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

2. Field Rework Research Team RT-153
Richard Calhoun Phillips Petroleum Co., Chairman
Jim Atkinson U.S. Steel
Andrew Beal Air Products & Chemicals
Joe Beffa Black & Veatch
Tom Falso Eichleay
Francis House Kellogg Brown & Root
David Rogge Oregon State University
Phill Stassi Jacobs Engineering Group, Inc.
William Wright Chemtex International

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

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

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

6. How BIG is the Problem? CII Survey Data CII Research Summary 10-2
12% rework on nine industrial projects
1997 Benchmarking & Metrics Data Report
3.4% for 19 industrial projects
CII Effects of Field Rework Research Team
5.8% for 78 industrial projects
Ranges between 0% and 27%

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

8. How Is Field Rework Tracked? Objective 1
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.

9. Rework Causes and Cures Objectives 2 & 3
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.
Not Rocket Science

10. Predicting Field Rework Objective 4
Project team answers 16 questions.
Scores are tabulated and multiplied by a factor and summed.
A1(X1) + A2(X2) … A13(X13) + Constant = FRI
An = Factor
Xn = Team score for a question

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

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

13. Information Availability
Design firm’s qualifications
Field verification of conditions by engineering
Quality of interdisciplinary design coordination
Availability of supplier information
Level of design rework

14. Staffing or Schedule Constraints
Compression of design schedule
Design overtime
Quality of supplier pre-qualification
Availability of skilled craftworkers
Construction contractor shift work
Construction contractor overtime

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

16. 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.