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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 RealityCindy RichartzAbbott for CII Do It Right The First Time Research Team CPI Conference Austin, Texas September 12, 2005
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)
Leadership in Safety… Commitment To Zero Field Rework Let’s Bridge the Gap in Field Rework.
From the research team’s interviews: “Without leadership, quality is nobody’s job…”
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
Field Rework Safety
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
The focus of our research was… Design Errors Field Rework Design Omissions Scope Creep
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
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
Opportunity: Leadership Key Findings: Education and Training Safety: three hours per month Rework: 30 minutes per month Implement Quality Based Training
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
Opportunity: Leadership Key Findings: Staffing Levels Per Project Safety: 4.0 Full Time Equivalent (FTE) Quality: 2.4 FTE Staff For Quality
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 Primarily Focused on PEOPLE • Leadership by example • Sufficient/capable resources • Employee involvement • Communications • Teamwork • Documentation • Absence of shortcuts • Auditing
Opportunity: Leadership The Do It Right The First Time Implementation Session How Is This Research Different? Key Findings Self-Assessment Checklist Q&A
Let’s talk about how WE can Make Zero Field Rework A Reality ! Sabine 3:30 - 4:30 pm 4:45 - 5:45 pm