass Slower Vehicles

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–

Accommodate Varying Speed

–

Separate Traffic

–

GuideTraffic

–

Delineate Lanes

Basic Functions of a Median/Center Lane –

Accommodate Left Turn Movements

–

Decelerate Safely

–

Facilitate Access

Basic Functions of an Outside Shoulder –

Change Tire

–

Decelerate Safely

–

Warn Vehicles (Rumble Strips)

–

Emergency Pullout

Basic or Secondary Functions of Drainage and Erosion Control –

Dry Base

–

Shed Water

–

Extend Pavement Life

–

Collect Stormwater

–

Treat Stormwater

–

Prevent Flooding (of Roadway)

Secondary or Lower Order/Minor Functions –

Construct Project

–

Plan Project

–

Obtain Approvals (Environmental, Permits)

–

Design Project

All-the-Time Functions –

Improve Safety

–

Enable Emergency Access

–

Remain within ROW

–

Meet Roadway Standards

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–

Comply with Environmental Requirements

Summary: FAST Diagramming Tips Stay at an Appropriate Level of Abstraction –

A FAST diagram for a major program at conceptual design will be at a higher level of abstraction than a FAST diagram of a smaller highway project at mid design.

–

Prepare separate FAST diagrams at varying levels of abstraction on project components, such as Drainage – but this is not typically done.

Numbers of Functions to Show on a FAST Diagram –

Include an appropriate number of functions that answer the “How-Why” relationships.

–

Don’t try and place too many functions on the FAST Diagram.

–

All of the functions generated can be listed in the VE report, with representative ones shown on the FAST diagram.

–

It’s okay to include a statement in the diagram that says “Refer to the VE Report for additional Basic and Secondary Functions.”

Techniques During the Study –

Start by asking team to generate functions for the overall project  Type them in Word as they are stated by the VE team

–

Generate additional functions for the major components of the project  Interchange; Mainline; Earthwork; Bridges; Drainage; Right-of-Way

–

Generate “Higher Order” functions for why the project is being done

–

Go back and add acronyms next to each function, in parentheses  H = Higher Order; B = Basic; S = Secondary; A = All the Time

Time to Allow for FAST Diagramming –

Budget 2 to 4 hours in a typical 40-hour study for Function Analysis and FAST Diagramming.

–

Stay within your time budget; you’ll need to preserve time for the development phase.

–

You should be able to complete Functional Analysis (generating functions) during this time, and starting on the FAST diagram.

–

If FAST diagram is not completed, have a smaller group work on it during lunch and/or evening hours, and present it back to the group.

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–

Refine the diagram as necessary based on the VE team’s input.

FAST Diagramming Techniques –

Yellow stickies with functions noted, arranged on a wall (old school), then photographed and transferred to a software program by an editor.

–

Project FAST diagram on screen from your laptop, using Power Point or Visio, and arrange the boxes as you discuss with VE team.  Need to be fast on the PC to do this.

Speaker Biography: Paul Johnson, CVS-Life; CH2M HILL; [email protected]; (208) 3836299 Paul Johnson is a Certified Value Specialist, CVS-Life, and has been a member of SAVE – The Value Society since 1987. For the last 25 years he has been employed with CH2M HILL, having led approximately 225 VE studies on transportation, public buildings, water and wastewater facilities, military facilities, environmental, and educational facility projects throughout the United States and Canada.

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