A New Quality Program for the Water Industry AWWA AFC 17 Alternative title slide October 2017

Project Management Triangle – Capital Projects Not enough time spent talking about quality at expense of cost/schedule. DBB, get what you get. Not good enough. No standard. Best water projects are ones you don’t hear about Easier to describe what quality ISN’T But in most cases, we advertise a project when the quality is there Some industries are good at quality NRC – Reg driven Manufacturing – profit driven What drives us? We do some quality things well Construction – specs refer to standards Engineering – not clear

“Quality” Quotes from Recent SOQs “QA/QC is embodied in all aspects of our work and is a key part of our firm’s culture. We pride ourselves on our consistently high quality of service and our deliverable products and we believe this is the result of the quality culture we cultivate in our employees and the process we employ on our work.” “[We] use an established quality assurance (QA) function and client collaboration strategy in developing a design quality control plan … that ensures the final design deliverable meets and is traceable to client requirements, provides evidence of thorough technical reviews, tracks all design changes, and supplies all appropriate information for purchasing and production.” “QA/QC pervades every activity of our planning, design, and construction/ commissioning specialists, and impresses itself in all aspects of our work.” “[We] have provided engineering services to Metropolitan for more than 25 years, and we have develop a complete understanding of your requirements and standards when it comes to quality management. In fact, some of the practices and methods [we] have incorporated into our firm’s overall QMP were adopted from work done on prior Metropolitan projects.”

Why a Quality Program? Demand for better work We always talk about quality, but loosely defined QA/QC now means “check” Consequences of quality deficiencies In-house design – schedule impacts Consultant deficient quality – cost impacts Give work product same level of attention as cost and schedule Goal: Improve quality of work by standardizing the process and establishing accountability.

Quality Program - Objectives Establish measures that provide confidence that Engineering staff and consultants work will meet requirements Define quality roles Specify who checks and approves Create requirements for in-house as well as consultant quality programs Describe the “defense-in-depth” approach to achieving quality Put administrative structure in place to support the program Minimize changes to existing MWD practices Apply same rules to in-house staff as consultants Establish ACCOUNTABILITY

Foundation for Metropolitan Quality Program Professional Engineers Act MWD Operating Policies MWD Administrative Code Industry practice Established programs (NRC, ISO) Current MWD practices

Quality Programs – Minimum Requirements Identify documents within scope of QP Define roles Define review and approval requirements Reviewers qualifications subject to approval All milestone review comments shall be resolved Define resolution ladder At least one reviewer different from originator Single-approver “duly representing the organization” (NOT client manager or PM) Program administration defined

Applies to Some Docs – Not All Facility Plans & Specs Plans for MWD Force Construction Engineering Reports Engineering Calculations Contractor Submittals Record Drawings (sort of) Engineering-related Permits Applications Equipment Procurement Documents Design Changes During Construction Specification Addenda

Quality Programs – Minimum Requirements Identify documents within scope of QP Define roles Define review and approval requirements Reviewers qualifications subject to approval All milestone review comments shall be resolved Define resolution ladder At least one reviewer different from originator Single-approver “duly representing the organization” (NOT client manager or PM) Program administration defined

Quality Roles for Project Staff Engineer (Originator) Designer Engineering Checker CAD Checker Professional Engineer Technical Reviewer Project Manager Design Manager Design Team Manager PM Team Manager Other Key Project Participants Customer ESG Approver Quality Engineer TCT Manager Chief Engineer

Quality Role - Originators The origination of design is the first step in delivering a quality product Engineer Develops the design approach that meets the technical objectives of the facility May develop supporting calculations, equipment sizing, layouts, and operational parameters Coordinates the design with other disciplines

Quality Role – Technical Reviewers Engineering Checker – In-house Design Assigned by the 1st level manager: ‘Highlighter check’ concept Performs a verification of numerical parameters, dimensions, calculations, input data, material selection, etc. Checks validity of assumptions made in calculations Performs coordination checks to ensure consistency from sheet to sheet and across disciplines Limited engineering check of consultant designs

Quality Role – Project Management Review Project Manager Reviews technical scope Assures that document meets the needs of the customer and other project stakeholders Confirms that a review and comment process was defined and accomplished Recommends consultant designs for approval by Metropolitan management

Quality Role – Professional Engineer Professional Engineer - Maintains responsible charge of the work As defined in the Act, the term "responsible charge" directly relates to the extent of control the PE maintains The extent of control may be achieved by making, reviewing or approving engineering decisions such as selection of: Engineering alternatives Design standards Methods or materials Decisions related to the preparation of engineering plans, specifications, or calculations

Quality Role – Approver Approver -Verifies that documents are prepared within policies, procedures and guidelines; and conforms with the Quality Program Acts as the ‘agent of [Metropolitan]’ Confirms that the document meets institutional needs and is acceptable to proceed to the next step Relies on the recommendations of other QP/project participants and reviewers, but is ultimately accountable for document

Quality Programs – Minimum Requirements Identify documents within scope of QP Define roles Define review and approval requirements Reviewers qualifications subject to approval All milestone review comments shall be resolved Define resolution ladder At least one reviewer different from originator Single-approver “duly representing the organization” (NOT client manager or PM) Program administration defined

Design Review & Approval Matrix

Quality Programs – Minimum Requirements Identify documents within scope of QP Define roles Define review and approval requirements Reviewers qualifications subject to approval All milestone review comments shall be resolved Define resolution ladder At least one reviewer different from originator Single-approver “duly representing the organization” (NOT client manager or PM) Program administration defined Quality program formalized Quality office established

Quality Program Administration QP Oversight Engineering records retention Audits Corrective actions Quality concerns

Quality Office QO staff administers the Quality Program Quality Engineer Develops and oversees the Quality Program Facilitates integration of the Quality Program into the design process Facilitates resolution of quality concerns, if requested Reviews consultant's quality program Provides Quality Program training Conducts audits to monitor compliance with the Quality Program

Quality Program Results (hopefully) Ultimately will add “Quality of Work” section to consulting agreements: If consultant found to not meet their own program, will rectify at their own expense Submit draft program along with SOQ or proposal Create a “culture of quality” at MWD and in the industry Reduce cost and schedule by minimizing rework and change orders Turn over better-performing, longer-lasting facilities to operations

Quality Program – Design Phase Customer Goals Industry codes & regs. Prior studies ESG Standards Design criteria Staff assignments ~ Design Origination

Comment Resolution Process Design Review & Comments Process Mandatory reviewers (Document Review Matrix) Supplemental reviewers (specified by project Approver) Only review requirement – ALL COMMENTS MUST BE RESOLVED Does not mandate intermediate reviews (i.e. 30/60/90) Review & Comment Resolution Process Comments Resolved Comment Resolution Ladder No Yes ~ ~

Comment Resolution Ladder 1st-Level Manager/PE Intermediate Manager Designing Engineer Commenter Chief Engineer

Document Approval ~ Document Approval Next Steps Single approver Engineering Document Approval Sheet Technical approval Institutional approval Engr. report Final design Bid document Procurement docs DF construction

Quality Program - Design Phase Consultant Design Consultant’s Origination & Design Review MWD Engineering & CAD Reviews Consultant Quality Program Evaluate review findings Approve Next Steps Conformance with objectives Conformance with scope Conformance with design criteria Check design approach Sample detailed check MWD staff CAD, engineers, supplemental reviewers as requested by Approver  DM, PM recommend the design

Testing and Acceptance Quality Program - Construction Phase Construct Facilities and Install Equipment Testing and Acceptance Procure Construction Materials and Fabricate Equipment ‘Defense in Depth’ approach to construction quality

Procure Construction Materials and Fabricate Equipment Contractor Submittals MWD Review Equipment Fabrication, Materials Procurement Shop Testing Delivery to Jobsite Vendor QA plan MWD shop inspection Material CERTS Equipment and materials ID Spec requirements Vendor data Test equip. calib. Test procedures Test reports Packing & shipping Site handing instructions Site storage instructions Installation instructions

Construct Facilities and Install Equipment Job Site Handling Construct Facilities and Install Equipment ~ Receipt inspection (Contractor & MWD) Onsite storage Isolation of non- conforming items Contractor inspections MWD inspections Control of special processes Material testing (e.g., concrete samples) Installation instructions

Testing and Acceptance Component Tests System Functional tests Facility Acceptance ~ Calibration of test equipment Test procedures Test Reports Close out punch list Turnover of construction records Turnover of as-built markups Spare parts Training O&M Manuals

Post Construction Phase Develop Record Drawings Send Project Documents to Storage Corrective Action Follow-through ~