Document Detail

Title: RS203-1 - Making Zero Rework A Reality
Publication Date: 11/1/2005
Product Type: Research Summary
Status: Supporting Product
Pages: 29
Uses the recent emphasis on zero accidents as a basis to study quality activities that can lead to zero field rework. Finds differences at the implementation level: more training, staff, and field personnel analysis of pre-task quality efforts all contribute to less rework.
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Abstract

The construction industry, led by CII members, has made great strides in improving its safety record over the last decade. The same cannot be said, however, regarding rework. Many industry participants have been claiming that rework, and “doing it right the first time,” are priorities, but the increasing rework activity on projects both large and small belies this claim.

The Construction Industry Institute formed the Do It Right the First Time Research Team to investigate field rework and find ways to improve this costly activity. The primary purpose of the research was to identify and describe the primary components of a comprehensive process for management and elimination of quality-error related costs for construction sites. While many errors and omissions occur in the scope development process and design, the focus of this project was limited to implementation of error-reduction activities on the project execution level and within the construction organization.

The research team first looked at methods and techniques that have been effective in implementing safety management and in reducing accidents and lost workdays in construction. It found that management support and pre-project tasks were consistent for both safety and quality activities. The 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 fulltime quality staff, and having field personnel analyze pre-task quality efforts all contribute to less rework.

Taking a cue from the CII research on safety, the research team now is urging the industry to take a similar look at rework. In addition to zero accidents, the industry needs an attitude of “making zero rework a reality.” If it does, the resulting low percentages of rework could pay for error reduction efforts.