Quality in Construction Works

An Introduction to QA/QC Concept and Quality Management System Based on ISO 9001:2008

Typical Slogan

“Open Challenge Quick Response”

The BIG QUESTION is: How do we meet the challenge and

achieve the benefits?

Our Only Answer

ISO TC176 Update - BIS

The Process Approach

ISO 9001

1. CUSTOMER FOCUS

2. LEADERSHIP

8 MANAGEMENT PRINCIPLES

3. INVOLVEMENT OF PEOPLE

4. PROCESS APPROACH

5. SYSTEM APPROACH

6. CONTINUAL IMPROVEMENT

7. FACTUAL APPROACH

8. MUTUAL BENEFICIAL SUPPLIER RELATIONSHIPS

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LEVEL 1 - QUALITY MANUAL

1. Quality Policy

2. Quality Objectives

3. Requirement Standard

4. Other Statutory and Regulatory Requirements

LEVEL 2 - QUALITY PROCEDURES

1. Control of Documents

2. Control of Records

3. Internal Quality Audits

4. Control of Non-conforming Products

5. Corrective Action

6. Preventive Action

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8

LEVEL 3 - QUALITY PLAN

1. Incoming Inspection Plan

2. In-Process Inspection Plan

3. Final Test Report/ Inspection Plan

4. Work Instruction

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LEVEL 4 - FORMS / FORMATS/RECORDS

1. Testing Report forms

2. Commissioning Report Forms

3. Inspection forms

4. Check Sheets/Check List

5. Miscellaneous Documentation Forms

1. Management Review

2. Competence, Training and Awareness

3. Planning and Production

4. Review of Requirement Related to Product

5. Design and Development Input

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23 MANDATORY RECORDS

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23 MANDATORY RECORDS

6. Design and Development Output

7. Design and Development Review

8. Design and Development Verification

9. Design and Development Validation

10. Control of Design and Development Changes

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23 MANDATORY RECORDS

11. Purchasing Process

12. Availability of Monitoring and Measuring Equipment

13. Preservation of Product

14. Customer Property

15. Control of Monitoring and Measuring Equipment

16. Standards used for Calibrating Monitoring and Measuring Equipment

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23 MANDATORY RECORDS

17. Identify and Enable Calibration

18. Result of Calibration and Verification

19. Internal Audit

20. Monitoring and Measurement of Product

21. Control of Non-conforming Product

22. Corrective Action

23. Preventive Action

Applying Quality Management System (ISO 9001) in Construction Works

QA/QC Concepts

• Quality Assurance Quality Assurance (or QA) covers all activities from design, development, production, installation, servicing and documentation.

QA/QC Concepts

• Quality Control Quality control refers to the process,

– most often implemented in manufacturing,

– monitoring the quality of finished products through statistical measures and

– an overall corporate commitment to producing defect-free products.

QA/QC Concepts

• Organizational Level.

At the organizational level, QA activities ensure that the program or organization is successful by overseeing the system implementation necessary for individual projects in the program, and making sure activities have the resources they need to be successful.

• Project Level (Design, Estimate and Initiation)

At the project level, QA activities support the success of an individual project by ensuring that accurate information is channeled to the right people at the right time so that decisions can be made during project implementation.

QA/QC Concepts

QA/QC Concepts

• Technical Level. At the technical level, QA activities ensure that the individual technical activities that generate, process, or synthesize data (or other information) for the decision process are performing within accepted limits.

ISO 9001:2008 QUALITY MANAGEMENT

SYSTEM IS QUALITY ASSURANCE

Roles of QA/QC Department

1. Verify that requirements are followed,

2. Verify that controlling and checking an activity have been done,

3. Ensure that approved working methods are established,

4. Evaluate the reported principal causes of non-conformances;

5. Evaluate the effectiveness of corrective action, and

6. Determine where improvements are required

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Quality Control

Role of Quality Controller includes:

1. monitoring,

2. Inspection,

3. reduction of variation,

4. elimination of known causes, and

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Quality Assurance Quality Control

A systematic set of activities to provide confidence that requirements are established

The process by which quality is compared with applicable standards;

An activity that establishes and evaluates the processes

An activity which verifies if the product meets pre-defined standards.

Helps establish processes. Implements the process.

Difference in responsibilities

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Quality Assurance Quality Control

Sets up measurements programs to evaluate processes.

Verifies if specific attribute(s) are in a specific product or service specific product or service

Identifies weaknesses in processes and improves them.

Identifies defects for the primary purpose of correcting the defects.

Prevents the introduction of issues or defects

Detects, reports and corrects defects

Difference in responsibilities

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Difference in responsibilities

Quality Assurance Quality Control Evaluates whether quality control is working for the purpose of determining weakness in the process.

Evaluates if the application is working for the purpose of determining defect in the functionalities.

Improves the process that is applied to multiple products.

Improves the development of a specific product or service.

QA personnel should not perform quality control unless doing it to validate quality control is working.

QC personnel may perform quality assurance tasks if and when required.

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The Organization

President

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QA/QC Manager

QA/QC Officer

Engineering Manager

Project Manager

Quality Controllers

(Project Engineers)

Auditors

Vice President

FUNCTIONS

President

Vice President

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QA/QC Officer Project Manager

Quality Controllers

(Project Engineers)

Auditors

Quality Activities Function

Construction Work Function

CONSTRUCTION WORK FUNCTIONS

President

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Project Manager QA/QC Site

Vice President

Subcontractors

CAD

Project Engineers

(Site Supervision)

QUALITY WORK FUNCTIONS

President

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QA/QC Site Manager

Project Engineers

(Quality Control)

Project Site Manager

Vice President

Subcontractors

CAD

As Applied to HOYA Project

As Applied to HOYA Project

As Applied to HOYA Project

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Quality Management Objectives

zero defect (no defects on project hand-over)

identify and solve problems before customer does

establish true quality control by making quality “built in” and not “inspected in”.

Why do we do this?

• For better efficiency,

• Fewer rejects,

• Reduce if not eliminate customer complaints,

• Improve customer relation

• Improve supplier relation.

• And to answer our slogan: – Open Challenge Quick Response

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CUSTOMER COMPLAINTS

Piping work related problem

28%

Ducting work related Problem

20% Equipment /Materials Related Problem

23%

Problem 4

15%

Problem 5

8%

Problem 6

4%

Problem 7

1.4%

Problem 8

0.6%

(Est. Repair Cost: Ph P 1.7M in Laguna Area)

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Cost of Quality

KEY: ADDED COSTS

Lost Revenue Dumping Costs Future Costs (Reclaim/ Environment)

Transport

Unload Container, Bags, Trucks etc Testing

Paperwork/Database

Future repercussions Root Cause Investigation Repairs B & C

Non-Conforming QA HOLD SCRAP B & C B & C

C REPAIR

C Quality Check

C Conforming

C Install

C C To Customer Conforming

A Non-Conforming

A QA HOLD

A STORAGE

A SCRAP

A Order Placed

A Order Made

A Delivery

B Replacement

Order

B Order Made

B Delivery

B Conforming

B Install

B B To Customer Field Testing

B Conforming

NORMAL COSTS

ADDED COSTS

Lost Revenue Dumping Costs Future Costs (Reclaim/Environment)

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Reflection

Preventing mistakes is much more time and cost-effective than correcting them.

Action Reflections

“Failure to prepare is

preparing to fail”

“Failure to plan is planning to fail”

End Of Presentation

Prepared by: Sid Calayag

Reference:

• Quality Management System

• ISO 9001:2008