Forecasting and Minimizing Field Rework Effects of Field Rework Research Team 2000 CII Annual Conference Nashville, Tennessee Jim Atkinson U.S. Steel Effects of Field Rework Research Team

Field Rework Research Team RT-153 Richard CalhounPhillips Petroleum Co., Chairman Jim AtkinsonU.S. Steel Andrew BealAir Products & Chemicals Joe BeffaBlack & Veatch Tom FalsoEichleay Francis HouseKellogg Brown & Root David RoggeOregon State University Phill StassiJacobs Engineering Group, Inc. William WrightChemtex International

RT-153 Objectives Identify methods being used to track rework.Identify methods being used to track rework. Identify the major causes of rework.Identify the major causes of rework. Identify practices that most effectively minimize field rework.Identify practices that most effectively minimize field rework. Develop a tool (Field Rework Index, FRI) that will foretell the degree of field rework.Develop a tool (Field Rework Index, FRI) that will foretell the degree of field rework.

Definition Field Rework is:Field Rework is: –Total direct cost of rework in the field regardless of initiating cause or source. Field Rework is not:Field Rework is not: –Change orders (not affecting previously installed work) –Off-site fabricator errors –Off-site modular fabrication errors

Calculation Total direct cost of rework performed in field Total field construction phase cost % Field Rework =

How BIG is the Problem? CII Survey Data CII Research Summary 10-2CII Research Summary % rework on nine industrial projects 1997 Benchmarking & Metrics Data Report1997 Benchmarking & Metrics Data Report 3.4% for 19 industrial projects CII Effects of Field Rework Research TeamCII Effects of Field Rework Research Team 5.8% for 78 industrial projects Ranges between 0% and 27%

>4% Rework  Avg 8% Cost Growth –1.5% <4% Rework  Avg –1.5% Cost Growth Cost Growth vs. Field Rework

How Is Field Rework Tracked? Objective 1 CII Quality Performance Management System (QPMS)CII Quality Performance Management System (QPMS) –Adaptations of QPMS elements –Company internal systems Research Report will present a simplified system for field rework tracking only.

Rework Causes and Cures Objectives 2 & 3 Analysis shows strongest relationships between:Analysis shows strongest relationships between: –Engineering rework and field rework –Owner organization alignment and field rework Conclusion: Improve upstream processes (pre-project planning and engineering) and downstream processes (construction) will improve.Conclusion: Improve upstream processes (pre-project planning and engineering) and downstream processes (construction) will improve. Not Rocket Science

Predicting Field Rework Objective 4 Project team answers 16 questions.Project team answers 16 questions. Scores are tabulated and multiplied by a factor and summed.Scores are tabulated and multiplied by a factor and summed. A 1 (X 1 ) + A 2 (X 2 ) … A 13 (X 13 ) + Constant = FRI A n =Factor X n =Team score for a question

What Are the Questions? Three categories of questions:Three categories of questions: –Team planning and organization –Information availability –Staffing or schedule constraints

Team Planning and Organization Alignment within owner organizationAlignment within owner organization Owner’s attitude on scope changeOwner’s attitude on scope change Degree of use of project execution planningDegree of use of project execution planning Change of design discipline leadersChange of design discipline leaders Commitment to using constructability by design and construction contractorsCommitment to using constructability by design and construction contractors

Information Availability Design firm’s qualificationsDesign firm’s qualifications Field verification of conditions by engineeringField verification of conditions by engineering Quality of interdisciplinary design coordinationQuality of interdisciplinary design coordination Availability of supplier informationAvailability of supplier information Level of design reworkLevel of design rework

Staffing or Schedule Constraints Compression of design scheduleCompression of design schedule Design overtimeDesign overtime Quality of supplier pre-qualificationQuality of supplier pre-qualification Availability of skilled craftworkersAvailability of skilled craftworkers Construction contractor shift workConstruction contractor shift work Construction contractor overtimeConstruction contractor overtime

When Will the FRI Be Published? That depends on you... FRI database needs more projects!FRI database needs more projects! –Confidence in predictors of rework –Improve accuracy and reliability Will not be released unless “statistical robustness” is demonstrated.

What Do I Do to Help? Contact Dr. David Rogge: Dept. of Civil Engineering Oregon State University Apperson Hall, Rm. 111 Corvallis, OR Phone: (541) , Fax: (541) Download copies of the FRI - EZ data collection form, complete, and return to Dr. Rogge.