QUALITY

MANAGEMENT
Quality Control:
Basic Concepts & Tools

Prof. Sanjay Bhoyar

Quality control

Basic concepts & tools

Statistical quality control

Fundamentals of statistics for quality

Statistical process control
Acceptance sampling

SANJAY BHOYAR

NICMAR, PUNE

References:

Quality Handbook for the Architectural, Engineering, and

Construction Community
Roger D Hart
Tata McGraw-Hill Publishing company Ltd
Introduction to Quality Control
Dr. Kaoru Ishikawa
Productivity Press (India) Pvt Ltd
Quality Management: A Process Improvement approach
Mark A. Fryman
Cengage Learning
Quality Control and Improvement
Amitava Mitra
Pearson Education Asia

SANJAY BHOYAR

NICMAR, PUNE

Major aspects of a project:

Time
Cost
Quality
safety

Quality

Safety

Time

Cost

SANJAY BHOYAR

NICMAR, PUNE

Quality:

The totality of features & characteristics of a

product or service that bears on it the ability to
satisfy a consumers need, at a reasonable cost.

Quality is an indicator of fitness for use

SANJAY BHOYAR

NICMAR, PUNE

Factors that adversely affect quality:

Poor design
Designs that are difficult to build
Incorrect methods of execution
Poor quality material & labour
Poor quality supervision
Unrealistic constraints of time & cost
Improper contract documentation
Poor communication

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NICMAR, PUNE

Quality Management aspects:

Quality Engineering:

Quality Control:

Quality Assurance:

Quality Improvement:

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NICMAR, PUNE

Quality Engineering:
Elements of Quality:

Quality Characteristics:

Quality of Design:

Quality of Conformance:

These elements together determine the quality

of the final product

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NICMAR, PUNE

Priority of quality characteristics (Quality weighting):

Each characteristic is
important
But, each characteristic is not
equally important

10-20%: major importance (A)

20-30%: minor importance (B)

60-70%: slight importance (C)

SANJAY BHOYAR

NICMAR, PUNE

Quality standards/ levels:

Quality target

Quality standards

Inspection criterion
Assured Quality level
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Economics of Quality:

What should be the optimum quality level?

Economics of quality of design

Economics of quality of conformance

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NICMAR, PUNE

Economics of Quality of Design:

Cost of quality increases with level of quality,

at an increasing rate
Value of quality increases with level of quality,
but at a decreasing rate
Optimum quality level is when the value
contribution is maximum

SANJAY BHOYAR

NICMAR, PUNE

Economics of Quality of Design:

Value of Quality

Cost of Quality

Cost/
value

Optimum Quality level

Increasing Quality level
SANJAY BHOYAR

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Economics of Quality of Conformance:

Quality of conformance is influenced by Quality Control

Cost of Quality
Cost of inputs: (construction cost)

Cost of control: (controlling cost)

Materials
Labour
Tools & equipment
Construction methods/ technology
Verifying & monitoring the quality of output
Correcting or replacing the poor quality work

Optimum quality corresponds to minimum total cost

SANJAY BHOYAR

NICMAR, PUNE

Economics of Quality of Conformance:

Cost

Total cost
Cost of construction

Minimum
Total cost

Cost of Quality control & correction

Optimum Quality Level
Increasing Quality level
SANJAY BHOYAR

NICMAR, PUNE

Quality Assurance:
All techniques & measures to provide a
confidence of accomplishing the desired
level of quality
QA includes the systematic processes of
recording all the measures taken to
achieve the desired quality level

SANJAY BHOYAR

NICMAR, PUNE

Quality control (QC):

Quality Control is part of Quality Assurance

The operational techniques & activities used

to ascertain that an established level of
quality is being achieved & maintained.

It is the process through which the quality

characteristics are actually embedded into the
product.

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NICMAR, PUNE

QA/QC constitutes:

Identification of the quality requirements of the

product/ structure
Setting up standards, procedures, documents etc
Detecting deviations from the standards set
earlier
Provide feedback & appropriate corrective
measures

SANJAY BHOYAR

NICMAR, PUNE

Tools for QA/QC:

Method statements
Checklists
Inspection
Testing
Statistical QC

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NICMAR, PUNE

Method statement:

Step-by-step procedures of execution of a

particular work/ activity

Includes

Preparatory works
Mixing of materials
Erection of temporary structures
Positioning & operations of equipment
Step-by-step execution
Precautionary actions
Finishing works
Protection works

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Importance of MS:
Enables the execution team in
execution of works
Identification & allocation of
resources
Provides the basis for preparing
checklists

For execution team

For inspection

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NICMAR, PUNE

Checklist:
Ready-reference for execution & inspection
Supports the systematic execution of works
through CMS
Objective assessment of the requirements for
ensuring safe, hassle-free, & correct execution
Includes the list of questions, to be answered
objectively as yes/no/NA
Questions are so framed, as to assess the
capability of the process to produce the
desired results

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NICMAR, PUNE

Important checklists:

Checklist for approval of source of materials

Checklist for site activities

Civil works
Mechanical & electrical works

Checklist for lifting, movement & placement of

different structural components
Checklist for post construction activities

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Checklist for source approval for

Cement:

1.
2.

3.

4.

5.

Name & address of the manufacturer/ supplier

Whether the supplier/ manufacturer is among the approved
list of the clients
Information regarding the other ongoing works where the
material is being supplied by the supplier
Whether the material satisfies the test requirement as per
clause --- of the manual
Whether the supplier can supply the material in the desired lot
size as per the site schedule.

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NICMAR, PUNE

Checklist for concrete pour:

1.
2.
3.

Nomenclature of item:
Structural drawing no:
Date of casting:

Sr
no

Description

1.

Staging & formwork

1.1 Is the staging & formwork approved as per

checklist as given in clause -- & -2.

Reinforcement

2.1 Is the reinforcement approved as per

checklist as given in clause -3.

Embeded parts

3.1 Are the embeded parts provided as per the

requirement?
3.2 Is the alignment & fixing of inserts correct?

Yes/no Rem
/NA
arks

4.

Arrangement of concreting

4.1

Are construction joints provided as approved?

4.2

Has old concrete surface been roughened?

4.3

Are materials approved as per clause --

4.4

Is batching plant calibration checked?

4.5

Has the concreting sequence been approved?

4.6

Has arrangement for protection from extreme

weather during or after concreting been made?

4.7

Are the platforms & access for materials &

labour movement provided?

4.8

Is adequate illumination arrangement provided?

4.9

Are safety measures as per safety assurance

record taken?

5.

During construction

5.1

Does the slump of concrete meet the

requirement?

5.2

Number of cube specimens taken

5.3

Is the previously placed layer of concrete

green to receive the succeeding layer for
amalgamation

5.4

Is proper vibration done to ensure

compaction?

For contractor
Name:
Designation:
Sign:
Date:

For Department
Name:
Designation:
Sign:
Date:

Checklist for post concrete inspection:

1.
2.
3.
4.

Nomenclature of item:
Date of casting:
Date of de-shuttering:
Date of inspection:

Sr no

Description

1.

Alignment/ dimensions of the member

1.1

Is the alignment correct?

1.2

Are the dimensions correct?

2.

Is any bulging noticed?

3.

Appearance of surface

3.1

Is there any honey-combing?

3.2

Are there any bubbles?

3.3

Is shutter finish obtained?

4.

Are there any cracks noticed?

Any other defects?

Yes/no/
NA

Remarks

Inspection & Testing:

Inspection:

Qualitative assessment of the work (including quality

characteristics)
Observation
Recording
Verification

Testing:

Quantitative assessment of the quality characteristics

Sampling
Testing
Verification

SANJAY BHOYAR

NICMAR, PUNE

Role of inspection in QC:

Inspection of materials

Raw materials

Inspection of temporary structures/

installations
Inspection during work

Process inspection
In-process products/ structures

Inspection of completed work

Finished product/ structures

Final inspection

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Importance of inspection:

Inspection reveals quality of materials

Inspection reveals improper implementation of

procedures

Defective workmanship
Need for improvement

Inspection provides appropriate information for QC

& appropriate feedback for quality improvement

Defective materials
Prevents defective materials going in process

What to control
Where to improve

Inspection reveals the requirement/ need for testing

Testing:

Verification that determines the capability of

an item to meet predetermined requirements
by subjecting the item/ sample to a set of
measurable operating conditions.

Quantitative assessment of the quality

characteristics

SANJAY BHOYAR

NICMAR, PUNE

Testingprocess

Identification of major quality characteristics

Setting standards
Specifying the tests to be conducted to judge the particular
quality characteristic
Preparing testing programme/ plan
Sampling
Testing
Analysis
Statistical treatment & inference
Certification/ approval
Non-conformance
Remedial actions

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NICMAR, PUNE

Raw materials
In-process materials
Semi-finished structures/ structural
components
Finished structures

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Field tests
Laboratory tests
Non-destructive testing

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Stages of QC:

Design control
Procurement control
Process control
Certification of work
Non-compliance

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NICMAR, PUNE

Design control:

Design is a technical management process

QC shall ensure that the design follows the
standards, & established procedures and
confirms with the reliability & safety of the
structure

Checklist shall be followed for various stages of

design
Loading
Construction materials
Modelling
Design
Detailing
Drawings & documentations

Procurement control:

All the materials shall be procured from the

approved sources
Procurement of services shall be according to a
procurement control document, which shall
include scope of work, technical specifications,
test/ inspection/ acceptances.

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Process control:

All operations/ processes shall be carried out

in accordance with the construction method
statements & as per specifications as set out in
tender
All the activities shall be done as per approved
procedures

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NICMAR, PUNE

Certification of work:

If the works have been carried out & inspected

as per the agreed procedures, it could be
deemed to have been approved

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NICMAR, PUNE

Non-compliance:

If the materials or works, after testing &

inspection, are not complying with the
requirements as per the agreed standards &
procedures,

Causes of failure shall be identified & remedial measures

taken
NDT/ full load tests shall be undertaken on
structures in doubt

On failure of standard tests,

Before rejecting a structure, detailed analysis should be

carried out, &
It should be established beyond doubt that the structure
has to be rejected

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Recurrence prevention:
(Permanent fix)

Eliminating the symptom

Eliminating the causal factor

Stop-gap measure
Less effective

Eliminating the root cause

Most effective
May require to revise the standards

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NICMAR, PUNE

5 Ms of QC:

Materials

Machines

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Methods

Manpower

Measurements
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QC Cycle: PDCA
Act

Decide
objectives
& targets

Take action

Check results
of work

Decide
methods of
attaining
objectives
Carry out
education &
training

Do work
Check

SANJAY BHOYAR

Plan

Do

NICMAR, PUNE

Summary:

For quality work,

Ensure proper work culture & ethics

Integrity
Everyone to concentrate on doing job better &
better every single day
Work ceaselessly towards the quality objectives
Follow an organizational approach
Continual improvement

SANJAY BHOYAR

NICMAR, PUNE