6SIGMA IMPLIMENTATION IN CONSTRUCTION INDUSTRY

DISSERTATION/SEMINAR-1/SEMINAR-2/SEMINAR-3/PROJECT STAGE-1
REPORT
ON
“SIX SIGMA IN CONSTRUCTION INDUSTRY”
Submitted in Partial Fulfillment of the Requirement for the Degree of
Bachelor of Engineering
(Civil)
Submitted by
Anuja Giridhar Bhoye.(72005671D)
Sakshi vinayak jadhav (71005706L)
Shital Siddharth bodkhe (72005678M)
Nikita Vasant Sonawane (72005761C)
DEPARTMENT OF CIVIL ENGINEERING
MATOSHRI COLLEGE OF ENGINEERING AND RESEARCH CENTER,
NASHIK,
EKLAHARE

Under the Guidance of

Asst. Prof. /Prof. /Dr. ……………………

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 6SIGMA IMPLIMENTATION IN CONSTRUCTION INDUSTRY

ABSTRACT
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. In this paper we proposed the Six Sigma is a statistical
methodology that provides a structured framework to organize and implement strategic process
improvement initiatives to attain reductions in process variability or defects. The basic theory of
six sigma, DMAIC (Define, Measure, Analyze, Improve & Control) methodology is been
discussed in this paper. A case study on a commercial building was conducted to which six sigma
principles were applied for few internal finishing works: Brickwork, Plastering, flooring and
Painting. A defect assessment sheet has been prepared to compute the process sigma level of the
existing practice of work and after applying DMAIC (Brickwork, Flooring and Painting). The
improvement is presented in terms of process sigma and standard deviation. The purpose of this
study is to analyze Six Sigma within construction context and evaluate its features through
Literature Review and Interviews with case study. This thesis aims at understanding the needs of
construction industry from process improvement perspective and matches these needs with the
expected outcomes of Six Sigma.

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INTRODUCTION
Problem statement
Total Quality Management which is a management philosophy, focuses on continually work
processes (Boddy, 2009). Particularly, Six Sigma became a useful method as performance
indicator and process improver for the companies from different industry. Increasing numbers of
companies start to integrate the full implications of Six Sigma (Lloréns-Montes and Molina,
2006).
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 (Lloréns-Montes and Molina, 2006). Six Sigma has statistical and business
perspectives and its applications are improved by Six Sigma Academy (LlorénsMontes and
Molina, 2006). However, construction work has fragmented and project-oriented work processes
compared to the manufacturing industry (Han et al., 2008). So, the evaluation of Six Sigma within
construction context becomes an interesting research question considering quality, performance
and management aspects.That’s why, this study discusses Six Sigma as a process improvement
method through some research questions and tries to understand its features and implications as a
quality initiative, performance indicator/improver and management strategy.
Construction management and technology are the two key factors influencing the development of
the construction industry. The productivity of the construction industry worldwide has been
declining over the past 40 years. One approach for improving the process is using Six Sigma
concepts in construction. Six Sigma is a quality improvement technique based on statistics was
used firstly by Motorola in 1980s by Bill Smith of Motorola to decrease cost, increase quality by
improving process and reduce the production time. It received little publicity until late 1990s. Six
Sigma results the application of a new form of management technique to construction. Essential
features of Six Sigma include a clear set of objectives for the delivery process, aimed at
maximizing performance for the customer at the project level, concurrent design, construction, and
the application of project control throughout the life cycle of the project from design to delivery.
An increasing number of construction academics and professionals have been storming the
ramparts of conventional construction management in an effort to deliver better value to owners
while making real profits. As a result, Six Sigma-based tools have emerged and have been

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successfully applied to simple and complex construction projects. In general, six sigma projects
are easier to manage, safer, completed sooner, and cost less and are of better quality. Sigma within
construction context becomes an interesting research question considering quality, performance
and management aspects.Six Sigma is a quantitative approach for improvement with the goal of
limiting defects from any process, specially a numerical goal of 3.4 defects per million
opportunities (DPMO). Six Sigma is reportedly easier to apply than many other quality
management programs because it provides information about the change needed and the programs
to execute the change. The strategy it uses is a five step improvement process: Define Measure,
Analyze, Improve and Control (DMAIC). This process is deeply integrated with the overall goals
of the organization and as such, requires top down implementation. The project work is carried out
to study the analysis of Six Sigma within construction context and evaluate its features through
Literature Review and Interviews with case study. After the evaluation of interviews with
contractor, site-supervisor, occupants and visual observations, defects and their reasons were
determined. Reasons
of poor quality in commercial units were listed as firstly poor workmanship, then improper or of
poor quality materia usage and lastly problems in design of detailing. Despite different
construction dates of units studied, the results show that nothing was learned from the previous
mistakes and same defects were repeated. This shows the importance of a system providing
feedback and evaluation of quality level of a construction project and quality improvement efforts
of the contractor, and measuring the progress over time like Six Sigma

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LITERATURE SURVEY

According to Sneha P. Sawant and Smita V. Pataskar [1] suggested that, Six Sigma is a Quality
improvement technique that has being implemented in manufacturing and other industries. Six
sigma is new to construction industry. This paper describes the basic theory of Six Sigma,
principles, methodology and various tools used. A case study of a residential building is taken in
which the Six Sigma principles are applied for internal finishing work, the Six Sigma
methodology has been adopted to improve the quality and is checked against the sigma level. The
findings suggest that proper training and management support and minor changes in current work
procedure can help improve the quality and ultimately customer satisfaction which is of prime
importance.Sunil v. Desale and Dr. S. V. Deodhar
[2] The authors suggested that, This paper comprises of literature review and discussing process
improvement methods used in the construction industry and analysis of features and principles of
six sigma and there in to review of a project manager, a field and a cost engineers on the same.
The interview on Six Sigma is based on, performance and management aspects. This study
defends and removes any doubt about the positive effects of Six Sigma on construction projects.
Particularly, Six Sigma can provide a broader quality concept, detailed performance measurement,
and coordination in repetitive process is and performance improvement. It has produced quality
improvements directly/indirectly with positive increase in production efficiency.According to
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[3] the objective of this research paper is to investigate how Lean and Six Sigma methodologies
are implemented together on construction projects through a case study and to measure the process
capability index (Cp) to measure the performance of Six Sigma efforts. Some of the conclusions
drawn from the literature review and case studies, and can be summarized as follows;
1. Both Six Sigma and Lean are strong production management tools and the combination
complements each other. Lean in principle eliminates anything that doesn‘t add value to the
customer and achieves reliable workflow. On the other hand Six Sigma aims to control and reduce
the variations by understanding the root cause.
2. The complexity of the construction project has its own unique and uncertain environments,
which made the use of Lean Six Sigma methodology somehow different from the other industries,
especially manufacturing.
3. The methodology of Lean Six Sigma was effective in reducing variability of daily panel
production rate. However, taking into account inherited uncertainty in construction processes, the
value of Cp can be applied flexibly to construction processes.In system
[4] D. Lade, A. S. Nair , P. G. Chaudhary, N. R. Gupta aims that, there has been a steep rise in the
production of Ready Mix Concrete (RMC) in India due to ever increasing demand of concrete
from the infrastructure as well as the real estate sector. It has become a great challenge for the
RMC manufacturers to supply consistent level of quality of concrete to the customers. In this
study, the quality performance of an RMC plant at Mumbai, India, using the Six Sigma philosophy
has been evaluated by using various quality tools. The existing sigma level of the process has been
found to be 1.23, which is very less than the manufacturing industry and RMC production process
has been found neither stable nor capable. Some recommendations for process improvement and
conclusions based on the observations of the present study are also presented at the end. Thanveer
M. Beary, Tariq S. Abdelhamid [5] proposes a Lean Construction and Six-Sigma based
assessment framework for the production planning process in the homebuilding industry which
will assist in finding improvement opportunities in the production planning process. The
framework can also be modified and used to assess and improve other construction industry
sectors. Six Sigma and Lean Construction are both powerful tools. Lean Construction aims at
creating a standard process by eliminating waste or unnecessary work and Six Sigma aims at
reducing variability in a process using scientific methods to identify areas that are root causes for
the variability. This study developed this idea further by applying the power of both tools to
production planning process in residential construction. Both Lean Construction and Six Sigma
were used in conjunction to develop a Production Planning Model. The aim was to develop a
system that helps in identifying defects in a construction production process, eliminating it and
thus creating a zero-defect process. Continuous improvement of the process is also important to
keep the process in control and make it efficient. According to Muharrem Firat Yilmaz [6] This
thesis includes Literature Review and three interviews. Literature Review had discussed process
improvement methods used in construction industry and analyzed the basic features and principles
of Six Sigma. Three interviews were conducted about the basic principles of Six Sigma and
Quality Concept. Interviewers are a Project Manager, Field and Cost Engineer. The approach of
the interview to Six Sigma is based on quality, performance and management aspects. This study
defends that there is no doubt about the positive effects of Six Sigma on construction projects.

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Particularly, Six Sigma can provide a broader quality concept, detailed performance measurement,
coordinated and repeatable process/performance improvement. It has increased quality
directly/indirectly and has positive effects on production efficiency. Since construction industry
includes lots of unrepeatable tasks and different process design techniques, Six Sigma does not
seem applicable as a whole management approach in construction industry. Furthermore, it can be
integrated to the existing management procedures of companies. Taking everything into
consideration, it is obvious that Six Sigma has a lot in order to accelerate fundamental and cultural
challenges construction industry needs.

METHODOLOGY

The basic idea of the concerned study focuses or deals with the thorough study and understanding
of the literature survey and understanding the current status or practices in construction and as to
how the application of Six sigma can result into a development of a process in projects which will
be efficient, safer to manage, completed sooner and of better quality. Sigma within construction
context becomes an interesting research question considering quality, performance and
management aspects. Recently, many organizations have attempted to achieve customer
satisfaction. One of the most important aspects of customer satisfaction is achieved through a high
quality product, which also means a low defect product. Traditionally, defects include products
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containing a flaw in the manufacturing process, customer dissatisfaction in the service department,
or documentation errors in an office It has proven its best results in various fields specifically in
manufacturing and recognizes that business quality is highest when the costs of delivering
products and services to meet the customer‘s requirements at the absolute lowest for both the
producer and purchaser. The following flow chart gives the details of work carried out with the
sequence of activities from start to end of the work.

OBJECTIVE
 To study the basic principles of six sigma concepts & DMAIC (Define, Measure, Analyze,
Improve, Control) methodology and various tools used in DMAIC methodology.

 To enhance the quality of ongoing process (internal finishing work of plastering) of a

construction project by eliminating defects. & to meet the quality standards & customer
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satisfaction.

AIM OF STUDY
To study the implementation of six sigma methodology as a quality process improvement in
finishing work (plastering work) of residential buildings for better customer satisfaction.

PROJECT FLOW

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Work Procedure

i. Finding out the exact problems of construction industries in market.

ii. Define the problems.
iii. Interviews of people within construction context to know the need of process improvement (i.e.
Six Sigma).
iv. Case study on applying DMAIC technique of Six Sigma methodology to internal finishing
work of a Building (Two buildings, Building A with regular method of Internal finishing and
Building B applying DMAIC technique for Internal finishing)-The evaluation of process sigma
level and sigma level in terms of standard deviation based on results obtained from the case study
was carried out.
v. Correlating/ analyzing the existing practices with refined/ modified practices.
vi. Conclusion.

Six Sigma principle is a statistics-based methodology that relies on the scientific methods to make
significant reductions in customer-defined defect rates in an effort to eliminate defects from every
product, process, and transaction. Increasing number of companies start to integrate the full
implications of Six-Sigma. It has proven its best results in various fields specifically in
manufacturing and recognizes that business quality is highest when the costs of delivering
products and services to meet the customer‘s requirements at the absolute lowest for both the
producer and purchaser. Six-Sigma is therefore developed as a business strategy and philosophy
built around the concept that companies can gain a competitive edge and stay ahead of the
competition around by reducing defects in their industrial and commercial processes. So various
construction industries are applying Six-Sigma for their process improvement and minimizing
defects by improving quality of work. As Six Sigma is a process improvement methodology and
has proven its best results in manufacturing industries because of the repetitive production, since
1980s. But still it‘s a relatively new concept for construction industry because of its unrepeated
work process. Previous researches about Six Sigma in construction say that Six Sigma as in whole
cannot be implemented in construction industry but some of the techniques and ideas will
definitely prove its best results on construction work process. The aim of this present work is to
find out the need of using Six-Sigma in construction context particularly for areas and zones in
state Maharashtra (India). Produce something with equal or better quality with lower cost is the
purpose of process improvement inconstruction industry.

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CASE STUDY 1
Site Survey and Data Collection
We have selected some activities like brick work, plastering, flooring using vitrified tiles, internal
coloring to improve the quality of internal finishing work of building using DMAIC methodology.

Site Details
Name of Project: PAVITRA PARK
Builder and Developers: ANIL CONSTRUCTION
Address: Kaluste road, Ghoti- Igatpuri, Nasik-422402
The Capital is a commercial Project of Anil Construction Group located in the heart of city of
Ghoti with state-of-the art office space built to international standards. The Capital offers a bounty
of comprehensive features and facilities for software development companies, BPOs, Bank's,
showrooms and corporate offices.
A. Regular method of internal finishing work of “PAVITRA PARK” : ―Saubhagya Arcadeǁ is
comprising of 4 buildings called building A, B, C and D. Amongst that building A and B are
nearly identical so they are selected for study. A checklist is prepared for internal finishing work,
which covers various points whose quality needs to be checked.To find out the problems faced by
construction companies and using Six sigma effectively in construction context for the benefits
and minimizing defects thereby improving quality of work. The questionnaire will

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Fig. pavitra park

be based on problems of construction industry and how six sigma can be used beneficially for
process and quality improvement. The questionnaire survey will be taken to know the need of
process improvement in construction. The questions will be regarding need of improvement in
quality, cost, productivity, productivity time, Customer satisfaction and Six sigma application.

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FUTURE SCOPE

In this study six sigma principles will be applied for internal finishing work (Plastering) of
residential project (100-120 Flats) and the sigma level for the same will be calculated from the
obtained data. The DMAIC methodology will beadopted to improve the quality of the existing
process.

Questions to be asked in interview for market survey:

i. What‘s the definition of quality according to construction industry requirements?

ii. What types or categories of problems are common?
iii. What‘s different about most common types of problems?

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iv. Are there locations where the problem is greater?

v. How those places where the problems occurs more unusual?
vi. What are the times, days, weeks or conditions when the problem is most prevalent? What‘s
going on that‘s unique during those times?
vii. How does quality, cost, productivity, productivity time, customer satisfaction, Six Sigma
collectively or individually affect construction work?
Rate them accordingly?

RESULTS
This section provide the detail calculations of comparative study of regular method of working on
internal finishing work versus Six Sigma methodology is given. By making this comparative
study of both the working methods we get the need and importance of process improvement
methodology in construction context for quality, cost, productivity, productivity time, customer
satisfaction and Six Sigma. In this work we have considered two different buildings for cost
comparison. Here X-Axis Represents Cost in Rs and Y- Axis represents items of work. Here
building A has used traditional technology for and construction and Building B which is done by
applying Six Sigma methodology

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Fig. Cost vs time for conventional and six sigma method

CONCLUSION
The proposed implementation identifies that vast literature was obtained on Six Sigma concept,
which gave a wide idea of existing practices of implementing DMAIC methodology which is a
concept of Six Sigma to the existing ongoing processes or activities in construction which objects

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at developing and providing a highly effective process improvement and quality improvement
technique in construction. The studies conducted deploy that Six Sigma applications are widely
accepted by manufacturing/ production industries and it is also possible to implement it in
construction. Past case studies disclose that it requires team efforts involving top management and
every worker in the organization to fully employ the concept. However awareness among
consultants, engineers, employees and regarding Six Sigma in construction should be produced for
the actual execution of the process/ activity.

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CASE STUDY 2
This case study is a comparative case study between two sites.
For study we had visited to sites and collected data we made two different collection with six
sigma and without six sigma
a) Designed parameters

Company Gothi construction

Type Without six sigma

Location Ray aambe (ghoti )

Area 25*30 sq.ft. (g)

Eastimated cost 1200000 rs

Eastimated time period to completion 6 month

Supervisor Local supervisor

Material quality ( eastimated ) Good

Construction type Residential

Poster No plan poster present

Workers Regular

Safety Safety precautions not taken

Gifts No gifts provides

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a) Actual parameters

Company Gothi construction

Type Without six sigma

Location Ray aambe (ghoti )

Area 25*30 sq.ft. (g)

Eastimated cost 1320000 rs

Eastimated time period to completion 9 month

Supervisor Local supervisor

Material quality ( eastimated ) Good

Construction type Residential

Poster Some mistakes occure due to poster not present

Workers Regular

Safety 3 workers got injured

Gifts Gifts are provide to workers on task completion

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b) Designed parameters

Company Anil construction

Type With six sigma

Location Igatpuri

Area 25*35 sq.ft. ( g + 1 )

Eastimated cost 2000000 rs

Eastimated time period to completion 1 year

Supervisor Wel trained supervisor

Material quality ( eastimated ) Good

Construction type Residential

Poster Plan poster is placed at eye site of workers

Workers Trained

Safety Safety 1st

Gifts Gifts are provide to workers on task completion

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b) Actual parameters

Company Anil construction

Type With six sigma

Location Igatpuri

Area 25*35 sq.ft.

Eastimated cost 2010000 rs

Eastimated time period to completion 11.5 months

Supervisor Wel trained supervisor

Material quality ( eastimated ) Good

Construction type Residential

Poster Plan poster is placed at eye site of workers

Workers Trained

Safety Not a single labour get injured

Gifts Gifts are provide to workers on task completion

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14

12

10

8
designed
6 actual

0
duration with 6 duration
sigma without
6sigma
Time difference between work with or without 6 sigma
2500000

2000000

1500000

designed
1000000 actual

500000

0
wihout six sigma with 6 sigma cost
cost

Time difference between costing with or without 6 sigma

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Case study 3
A residential building comprising of 18 buildings of 2BHK flats is considered for study. A
checklist is prepared for internal finishing work, which covers various points whose quality needs
to be checked. The checklist as shown in TABLE 2, is prepared. The data is filled in the checklist
for three – 2BHK apartments which comprise of 144 flats. The one which conforms to standards
are marked as „√‟ else „X‟. The number of „X‟ leads to defects and total number of checks leads
to opportunities.
The summary of data for the three buildings is as shown below:

Sr. no. Building Defects Opportunities

1 B 619 18336
2 C 545 18336
3 D 570 18336
Total 17334 55008

Therefore, DPMO = (17334/55008) X1,000,000

DPMO = 31522.68
Based on sigma conversion table,
Sigma = 3.36
Hence we can conclude that current performance of the companyis 3.36 sigma level.
Let us set a target sigma level to be 4.5

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Sr. Poiny description Rooms

no.

L pass kit ut Bed Bed Tl Tl Ter Rem

R 1 2 1 2 ark

1. Tiling work

a Floor tiling work

1 Flooring tiles & skirting fixed

properly

2 Colour/ shade variation

uniform in floor tiles.

3 Floor tiles and skirting are

thoroughly cleaned .

4 Cracks obsereved in flooring /

skirting.

5 No loose patches (voids ) in

flooring after knocking.

6 Butt filling / grooves /offset

of skirting .

7 Skirting are in line and level

and right angles at corner and
around column offset.

8 Flooring joints match

properly

9 Proper slope maintained for

allfloores

10 No waterlogging in flooring
after pouring water

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11 Window / ventilators in toilets N NA N N NA NA NA

properly finished with wall A A A
tiles

12 Proper slope towords nahmi N NA N N NA NA

trap given at all A A A

13 Cutouts for water taps N NA N N NA NA NA

properly finished. A A A

DMAIC Methodology
By studying the checklist we have selected some activities like flooring using vitrified tiles, dado
tiling, wooden doors, terrace water proofing using brick bat which adversely affect the sigma level
of quality. Out of the above mentioned activities, in this paper we have tried to improve the quality
of flooring by using DMAIC methodology

1. Define: SIPOC
Suppliers Inputs Process Outputs Customers Whenever we want to start any process improvement
activity, it is important to get the high level understanding of the process. SIPOC helps us to agree
the boundaries of what we will be working. Shown below in the TABLE 3 is the SIPOC process
for flooring using vitrified tiles.

2. Measure: Pareto Charts Each construction activity is a set of various dependent activities;
Pareto chart helps to identify the most significant factors, shows where to focus efforts and allows
better use of limited resources. Chart (FIG 2) below shows us the Pareto Analysis for flooring
using vitrified tiles. A Pareto Chart can answer the following questions:

 What are the largest issues facing our team or business?

 What 20% of sources are causing 80% of the problems?
 Where should we focus our efforts to achieve the greatest improvements?
. Analyze: Cause and Effect Diagram Cause and Effect diagram helps us to visualize in a
graphical manner the outcome and various factors that influence that outcome. It graphically
illustrates the relationship between a given outcome and all the factors that influence the

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outcome.This type of diagram is sometimes called a "fishbone diagram" because of the way it
looks.

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4. Improve: Corrective Action As per the „Preventive and Corrective Actions Guidelines’ given by
R.M. Baldwinthe Corrective Action is defined as, a term that encompasses the process of reacting
to product problems, customer complaints or other nonconformities and fixing them. The process
includes: • Reviewing and defining the problem or nonconformity • Finding the cause of the
problem • Developing an action plan to correct the problem and prevent a recurrence •
Implementing the plan • Evaluating the effectiveness of the correction. Thus, from the above
analysis following corrective actions were taken: i) Skilled labors were employed and proper
training was given to them. ii) The Mix design for substrate was revised from 1:8 to 1:4:4 were
there was 1 part of Cement, 4 parts of Fine aggregate and 4 parts of Coarse aggregate. iii) Tiles of
better quality were used.

5. Control : Control Plan

Control plan will help us to keep a check on the various preventive measures which are taken to
achieve the desired result. As per the „Guide to Control Plans’a control plan is the documented
description of those procedures, checks or assigned activities necessary to verify that production
units continue to conform to the type approval requirements with regard to specification, marking
and performance. The aim of the control plan information is to show that the appropriate level of
control exists in relation to those aspects of the product, which are critical to its continued
compliance. Thus we shall use the checklist which is prepared earlier as a control plan.V

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CONCLUSION

We have seen how various factors have high impact on the quality of the construction. These
factors must be identified as early as possible so that the quality can be improved. Detailed
methodology has been implemented based on Six Sigma principles which give us systematic
approach to identify and improvise the current process. Six Sigma also provides scale to measure
whether the quality has been improved or not.

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REFERENCES

[1] Sneha P. Sawant and Smita V. Pataskar; “Applying Six Sigma Principles in Construction
Industry for Quality Improvement”, The International Conference on Advances In Engineering
And Technology – ICAET (2014).
[2] Sunil v. Desale , Dr. S. V. Deodhar; “Lean six sigma principal in construction: A literature
review related to conclusion”, International Journal of Emerging Technology and Advanced
Engineering, ISSN 2250-2459, ISO 9001:2008 certified journal, Vol. 3, Issue 5, May (2013).
[3] Celep Oguz, Yong-Woo Kim, John Hutchison, Seungheon Han; “Implementing lean six
sigma: A case study in concrete panel production”.
[4] A. D. Lade, A. S. Nair, P. G. Chaudhary, N. R. Gupta,(2015) “Implementing Six Sigma
Approach for Quality Evaluation of a RMC Plant at Mumbai, India, IOSR Journal of Mechanical
and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684,p- ISSN: 2320- 334X, Volume 12, Issue
2 Ver. I (Mar - Apr. 2015), PP 01-04
[5] Thanveer M. Beary, Tariq S. Abdel hamid, (2005),“Production planning process in residential
Construction using lean construction and six sigma Principles”. DOI: 10.1061/40754(183)16.
[6] Muharrem Firat Yilmaz “Six Sigma within Construction Context : As a Quality Initiative,
Performance Indicator/Improver, Management Strategy Six Sigma Project Management”(2012)

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