Making Zero Field Rework A Reality Cindy Richartz Abbott

1
Making Zero Field Rework A RealityCindy
Richartz Abbott

• for
• CII Do It Right The First Time Research Team
• CII Annual Conference
• Grapevine, Texas
• July 20, 2005

2
Accidents Will Happen
3
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
7.10
Total Recordable Incidence Rate
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
1.03
1.02
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)
4
Leadership in Safety
Commitment To Zero Field Rework
Lets Bridge the Gap in Field Rework.
5
From the research teams interviews
Without leadership, quality is nobodys job
6
From the research teams 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
7
Field Rework
Safety
8
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
9
The focus of our research was
Design Errors
Field Rework
Design Omissions
Scope Creep
10
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
11
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
12
Opportunity Leadership
Key Findings Education and Training
Safety three hours per month
Rework 30 minutes per month
Implement Quality Based Training
13
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
14
Opportunity Leadership
Key Findings Staffing Levels Per Project
Safety 4.0 Full Time Equivalent (FTE)
Quality 2.4 FTE
Staff For Quality
15
Opportunity Leadership
Key Findings Incentives for Crafts
Safety 14 of 22 projects
Quality 3 of 22 projects
Craft Level Involvement
16
RT 203 Self-Assessment Elements
Primarily Focused on PEOPLE

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

17
             
18
Opportunity Leadership
The Do It Right The First Time Implementation
Session
How Is This Research Different?
Key Findings
Self-Assessment Checklist
QA
19
Lets talk about how WE can Make Zero Field
Rework A Reality !
Ft. Worth 5-7 430 pm-530 pm today 1100
am-1200 pm tomorrow