When a project is awarded, the project manager will be tasked with putting together a project team to complete the project on time and within budget. For a project to be done well, the project manager must always bear in mind an issue not always considered to be important: quality management.
The very first thing to understand about quality management is that quality management does not determine the quality of the product. The product quality is determined by the client. In our business, the product is the building or the infrastructure works. Ultimately the project team must deliver a product to the quality expected by the client. This can be issued through quality management.
I would say that to deliver quality product the project team’s approach should be ”Don’t just do what you are told, do what needs to be done, plan to get it done right and focus on how it is to be carried out.” Why? This is because the task to get the project done is similar to “being told what to do by the client”.
The project manager cannot simply assume that he knows all his client’s requirements as that written in the contract document. There are many other areas that need to be done which are not explicitly written in the contract. Therefore, there is a lot more for him to find out and to learn from his client about “what needs to be done” to his satisfaction through formal meetings or several informal discussions. In fact a quality product is all about meeting the client’s requirements and even exceeding their expectation if possible.
Sometimes there is also a tendency to think that 'quality' means the best material, the best equipment and absolutely zero defects. However, in most cases, the client does not expect, and even cannot afford a perfect product. On the other hand, a flawlessly designed, defect-free drawing that does not meet the client's needs is also not considered a quality product. Therefore, the purpose of quality management is to first understand and manage the expectations of the client in terms of quality, and then put a proactive plan and process in place to meet or even exceed those expectations.
What you are told? … It may not be right…
In many instances, the project manager is being told to do something or everything at one go without knowing what needs to be done first, and how to do it right. The consequence of this is that a wrong move is made if there is no proper planning, which may also result in rework. Likewise this could be one of the most common project management mistakes; problems of quality always show up in a number of areas during or at the end of the project. For instance:
Rework. This is the primary problem caused by poor quality work during the construction. Rework means that you have to do the same work because the original effort was not satisfactory. This is the work required because the original construction and testing process was not thorough and defects still exist in the handing over period.
Higher maintenance and support costs. If defects are caught within the design development process, there is also a cost associated with this rework. However, many times quality problems surface during or after the project completion. This situation just hands the problem off to the maintenance department. High maintenance costs from a poor quality product can be a sign that the project team willingly handed over a less than acceptable product, or else they did not realize the poor quality because of their lack of supervision or testing and the inspection processes were also inadequate.
Client dissatisfaction. If a product that is delivered is of poor quality, the client will not be happy. This unhappiness may be transferred to the maintenance department and subsequently to our company itself. However, if this particular client has a choice, he may not want our service in the future.
Missed deadlines and budget. In many cases, most of the projects that do not manage quality well end up with a lot of rework, which in turn leads them to miss the deadlines and exceed the budget. This can cause the overall project progress to be delayed, or it may change the financial cost of the entire project.
Poor morale. No one likes to work for a company that has poor processes or produces poor quality products. No one likes to work on projects that are missing their deadlines because of rework. People tend to find excitement and challenge in building a quality product. However, their motivation level goes down when they have to continually repair and rework on those defects that don’t work correctly. In addition to poor morale in general, specific costs can include increased absenteeism, higher turnover and less productivity from the staff.
What needs to be done? …Need to adopt a proper PDCA cycle…
Quality management is not an event that we consider once in a while. Quality management is an ongoing process that the team needs to focus on throughout the project. When the project begins, the project manager should prepare an overall Project Quality Plan (PQP) containing but not only limited to these three major components:
Completeness and correctness criteria. Remember that the client determines the quality and not the project manager. This might make the project manager uneasy, since he may not be sure of the client's expectations. That is where completeness and correctness of the criteria come in. The project team and client then have to have a common expectation of what is required for each deliverable item to be accepted as all these criteria may be stated clearly in the inspection test plan (ITP).
Quality control process. Quality control (QC) refers to the ongoing activities that the project team will perform to ensure that the products are of high quality. This can include all incoming inspections, ongoing inspection, and walkthrough with client representatives, testing and commissioning of all major components, come with the completeness of checklists and records, and etc.
Quality assurance process. Quality assurance (QA) processes are the activities designed to ensure that the overall processes used to create the products are of high quality. These types of activities include third party audits, internal quality audits, checklists to ensure that all parts of a process were completed, sample submissions, method statements an other deliverable approvals, etc.
Everyone on the project team needs to have a quality mindset to ensure that work is completed with a minimum amount of defects – the first time. The project manager and team members need to understand that the first goal of quality management is to deliver products with least defects. The second goal is to correct any remaining defects as early as possible.
In most cases, quality problems usually tend to show up late in the project or during the testing process. Nevertheless, if we have a good quality process in place, our testing should confirm that everything is working correctly. Then we can quickly work toward final approval. In conclusion, always REMEMBER: Our client is also our customer. Don’t just do what you are told, do what needs to be done, adopt Plan Do Check and Action (PDCA) cycle, keep the level of our customer satisfaction high and aim for continual improvement.