Assignment # 3 Construction Quality & Productivity Management
Quality Control Tools
1. Cause and Effect Diagram:
A fishbone diagram, also called a cause and effect diagram, is a visualization tool for categorizing
the potential causes of a problem in order to identify its root causes.
How to create a fishbone diagram:
Once a problem that needs to be studied further is identified, teams can take the following steps
to create the diagram:
The head of the fish is created by listing the problem in a statement format and drawing a box
around it. A horizontal arrow is then drawn across the page with an arrow pointing to the
head, this acts as the backbone of the fish.
Then at least four overarching “causes” are identified that might contribute to the problem.
Some generic categories to start with may include methods, skills, equipment, people,
materials, environment or measurements.
For each overarching cause, team members should brainstorm any supporting information
that may contribute to it. This typically involves some sort of questioning method, such as
the 5 Whys or the 4P’s (Policies, Procedures, People and Plant) to keep the conversation
focused.
This process of breaking down each cause is continued until the root causes to the problem
have been identified.
2. Check Sheet:
A check sheet is a structured, prepared form for collecting and analysing data. This is a
generic data collection and analysis tool that can be adapted for a wide variety of purposes and is
considered one of the seven basic quality tools.
Format of Check sheet:
The defining characteristic of a check sheet is that data are recorded by making marks ("checks")
on it. A typical check sheet is divided into regions, and marks made I different regions have
different significance.
Check sheets typically employ a heading that answers the Five W’s:
Who filled out the check sheet
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Assignment # 3 Construction Quality & Productivity Management
What was collected (what each check represents, an identifying batch or lot number)
Where the collection took place (facility, room, apparatus)
When the collection took place (hour, shift, day of the week)
Why the data were collected
Function of Check sheet:
Kaoru Ishikawa identified five uses for check sheets in quality control;
To check the shape of the probability distribution of a process
To quantify defects by type
To quantify defects by location
To quantify defects by cause (machine, worker)
To keep track of the completion of steps in a multistep procedure (in other words, as a
checklist
3. Control charts:
Control charts, also known as Shewhart charts (after Walter A. Shewhart) or process-behaviour
charts, are a statistical process control tool used to determine if a manufacturing or business
process is in a state of control. It is more appropriate to say that the control charts are the
graphical device for Statistical Process Monitoring (SPM).
When to use a control chart:
When controlling ongoing processes by finding and correcting problems as they occur
When predicting the expected range of outcomes from a process
When determining whether a process is stable (in statistical control)
When analysing patterns of process variation from special causes (non-routine events) or
common causes (built into the process)
When determining whether your quality improvement project should aim to prevent specific
problems or to make fundamental changes to the process
Characteristics of Control Charts:
If a single quality characteristic has been measured or computed from a sample, the control chart
shows the value of the quality characteristic versus the sample number or versus time.
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Assignment # 3 Construction Quality & Productivity Management
In general, the chart contains a center line that represents the mean value for the in-control
process. Two other horizontal lines, called the upper control limit (UCL) and the lower
control limit (LCL), are also shown on the chart.
These control limits are chosen so that almost all of the data points will fall within these
limits as long as the process remains in-control.
Control Chart Basic Procedure:
Choose the appropriate control chart for your data.
Determine the appropriate time period for collecting and plotting data.
Collect data, construct your chart and analyse the data.
Look for "out-of-control signals" on the control chart. When one is identified, mark it on the
chart and investigate the cause.
4. Data collection:
Data collection is the process of gathering and measuring information on variables of interest, in
an established systematic fashion that enables one to answer stated research questions, test
hypotheses, and evaluate outcomes. The data collection component of research is common to all
fields of study including physical and social sciences, humanities, business, etc. While methods
vary by discipline, the emphasis on ensuring accurate and honest collection remains the same.
Importance of Data collection:
Regardless of the field of study or preference for defining data (quantitative or qualitative),
accurate data collection is essential to maintaining the integrity of research. The selection of
appropriate data collection instruments (existing, modified, or newly developed) and clearly
delineated instructions for their correct use reduce the likelihood of errors. A formal data
collection process is necessary as it ensures that the data gathered are both defined and accurate.
Data integrity issues:
The main reason for maintaining data integrity is to support the observation of the errors in
data collection process. Those errors may be made intentionally or non-intentionally.
There are two approaches that may protect data integrity and secure scientific validity of
study results invented by Craddick, Crawford, Rhodes, Redican, Rukenbrod and Laws in
2003:
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Assignment # 3 Construction Quality & Productivity Management
a) Quality assurance – all actions carried out before data collection
b) Quality control – all actions carried out during and after data collection
5. Flow Chart:
Variations: macro flowchart, top-down flowchart, detailed flowchart (also called process map,
micro map, service map, or symbolic flowchart), deployment flowchart (also called down-across
or cross-functional flowchart), several-levelled flowchart. A flowchart is a picture of the separate
steps of a process in sequential order. It is a generic tool that can be adapted for a wide variety of
purposes, and can be used to describe various processes, such as a manufacturing process, an
administrative or service process, or the project plan.
When to use a Flow Chart:
To develop understanding of how a process is done
To study a process for improvement
To communicate to others how a process is done
When better communication is needed between people involved with the same process
To document a process
When planning a project
Flow Chart Basic Procedure:
Define the process to be diagrammed. Write its title at the top of the work surface.
Discuss and decide on the boundaries of your process: Where or when does the process start?
Where or when does it end? Discuss and decide on the level of detail to be included in the
diagram.
Brainstorm the activities that take place. Write each on a card or sticky note.
Arrange the activities in proper sequence.
When all activities are included and everyone agrees that the sequence is correct, draw arrows
to show the flow of the process.
Review the flowchart with others involved in the process (workers, supervisors, suppliers,
customers) to see if they agree that the process is drawn accurately.
