QUALITY ANALYSIS IN CONSTRUCTION

PROJECTS USING SIX SIGMA CONCEPT

R Manoj Kumar1, R Vidjeapriya2

1
M E Student, Department of Civil Engineering,
College of Engineering, Anna University, Chennai, Tamil Nadu,(India)
2
Associate Professor, Dept. of Civil Engineering,
College of Engineering, Anna University, Chennai, Tamil Nadu, (India)
ABSTRACT
Six sigma is new to construction sector and this philosophy is to reduce the defects in the construction process.
The critical objective of construction industries nowadays is to complete a project within a stipulated time and
cost as per the required standards and specifications, minimization of waste and efficient use of resources. Six
Sigma principles with an effective methodology in construction helps in reducing variation and eliminating the
root causes of defects. Six Sigma can provide a broader quality concept, detailed performance measurement,
coordinated and repeatable process/performance improvement. In order to improve the process in construction
it is important to understand the factors affecting the construction process and analyze the factors for the
construction improvement. This paper aims to improve the quality of concrete structures, paint work, brick work
, welding and joints of a building by using DMAIC methodology. From the point of view of achieving Six Sigma
concept on site the recommended corrective action plans on the defect is done. Thus the questionnaire fulfils the
criteria for control plans of the construction activities in the final stage. The answered questionnaires were
collected then by using SPSS software, the collected data’s is analyzed. The results of the study indicate that the
implementation of Six Sigma in construction context will be achieved its aim by reducing the defects. This
process suggest that proper training and management support and minor changes in current work procedure
can help improve the quality in construction process and ultimately customer satisfaction which is of prime
importance.
Keywords: define measure analyze control (dmaic) , six sigma, statistical package for social studies
(spss)

I. INTRODUCTION
Six Sigma is a rigorous, focused, and highly effective implementation of proven quality principles and
techniques. Six Sigma aims for virtually error-free business process. Sigma, σ, is a letter in the Greek alphabet
used by statisticians to measure the variability in any process. Increasing numbers of companies start to integrate
the full implications of Six Sigma. Six Sigma is a quality improvement technique based on statistics, was used
firstly by Motorola in the 1980s. It helps to decrease costs, increase quality by improving process and reduce the
production time. Total Quality Management which is management philosophy focuses on continually work

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processes. Particularly, Six Sigma became a useful method as a performance indicator and process improver for
the companies from different industry. Six Sigma has statistical and business perspectives and its applications
are improved by Six Sigma Academy. Construction work has fragmented and project-oriented work processes
compared to the manufacturing industry. So, the evaluation of Six Sigma within construction context becomes
an interesting research question considering quality, performance and management aspects. The importance of
quality improvement and excellent performance in the highly competitive world market, lead many
organizations, their top managers, project managers, and engineers to implement the new philosophies such as
pull scheduling and lean principle at their organizations. This paper describes the Six Sigma principle and
framework as a quality improvement strategy through the successful business.
1.1 OBJECTIVES
 To study the various defects in construction site which influence the quality of project.
 To apply six sigma concepts in construction projects for quality improvement using DMAIC (DESIGN,
MEASURE, ANALYSE, IMPROVE, CONTROL) methodology.
II. METHODOLOGY
Six Sigma continuous improvement methodology which known as DMAIC (define, measure, analyze, improve,
control) aims to enhance the efficiency of the existing processes and increase customer satisfaction through
designed products and services. DMAIC framework is an integration of several techniques such as QFD (quality
function deployment), SPC (statistical quality control), DOE (design of experiments), and FMEA (failure mode
and effects analysis) in a logical direction . In this study, a survey-based approach is used to identify the
Continuous Improvement initiatives commonly practiced in construction companies as well as understanding
the approach of these companies to Six Sigma. This approach is more suitable when the current design of the
products, services and processes are correct and satisfactory regarding to the requirements, customers and
business. It emphasizes the identification and avoidance of variations. Moreover, six sigma principles underline
the explicit recognition of the root causes of defects and statistical process control to sustain continuous
improvement. This methodology offers structured framework in following steps to establish systematic
continuous improvement.
(i) Define- In this step it is necessary to define customer requirements and any things do not meet those
requirements known as defect, determine key processes, key roles and team charter, define project goals and
scope, and estimate the risks and financial impact.
(ii) Measure-Identify and collect the appropriate data which are relevant to the defects and the processes need
improvement. Measure the processes performance and establish the measurement system based on Six Sigma
techniques and tools.
(iii) Analyze-Study and analyze the data collected in previous step to find out the root causes of the defects and
unsatisfactory performance.
(iv)Improve-Identify alternative solutions and methods based on the knowledge derived from analyze step,
study and assess the potential solutions to distinguish the most successful improvement solution. Implement that
successful method.

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(v) Control-Establish a control plan to ensure that expected improvement has been achieved, and the knowledge
and experiences have been documented and shared to remain at attained high level performance.
The most common reasons for industries to implement Six Sigma to resolve issues facing the construction
industries :
• Cost reduction
• Cycle time reduction
• Error and waste reduction
• Increase competitive advantage
• Improve customer satisfaction
• Change company culture
• Improve quality.
In the construction industry, the use of the six sigma principle for performance assessments, particularly aimed
at high quality and variability control. Introduced the six sigma principle as one of the approaches to
augmenting productivity, which concentrated on reducing cycle time and eliminating any defects or errors
engaged in the processes.

2.1 QUESTIONNAIRE DESIGN

The survey questionnaire is designed to probe the cross sectional behavioural pattern of the six sigma in
construction industry. The questionnaire was prepared for the survey was formulated by seeing the relevant
literature in the area of construction six sigma. The interviewer was free to ask additional question that focused
on issues during the course of interview. This survey is conducted on some zones in Chennai, Tamil Nadu. The
freedom to follow the interview to ask for clarification and the focus on specific projects, knowledge made the
interviews insightful.
2.2 DATA COLLECTION
 Questionnaires were mailed to respondents (Site engineers, Consultants, Contractors and Project managers).
 Completed forms were requested to be mailed or faxed back to the study, and the response for this request
was poor.
 Forms were given to respondents to complete, and completed forms were collected later.
 In many instances, forms were completed at the meeting; this method had the added benefit of making
clarifications to respondents about questions in forms;
 The data„s collected from some companies in Chennai.

III. QUESTIONNARIE SURVEY

The primary goal of Six Sigma is to improve customer satisfaction, and thereby profitability, by reducing and
eliminating defects. It uses in-depth studies of small groups of people to guide and support the construction of
hypotheses. The results of qualitative research are descriptive rather than predictive. A qualitative strategy was
adopted in this study due to the fact that it can be used at both the data collection and data analysis stages of a
research project. The qualitative research type are typically more flexible i.e., they allow greater spontaneity and

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adaptation of the interaction between the researcher and the study participant. In qualitative research, only a
sample (that is, a subset) of a population is selected for any given study. The interview was used specially for
identifying other factors six sigma methods. After preliminary data gathering, questionnaire survey has carried
out to reach the objective of this study among brick work, tile work and painting work based on six sigma
concepts involved in construction projects. Questionnaire survey specifically has been used for evaluation of
various modes of six sigma concepts. The general methodology of this study relies largely on the survey
questionnaire which will be collected from the site engineers, contractor, consultant and project manager by
mail or by personnel meeting. A thorough literature survey was initially conducted to identify the factor of six
sigma performance of construction industry as a whole six sigma. This study has adopted the more general and
broad definition of six sigma.

IV. EVALUATION
Relative importance index (Rii) analysis was employed to measure the likert (ordinal) scale. in this study, five
scale rating was used and the weight was give as below:
1 – Strongly Disagree/ least Important;
2 – Disagree/ Of Little Importance;
3 – Neutral/ Neither Important;
4 – Agree/ Important;
5 – Strongly Agree/ Most Important
The RII was calculated by using the formula as below
RII=ΣW/AN
Where,
W=weight of scale
A=highest weight (5„in this case)
N=total number of respondent.

4.1 RELIABILITY ANALYSIS

Reliability test is conducted to check the stability and consistency of a data by using cronbach alpha method that
is widely adopted Reliability of the data is considered at low level when cronbach alpha is less than 0.3 which
means the data is not reliable and cannot be adopted. Reliability is at high level when cronbach alpha is more
than 0.7.

4.2 RELATIVE IMPORTANT INDEX (RII)

The questionnaires are collected and analyzed using statistical software package SPSS v 23. The ranking of
factors was calculated based on Relative Importance Index. Hierarchal assessment of factors was carried out to
determine ranking of the factors based on level of significance. It was assessed based on Relative important
index (RII) value and calculated for each group of respondent„s i.e. contractor, consultant and owners and also

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the overall respondents as presented. It shows that top 5 most significant factors of delay factor ranked by
overall respondents are material market rate, contract modification, high level of quality requirement, project
location, depends on the fresher„s to bear the whole responsibility. Material market rate was ranked first (RII) as
agreed by the entire respondent.

4.3 MULTIPLE REGRESSION ANALYSIS

A statistical tool that allows to examine how multiple independent variables are related to a dependent variable
and also allows to take information about all of the independent variables and use it to make much more
powerful and accurate predictions about why things are the way they are. This latter process is called “Multiple
Regression”. Multiple regression is an extension of simple linear regression. It is used to predict the value of a
variable based on the value of two or more other variables. The variable which is to be predicted is called the
dependent variable. The variables using to predict the value of the dependent variable are called the independent
variables. For example, use of multiple regression to understand whether exam performance can be predicted
based on revision time, test anxiety, lecture attendance and gender. Alternately, multiple regression can be used
to understand whether daily cigarette consumption can be predicted based on smoking duration, age when
started smoking, smoker type, income and gender. Multiple regression also allows to determine the overall fit
(variance explained) of the model and the relative contribution of each of the predictors to the total variance
explained. The "quick start" guide shows how to carry out multiple regression using SPSS Statistics, as well as
interpret and report the results from this test.

V. RESULT AND DISCUSSION

The collected data were analyzed by using the SPSS software. The questionnaire has been collected on
following two modes direct interview and through mail.
5.1 RELIABILTIY TEST
TABLE 5.1 RELIABILITY STATISTICS USING SPSS
CRONBACH‟S ALPHA NO. OF QUESTIONS
0.968 62
The above table shows the calculated cronbach value using spss. The value is found to me 0.968
which is a very reliable source.

FIGURE 5.1 SHOWS THE SPSS REPORT OF RELIABITY ANALYSIS

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5.2 SPSS REPORT AND RESULTS

Based on the various factor of questionnaires, analysis for defects in concrete structures, paint work,
brick work, welding and joints with the corresponding mean value and arrange in rank wise. From the
ranking order the top five ranks are selected and separates it for the further evaluation.

Figure 5.2 SPSS TEST REPORT-1

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The following table 5.1 shows the top ranks of defects in concrete structures

Table 5.1 TOP RANKING OF DEFECTS IN CONCRETE STRUCTURES

SL.NO DESCRIPTION RANK

1 DUE TO EXTERNAL FACTORS 1
2 CRAZING 2
3 EFFLORESCENCE 3
4 ROCK POCKETS 4
5 HONEY COMBING 5

The following table 5.2 shows the top ranks of defects in paint work

Table 5.2 TOP RANKING FOR DEFECTS IN PAINT WORK

SL.NO DESCRIPTION RANK

1 ENVIRONMENTAL FACTORS 1
2 GRINNING 2
3 BLOOMING 3
4 SAGGING 4
5 FLAKING 5

The following table 5.3 shows top ranks of defects in brick work

Table 5.3 TOP RANKING OF DEFECTS IN BRICK WORK

SL.NO DESCRIPTION RANK

1 EXTERNAL FACTORS 1
2 THERMAL EXPANSION 2
3 SHRINKAGE EFFECT 3
4 SULPHATE ATTACK 4
5 LEVELING 5

The following table shows the top ranks of defects in welding and joints

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 Table 5.4 TOP RANKING OF DEFECTS IN WELDING AND JOINTS

SL.NO DESCRIPTION RANK

1 INADEQUATE JOINT 1
PENETRATION
2 CORROSION 2
3 CRACK 3
4 UNDERCUT 4
5 TUNGSTEN INCLUSIONS 5

VI. CONCLUSION
The aim of this thesis is to develop a project questionnaire model based on the theory of Six Sigma.
Questionnaire were prepared based on each of the DMAIC phases in the Six Sigma model. The SPSS V.23
software used to analyses the questionnaire factors. The top ranking factor in concrete structures, paint work ,
brick work, welding and joints were found. Results will give a guide on how to implement the project six sigma
model in construction projects thereby increasing the quality. Using the result, Recommendations and
mitigation measures can be given to the construction sites.

REFERENCES

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