Design Quality Control: Lessons From The New NY Bridge – Tappan Zee Hudson River Crossing

1. Design Quality Control: Lessons From The New NY Bridge – Tappan Zee Hudson River Crossing Presented by: Dan Domalik, PE, CMQ/OE, CQA HDR Engineering 2014 Ohio Transportation Engineering ConferenceSession 17 October 28, 2014

2. Design-Build Team

3. Design Quality Control: Lessons From The New NY Bridge – Tappan Zee Hudson River Crossing Agenda

4. Agenda • Agenda • The Project • The Design Quality Process • Lessons Learned • Closing

5. Design Quality Control: Lessons From The New NY Bridge – Tappan Zee Hudson River Crossing The project

6. Bridge Location New NY Bridge George Washington Bridge WTC

7. Bridge LocationTarrytown – Nyack, NY • New York State Thruway • 3.1-mile crossing of Hudson River in lower Hudson Valley (25 miles north of NYC) • Traffic volume >130,000 AADT

11. Design Quality Control: Lessons From The New NY Bridge – Tappan Zee Hudson River Crossing The design quality process

12. Quality Product or Process?

13. Design Quality Organization

14. Design Quality Process

15. QC Documentation Form (QCDF) • Planning document • Defines scope of checking/reviews • The “IOU” for quality • Approved by • Responsible Professional • Design Discipline Lead • Design Manager • Design QC Manager • Used by designers, checkers, reviewers, and auditors

16. Reviews: IDR – CR - QCR

17. Quality Audit & Certification

18. Bluebeam Revu

19. ELVIS

20. Design Quality Control: Lessons From The New NY Bridge – Tappan Zee Hudson River Crossing Lessons learned

21. Train! Train! Train! • Train early, train often, train forever, train differently • Vital to train everyone effectively in QCP • Live and remote training • Track attendance • Give quiz • Removes excuses • Creates buy-in

22. Matrix Organization:Production • Area Managers are critically important • They are front line leaders and error-trappers • Driving the schedule means delivering quality on time

23. Top Management Support • Get top management to champion quality • Vocal support for quality • Enlist their help – Escalation, backup, etc.

24. Follow the Project Requirements • Meet the project requirements! • Quality = Conformance to Requirements • Don’t let your ‘better idea’ violate the contract • Know and follow the • Proposal commitments • Technical Provisions • Client Standards • Design Criteria

25. Design Quality Audits • Perform thorough audits • DQCM team audited all design packages for quality plan compliance • Closed audit required for Design Manager certification

26. Be Proactive • Don’t wait for information • PULL IT if you need it • PUSH IT if you have it • Do more ‘pushing’ of information to others • “Who would care about the change I just made?”…TELL THEM • Stay ahead of QC milestone start dates • Start QA audits before packages are complete

27. Beware Insincere “Compliance” • Bad attitude toward quality procedures is dangerous! • There are clues if you look for them • Stay focused on intent, not a coloring exercise • Intent of person and of procedure more important than coloring in the lines • Maintain goodwill towards quality procedures

28. QM Is Engaged Member of Team • Quality Manager must be an engaged member of the team • On-site presence was crucial for speed and buy-in • Auditors can be remote • QM should be part of the management team

29. Stay Close to Sub-Consultants • Subs typically do not have the same quality tools and habits as the prime • Require slightly different training & more training • DQCM provides more oversight and auditing

30. QUALITY TRUMPS SCHEDULE • Quality and Schedule can be ‘natural enemies’ if not properly planned and managed • Remember ‘Fast, Cheap, or Right…Pick Two’ • Root cause analyses have pointed to schedule pressure as an underlying cause of quality failures • “It will go out when it is right and the backup is there.” • Top management supports this message

31. QUALITY TRUMPS SCHEDULE “Yeah, but remember….the design was delivered on time and under budget!”

32. Design Quality Control: Lessons From The New NY Bridge – Tappan Zee Hudson River Crossing closing

33. Closing Thoughts on TZ Quality • Know the client and the project • Define QA/QC processes that work • Staff the job properly • Subs are people, too • Manage the risks • Provide reasonable deadlines • Provide adequate budgets • Educate the team about quality requirements • Provide tools and resources • Sweat the small stuff • Monitor continuously • Over-communicate • Audit work process and product • Measure progress • Continuously improve

34. www.newnybridge.com

35. Design Quality Control: Lessons From The New NY Bridge – Tappan Zee Hudson River Crossing Presented by: Dan Domalik, PE, CMQ/OE, CQA HDR Engineering 2014 Ohio Transportation Engineering ConferenceSession 17 October 28, 2014