TOWARDS BETTER QUALITY

NILESH DESHMUKH
 VISION STATEMENT
“We believe that if projects are
engineered in such a way, that they
are delivered in time, with
progressive quality and safety
standards, ROHAN will develop
HAPPY CLIENTS”
 GOAL
To achieve ZERO DEFECTS
What is Zero defect
A tool aimed at the reduction of defects through prevention

What is it for?
It is directed at motivating people to prevent mistakes

How does it work

By developing a constant, conscious desire to do their job
right at the first time
 STEPS TO GOAL
Change in attitude
Man Make some Policy decisions
Improve Workmanship

Machine Use of machinery in correct manner

Improvise Processes and controls

Regularise Audits for feedbacks
Method Facilitate Analysis on issues
Improve documentation of all activities

Use of Good Material

Material

Money Invest in qualitative infrastructure

RESILIENCE
WHAT IS
 Conformance to requirements specified by Clients

An essential requirement of products is that they meet the

needs of those members of society who will actually use
them. This concept of fitness for use is universal…The
popular term for fitness for use is quality, and our basic
definition becomes quality means fitness for use
J.M.JURAN

Quality is the totality of features and characteristics of a

product or service that bear on its ability to satisfy stated or
implied needs
I.S.O.
CONSTRUCTION INDUSTRY FACTS
Clients who implement a robust quality management
program can reduce their error rate significantly

Clients demand that Contractors and there subcontractors

comply with the Project Specific QC requirements and a
full-time QC Manager

Only 10-15% of General Contractors have formal written

quality management program
Only 5-10% of trade subcontractors have a formal written
quality management program

CII report says- average contractor makes 10 errors out of

a 100 items
- the best contractor made 1 error out of 200 and
- the worst made 19 errors out of 100
 CONSTRUCTION DEFECTS –
SOME POSSIBLE IMPACTS TO ORGANISATION
There are 3 ways construction defects happen:
 Faulty design
 Faulty materials
 Faulty workmanship
In many cases, construction defect is a combination of these 3 causes

Time for
Rework

Cost of Rework Bad reputation

Cost of Long tail for

insurance claims

Shift in focus Cost of Repair

 QUALITY MANAGEMENT PRINCIPLES
Eight QMS Principles have been identified to be
used by top management to lead the organisation
towards improved performance
1. Customer focus
2. Leadership
3. Involvement of people
4. Process Approach
5. System Approach
6. Continual improvement
7. Factual approach to decisions
8. Mutually beneficial supplier relationships

Quality System shall be Suitable,Effective,Documented,Auditable

 Resource
planning

QUALITY
Product Management
Realisation MANAGEMENT responsibility
SYSTEM

Measurement
, Analysis,
Improvement
 Documented Work
processes via systematically
quality by
procedures following your
& quality plans procedures
PLAN DO
INPUT PROCESS OUTPUT
RECORD
Act upon
ACT CHECK
results by Verify with
implementing quality audits
CAPA and & by
conducting documenting
Management Non-
Reviews. conformances

REALIZATION OF BENIFITS
QUALITY DOCUMENTATION

Quality
System Manual

Business/Functional
Processes

Procedures, QAP, Guidelines,

Method Statements

Formats, Checklists
QUALITY MANAGEMENT TERMINOLOGY
Quality Management Program (QMP)
Formal written document that describes the QMS. Also called a Quality
Management Manual

Quality Management System (QMS)

People and processes that are in place to ensure construction meets
quality requirements

Quality Assurance (QA)

Program for the systematic monitoring and evaluation of various
aspects of project, service or facility to ensure that standards of quality
are being met. This is the process that validates the QC program is in
place and is effective

Quality Control (QC)

Set of activities, designed to ensure adequate quality, Inspections,
testing and documentation are part of QC
 Objectives of the Quality Management

To make the most efficient and effective use of the resources

Material Manpower

Method Money

Machine/
Equipment
Proper utilization of resources will result a higher productivity,
improve performance and customer satisfaction
 Essentials of Quality

Processes Policies

Procedures

Engagement for QMS

Training Openness
Trust

Inspiration
 Benefits of systematic Quality Management
Program

 Number of non-conformances will be reduced

 Number of punch-list items will be reduced
 Rework & repair costs will decrease
 Customer service survey scores will increase
 Number and severity of warranty call-backs will
be reduced
 Profitability will increase
 Cost of your insurance will be reduced
 Construction completion dates will be
maintained or improved
Quality Planning in Projects
- Deployment Plan
- Qualified manpower
Resource Planning - Calibrated Measuring instruments
- Approved raw materials
- Sufficiency and capacity of P&M

- Reference manuals
- Standard Operating Procedures
Standard references - Method statements/Guidelines
- Failure Mode Effect Analysis

- Finishing Schedule
Planning for Special - Welding Schedule
- Painting Schedule
process control - Concrete Mix Design

- Storage & preservation audit

- Construction process audit
Quality Audit Plan - Contractor performance assessment
- Quality rating
 Quality Assurance
- DCI (Document Control Index)
- Drawing issue Register
Drawing & - Controlled copies
Document Control - Identification & disposal of
SUPERSEEDED drawing

- Project specifications/ Contract

Identification of - Constructability Review
Project Specific - Quality Function Deployment
- Risk Mitigation Plan
requirement - Field Quality Assurance Plan

Training and - Identification of training needs

Workmen - Training Calendar
- On-site training/ Classroom training
Qualification
Quality control & review at site
Protocol Control Index Monitoring records w.r.t. FQAP

Site Observation To record variations in quality in

Register construction

Quality review Information of quality performance

meetings and escalation

Performance Assessment of performance of

monitoring of skilled welders, masons, vibrator
workmen operators, painters, cable jointers

For escalation of quality issues to

MIS report to HO
management
 Quality execution at site

Site Engr & Site

Store-in- Engineers
charge PROCESS
CONTROLS
• Receipt • Control points as in
Inspection Field QAP
Report(RIR/SRN) • Resolution of
• Workmen
variations through
• Material qualification ‘Site Action Request’
Deficiency • Standard formats, • Control on
Report(MDR) procedures fabrication works
• Control on Special
RECEIPT processes INSPECTION &
INSPECTION TESTING AT SITE
Site team
 Summary of interaction
1.Together we can build good quality culture.
2. It is necessary to develop the manpower and the labour contractors with trainings
3.We have to develop a group of skilled workmen which can be used departmentally
across the sites
4.We have to encourage use of improvised tools & tackles
5. ‘Being innovative’ is essential to make our organisation successful on all fronts
6.It is necessity to have standard processes in place.
7.We have to improve in maintaining records of activities
8. Start training on quality and various construction activities
9. Identify final mandatory checks in all activities at site before commencement of
next activity
10. Initiate ‘Quality observation register’ system to capture workmanship related
issues and monitor closure of them on regular basis, which will certainly help
reduction in snag list points
11.Motivate, give appreciation and recognition for good quality work at all levels.
12. Start quality induction to wokmen, labour contractors at site.
13.Start Quality audits at all sites
14. Start MD’s award for good quality work.
15.Identify ‘Best Quality conscious person’ on monthly basis at all projects.