Please comply with the Lean Construction Institute’s Usage ... · Built in Quality – Getting...
Transcript of Please comply with the Lean Construction Institute’s Usage ... · Built in Quality – Getting...
Please comply with the Lean Construction Institute’s Usage Policies and Attribution Guidelines at http://www.leanconstruction.org/usage.pdf
when using this file. Thank you.
OUTLINE
Our Approach to Built-in Quality (BiQ)–Key Points/Questions
Challenges We Have Faced–Key Points/Questions
Learning Exercise – Making the Perfect Cup of Coffee –Key Points/Questions
What is “Quality”?
Consistently producing a product (outcome) that meets the Customers’ expectations and is fit for the purpose intended.
Purpose of BiQ –
• Information• Access/Space• Prior Work
(handoffs)• External
Approvals
•Material•Equipment/Tools•Methods/Skills•Labor
Provide Worker Everything Needed to Succeed:
Layout
Identify Operations, Break Into Tasks
OrderMaterial
BottomTrack
TopTrack
Install Studs
Frame Interior Full-Height Walls
Expectations
DesignOperations Results
Reject
Perform Work Inspect
BiQQA/QC
Customerso Traditionalo Externalo Internal
Conditions of Satisfaction Sources
o Documentedo Undocumented
Product Checklist
Step 1 - Expectations
Expectations
DesignOperations Results
Reject
Perform Work Inspect
BiQQA/QC
Past Failures Possible Counter Measures
o Poke Yoke/Error Proofingo Verification/“Testing”
Produce Standard Work Design Training Program Design Audit Program
Step 2 – Design Operations
Expectations
DesignOperations Results
Reject
Perform Work Inspect
BiQQA/QC
First Run Study “Game Tape” Process Audit (process) Inspect (product) Reflect & Adjust
Step 3 – Perform Work & Learn
Identify Customers For Product (User, A&E, IOR, Trade)
Customer(s) Confirm Product COS Performer Confirm w/ Customer(s)
Intellectual Understanding of Product COS
Performer Explore Product COS Options to Improve Production Ability
Customer(s) and Performer Revise or Confirm Product COS
Performer Develop Product Quality Checklist
Customer(s) Confirm that Checklist Expresses Product COS
Customer(s) Identify Past Failures Performer Identify Internal Past
Failures Performer Design Process to
Produce Product COS Performer Confirm Process
Counter-measures Address Past Failures
Performer Physically Test Process to Evaluate if Produces Product that meets COS
Customer(s) Confirm That Physical Test Satisfies COS
Performer Adjust Process Based Upon Test Results
Performer Develop “Mistake Proof” Devices or process to Assure Process/Product Quality
Performer Develop Process Checklist including essential features/past failures
Performer Develop Visual Controls for “Complete”
Performer Develop Assessment Protocols (Self, Foreman, Boldt, Next Trade, A/E, IOR)
Performer Develop Mistake Reporting System for Process & Product to PDCA
Performer Develop Swarm Response to Product Failure (Who + What, Fix-it, 5Y-it, Adjust Process, Notify)
Performer Develop Training For Foreman & Labor to Assure Understanding of Product & Process COS
First Run Study/Mock-up to Field Test
Identify variance, take action to correct
Product Process Control
IMPLEMENTATION
Lesson 1: If the work scope seems easy it does not mean that doing a BiQ is quick and easy!
IMPLEMENTATION
Lesson 3: You are responsible for finishing BiQ, printing it and checking that it’s used.
Implementation
Challenges– I know how to build it, this was approved before, I do this all
the time.– Knowledge is king
Successes– Actual field use– Learn from challenges, and pay it forward
Learnings– Trust, Paradigm shift, Why – The more knowledge the collective team has, improves
results
Develop a BiQ for that Perfect Cup
Roles– Facilitator– Coffee Drinker– Material Supplier (consumables)– Equipment Supplier (durables)– Coffee Production Team
Tools– Process Map– BiQ Worksheets– BiQ Development Checklist– Coaches
Layout
Identify Operations, Break Into Tasks
OrderMaterial
BottomTrack
TopTrack
Install Studs
Frame Interior Full-Height Walls
Customers• Traditional• External• Internal
Conditions of Satisfaction
Sources• Documented• Undocumented
Product Checklist
Past Failures Possible Counter Measures Poke Yoke/Error Proofing• Verification/
“Testing” Produce Standard
Work Design Training
Program Design Audit
Program
First Run Study “Game Tape”
Process Audit (process) Inspect (product) Reflect & Adjust
Expectations Process Control