Lean Construction Ireland Annual Book of Cases 2021 27 l f s s 2 Fishbone and 5Whys A Fishbone Diagram and 5Whys were used to ascertain the root cause of the problem using the 6M methodology (Measurement, Materials,Method,Mother Nature,Manpower and Machine).During a brain storming session with the quality team and operations, it became apparent that the existing company culture, commitment, and leadership were of the top 3 issues that needed to be considered. Case 4 Lean Initiative Improvements & Impact Improve Framework for Data Capture A framework was developed in MS Excel supported by Power BI to improve data capture capability and presentation.This framework ensured the logging and tracking of key data in terms of impact, contributing factors and costs.This level of information allowed for improved data analysis, on which decisions can be based and actions taken. A key principle of Total Quality Management (TQM) is fact-based management. We need to ensure decisions are based on fact and not precedent or opinion. Recording of non-conformances increased from 3 in Quarter 1, 2022 to 13 in Quarter 1,660808 2022, due to the increased data capture capabilities. The process for non-conformance and corrective action was revised to reflect the updated controls as illustrated in Figure 9, Control of Non-Conforming Outputs & CorrectiveAction Process. Figure 9: Control of Non-Conforming Outputs & CorrectiveAction Process Existing forms were revised to capture detailed operational data at project level. A summary of the details feed into the NonConformance Master Register to collate all internal and external failure costs.These forms were developed to ensure the impact of the issues were considered, together with the contributing factors, remedial work, root cause analysis and associated costs. Figure 10: Non-Conformance and CorrectiveAction Reports Training Presentation ANon-Conformance and CorrectiveActionTraining Presentation and knowledge check was developed to communicate the improvements and raise awareness on the impacts of the cost of quality on construction projects, both good and bad.The training, together with knowledge check, was delivered through an in-house, self-delivered training portal that now forms part of the company induction process. Control Training Programme Roll out of the cost of quality training programme and knowledge check commenced in December 2021,with invites from the inhouse training platform issued to relevant roles within site and management staff.To date, 91 out of 347 direct employees have completed the training and knowledge check as shown in Figure 11, Completion of Figure 8: 5Whys. Figure 11: Completion of Cost of Quality (COQ)Training
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