Quality in Construction

QUALITY IN CONSTRUCTION
WORKS
DR. K.M. SONI
CHIEF ENGINEER, CPWD, MUMBAI

QUALITY
 MOST COMMONLY USED
 MOST DIFFICULT TO DEFINE
 PREDICTABLE DEGREE OF
UNIFORMITY, DEPENDABILITY,
AT LOW COST SUITED TO THE
MARKET (DEMING)
 FITNESS FOR USE (JURAN)
23rd October 2016 2
Quality in Construction Works -
Dr K M Soni

QUALITY
 CONFORMANCE TO
REQUIREMENTS (CROSBY)
 LOSS IMPARTED BY A
PRODUCT TO SOCIETY
(TAGUCHI)
 CORRECTING AND
PREVENTING LOSS , NOT
LIVING WITH LOSS (HOSHIN)
23rd October 2016 3
Dr K M Soni

QUALITY(ISO)
 Defined as “The totality of
characteristics of an entity that
bears on its ability to satisfy
stated and implied needs”
23rd October 2016 4
Dr K M Soni

ENTITY
 Entity may be a product, process
or even an organization
 Construction has product as well
as process
23rd October 2016 5
Dr K M Soni

STATED NEEDS
 Stated needs may be available in
the form of specifications,
conditions or bill of quantities
23rd October 2016 6
Dr K M Soni

23rd October 2016 7
Dr K M Soni

23rd October 2016 8
Dr K M Soni

23rd October 2016 9
Dr K M Soni

IMPLIED NEEDS
 Not defined
 Sometimes not even expressed
 Even may be unspoken needs
23rd October 2016 10
Dr K M Soni

Implied Needs
 Implied needs are part of the
dimensions of quality.
 The dimensions of quality for a
product and Service
Dr K M Soni

Product
 Dimensions are performance,
features, reliability, conformity to
specifications /standards,
durability, serviceability,
aesthetics and perceived quality.
Dr K M Soni

Service
 Time and timeliness service,
completeness, consistence,
courtesy, accessibility and
convenience, and responsiveness
are the dimensions of quality for
a service
Dr K M Soni

Works
 Thus for a construction work, the
dimensions of a product as well
as a service are to be considered
for a quality work. In fact, product
plays a major role during
construction and service
dimensions play a major role
during maintenance
Dr K M Soni

https://blog.codinghorror.com/the-iron-stool/
Dr K M Soni

QUALITY
 DIFFICULT TO EXPRESS
 LIKE BEAUTY
 CUSTOMER ORIENTED
Dr K M Soni

QUALITY
 Is it not achievable?
 Quality gurus do not agree to the
statement that quality is not
achievable.
Dr K M Soni

ABOUT QUALITY
(CROSBY)
 Quality is free
 quality is not: luxury,
unaffordable, intangible therefore
not measurable
 Quality is not: originated by
workers or something that
originates in the quality
department
Dr K M Soni

Basic tenets
 Quality improvement is everlasting
process
 Quality philosophy begin at the top
 QC dept. should believe in zero
defects
 Quality education and training should
be excellent
 Mgt. is patience and never ceases its
concern for quality
Dr K M Soni

Deming
 About 85% of all quality problems are
caused by harmful management
practices. It has also been stated that
consequently, CEO intent on changing
the way production workers perform –
without changing the obsolete
management system – will, at best,
address only 15% of the problems.
Dr K M Soni

Juran
 Juran, another quality guru is of
the view that senior managers
must personally take charge of
leading change related to quality.
If they try to delegate that, they
will not get good results.
Dr K M Soni

Ishikawa and Taguchi
 According to Ishikawa, a Japanese
quality guru, bad quality, meaning
wastage, had an effect not only on
business creating the waste but also
on its customers and on society as a
whole. Another Japanese quality guru,
Taguchi described quality as the loss
imparted to the society from the time a
product is shipped and quantified as
“Loss function”.
Dr K M Soni

Quality eras
 Inspections
 Quality Control
 Quality Assurance
 Total Quality Management
Dr K M Soni

Inspections
 Do not contribute greatly
to reducing the error rate
in production.
 The problem is addressed
after it has arisen.
 Thus, even 100 %
inspections will not mean
that all the defects have
been removed or rooted
out.23rd October 2016 24
Dr K M Soni

Quality Control
 “all those operational techniques and
activities that are used to fulfill requirements
for quality” (ISO). Therefore, emphasis in
quality control is on techniques and activities.
Inspections, monitoring and feedback are
carried out in quality control. It has nothing to
do directly with the customer‘s satisfaction.
Operational techniques and monitoring also
lead to “paper quality” in which the papers
assure the quality with or without any
consideration of the work.
Dr K M Soni

Quality Assurance
 “all the planned and systematic activities,
implemented within the organization for
quality management, to provide adequate
that a product or service will satisfy given
requirements for quality.” Therefore, quality
assurance is essentially a preventive activity
and is therefore to be systematically planned
in advance. The activity includes
identification and planning of the checks,
inspection and control of process as a part
of quality control.
Dr K M Soni

Quality Assurance
 Quality assurance also means
establishment of a quality system
which can demonstrate the
requirements. Unfortunately, in many
organizations, names have changed
from the quality control units to quality
assurance units without any change in
the working or strategy or even in the
attitude of the quality personnel.
Dr K M Soni

http://microjcode.com/quality-
assurance-qa/
Dr K M Soni

https://quotesgram.com/process
-quality-quotes/
Dr K M Soni

TQM
 Whole idea of quality is to reduce
error whether human, machine,
method, material or information.
This error can be caused at any
stage of management and
workers and thus, involvement of
everyone is essential in TQM.
Dr K M Soni

Concept of TQM
 Question is whether error can be
stopped and the answer is very simple
– no as it is natural to make errors.
But the errors have to be eliminated
and not at later stage but right at the
stage it is likely to occur or it has
occurred by preventing it or correcting
it as the case may be. It cannot be
passed on to other person or process.
Thus, TQM includes self inspection.
Dr K M Soni

TQM
 TQM means “Total” in
 every product,
 every process,
 every job and
 every person.
Dr K M Soni

https://www.linkedin.com/pulse/
customer-focus-tqm-paul-
weenink23rd October 2016 33
Dr K M Soni

TQM
 TQM is also a philosophy based
on the quest for progress and
continuous improvement. In
Japanese, process of continuous
improvement has been termed as
Kaizen.
Dr K M Soni

Waste Analysis
 In quality improvement, waste and total cost
must reduce. Quality improvement can only
result from planned management action.
Importance of TQM can be understood from
the statement of Crosby’s four eras of quality
as organizations adopting inspections only
say, “We don’t know why we have quality
problems” while in TQM, they say,”We know
why we don’t have quality problems”.
Dr K M Soni

https://www.pinterest.com/pin/3
68239707006749600/23rd October 2016 36
Dr K M Soni

TQM
 TEAMWORK
 PARTICIPATORY APPROACH
 CUSTOMER ORIENTED
 ZERO DEFECTS
Dr K M Soni

http://kalyan-city.blogspot.in/2012/04/how-to-
implement-total-quality.html
Dr K M Soni

TQM BELIEFS
 PEOPLE ARE UNTAPPED
RESOURCES
 PEOPLE WHO DO THE WORK
ARE IN THE BEST POSITION TO
IMPROVE ORGANIZATIONAL
PROCESS
 CONTINUAL IMPROVEMENT
Dr K M Soni

Contd.
 Values drive behaviour
 Prevention as opposed to
detection
 Organization wide involvement
and commitment
Dr K M Soni

Crosby 14 steps
 Crosby has described fourteen step
programme to achieve quality as
management commitment, quality
improvement teams, quality
measurement, cost of quality
evaluation, quality awareness,
corrective action, zero defects
planning, supervisory training, zero-
defects day, goal setting, errors cause
removal, recognition, quality councils
and ‘do it all over again’.
Dr K M Soni

Deming’s 14 Points
 create constancy of purpose, adopt new
philosophy, cease dependence on mass
inspections, end the practice of awarding
business on the price tag only, improve
constantly and forever the system of
production and service, institute training,
institute leadership, drive out fear, break
down barriers between staff areas, eliminate
slogans, exhortations, and targets for the
workforce, eliminate numerical quotas,
remove barriers to pride of workmanship,
institute a vigorous program of education
and training and take action to accomplish
the transformation.23rd October 2016 42
Dr K M Soni

QUALITY, QUANTITY AND
SPEED
 IS IT POSSIBLE TO ACHIEVE
ALL THREE?
 IT IS SAID TO OPT FOR TWO
OUT OF THREE.
 WHICH TWO?
Dr K M Soni

QUALITY Vs
Mechanization
 Mechanization is defined as the use of
machines to replace manual labour or
animals and can also refer to the use
of powered machinery to help a human
operator in some task. The use of
hand operated tools is not the part of
the mechanization but it is really a
matter of concern that even these
tools are not the part of every
construction process.
Dr K M Soni

Benefits of Mechanization
 improvement in productivity,
quality, speed, construction
technology advancement,
industrial technology
advancement, economy due to
scale of work, employment
potential etc. &
Dr K M Soni

Mechanization
 Mechanization helps in the quality of
product and in improving process
capability to improve the process to
provide a major contribution in TQM.
 Mechanization thus helps in improving
the quality by way of three reasons
which are the basic components in
civil engineering construction i.e.
labour, product (material) and process
(method of construction).
Dr K M Soni

Mechanization
 Ultimately mechanization helps in
productivity and also brings down
the cost due to reduction in poor
quality costs. It ensures the
dimensions of the quality and
thus enhances customer
satisfaction
Dr K M Soni

Continuous Improvement
 TQM is not one time concept and is
based on continuous improvement.
Hence continuous improvement is
essential in product, process, and
management.
 Education and training are very
important for continuous improvement
process.
Dr K M Soni

TQM
 Therefore, the management has to believe
first in TQM concept that the same is
possible and then make sure that education
and training is imparted to all their
employees. Early in the process, all levels of
management must be trained to implement
their part of the quality improvement
programme. Continuous improvement helps
in customer delight i.e. the state in which
customer gets more than what he expects for
satisfaction.
Dr K M Soni

Personnel in civil works
 Architects
 Engineers
 Contractors
 Accountants
 Clients
 Suppliers
Dr K M Soni

TQM
 TOTAL, QUALITY,
MANAGEMENT IN ALL
PERSONNEL INVOLVED IN A
CIVIL WORK
 IS IT POSSIBLE?
 HOW?
Dr K M Soni

QUALITY IN (T,Q,M)
 ARCHITECTS
 ENGINEERS
 CONSULTANTS
 CONTRACTORS
 QUALITY MANAGERS
 SUPPLIERS
Dr K M Soni

ACCIDENTS ARE CAUSED
BY
 UNSAFE ACT: ATTRIBUTED TO
INDIVIDUAL
 UNSAFE CONDITIONS:
ATTRIBUTED TO ENGINEERING
– ENGINEERS/MANAGEMENT
RESPONSIBILITY
Dr K M Soni

SAFETY AND QUALITY
 COMPLEMENTARY
 SAFE STRUCTURE
 SAFE MATERIALS
 SAFE CONSTRUCTION
 SAFE ENVIRONMENT
Dr K M Soni

APPROACH TOWARDS
SAFETY
 SWAMP : SAFETY WITHOUT
ANY MANAGEMENT PROCESS
(16%)
 NORM : THE NATURALLY
OCCURING REACTIVE
MANAGEMENT – RELUCTANT
COMPLIERS (77%)
 WORLD CLASS: WHERE MOST
ARE READY TO COMPLY (7%)23rd October 2016 55
Dr K M Soni

SAFETY COST
 DIRECT COST
 MEDICAL CARE
 COMPENSATION
 LOSS OF PROPERTY/EQUIPMENT
 REPLACEMENT COST
 INDIRECT COST
 LOSS OF PRODUCTION
 COST OF TIME SPENT ON
INVESTIGATION
 COST OF TIME SPENT WITH
REGULATORY AUTHORITIES23rd October 2016 56
Dr K M Soni

CONTRACT AND
QUALITY
 QUALITY IN CONTRACT
DOCUMENT
 SAFETY IN CONTRACT
DOCUMENT
 NOTHING COMES FREE” – PAY
FOR IT, ULTIMATELY IT MAY BE
REWARDING
Dr K M Soni

QUALITY IS NOT
 ABSOLUTE
 SPECIFICATIONS
 THAT CONCERNS ONLY TO
WORKERS OR ENGINEERS
Dr K M Soni

QUALITY IS
 RELATIVE TERM
 THAT SATISFIES CUSTOMER NEEDS
 STARTS FROM TOP
 PLAN, DO, CHECK, ACT CYCLE
 FUNCTION OF DURABILITY, SAFETY,
CONTRACT DOCUMENT, HRD,
MECHANIZATION
 RELATED TO QUANTITY AND SPEED
Dr K M Soni

QUALITY CANNOT BE
ACHIEVED ONLY THROUGH
 INSPECTIONS/QC/QA
 WITHOUT CONTRACTOR’
INVOLVEMENT
 STIPULATION OF MEN, MATERIAL,
METHODS, SAFETY, AND OTHER
FACTORS AFFECT QUALITY IN
CONTRACT DOCUMENT
 ACCEPTANCE OF LOWEST BID IF
BELOW MR
 HIGH WASTAGE23rd October 2016 60
Dr K M Soni

QUALITY CAN BE
ACHIVED THROUGH
 T – TOTAL INVOLVEMENT
 Q – QUALITY/CONTINUOUS
IMPROVEMENT OF SERVICE TO
CUSTOMERS, PERSONNEL AND
SYSTEM
 M – MANAGEMENT : MANAGING
THE RESOURCES WITH ZERO
WASTAGE
Dr K M Soni

THEREFORE, QUALITY
IS AN OUTCOME OF A
TEAMWORK
Dr K M Soni

QUALITY ASSURANCE
IN CPWD
 HAS A MINMUM QA PLAN FOR
ALL THE WORKS ABOVE THE
TENDERING LIMITS OF CLASS V
CONTRACTORS
Dr K M Soni

BASIC PARAMETERS
 Lot size, number of required tests and
frequency of testing defined
 Machinery and T & P required to be
deployed by the contractor at site with
a time schedule for their availability.
 Testing equipments to be arranged by
the contractor along with requirement
of setting up field laboratory.
Dr K M Soni

Contd.
 Acceptance criterion for various items
of work, materials, workmanship and
process indicating the codes,
specifications and standards
applicable.
 Shuttering schedule showing the
quantity of shuttering to be brought at
site either in one lot or at different
stages of work as per the
requirements of the work.
Dr K M Soni

Contd.
 Responsibility of the contractor to
maintain all the registers of tests
carried out at site or in outside
laboratories.
 Method of taking samples in
presence of departmental
engineers.
 Cost of samples and tests to be
borne.23rd October 2016 66
Dr K M Soni

Contd.
 Witnessing of tests to be carried
out in field lab.
 Submission of copy of the test
registers before making payments
to the contractor.
 Procedure of maintenance of
Material at Site (MAS) Register.
Dr K M Soni

Responsibility
 Field engineers
 Overall responsibility with
Superintending Engineer
Dr K M Soni

Quality management
teams
 AT CIRCLE LEVEL
 AT REGIONAL LEVEL
 AT CENTRAL LEVEL
Dr K M Soni

EMPHASIS ON
 MATERIALS
 PROCESS
Dr K M Soni

Dr K M Soni

Quality in Construction

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