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Making Zero Field Rework A Reality Cindy Richartz Abbott . for CII Do It Right The First Time Research Team CPI Conference Austin, Texas September 12, 2005. Accidents Will Happen…. Industry*. CII. * OSHA Construction Division, SIC 15-17 Reflects OSHA Reporting Change.

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making zero field rework a reality cindy richartz abbott

Making Zero Field Rework A RealityCindy RichartzAbbott

for

CII Do It Right The First Time Research Team

CPI Conference

Austin, Texas

September 12, 2005

slide3

Industry*

CII

* OSHA Construction Division, SIC 15-17 Reflects OSHA Reporting Change

Safety Performance – TRIR

16.00

14.30

14.20

13.10

13.00

14.00

12.20

11.80

12.00

10.60

9.90

Opportunity

9.50

10.00

8.80

8.60

8.30

7.90

7.19

Total Recordable Incidence Rate

7.10

8.00

6.80

6.12

5.32

6.00

4.31

3.44

3.00

4.00

2.66

2.30

1.67

1.59

1.60

1.23

1.16

1.02

1.03

2.00

0.88

0.00

1989

1990

1991

1992

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

325

413

477

497

527

613

644

770

518

765

995

936

1,117

1,073

1,140

1,195

Year and Work Hours (MM)

slide4

Leadership in Safety…

Commitment To

Zero Field Rework

Let’s Bridge the Gap in Field Rework.

slide5

From the research team’s interviews:

“Without leadership, quality is nobody’s job…”

slide6

From the research team’s data analysis:

CII Safety

Limited data

No recent improvement

Field Rework

???

1989

1990

1991

1992

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

slide7

Field

Rework

Safety

slide8

Do It Right The First Time Research Team

Lew Coles DuPont, Chair

George Fenton Victaulic

Chris Gower GlaxoSmithKline

Paul Lee Eli Lilly and Co.

John Lucente Ontario Power Generation

Jim Nelson Bechtel

John Nowoj M.A. Mortenson Co.

Cindy Richartz Abbott

Gary Smith North Dakota State University

Steve Sumner Smithsonian Institution

slide9

The focus of our research was…

Design Errors

Field Rework

Design Omissions

Scope Creep

slide10

Research by CII Research Team 160A:

Focus on Shutdowns, Turnarounds, and Outages

Drug and

alcohol testing

Accident/incident

investigations

Evaluation,

recognition, and reward

Staffing for safety

Opportunity

“Making Zero Accidents A Reality”

Worker participation

and involvement

Orientation and

specialized training

Pre-project/pre-task

planning

Contract type

Demonstrated management

commitment

Subcontract management

slide11

Business Case

Direct Costs

Labor

Overhead

Material

Indirect Costs

Schedule impact

A/E involvement

Owner involvement

Business loss

Ongoing quality issues

Negotiated settlements

Team morale

slide12

Opportunity: Leadership

Key Findings: Education and Training

Safety: three hours per month

Rework: 30 minutes

per month

Implement Quality Based Training

slide13

Opportunity: Leadership

Key Findings: Education and Training

Refreshing craft worker knowledge

Introduce new materials or methods through field demonstrations or mock-ups

Establishing firm construction quality goals and expectations

slide14

Opportunity: Leadership

Key Findings: Staffing Levels Per Project

Safety: 4.0 Full Time Equivalent (FTE)

Quality: 2.4 FTE

Staff For Quality

slide15

Opportunity: Leadership

Key Findings: Incentives for Crafts

Safety: 14 of 22 projects

Quality: 3 of 22 projects

Craft Level Involvement

rt 203 self assessment elements
RT 203 Self-Assessment Elements

Primarily Focused on PEOPLE

  • Leadership by example
  • Sufficient/capable resources
  • Employee involvement
  • Communications
  • Teamwork
  • Documentation
  • Absence of shortcuts
  • Auditing
slide18

Opportunity: Leadership

The Do It Right The First Time Implementation Session

How Is This Research Different?

Key Findings

Self-Assessment Checklist

Q&A

slide19

Let’s talk about how WE can

Make Zero Field Rework A Reality !

Sabine

3:30 - 4:30 pm

4:45 - 5:45 pm