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RR203-11 – Making Zero Rework A Reality: A Comparison of Zero Accident Methodology to Zero Rework and Quality Management

Executive Summary:

While the construction industry has made great strides in improving its safety record over the last decade, the same cannot clearly be said regarding rework. Rework measures over the past decade have not shown any measurable improvement. Therefore, the Construction Industry Institute sponsored the “Do It Right the First Time” Research Team to investigate what can be learned from safety program implementation that might impact rework. The research identified and described the major components of a comprehensive process for management and elimination of quality-error related costs for construction sites. The focus of this project was on the implementation of error-reduction activities on the project execution level.

The research team looked at methods and techniques that have been effective in implementing safety management and in reducing accidents and lost workdays in construction. A survey that engaged respondents on safety management and quality or rework questions was developed. It found that management support and pre-project tasks for were consistent for both safety and quality activities. One difference occurs in the implementation level between planning and field execution. Most importantly, the research found that worker involvement is needed to resolve the continuing problem of rework. Specifically, the research team found that increasing training on quality issues, identifying quality rework problem areas, increasing full-time quality staff, and having field personnel analyze pre-task quality efforts all contribute to less rework.

Table of Contents:

Executive Summary

List of Figures

List of Tables

1. Introduction

1.1 Background

1.2 Value Added

1.3 Beneficiaries of the Research

1.4 Purpose

1.5 Objective and Tasks

1.6 Methodology

1.7 Limitations of the Research

2. Literature Review

2.1 Introduction

2.2 Safety Management

2.3 Rework Reduction Management Systems

2.4 Other Rework Studies

2.5 Possible Shift Needed

2.6 Education and Training for Rework Reduction

2.7 Integrated Quality and Safety Management Systems

2.8 Literature Review Summary

3. Methodology

3.1 Introduction

3.2 Survey Development

3.2.1 Demonstrated Management Commitment

3.2.2 Staffing for Safety

3.2.3 Pre-project and Pre-task Planning

3.2.4 Education

3.2.5 Worker Participation and Reward

3.2.6 Subcontract Management

3.2.7 Accident or Incident Investigations

3.2.8 Drug and Alcohol Testing

3.2.9 Contract Type

3.3 Survey Content

3.4 Survey Distribution

3.5 Follow-up Data Collection

4. Analysis

4.1 Survey Demographics

4.2 Data Classification

4.3 Demonstrated Management Commitment

4.3.1 Management Accountability

4.3.2 Standards Adoption

4.3.3 Audits by Management

4.3.4 Prequalification

4.3.5 Reporting

4.3.6 Project Goals Established

4.4 Staffing

4.4.1 Full-time Staffing and Part-time Staffing Levels

4.4.2 Functional Integration

4.4.3 Qualifications

4.4.4 Staff Reporting Hierarchy

4.5 Pre-project and Pre-task Planning

4.5.1 Site Specific Planning

4.5.2 Job Hazard Analysis

4.5.3 Risk Management and Communication

4.5.4 Pre-Task Planning

4.5.5 Constructability Review

4.6 Education and Training

4.6.1 Training Time

4.6.2 Budgets

4.6.3 Skills Based Training

4.6.4 Tool-box Talks

4.6.5 Standard Orientations

4.7 Worker Participation and Involvement

4.7.1 Stop Work

4.7.2 Behavior Based

4.7.3 Craft Level Input for Audits

4.8 Evaluation, Recognition and Rewards

4.8.1 Contract Incentives

4.8.2 Craft Incentives and Frequency

4.8.3 Discipline Process

4.9 Subcontract Management

4.9.1 Subcontractor Planning

4.9.2 Qualification

4.9.3 Subcontract Goals

4.10 Investigations and Reporting

4.10.1 Sanctions

4.10.2 Near Misses, Investigations and Reporting

4.11 Drug and Alcohol Testing

4.12 Data Analysis

4.13 Rework Reduction vs. Safety Management System

4.14 Root Cause Analysis

4.15 Contract Type

4.16 Comprehensive Processes

4.17 Summary of Data Analysis

5. Conclusions and Recommendations

5.1 Conclusions

5.1.1 Demonstrated Management Commitment

5.1.2 Staffing Levels

5.1.3 Safety Planning pre-project and pre-task

5.1.4 Education

5.1.5 Worker Participation and Reward

5.1.6 Subcontract Management

5.1.7 Accident or Incident Investigations

5.1.8 Drug and Alcohol Testing

5.2 Recommendations


Appendix A: Survey

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