Making Zero Field Rework A Reality Cindy Richartz Abbott

1. Making Zero Field Rework A RealityCindy RichartzAbbott for CII Do It Right The First Time Research Team CPI Conference Austin, Texas September 12, 2005

2. Accidents Will Happen…

3. 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)

4. Leadership in Safety… Commitment To Zero Field Rework Let’s Bridge the Gap in Field Rework.

5. From the research team’s interviews: “Without leadership, quality is nobody’s job…”

6. 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

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

18. Opportunity: Leadership The Do It Right The First Time Implementation Session How Is This Research Different? Key Findings Self-Assessment Checklist Q&A

19. Let’s talk about how WE can Make Zero Field Rework A Reality ! Sabine 3:30 - 4:30 pm 4:45 - 5:45 pm