Inspection forms are worthless
if they don’t help solve your current quality issues. Why
use them if checking boxes is only a routine while the real problems
are not even mentioned? "Typical builder checklists might
as well be laminated," says Mark Hodges, VP of Operations,
K. Hovnanian. "Complete with check marks!"
HotSpot inspection forms change
all that. HotSpot checkpoints are constantly adjusted to focus
on current quality issues and related improvement efforts. When
new problems are encountered, they are added as HotSpot checkpoints.
When preventive actions get the problem under control, it comes
off the HotSpot checklist. The HotSpot inspection forms change
as needed, to bring attention to the issues that demand a response
from field personnel. The forms also list key specifications,
but only as reminders.
Getting Started
Schuck and Sons, a Phoenix framing
contractor, is changing from a traditional checklist format to
HotSpot. They are part of an ISO 9000 framing quality assurance
project, in partnership with Del Webb, the Partnership for Advancing
Technology in Housing (PATH), and the NAHB Research Center. The
reminder section of the form lists critical requirements from
the old sheet for information purposes only.
On a daily basis, HotSpot forms
are used like traditional inspection forms, except that they
are shorter and easier to use than before.
Updating HotSpot Inspection Forms
Updating HotSpot inspection forms
is a central element of the quality improvement process for All-tech
Construction, a New Jersey framing contractor participating in
the ISO 9000 framing quality assurance demonstration project
with their partner K. Hovnanian. Here’s how they are using
HotSpot forms in a six-step quality improvement process:
- Quality issues are identified
through job inspections by area superintendents, builder feedback,
and comprehensive quality reviews.
- HotSpot checkpoints are added
to the inspection form to address quality improvement areas.
- In weekly production meetings,
production supers are trained on procedures to prevent problems.
The training uses one-page diagrams that address specific problem
areas. The new HotSpot inspection forms are then distributed
and discussed.
- In toolbox talks, production
supers use the training diagrams to train the framing crews with
the superintendent monitoring the new use of the procedures.
- HotSpot inspection forms are
used by superintendents on every job. Results provide feedback
on the effectiveness of the improvements.
- Finally, success is celebrated.
When HotSpots are no longer an issue, the item is posted in the
production meeting room as a quality success. The checkpoint
comes off the HotSpot part of the form and gets put on the reminder
section. In time, it may leave the inspection form altogether.
Everyone seems to like the HotSpot
approach because it supports an inspection process that experienced
construction superintendents use every day: keep all requirements
in mind while paying special attention to the quality issues.
It just helps them do it better.