Quality control

&
quality assurance

Quality Management In Construction

BECM 4211
 Quality Control
• Feigenbaum (1991): 4 steps in quality control

1. Setting Standards: Determining the required

cost–quality, performance– quality, safety–quality,
and reliability–quality standards for the products.

2. Appraising Conformance: Comparing the

conformance of the manufactured product, or the
offered service to the standards.
3. Acting When Necessary: Correcting problems and
their causes throughout the full range of those
marketing, design, engineering, production, and
maintenance factors that influence user satisfaction.

4. Planning of Improvements: Developing a continuing

effort to improve the cost, performance, safety, and
reliability standards.
 Quality Control*
• Gryna (2001):The control process involves observing
actual performances, comparing it with some standards,
and then taking action if observed performance is
significantly different from the standard. The control
process is in the nature of a feedback loop as shown in
Figure.
Importance of QC in Construction
Management*
❑Eliminate waste
❑Save unnecessary costs
❑Reduce time in project completion
❑Improve Efficiency
❑Satisfy and meet customer’s requirements
❑Provide greater lifespan to the built facility
 Quality Control
Control involves a universal sequence of steps as follows:

• 1. Choose the control subject, that is, choose what we intend

to regulate.
• 2. Establish measurement.
• 3 Establish standard of performance, product goal, and
process goals.
• 4. Measure actual performance.
• 5. Compare actual measured performance against standards.
• 6. Take action on the difference.
 Quality Control Tools*
The following are the most commonly used quality control tools
for a variety of applications to improve the quality process:

• 1. Cause-and-effect diagram
• 2. Check sheet
• 3. Control chart
• 4. Data collection
• 5. Flow chart
• 6. Histogram
• 7. Pareto analysis
• 8. Pie chart
• 9. Run chart
• 10. Scatter diagram
• 1. The cause-and-effect diagram is also called an
Ishikawa diagram or fishbone diagram. It is used to
organize and graphically display multiple causes with
a particular effect.

• 2. A check sheet is a structured list, prepared from the

collected data, to indicate how often each item
occurs.
• 3. The control chart is the fundamental tool of
statistical process control. It is a graph used to
analyze variation in a process.

By comparing current data to historically determined

lines, one can arrive at a conclusion regarding whether
the process is stable or is being affected by special
cause of variation.
• 4. Data collection objectives are to

• Identify the problem

• Report the problem
• Verify the problem
• Analyze the problem
• Correct the problem
• 5. A flowchart is a pictorial tool that is used for
representing a process in sequential order.
Flowcharts can be applied at all stages of the project
life cycle.

• 6. The histogram is a pictorial representation of a set

of data. It is created by grouping measurements into
cells, and it displays how often the different values
occur.
• 7. Pareto analysis is a graphical representation of
frequency of occurrence.

• Pareto charts are used to identify those factors that

have the greatest cumulative effect on the system,
and thus, less significant factors can be screened out
from the process.
• 8. The pie chart is a circle divided into wedges to
depict proportion of data or information in order to
understand how they make up the whole. The
portions of entire circle or pie sum up to 100%.

• 9. The run chart is a graph plotted by showing

measurement (data) against time. Run charts are
used to know the trend or changes in the average
and also to determine if the pattern can be attributed
to common causes of variation, or if special causes of
variation were present.
• 10. The scatter diagram is a plot of one
variable versus another. It is used to
identify potential root cause of problems
and to evaluate causeand- effect
relationship.
 QC Process in Construction

• It is very important to have a good quality control process

on a project. Depending on the project or the client or
executing agent for construction the QC/QA process could
be very proscriptive.

QC – QC is ultimately just making sure that they are

completing the work safely and in compliance with the
contract.

QA – QA is spot checking contract compliance, test

results, and ultimately just making sure that the Quality
Control Processes is working.
 Best practices in QC*
🡪 Quality Control (QC) – Depends on the contract but best
practices require;

• The Construction Contract defines the quality standards

and the QC testing requirements

• The contractor must prepare a detailed quality control plan

for each definable feature of work detailing how the quality
standards will be achieved. The plan must be approved
before work can begin.

• The contract requires that the QC testing lab be validated

by the approved source.
 QC Document

Document QC activities into a Management System which

includes;

1. Non compliance Reports

2. RFIs (Request for information)
3. Change orders requests
4. Safety violations
5. Daily field reports
6. Test results
7. Permits
8. Close Documents
9. QA/QC plan - Testing program
Employs Three-Phase Inspection System

– Preparatory : Before the work starts the QC manager

conducts a meeting to go over all the approved
submittals, work plan, safety plan, etc with all parties
involved in order to make sure the feature of work is ready
to begin and makes sure everyone is on the same page.

– Initial: As the work is beginning the QC manager

conducts an inspection of the work to make sure the work
is being performed as plan. The crew is working safely
and with the correct material.

– Follow-up: Throughout the work the QC manager

conducts inspection as per contract and as required
 Construction QC Factors
• 1. Human control:
As the main activity part of construction process, the overall
quality and individual ability of human will determine the
results of all quality activities.

So, human are considered as both the controlled targets

and controlling motivation of other quality activities. (Cheng
Hu)

The contents of human control includes the overall quality of

organization and individual's knowledge, ability, physical
condition, psychological state, quality consciousness,
behavior, concept of organizational discipline, and
professional ethics.
• 2. Materials control:

Materials (including raw materials, finished products, semi-

finished products, components and parts) are material conditions
of construction, and material quality is one of necessary
conditions to ensure construction quality. (Cheng Hu)

Main contents of quality control of materials:

• (1) Material procurement

• (2) Material testing
• (3) Storage and usage
• 3. Control of construction machinery and equipments:

Construction machinery and equipments are

✔ essential facilities for the modern construction,

✔ reflecting the construction power of the enterprise, and
✔ having a direct impact on the project progress and quality.

Actually, the quality control is to make the type and performance

parameters of construction machinery and equipment match the
conditions, technology and other factors of the construction site.
(Liang Shilian)
• (1) The contractor should select construction machinery and
equipment in accordance with advanced technology, economic
rationality, production application, reliable performance and
safety, with the applicability and reliability to a specific project.

• (2) The performance parameters should be made sure

correctly in accordance with the requirements of construction
and quality assurance.

• (3) Construction machinery and equipment should be regularly

calibrated, so as not to mislead the operator. Besides,
mechanical equipment selected must be matched with the
adapting operation workers.
• 4 Control of construction methods:

• (1) Construction program should be constantly refined

and deepened with the progress of the project
construction.

• (2) When selecting the construction program, some viable

options of major projects should be prepared, presenting
main contradictions, advantages and disadvantages, so
as to discussion and comparison, then the best option will
be selected.

• (3) When developing programs for the major projects, key

parts and difficult projects, such as the new structure, new
materials, new technology, large-span, large cantilever,
the tall structure parts, and so on, the possible
construction quality problems and treatment should be
fully assessed.
• 5 Environmental control:

Creating a good environment will play an important role in

guaranteeing the quality and safety of construction projects,
achieving civilized construction, and setting social image of
construction corporation.

Control of construction environment includes not only the

understanding, restriction, transformation and usage of natural
environment, but also activities of creating working environment
and environment management. (Cheng Hu)
• The management of process quality control points
includes two aspects:

A. The design of measures of quality control

B. The implementation of quality control
 A. The design of measures of quality
control points

•  Listing the quality control points list

•  Designing construction flow chart of control points
•  Analyzing the processes to find the dominant factors
•  Setting the process quality control table, to make clear
control ranges and requirements for the dominant factors
•  Working out work instruction assuring quality
• Drawing up network diagram, marking the measuring
instruments, numbers, precision etc. in order to do
accurate measurement
•  Auditing the quality control points by the leadership of
the designers
 B. The implementation of quality control points

•  Clarification: The design of control measures of control

points should be explained clearly to the operation team,
to make workers understand operating essentials.

•  Inspection:The quality controllers must give guidance,

inspection, checking and acceptance on construction
sites.

•  Instruction: Workers should do the operation according

to working instruction, ensuring the quality of each aspect
of the operation.
•  Data collection: The construction site should be
checked seriously and regularly, and the data should be
recorded.

•  Data Analysis: The analysis and improvement

should be done constantly with the method of data
statistics until the quality control points get qualified.

•  Duties and responsibilities: of workers and quality

controllers should be clear in the implementation of quality
control points.
 The method of quality control*
• A. Quality control by statistical methods:
• The use of statistics is essential in interpreting the results of testing on
a small sample. There are two types of statistical sampling which are
commonly used for the purpose of quality control in batches of work or
materials (Quality Control and Safety During Construction):

• (1) The acceptance or rejection of a lot is based on the number of

defective (bad) or nondefective (good) items in the sample. This is
referred to as sampling by attributes.
• (2) Instead of using defective and nondefective classifications
for an item, a quantitative quality measure or the value of a
measured variable is used as a quality indicator. This testing
procedure is referred to as sampling by variables.
• B. PDCA:
• PDCA Cycle, which is composed of 4 stages of P (plan),
D (do) , C (check), A (action).
Quality Assurance

• In today’s workenvironment quality assurance is viewed as

an umbrella under which quality management activities take
place and the owner’s primary quality assurance role is one
of acceptance.Use of the term quality assurance is now
favored over the previously used abbreviation QAQC or
QCQA.
Quality Assurance*
• ISO 9000 (or BS 5750): quality assurance is
“those planned and systematic actions
necessary to provide adequate confidence that
product or service will satisfy given
requirements for quality.”
Quality Assurance
• Quality assurance is the activity of providing evidence to establish
confidence among all concerned that quality-related activities are being
performed effectively. All these planned or systematic actions are
necessary to provide adequate confidence that a product or service will
satisfy given requirements for quality.

• Quality assurance covers all activities from design, development,

production/ construction, installation, and servicing to documentation, and
also includes regulations of the quality of raw materials, assemblies,
products, and components; services related to production; and
management, production, and inspection processes.

• Quality assurance in construction projects covers all activities performed by

the design team, contractor and quality controller/auditor (supervision staff)
to meet owners’ objectives as specified and to ensure that the project/
facility is fully functional to the satisfaction of the owners/end users.
Elements of QA
The elements of an acceptable quality assurance program
include:

▪ quality control by the contractor

▪ acceptance sampling and testing and inspection
▪ independent assurance
▪ qualified personnel
▪ accredited laboratories, and
▪ a dispute resolution process.

These elements work together to ensure an effective quality

assurance program. Any elements missing from the program
increase the risk of a reduced service life.
Need For QC & QA In Construction:

•Concern for project managers. Even minor defects in

constructed facilities can cause heavy loss

•Quality control during construction consists largely of

insuring conformance to these original design and
planning decisions
ORGANIZATION FOR QC & QA
A variety of different organizations are possible for quality control
during construction.Most common practice is to have two groups:

1.for quality control.

2.for quality assurance.

• In large organization separate departments are formed.

• Specific Individuals are assigned with these functions on small

projects.

• In both the cases project manager is concerned for the work.

QUALITY CONTROL AND ASSURANCE PLAN

An inventory agency responsible for coordinating

QA/QC activities. A QA/QC plan should clarifies:

• general QC procedures
• Source category-specific QC procedures
• QA review procedures
• Reporting, documentation, and archiving procedures
 OJECTIVES OF QA PLAN*
• Describe the quality program and organization to be
implemented so that the project is constructed in
accordance with the contract requirements and
industry standards.

• Describe guidelines for inspection and documentation

of construction activities.

• Provide reasonable assurance that the completed

work will meet or exceed the requirements of the
construction drawings and specifications.
QA Testing
• The CQAO will be responsible for the QA materials
sampling and testing program.

• QA testing is provided for the verification of the

adequacy and effectiveness of the contractor’s QC
testing.
Quality Assurance Method Application Matrix
Quality Assurance Method Application Matrix
Why Quality Assurance Programs
fail?*
• – Starting site work without an acceptable, approved Quality
Control Plan
• – Inadequately developed Quality Control contract provisions
• – Inadequately enforced Quality Control contract provisions
• – Delay in submitting an acceptable Quality Control Plan
• – Inadequate qualifications of personnel in the quality control
organization
• – Untimely or incomplete reports
• – Failure to take corrective action when deficiencies exist
• – Late or incomplete reporting of tests and inspections
• – Lack of interest by contractors or management personnel.
Quality Engineering*
• Feigenbaum (1991):

Defines quality engineering technology as “the body of

technical knowledge for formulating policy and for
analyzing and planning product quality in order to
implement and support that quality system which will
yield full customer satisfaction at minimum cost”.
Quality Engineering*
Quality Management*

The ASQ glossary defines quality management

as:
• “The application of quality management
system in managing a process to achieve
maximum customer satisfaction at the lowest
overall cost to the organization while continuing
to improve the process.”
Quality Management*
Cost of Poor Quality*
• Cost of poor quality (COPQ) is defined as the
costs associated with providing poor quality
products or services.
• In other words, it is the total financial losses
incurred by the company due to performing
incorrect things.
• For example, scrap, rework, repair, warranty
failure.
Cost of Poor Quality*
Sources:
I. Prevention Costs: Quality planning, Education and
training, Conducting design reviews etc.
II. Appraisal Costs: Test and inspection (receiving, in-
process and final), Supplier acceptance sampling,
Product Audits.
III. Internal Failure Costs: In-process scrap and
rework, Troubleshooting and repairing, Design
changes.
IV. External Failure Costs: Sales returns and
allowances, Replacing defective products, Service
level agreement penalties.
Cost of Poor Quality*
Why Cost of Poor Quality (COPQ)?

❖ COPQ tells how profit is affected by the quality.

❖ It speaks the language of management.
❖ Helps to prioritize improvement actions.
❖ Optimize the resources and also helps in
identifying wastes in the system.
❖ Improves continuous improvement culture
Graphical representation of the effect of
having cost of quality*