7 Effective Steps for Handling your Nonconformances
Monday, January 16th, 2012Whether you are dealing with difficult or simple nonconformances, your construction quality control plan should outline a methodical process to manage them. That way, you will continually deliver quality results. Your customers will have confidence that you firmly control plan deviations till you find the appropriate resolution.
In quality assurance circles, we do not use the term nonconformance for all defects. Instead, we keep the term for defects that you cannot quickly or cost effectively fix to meet your project’s quality standards.
Here’s one example of a straightforward nonconformance. If you poured a concrete foundation that was an inch too wide, you’d need to chip off the additional width or rework the foundation to correct it.
This situation may not have a dangerous affect on form, fit, or function. So, redoing it potentially doesn’t appear sensible. However if you decide to use-as-is, you will need to get your project owner’s approval. This added step means you won’t be able to deal with the defect in a timely manner therefore you’ll have to handle it as a nonconformance.
Step 1: Marking
Step one is to identify the area visibly to put a stop to use or unintended cover-up. This is particularly important since making a decision on the right corrective action or getting your customers’ approval will most likely take a while.
You’d most likely mark the foundation nonconformance with barrier tape. For other nonconformances, you can use paint, tape, a tag, or another visible signal. Regardless of how you choose to mark your nonconformances, make sure that they can not be concealed by mistake.
Step 2: Controlling
If continuing to work can adversely impact quality or cover the defect, then stop work in the area till you can correct the nonconformance. Your field staff should decide what, if any, limitations they should put on working in the area.
It is also best-practice to review previously finished work of the same nature to make certain it doesn’t have similar defects.
Step 3: RecordingOnce you have marked and controlled the nonconformance area, the very next step is to finish a nonconformance report. Use the report to describe the deviation and present it to a higher authority for a disposition (decision on how to proceed).
A nonconformance report also is a record of actions taken including decisions that’ll be made on the disposition, corrective action, and preventive action for the nonconformance.
Step 4: Settling on a Disposition
Next, you will make a choice on the disposition of the nonconformance. You can handle a nonconformance in one of four common ways: replace, repair, redo, and use-as-is. Consider the definitions below when deciding the most sensible plan.
REPLACE: Use this remedial action when replacing the nonconforming product or material with a conforming product or material will fix the deficiency.
REPAIR: Use this correcting action when re-machining, reassembly, reprocessing, reinstallation, or completion of the operations will fix the nonconformance.
REWORK: Use this corrective action when redoing will make the nonconformance sufficient for its intended use, even though it might not meet all plan standards. Remember , your customer must approve the change.
USE AS-IS: Use this corrective action when the nonconforming item is satisfactory for its intended use. Any use as-is items that don’t meet all design necessities must be accepted by your project owner.
Remember, if the corrective actions will not bring the nonconformance into spec, then you should always seek your client’s approval.
Step 5: Corrective Actions
After you perform the corrective action, you will need to verify that you have fixed the issue or corrected it to the level indicated by the disposition on the nonconformance report.
Occasionally corrective action training is necessary. This would be helpful if staff aren’t familiar with the sort of fix or redo that must be done or they don’t seem to be acquainted with the best way to install a replacement.
Step 6: Reinspecting
After you’ve eliminated the nonconformance, reinspect your work and remove your marks.
Step 7: Preventing
Correcting issues found during quality inspections isn’t acceptable. You should regularly look for methods to improve quality and prevent similar issues from occurring in the future.
As an element of your systematic approach, you need to look at the frequency, seriousness, and detectability of the nonconformances you’ve found on your present project as well as your past. You can do this by reviewing company quality performance and customer feedback.
Training is an aspect of prevention that you should not overlook. Once you’ve identified the reasons behind your nonconformances, include regular coaching and/or toolbox talks geared at stopping future occurrences.
Conclusion
Deficiencies and nonconformances are a normal part of construction. Having a systematic approach to finding, resolving, and preventing future occurrences is the main difference between a top construction company and an average one.
Visit the FirstTimeQuality.com web site for more tips on improving construction quality control and quality assurance processes. You may also Download your FREE Nonconformance Report Template and begin recording your nonconformances.