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

2. 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

3. “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.”

4. 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.

5. 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

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

7. 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

8. 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

9. 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

10. 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

11. 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

12. 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

13. 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

14. 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

15. 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

16. 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

17. Design Review & Approval Matrix

18. 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

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

20. 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

21. 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

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

24. 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 ~ ~

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

26. 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

27. 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

28. 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

29. 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

30. 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

31. 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

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