penn dot's quality program, frank collella, consultant, papa
TRANSCRIPT
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Presentation toNCAUPG/OAPC
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Industry Objectives
• Ensure best quality pavements
• Assisting with QC/QA processes
• Improve the durability asphalt pavements
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Currently
• Managing for pay
– Driven by current acceptance method
• Not focused on process capability
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PASIN-Quality Management System
• Managing for quality
• Process capability
• Process improvement
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PASIN Participants
– Pennsylvania Department of Transportation
– Federal Highway Administration
– Pennsylvania Asphalt Pavement Association
– American Council of Engineering Companies
– PA Aggregate and Concrete Association
– AASHTO Materials Reference Laboratory
– Pennsylvania Turnpike Commission
– NECEPT
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PASIN Implementation
1. Saywhat
you do
1. Saywhat
you do
2. Dowhat
you say
2. Dowhat
you say
3.Prove it
3.Prove it
4.Improve
it
4.Improve
it
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PASIN QMS Elements
• Management review• Customer focus• Corrective and preventive actions• Control of non-conforming product• Control of documents• Control of records• Internal audits• External audits
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PASIN Quality Manual
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Activities to Date
• Baseline Assessment
• Conducted five pilot projects
‒ First round - a struggle
‒ PASIN implementation templates
‒ Warranty link
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AARs
• Increased profits
• Improvement in quality
• Senior management involvement
• Customer focus
• Corrective actions
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Vision
• Quality Management System principles
• Standard operating procedures
• Culture change
‒ Unplanned - results unpredictable
‒ Planned - desired results
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Culture Change - PennDOT
Limited
Involvement
QA Staff-QC PlanReview
District Staff-QCPlan Review
QA – ExternalAudits
Inspector-Contractor Audits
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Best Practices ~ FMEA
• Failure Mode and Effect Analysis
– Failure causes
– Effects analysis
• Derived by PASIN Core Team
• Refined by industry work groups
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Best Practices
“Techniques, methodologies, processes
or procedures that through experience
and research, have proven to reliably
lead to performance results recognized
as exceeding those achieved by most
organizations.”
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Best Practices ~ Plant
Results in…”asphalt pavement that is: Consistent in quality Maximizes durability”
Total - 74
New Best Practices
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Best Practices ~ Laydown
• Improve laydown quality control
• Total - 42
• New Best Practices
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Best Practices ~ Implementation Plan
HMA PASIN Implementation Plan
Hot Mix Asphalt
PASIN Implementation Plan
Project Name and Number
Submitted by: Date: ___2008
Organization Name
Hot Mix Asphalt
Implementation Plan
Contractor
Submitted by
and date
PASIN Team
Approved by
and Date
CONTRACTOR’S
LOGO
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PASIN Implementation
1. Saywhat
you do
1. Saywhat
you do
2. Dowhat
you say
2. Dowhat
you say
3.Prove it
3.Prove it
4.Improve
it
4.Improve
it
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PASIN Implementation
PASIN Support:
Quality Manager Management Plant personnel Paving personnel PASIN Implementation Team External certified auditors
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Implementation Plan
Company Management Team
Management
Production personnel
Paving personnel
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Implementation Plan
Company Best Practices Support:
Develop/modify processes to meetpilot requirements
Develop and/or use required forms toassess process effectiveness
Support training by Quality Manager
Provide implementation information forinternal and PASIN external auditors
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Implementation Plan
Contractor Internal Audit Team
Manage internal auditso schedule, implement audits and
keep records
Publish audit report
Communicate results of auditso company senior management
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PASIN Implementation
PASIN Implementation Team:
PennDOTo ADEo Bureau of Construction and Materialso Others
PA Asphalt Pavement Association
Consultants
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ManagementReview
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(Source: PASIN Quality Manual – Section 5)(Source: PASIN Quality Manual – Section 5)
Management Review
Management Commitment:
Monitor motoring public satisfaction Control QMS processes and products Maintain and improve QMS
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(Source: PASIN Quality Manual – Section 5)(Source: PASIN Quality Manual – Section 5)
Management Review (cont.)
Management Actions:
Establish a quality policy andmeasurable goals
Ensure availability of resources
Conduct periodic management reviews
Communicate importance of satisfyingcustomers’ needs
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(Source: PASIN Quality Manual – Section 5)(Source: PASIN Quality Manual – Section 5)
Management Review (cont.)
PASIN Quality Policy:
“We will satisfy those we serve by consistently
designing, constructing and maintaining durable, highquality asphalt highways through the use of processes
that have minimum adverse effect on surroundingcommunities and are continuously improved.”
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(Source: HMA Plan Implementation Template)(Source: HMA Plan Implementation Template)
Management Review (cont.)
Standard Agenda:
Quality goals Production goals Scheduling Resources QC test results Acceptance test results Audits Customer complaints Non-conformances Corrective and preventive actions
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(Source: HMA Plan Implementation Template)(Source: HMA Plan Implementation Template)
Management Review (cont.)
Introduction Methodology
Quality Policy Quality Objectives Management Review Team Members Standard Management Review Agenda
Implementation Plan
Action Item Responsibility Timeframefrom NTP Date
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InternalAudits
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(Source: PASIN Quality Manual - Section 8)(Source: PASIN Quality Manual - Section 8)
Internal Audits
Internal audit plan
Auditors from the company
Coaching from the PASIN team
Internal Audit Report
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Internal AuditsInternal Audits(Source: PASIN Quality Manual - Section 8)(Source: PASIN Quality Manual - Section 8)
Has the process been planned?
Is the process carried out according to plan?
Are the planned results being achieved?
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Internal AuditsInternal Audits(Source: PASIN Quality Manual - Section 8)(Source: PASIN Quality Manual - Section 8)
Are opportunities for improvementbeing identified and implemented?
o By correcting non-conformitieso By identifying root causes of problems and
implementing corrective actiono By identifying trends and the need for
preventive actiono By innovation
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Internal AuditsInternal Audits(Source: PASIN Quality Manual - Section 8)(Source: PASIN Quality Manual - Section 8)
Introduction Methodology
Auditor Qualification Auditor Training, Approved Auditors Audit Plan Audit Schedule
Implementation Plan
Action Item Responsibility Timeframefrom NTP Date
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Corrective andPreventive
Actions
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Corrective and Preventive ActionsCorrective and Preventive Actions(Source: PASIN Quality Manual - Section 8)(Source: PASIN Quality Manual - Section 8)
Problems or potential problems
o Identifyo Recordo Analyzeo Resolveo Prevent
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Corrective and Preventive ActionsCorrective and Preventive Actions(Source: PASIN Quality Manual - Section 8)(Source: PASIN Quality Manual - Section 8)
Action:
o Establish a Corrective & PreventiveAction Reporting System thatspecifies the use of a formalizedproblem solving approach of adegree appropriate to themagnitude of the problem.
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Corrective and Preventive ActionsCorrective and Preventive Actions(Source: PASIN Quality Manual - Section 8)(Source: PASIN Quality Manual - Section 8)
Introduction Methodology (Root Cause Analysis)
Corrective Actions Preventive Actions Closure Tracking and Verification
Implementation Plan
Action Item Responsibility Timeframefrom NTP Date
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Internal AuditsInternal Audits(Source: PASIN Quality Manual - Section 8)(Source: PASIN Quality Manual - Section 8)
Example Audit Plano Scope
o Organize the audit team
o Determining the starting and endingpoints of the audit (Process Flow Diagram)
o Review company documentation
o Develop and Approve audit checklists
o Schedule audit
o Complete audit reports
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Most ImportantMost Important
Management Review
Internal Audits
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Key for SuccessKey for Success
Every employee involvedknows what they areresponsible for as well as
what everyone else isresponsible for.
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Questions?