The QC Manager s Role and Responsibilities

Transcription

1 The QC Manager s Role and Responsibilities November 2018 QC Manager Course Release 10, Module 3 1 Introduction to Lesson 3, QC Manager s Role and Responsibilities. Release 10 November

2 Learning Outcomes Describe QC Manager s role & responsibilities Describe the QC Manager s duties Describe the QC Manager s reporting requirements November 2018 QC Manager Course Release 10, Module 3 2 Release 10 November

3 Plan QC Needs Est. QC Manpower Qualified Subs Establish Rework Goals Administer QC Plan Monitor QC Activities Provide Monthly Certification Maintain Records Evaluate Performance MAC Pre-Bid Pre-Construction Construction Post-Construction Prepare QC Plan Qualified QC Staff Qualified Labs Producer s QC Plan Verification Sampling/Testing Records Material Certifications MAC MAR Issues Resolved Warranty Items November 2018 QC Manager Course Release 10, Module 3 3 These are the major phases for the QC Manager s role and responsibilities of a project. The QC Manager should be involved in all phases, beginning with the pre bid phase. However, some of the work tasks within the major phases shown in the slide above may not be assigned to the QC Manager. The tasks assignments will be determined by the Prime Contractor. During the pre bid phase, QC Managers may interact with estimating to ensure QC inspection, sampling, testing and staffing is accounted for in the bid and to determine if the anticipated subcontractors and producers have the required FDOT qualifications/certifications. Once the contract is awarded, the QC Manager must bring together all of the project requirements and documents. The CTQP qualifications of the anticipated Inspection staff needs to be verified, and a schedule of manpower and equipment resources developed to ensure the project is properly staffed and equipped from a QC standpoint. During the construction or production phase, the QC Manager is responsible forensuring that the required inspection, sampling, testing and reporting is performed by the Inspection staff. They are responsible for the administration and supervision of the staff and coordinating and handling of deficient materials and QC, Verification and Resolution conflicts. Additionally, revisions to the QC Plan may be required based upon project needs. Each month, they must ensure the Contractor Certification is completed and submitted. They must ensure the QC personnel have access to the contract documents. As the old saying goes, it isn t over until the paperwork is done and construction is no different. The QC Manager must finalize all QC reports and documentation, together with material certifications, etc. Release 10 November

4 November 2018 QC Manager Course Release 10, Module 3 4 Unfortunately, as a QC Manager, you are more or less serving two bosses, your employer, (the Contractor) and the Department. Your concern is ensuring that the quality required for the project is met. You may find yourself pulled in two directions at once. Your desire to serve your firm and help production, while at the same time, meeting the Department s quality requirements. It is important that you maintain your integrity and not be pushed into doing something that can result in the suspension or revocation of your QC Manager Qualification. It is important to remember, if you do your job properly, you are an asset to both the Contractor and the Department. Release 10 November

5 Serve as Contractor s Quality Representative Enter and Maintain QC Plan in MAC Prepare and Maintain non standard Job Guide Schedule (JGS) for Lump Sum projects, including Design Build On system LAP Other non standard projects Administer and Monitor QC Operations Provide Monthly Certification November 2018 QC Manager Course Release 10, Module 3 5 Listed above are some of the functions of the QC Manager, which will be covered in detail in this lesson. Release 10 November

6 Who should the QC Manager report to? Prime Contractor s Senior Management - Area Manager - General Area Superintendent - Project Manager (Projects >$20 million) - Foreman - Superintendent Do they have any authority over the Production staff? YES, the QC Manager has the authority to stop work when the end quality is at risk. November 2018 QC Manager Course Release 10, Module 3 6 Release 10 November

7 Should the Inspectors report to the QC Manager? They should report to the QC Managershould not report to Production. Do the Inspectors have any authority to stop work? QC Inspectors may not have the authority to stop work or direct production - they should document and report any irregularities or non-compliant issues/tests to the QC Manager. November 2018 QC Manager Course Release 10, Module 3 7 Release 10 November

8 Review Contract Documents Plan QC Program Operations Identify QC inspection, sampling & testing requirements Identify potential Inspectors/Technicians Identify potential QC problem areas November 2018 QC Manager Course Release 10, Module 3 8 The QC Manager looks at the project from the QC program standpoint and somewhat begins to formulate answers to questions such as What inspection, testing and sampling is required?; What are the manpower resources needed to perform the QC inspection, sampling & testing?, etc. These all have an impact on the cost to the project, hence impacts the Bid. Though small in comparison to project materials, labor and equipment costs, but can range from 1 3% or more of a project. As a QC Manager your involvement in the pre bid process can be of a substantial benefit to the Contractor. QC costs money and depending upon project requirements can range from 1 3% of the project cost. If you begin to formulate what s required in the QC Program, you will find there are many questions that need to be answered such as: What inspection, sampling & testing is required? What Inspectors/Technicians are available? Are there any parts of the project that can create problems for QC? These all represent a cost a financial impact to the project. On the other hand, they may be opportunities for reduced frequencies of testing, thereby being able to effect some sort of savings. Release 10 November

9 Prepare QC Budget Estimate QC inspection, sampling & testing manpower, per phase Estimate QC Costs, per phase Provide the bid Estimators the QC Costs November 2018 QC Manager Course Release 10, Module 3 9 Attention needs to be paid to any special requirements, as these can impact costs also. For example, sampling structural concrete at the point of final placement may increase manhours. How is the construction planned. Will there be very large concrete pours, or multiple pours occurring simultaneously, requiring additional manpower? Estimating is relying on you to provide a fairly accurate estimate of QC costs for inclusion into the bid. What manpower resources are required, for each phase, for each construction type? How many Inspectors versus Technicians will you need? Will any CTQP training be needed for the QC Inspection staff to be capable of fulfilling the project inspection, sampling & testing needs? If subcontracting QC inspection, sampling & testing, obtain quotes from several qualified firms. Keep in mind that certain requirements, such as QC sampling for Maximum Density Test for Stabilizing (Section 160), where QC samples and splits for VT and RT, adds costs (Extra bags, time and large storage facility). Willtherebemultipleconcreteplacementsites,concurrently?Ifso,each must be staffed by a qualified technician. If not, one technician may be capable of handling concrete placements, depending upon project size and conditions. Following your assessment of the QC needs, develop an estimate of the QC costs and provide it to the Estimator for use in the bid. Release 10 November

10 Verify Qualifications/Certifications Verify Subcontractor/Producers QC Plan Acceptance Verify Inspector/Technician CTQP qualifications Verify Laboratory Qualification/Certification Evaluate past performance by subcontractors Coordinate Qualification Results with Estimating November 2018 QC Manager Course Release 10, Module 3 10 You will probably be charged with determining the qualification/certification of QC personnel, subcontractors and producers anticipated for use on the project. This may include anticipated suppliers/producers (including past performance of QC activities), QC Inspection staff, any additional CTQP training required, qualified/certified laboratories. You need to communicate with estimating especially if there appears to be some significant problems (For example: your firm is determined to use XYZ as the concrete producer, but they do not have an approved QC Plan or their plan was suspended, etc.) As a QC Manager, you should be charged with determining the qualification/certification of QC personnel, subcontractors and producers being considered for use on the project. You may need answers to the following questions: Do anticipated suppliers/producers meet the QC requirements for the project? If not, others should be sought or coordinate with the PA and producer to develop an action plan to make the facility acceptable by the time the material needs to be produced for the contract. Also, give thought to having back up subcontractors/suppliers, should problems arise with a particular subcontractor/supplier. Release 10 November

11 Does the QC Inspection staff have all of the required CTQP qualifications? IssomeCTQP training needed to meet the needs of the project? Will the qualifications expire during the contract time? Is the anticipated Laboratory qualified/certified? If not, another is needed. In addition to having any required qualifications, what has been the recent past performance, related to QC, of the anticipated subcontractors? Remember, astheprime, you are responsible for their actions. You want subcontractors that are as concerned about quality as is the Prime Contractor. Release 10 November

12 Establish Rework Goals Estimate rework potential, per phase Establish reasonable rework goals Original Activity Rework ID Rework Duration Standby Rework Gear up Continuation of Original Activity November 2018 QC Manager Course Release 10, Module 3 11 Rework Activities in the field that have to be done more than once in the field, or activities which remove work previously installed as part of the project regardless of source, where no change order has been issued and no change of scope has been identified by the owner. Very few, if any, transportation construction projects are completed that don t have some rework of something required at some point in time. As the QC manager, you need to estimate the potential amount of rework that may occur on each phase of the project, especially as it relates to and how it impacts QC (manpower, costs, etc.). A typical rework goal on medium to large projects here in Florida is 50 cents aman hour. Example If the job has 100,000 man hours to build the work, the goal of total rework allowed on the job would be $50,000.00, throughout the duration of the project. Tracking these costs, through a simple Excel spreadsheet is easy and provides a indication of whether the program is working or not. This goal also depends on the experience level of the people (craft) and supervision building the work. In today's labor market this is a big one. As shown above, rework costs money, in some cases substantial monies, especially if not accurately anticipated. Release 10 November

13 Human Resources Capability Unclear Instructions To Workers Inadequate supervision & Job Planning Late Design Changes Poor Document Control Engineering & Reviews Scope Changes Errors and Omissions Excessive Overtime Insufficient Skills levels Constructability Problems Late Design Input Construction Planning & Scheduling Leadership & Communications Ineffective Mgmnt of Project team Lack of Operations (End User) Perceives Buy-in Unrealistic Schedules Insufficient Turnover & Commissioning Resourcing Lack of Safety & QA/QC commitment Non-compliance With specifications Poor Communications Untimely Deliveries Materials not in right place when needed Material & Equipment Supply Contribute To Re-work Prefab & material not to Project Requirements November 2018 QC Manager Course Release 10, Module 3 12 Shown above is what is commonly referred to as a Rework Cause Classification Chart. As you can see, there are numerous potential causes that impact the amount of rework needed. On many construction projects, especially the large ones, there is someone assigned as a Rework Manager, who is responsible for tracking and managing rework tasks. Studies have been conducted and have shown that an increased emphasis is needed during the project s design and engineering phases to potentially avoid further field rework during the construction stage. Additionally, insufficient experience, training and expertise, on the Construction side, have resulted in increased rework items. With that in mind, the QC Manager, should thoroughly review the Contract documents and be alert for items that can effect rework. A QC Manager needs to be knowledgeable of Rework, especially how it relates and impacts QC inspection, testing and inspection. An effective QC program is the most effective way to minimize rework. In many instances, the rework task will have a QC component with it. There are many resources available to you, such as the Construction Industry Institute, which have educational material on this topic. Release 10 November

14 Establish Rework Goals Past job cost Experience level of personnel (Management & Craft) Suppliers past problems Subcontractor past problems November 2018 QC Manager Course Release 10, Module 3 13 The following items help establish Rework goals: Past Job Cost For each job, costs are summarized for all re work (Direct or Indirect) to provide a better understanding of actual impacts of re work. The cost is reported at the Foreman / Field Engineer level to Management and tied to the activities internal cost code. Project Management holds individuals accountable for reporting re work issues at all levels. These costs are maintained for each project, by work type, which forms a historical base, and is used by management in the estimate to account for future problems. Experience level of personnel (Management & Craft) This plays a big role in the amount of re work the job may experience. In today s market this must be considered, because you don t always have the A team sitting on the bench ready to go construct a project. You must use the tools that you have and, therefore, Management has developed a number or factor, which is applied during the estimate phase of the job. Suppliers past problems Based upon historical data, a number or factor is applied when using certain suppliers. The suppliers quote may be low at estimate time, but you know based on past experience that you will have certain problems that may require rework with certain suppliers. Subcontractor past problems (Same as Above) There is a number to anticipate when using certain subcontractors for building work. The subs quote may be low at estimate time, but you know based on past experience that you will have certain problems that may require re work with certain parts of the job. Release 10 November

15 Establish Rework Goals Past Owner relations issues Equipment availability problems Quality of Contract Plans November 2018 QC Manager Course Release 10, Module 3 14 Past Owner relations issues Owners often cause impacts and re work due to the lack of focus on what is best for the project. For instance, if they are aware of potential conflicts or problems, they often don t communicate these to the Contractor and await for the problem to arise during construction, possibly effecting the costs or schedule. These types of Owners have a number or factor applied to them during the Estimating phase. Equipment availability problems Equipment can often be a factor in determining re work goals. If you have limited numbers of equipment to build the job you may not always get the best. This is considered in the re work goal for the job (If your paving an interstateand your asphalt paver in not the best one you have in the fleet you may anticipate removinga few areas because of using older equipment). Quality of Contract Plans The condition of the contract plans often breeds re work on the job. Today's project sizes and complexities often produce multiple EOR s on the same contract and, as shown in many studies, they often fail to communicate effectively among themselves. Failure to compare each others design and how the pieces fit together on the job often causes re work. After considering all the above factors, a job re work goal is created in the estimatephase by the senior management. Release 10 November

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17 QC Plan Preparation Finalize Project QC requirements Prepare QC Administrative Tools Prepare Earthwork Record System Prepare LOT numbering system Determine if MAC access is needed November 2018 QC Manager Course Release 10, Module 3 16 You will need to finalize the QC requirements by construction type and prepare the QC Plan for the project and any QC administrative tools anticipated for use, such as checklists, Control Charts, filing system, etc. Your QC Plan is submitted to the Project Administrator for approval as discussed in Chapter 5. It is incumbent upon you to stay on top of the Approval process to ensure that it gets approved, including providing any additional information that might be requested for approval. The point is, just because you submitted it, you can t just sit back and wait. Remember, you basically cannot start construction on any QC program material without the Approved QC Plan. Hopefully you or one of your staff is familiar with the FDOT Plot Program for coding of the Earthwork Record System. This must be completed before construction starts, therefore it is something that needs to be an early assignment. Depending upon the size of theproject and the skills of the individual doing the coding, this may take some time. The Department offers training in the use of the Plot Program if needed. You then need to number the LOTs for all phases of construction, since LOT numbers are how areas of the material placed are identified. Account for tasks needing lead time, such as the coding of the Earthwork Record System in Earthwork and the numbering of LOTs for the various materials (concrete, asphalt, earthwork). MAC is the system used to record QC sampling and testing. You need to setup access for those required, get those trained that need it and ensure that everyone involved understands the importance of accurate, timely data entry. Release 10 November

18 Managing the LOT System LOT sizes/definitions are in SSRBC LOT numbers identify the locations of materials place Asphalt, Concrete and Earthwork have different LOT sizes/definitions LOT identification system is very important Communicate your LOT numbering system to all November 2018 QC Manager Course Release 10, Module 3 17 As a QC Manager, you might find it helpful to use one of the methods used by some ofthe most respected and successful QC managers in the industry today. On the next several slides we will review a very simple, complete, accurate and easily managed LOT numbering system used by some of the successful QC managers. Whatever method or system you use, you need to inform and educate all personnel who will be involved in their use. You may have to obtain approval from the Materials Office Materials Certification personnel for deviating from an approved numbering system. Within these materials are various subsections, such as concrete mix designs, embankment materials, etc. Each has it s own LOT Index, the system where the results for alotare recorded. Regardless of the system you use, it is important that you conduct a meeting prior to the start of production, and communicate the system to those involved. They must have an understanding of the system to make it work efficiently and effectively. Release 10 November

19 Concrete LOT numbers by Concrete Mix Design Per Contract Number Asphalt LOT numbers by tons Per Mix Design Per Contract Number Type II Bridge Deck (50 CY or 1 days production) Asphalt LOT 76 LOT 32 LOT 32 Sta Sta November 2018 QC Manager Course Release 10, Module 3 18 Concrete lots are tracked contract and mix design. In general, LOTs for concrete are typically 50 CY or a day s production, whichever is less. This is fairly straight forward, it then just becomes a matter of the placement of the mix design. The Sample Number/Lot Numbering system and report is designed to assist with tracking concrete lots and samples. Asphalt is set forth LOTs by tons per contract per mix design, therefore, asphalt LOT numbers come from the tons placed. Release 10 November

20 In summary; Put some thought into this If needed, seek help from successful QCMs or FDOT Be consistent Educate others November 2018 QC Manager Course Release 10, Module 3 19 Insummary,howyounumbertheLOTshasanimpactonyouandothers.Putsomethought into it. The District Materials and Research Office (DMRO) or State Materials Office (SMO) Materials Certification personnel may be contacted for assistance in numbering lots. Release 10 November

21 QC Awareness Conduct pre construction QC meeting Champion QC effort Provide QC Tools Review QC Process/Recording/Reporting November 2018 QC Manager Course Release 10, Module 3 20 Quality Control is one of those things that needs a Champion. Yes, you might have the title of QC Manager, but you need to Champion it, or it really doesn t happen. A Leader needs to Lead and you need to promote,design for,train for,plan for,and expound upon Quality Control. Conducting a pre construction QC meeting, not only for QC personnel but also production personnel if possible, can lead to a better understanding by the team members of QC requirements and goals. This leads to an increased chance of achieving the project QC goals. If there are any project specific requirements, discuss them with the Project Administrator early so you both are aware of the special requirements and how they will be incorporated into MAC. Provide all those in need, any QC tools that have been developed for the project. Ensure they understand the purpose and use of these tools and what you, as the QC manager, expect to gain by their proper use or completion of them. Review the process for recording, reporting and distribution of sampling and testing results and reports. Ensure that all QC Inspection personnel understand the proper procedures. Additionally, you will have arranged for MAC access at the appropriate levels for project personnel. Release 10 November

22 November 2018 QC Manager Course Release 10, Module 3 21 Construction is starting, so let s review the main QC functions during construction. Release 10 November

23 Administer QC Plan Update the QC Plan with addendums as necessary Provide interpretation of contract documents Assist in Internal Work Plan preparation Review QC Process/Recording/Reporting Results November 2018 QC Manager Course Release 10, Module 3 22 Part of administering the Quality Control is to monitor test results, detect anomalies, provide revised processes if needed, revise the QC Plan if needed, and assist in internal work plan development and assist in the interpretation of contract documents related to QC. Things such as structural concrete mix designs, personnel changes, etc. are causes for revisions to the QC Plan. Some Contractors have Project Supervision staff develop Internal Work Plans for all operations. These work plans include Budgets and Goals, Equipment and Crew needs, Cost Codes, Quality Requirements, Step by Step, Safety Provisions, Material Handling, Lay down Sketches, What If's (Plan B), Daily Schedule, Quality Analysis, etc. This is typically prepared by the engineer in charge of the operation and reviewed by the Project Manager, Job Sponsor and Quality Control Manager. The work plan is also reviewed with the crewweekly and revised to reflect any changes in the operation. The work plan is a good tool to use in any operation because it requires supervision to think about how the work is going to be built and put it on paper before the start of the operation. Release 10 November

24 November 2018 QC Manager Course Release 10, Module 3 23 There are a variety of forms that are to be completed by QC, some monthly and others daily. To access this list of forms the Contractor QC needs, visit the forms and procedures internet site Release 10 November

25 Administer Inspection Program Assemble Inspection staff; verify CTQP qualifications Ensure QC staffing manpower meets the schedule Provide training of Inspectors (internally) and arrange for external training to meet discipline requirements Manage Inspection staff November 2018 QC Manager Course Release 10, Module 3 24 As the QC Manager, a large portion of your duties involves the administration and supervision of the QC staff. You need to determine the qualifications of each individual and include the appropriate QC technicians on the Contractor QC Plan. This lets all know who is qualified for what and avoids unqualified personnel performing inspection, sampling or testingtasks. You also need to ensure that the proper manpower resources are available for the QC tasks required per phase. Based upon the QC staff, some internal or external training may be needed and asqc Manager, you will probably be responsible for arranging any required training and ensuring that qualifications are maintained. Release 10 November

26 Administer Inspection Program Ensure adherence to required specifications, procedures and methods for personnel & equipment Coordinate Verification and Resolution testing activity Ensure adherence to QC Operation elements by Inspection staff Conduct/Attend internal and external project meetings Conduct/Attend pre operations meetings November 2018 QC Manager Course Release 10, Module 3 25 As the QC Manager, you are responsible for the administration, management and evaluation of the QC Operations. You need to ensure that all personnel and equipment are current in any required qualifications or calibrations and develop a schedule, if needed, to maintain them. If Independent Assurance evaluations are performed on the QC Technicians, you need to take some active participation and ensure that the proper procedures and requirements of the test methods are being followed. You may need to provide coaching to evaluated QC technicians if they receive a strike. YoumayneedtogetinvolvedinQCvsVerificationissuesorproblems,orneedtocoordinate them. Recognize that Verification sampling and/or testing must be performed and incorporate that time into your schedule and plan. By fostering a working relationship with the Verification staff, unanticipated problems may be resolved quickly, without impacting the schedule or cost. Coordination between QC and VT is vital to ensure the sampling and testing is performed and identified under the appropriate MAC Specs. QC and VT must agree on the MAC Spec, category, type, sample purpose. As QC Manager, you may need to Release 10 November

27 coordinate communication with the PA to ensure the materials are proper identified. You may need to conduct or attend both internal and external meetings where QC issues are being discussed or resolved. Should you note that QC requirements are not being adhered to, you may need to schedule a meeting to get everyone back on track. You may also need to attend meetings to represent your company with the Owner to address QC issues. Pre operations meetings should be held and attended by QC and Production personnel prior to commencing an operation for the first time. Items such as new specifications, specification issues, memos, etc. can be discussed. Release 10 November

28 Evaluate QC Performance Monitor, Evaluate & Report QC performance Coordinate Resolution of MAR issues Record QC lapses & provide preventive solutions Track rework goals Evaluate current practices and recommend improvements Attend Project Progress meetings November 2018 QC Manager Course Release 10, Module 3 26 You will be responsible for the monitoring of QC inspection, testing, reporting and the evaluation of the results, together with the accurate and timely reporting of results. As discussed earlier, if you ensure that everyone understands the reporting and distributions requirements, there should be minimal problems associated with the reporting. In instances where material is not up to specification, but you want to leave itinplace,you may be responsible for initiating the Engineering Analysis Report (EAR) in anefforttohave the Department accept the material based upon an EAR. It will be your responsibility to provide solutions to problems encountered by QC. For instance, if density tests are not performed at the required frequencies, then you need to find out why and provide a solution. You need to follow up and ensure that when you have provided solutions to problems, there is a mechanism that permits you to determine whether or not the solution is working. The system you use for tracking rework goals should display the projected versus actual rework goals. Naturally, if there appears to be problems with current practices and procedures being used, it would be incumbent upon you to provide alternatives or solutions, which are acceptable to all parties, and hopefully impacts the schedule and costs minimally. Project Progress meetings offer an opportunity for all parties to discuss upcoming events, problems encountered and potential solutions that may be employed to resolve any conflicts or problems. Some of these meetings may be related to QC, some not, but it is important that you stay in the loop. Naturally, you should conduct QC meetings as appropriate. Release 10 November

29 Track Re work Costs Spreadsheet Tracking Prepare summaries of re work events Focus on improving processes to minimize re work November 2018 QC Manager Course Release 10, Module 3 27 The rule of thumb on concrete re work is that direct costs are approximately 285% above the cost to build it right the first time. The job management team uses spreadsheets on actual re work cost and impacts and compares these against the re work goal for the job. This is a good measure to seeifyour program is effective or if you need to improve on a certain area. Another good practiceisto put together a summary of the re work event and share with personnel of the job to learn from mistakes. This information can be sent to other projects in hopes of preventing of the same event somewhere else throughout the company. The intent of having goals on re work is What Gets Measured Gets Attention. If you see where you re having problems with re work, you can focus on improving the process to help the project be more financially successful and give the Owner the best product in the lowest amount of time. Release 10 November

30 Identify Process problems Identify QC problems Assist in meeting/improving processes November 2018 QC Manager Course Release 10, Module 3 28 Control charts can do a variety of things for the QC Manager and we will now look at a few examples where the use of control charts were beneficial to the contractor. In Lesson 4, we will see that control charts are effective tools that can be used by the QC Manager to monitor performance and improve processes during construction. They can assist in spotting problems, fine tuning processes and production, to the benefit of the Contractor. Release 10 November

31 Density / Moisture Relationship for 121 Proctor (T 180) November 2018 QC Manager Course Release 10, Module 3 29 This is an example of a control chart prepared by the QC Manager to monitor the Moisture and Density results for the previous slide. Control charts are a helpful tool for QC Managers to monitor Quality Control. More details on control charts will be covered in Chapter 4. Release 10 November

32 Engineering Analysis Report (EAR) Initiated by Contractor Submitted to Project Administrator Follow FDOT EAR Guidelines November 2018 QC Manager Course Release 10, Module 3 30 There are instances where material may not meet the project requirements but based upon analysis by a Specialty Engineer, may be left in place, though generally at a reduced payment. The Department has published guidelines for the development of an EAR, so you should take advantage of this document and ensure the Specialty Engineer utilized is aware of and follows these guidelines. Release 10 November

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34 Materials Acceptance Resolution (MAR) MAC records most materials acceptance issues as part of the Materials Certification (MC) Review in a process known as Materials Acceptance Resolution or MAR The PA coordinates with the Materials Office MC Reviewer If the material is designated to have an Engineering Analysis Report, the PA will notify the Contractor November 2018 QC Manager Course Release 10, Module 3 32 Defective Material not meeting specifications or project requirements, which the Contractor desires to leave in place is documented in MAC as part of the Materials Certification (MC) Review. The QC Manager is responsible for coordinating any Engineering Analysis Report (EAR) submittal to the Project Administrator in the case of defective material being left in place and accepted. If the MAR process determines that an EAR is needed, the PA will notify the Contractor. Outside of MAC, the Contractor submits the proposed scope of the EAR to the PA. The PA forwards the scope to the DMRE. The DMRE reviews the scope and may provide additional or revised requirements. The PA returns the scope to the Contractor who then has the Specialty Engineer perform the EAR and provides the final report to the PA. The PA attaches the final report to the MAR issue in MAC and the final resolution is recorded by the PA, DMRE, DCE and possibly the Director of the Office of Construction (when the DMRE and DCE do not concur). These resolutions are recorded in MAC. Release 10 November

35 Record Management Oversee MAC data entry Verify QC record completeness and submittal Verify completion & submittal of Certification Documents Consult on Final Estimate issues November 2018 QC Manager Course Release 10, Module 3 33 It isn t over until the paperwork is done. A truism in today s construction industry, especially as it relates to QC. The Department uses MAC for the storage of all sampling and testing information. The QC sampling and testing data must be entered into this system. You need to ensure that data entry personnel have the appropriate access and training to use the system. Untrained, inexperienced and careless personnel will only create problems in the data entry,whichare problems for you. Choose carefully. Each month you will be responsible for submitting the Contractor Monthly Certification(s), Forms & , certifying as to the accuracy and completeness of the sampling, testing and reporting performed. There are a number of other certification documents that are required for material acceptance that the contractor must submit to the PA. At times, material acceptance issues become payment issues; for example, a bonus on the asphalt for a Percent with Limit (PWL) result greater than 1.00 or a reduction in payment due to a structural concrete compressive strength failure within 500 PSI of the minimum compressive strength. The QC Manager may be asked to consult to ensure the testing data that created the payment issue is correct. Release 10 November

36 105-4 Contractor Certification of Compliance. Provide the Engineer with a notarized monthly certification of compliance with the requirements of this Section, to accompany each progress estimate, on a form provided by the Engineer. The Department may not authorize payment of any progress estimate not accompanied by an executed certification document. Final payment in accordance with 9-8 will not be made until a final notarized certification summarizing all QC exceptions has been submitted. November 2018 QC Manager Course Release 10, Module 3 34 SECTION 105 CONTRACTOR QUALITY CONTROL GENERAL REQUIREMENTS Contractor Certification of Compliance. Provide the Engineer with a notarized monthly certification of compliance with the requirements of this Section, to accompany each progress estimate, on a form provided by the Engineer. The Department may not authorize payment of any progress estimate not accompanied by an executed certification document. Final payment in accordance with 9 8 will not be made until a final notarized certification summarizing all QC exceptions has been submitted. Release 10 November

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38 What is the intent of this form? What is an Exception? November 2018 QC Manager Course Release 10, Module 3 36 This opening statement of the form is the Contractor and QC Manager certification that the QC sampling and test results were performed in substantial compliance with the specifications and Project QC Plan. Release 10 November

39 Exceptions For the Monthly Certification, List the Following: 1. QC samples that did not compare with VT samples and had VT results upheld by RT samples. 2. Any samples that had Engineering Analysis Report or Delineation Test(s) performed. 3. Any failed QC samples. 4. Any QC samples that do not have results entered into MAC. November 2018 QC Manager Course Release 10, Module 3 37 Exceptions: For the monthly certification, list the following: 1. QC samples that did not compare with VT samples and had VT results upheld by RT samples. 2. Any samples that had Engineering Analysis Report or Delineation Test(s) performed. 3. Any failed QC samples. 4. Any QC samples that do not have results entered into MAC. Release 10 November

40 Exceptions For the Monthly Certification, List the Following: 5. Any QC samples that were performed by unqualified technicians or laboratories. 6. Any materials placed without an approved QC Plan or when the QC Plan is suspended. 7. Any materials provided from an unapproved producer or supplier. 8. Results of any failing Chloride content limits as defined in Specification November 2018 QC Manager Course Release 10, Module Any QC samples that were performed by unqualified technicians or laboratories. 6. Any materials placed without an approved QC Plan or when the QC Plan is suspended. 7. Any materials provided from an unapproved producer or supplier. 8. Results of any failing Chloride content limits as defined in Specification The following would not be listed as an exception on the subject form: 1. QC samples that have been tested but not verified. 2. QC samples that have been tested and had verification test results that did not compare. For the final certification, all exceptions to QC sampling and testing must be shown on the certification. Release 10 November

41 Who signs this form? November 2018 QC Manager Course Release 10, Module 3 39 Quality Control Manager: Type the Quality Control Manager s name. Title: Type or print the title of the person signing the certification. Signed By: The electronic form allows for a digital signature when the you have completed the requirements for a digital signature identity. Contractor: Type the name represented by the signature in the Contractor signature block. This is an officer or director of the Contractor with an authority to bind thecontractor. Title: Type or print the title of the person signing the certification. Signed By: The electronic form allows for a digital signature when the you have completed the requirements for a digital signature identity. Release 10 November

42 What does signing this form mean to you? November 2018 QC Manager Course Release 10, Module 3 40 The signing of this form is a serious matter and not to be taken lightly. By signing this form you are certifying that everything was performed as it should be. If you sign this form, knowing that it is not true, you can be held liable and prosecuted under State and Federal laws. Also, the final version is a contract document and could hold payment and eventually lead to the Contractor s Certificate of Qualification being suspended. Release 10 November

43 Can your QC Manager Qualification be suspended? YES Can a QC Manager be disqualified? YES November 2018 QC Manager Course Release 10, Module 3 41 CTQM Chapter 7 covers the suspension process. Release 10 November

44 CPAM, Chapter 13.1 & CTQM Chapter 7.6 If the PA or Resident Engineer issues Deficiency Letter (DL) to Contractor as a direct result of deficient QC Operations due to the QC Manager s failure to properly apply the specifications and Quality Control procedures, a letter of warning (or suspension) must also be sent to the QC Manager. November 2018 QC Manager Course Release 10, Module 3 42 Requirements are documented in CTQP Chapter 7 and CPAM Chapter 13 CPAM describes issuing an DWL or DL. CTQM describes DLs issued as a direct result of deficient QC Operations due to the QC Manager s failure to properly apply the specifications and Quality Control procedures. Release 10 November

45 Qualification Suspension by a 3 letter system 1 st Letter of warning issued by the State Construction Training Coordinator (SCTC) 2 nd Letter of warning issued by SCTC within one year of first 3 rd Letter suspends qualification November 2018 QC Manager Course Release 10, Module 3 43 CTQM QC Manager Suspension Process Letters of warning written to a QC Manager could lead to qualification suspension in accordance with the following three step system: 1st Letter Documented letter of warning from the State Construction Training Manager. If no other letters are issued within one year (365 days), then the record of the 1st letter of warning shall be deleted from the Manager's qualification record. 2nd Letter Documented letter of warning from the State Construction Training Manager within one year of the 1st letter of warning. If no other letters are issued within one year (365 days), then the record of the 1st and 2nd letter shall be deleted from the Manager's qualification record. 3rd Letter Suspension of qualification in the TQDBS by the State Construction Training Manager. Should the need arise to send a 3rd letter within 365 calendar days of the 2nd letter of warning, the QC Manager s CTQP qualification shall be suspended. The State Construction Training Manager shall inform the CTQP Manager to suspend the Manager's qualification in the TQDBS via letter or e mail. Release 10 November

46 The suspension shall be for one calendar year (365 days). This decision may be appealed to the Director, Office of Construction. The Director s decision is final. Prior to having the qualification reinstated, the technician must meet all initial QC Manager qualification requirements including passing the QC Manager s examination. One copy of the suspension letter shall be given to the QC Manager, one copy to the manager's supervisor (or prime contractor's representative), one copy sent to the State Construction Training Manager, and the original shall be retained in the project files. This suspension shall apply to the QC Manager qualification only. These warning letters are not considered as strikes and they are not tracked in MAC.The State Construction Office maintains a tracking system to record when QC Managers receive warning letters and the number of letters received. Release 10 November

47 Project Completion Asphalt Amounts/Certifications/Reports MAC Sampling & Testing Material Certifications Earthwork Record System Resolve MAR Issues November 2018 QC Manager Course Release 10, Module 3 45 Upon completion of the project, the QC Manager has numerous responsibilities related to finalizing records, certifications and documentation. Shown above is a list of items, which is not to be considered all inclusive, that the QC Manager may need to deal with upon completion of the Project. Release 10 November

48 Any Questions? November 2018 QC Manager Course Release 10, Module 3 46 Release 10 November