Paper Tugas 6

Journal of Management in Engineering.
Submitted February 8, 2012; accepted September 12, 2012;

posted ahead of print September 18, 2012. doi:10.1061/(ASCE)ME.1943-5479.0000155
Applying Six Sigma to Quality Improvement in Construction
Kuo-Liang Lee*
Department of Industrial Management, Ching Yun University,

Downloaded from ascelibrary.org by INSTITUT TEKNOLOGI BANDUNG on 10/21/12. Copyright ASCE. For personal use only; all rights reserved.
Jungli, 320, Taiwan, ROC
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Su Yang
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Department of Civil Engineering, Ching Yun University,
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Jungli, 320, Taiwan, ROC
*Corresponding author. Tel.: +886-3-4581196; fax: +886-3-4683298.

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E-mail: lee12050@gmail.com
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ABSTRACT
Taiwan is in a seismically active zone, because it is located in the earthquake-prone

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Pacific ring of fire. The cracks in lightweight partition walls caused frequent
earthquakes decrease customer satisfaction and increase repair costs in the case
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company. This research demonstrates a Six Sigma team how to determine and
improve the key input variables affecting the cracks in lightweight partition walls. A
case study methodology used in this research to illustrate the tools of Six Sigma by
using the project charter to define problems, by using a tools of process mapping to
display all the input and output variables affecting cracks in lightweight partition
Copyright 2012 by the American Society of Civil Engineers
J. Manage. Eng.
Journal of Management in Engineering. Submitted February 8, 2012; accepted September 12, 2012;
walls, by using the C&E (cause-and-effect) Matrix to select highly correlated input
variables, and by using failure modes and effects analysis (FMEA) to identify causes
of the cracks. Unlike conventional Six Sigma, finite element analysis (FEA)
simulation software ABAQUS was used instead of statistical tools to verify variables
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and to identify initial causes of cracks because data collecting was time-consuming.
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The results showed that a 1 cm preset spacing between the board and the main
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structure substantially reduces cracks caused by earthquakes. A new earthquake-proof
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construction method has been developed based on the finding of this research and
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granted a new patent (M 431196) by Intelligent Property Office in Taiwan recently.
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Keywords: Six Sigma, lightweight partition wall, case study.

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INTRODUCTION
Because of advances in construction engineering technology, trends in building
high-rise and large-scale buildings, and the demand for reduced loading and
construction periods, lightweight partition walls are being used instead of brick
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partition walls. As Taiwan is located in the seismically active zone, a building
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damaged of varying severity by earthquakes is common. Although poor quality of
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lightweight partition walls, which are a commonly used in construction engineering,
does not affect the safety of a building structure, cracks or even collapses caused by
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earthquakes can result in customer complaints. This research demonstrates a Six
Sigma project of determining and improving the key input variables affecting the
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cracks in lightweight partition walls. This study demonstrates a Six Sigma project to
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identify the variables affecting cracks in lightweight partition walls. In this case study,
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an innovative method with retaining the original functions of the lightweight partition
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walls (e.g., fire prevention, moisture protection, heat insulation, etc.), and improving
quality to minimize cracks was found.
Since the Six Sigma concept was first developed by Motorola in 1986 (Antony, Jiju,
2006), several companies, including, General Electric (GE), Honeywell, Bombardier
and Sony have reported significant benefits from Six Sigma initiatives (Antony and
Banuelas, 2002).
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The effectiveness of Six Sigma approach depends on business strategy, top-down
involvement, and customer focus and it has an impact on profits if it is successfully
deployed (Salzman, 2002). Harry (1998) indicated that Six Sigma is a serial analytical
and statistical method for eliminating process variations and obtaining breakthrough
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improvements in products or service quality. From a statistical perspective, the goal of
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Six Sigma is to achieve a rate of 3.4 defects per million (McCarty and Fisher, 2007;
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Aboelmaged, 2010); sigma is a term representing variation around the process mean
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(Montgomery, 2001). The Six Sigma scheme is a project-driven management
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approach (Andersson et al.,2006). A Six Sigma project must be carefully selected and
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planned to maximize its benefits. The project must be feasible, organizationally and
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financially beneficial, and customer-oriented (Brue and Launsbry, 2003). The project
should also be well documented in order to track project objectives, constraints, costs,
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schedules, and scope (Meredith and Mantel, 2000). The project must then be reviewed
periodically to assess project status and the performance of the Six Sigma tools and
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techniques The techniques employed in Six Sigma projects include project
management tools and methodology, advanced data analytical tools, customer
requirement analysis, and financial result evaluation and report (Raisinghani et al.,
2005).
The define–measure–analyze–improve–control (DMAIC) phases of the Six Sigma
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Management approach provide is a structured problem-solving procedure widely used
in quality and process improvement (Hu et al., 2005; Banuelas et al., 2005). The
DMAIC structure encourages creative thinking about the problem and its solution
within the definition of the original product, process, or service (Montgomery and
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Woodall, 2008). In define (D) phase, the business improvement opportunity is
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identified. Then the problem is defined along with critical customer requirements,
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project scope and preliminary project plan (Raisinghani et al., 2005). The project
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charter and Six Sigma improvement are established (Montgomery and Woodall, 2008).
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In the measure phase (M), data is collected and tools to be applied are identified
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(Raisinghani et al., 2005). Analyzing data to understand reasons for variation and
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identifying potential root-cause and establishing the relationships between different
variables and causes are established using sophisticated statistical techniques in the
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analyze (A) phase (Raisinghani et al., 2005; Montgomery and Woodall, 2008). The
causes of problem are identified, measured and analyzed, the experts generate and
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select potential solutions in the improve (I) phase. The last and most important phase
of Six Sigma implementation is the control (C) phase. The ongoing process
management plans, mistake-proof process are in this phase to make sure key input
variables is monitored and maintained over a longer period of time (Montgomery and
Woodall, 2008).
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Six Sigma methodologies were first applied in manufacturing; however, once
organizations realized the benefits of Sigma Six, it use was rapidly expanded to
different functional areas such as marketing, engineering, purchasing, servicing, and

administrative support (Henderson and Evans, 2000; Rajagopalan et al., 2004;
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Roberts, 2004). In comparison to other industries, the Six Sigma is a new quality
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control technique for construction industry. This case study applied the DMAIC steps
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of Six Sigma by using the project charter to define problems, by using a tools of
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process mapping to display all the input and output variables affecting cracks in
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lightweight partition walls, by using the C&E (cause-and-effect) Matrix to select
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highly correlated input variables, and by using failure modes and effects analysis
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(FMEA) to identify causes of the cracks. Conventionally, there are many statistical
methods and quality management tools are applied in analyze phase, such as Design
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of Experiments (DOE), Response Surface Methodology (RSM), Robust Design,
Statistical Process Control (SPC), Quality Function Deployment (QFD), Failure Mode
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and Effect Analysis (FMEA), Capacity Analysis, Hypothesis Testing, Analysis of
Variance (ANOVA), Regression Analysis, and so on (Hoerl, 2001; Elshennawy, 2004;
Montgomery and Woodall, 2008). However, statistical tools cannot be applied to all
situations. Tang et al. (2007) indicates that common statistical methods for quality
engineering and quality management tools are usually insufficient for tackling many
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business-improvement related problems such as production and service planning and
scheduling, inventory control and management, supply chain management, operations
scheduling and workforce scheduling. OR/M techniques such as forecasting, queuing,

simulation and modeling are suggested to be essential tools in the ‘Analyze’ phase
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since system level analysis is usually needed in a transactional environment. In the
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‘Improve’ phase, queuing and mathematical programming techniques are usually
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needed for transactional environments (Tang et al. 2007). Montgomery and Woodall
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(2008) address that discrete-event computer simulation is another powerful tool useful
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in service and transactional business in the Analyze phase. Therefore, the suitable
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tools can be used to verify variables depend on the situation of projects. In this
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research, we are looking forward finding whether the cracks in partition wall are
caused by different setting of key input variables under certain seismic force. If we
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wait the unexpected earthquake occurrence and then collect data, it could take a lot of
time. Hence, the finite element analysis simulation software ABAQUS was used
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instead of statistical software to verify the key variables. Finally, the control plan is
adopted to control and reduce the occurrence frequency of various key input variables
effectively for continuous quality improvement.
LIGHTWEIGHT PARTITION WALL
Conventional partition walls in Taiwan are mainly constructed from reinforced
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concrete (RC), brick and wood. However, due to the declining labor force, increasing
salaries, increased construction costs, and changes in the Taiwan construction
environment in recent years, conventional partition walls can no longer meet all
demands. As traditional construction methods require heavy building materials and
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large manpower, it has been replaced by construction method of lightweight, high
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quality, short construction period, and low working capacity. Therefore, lightweight
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dry wall systems have become the mainstream approach for building partition walls in
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office buildings. The three main lightweight partition wall systems are framework
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partition system, panel partition system, and block laid partition system. This study
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treats the framework partition system as an example. The example used in this study
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was the framework partition system. Plasterboard is the main material of framework
panel wall, as the material combination of framework panel wall has large flexibility.
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The technical data used in the Taiwan construction industry are mostly obtained from
the U.S. and Japan; thus, differences in materials include studding, fixed screw
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spacing, and structural support. Figure 1 shows the work flow for constructing the
framework partition wall.
IMPLEMENTATION OF A SIX SIGMA PROJECT
This study improved the projects according to the DMAIC steps of Six Sigma. The
tools of traditional Six Sigma Management, such as Process Mapping, C&E Matrix,
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and FMEA were used in this research. Specially, the finite element analysis simulation
software ABAQUS was used instead of statistical software to verify the key variables.
Project initiation and definition

The research scope of this case is the work flow for engineering lightweight partition
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walls. Since Taiwan is located in a seismic zone, earthquakes often cause cracks in
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partition walls, which can result in cosmetic or even structural damage. According to
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the customer satisfaction report provided by the case company, the most common
customer complaint was cracks in the lightweight partition wall surface after
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earthquakes. The dissatisfaction rate of customer was 87%. Frequent customer
complaints about this problem resulted in considerable expenses for crack repair by
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the case company. The annual rework cost for repairing lightweight partition wall
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crack for customers is approximately NTD 1,700,000. However, the repairs did not
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help to prevent cracks in subsequent earthquakes. Therefore, the top management of

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the case company established a Six Sigma project team to improve customer
satisfaction and reduce the rework cost. The project team used project charter to
define items, including reasons for selected topics, problem description, project goal,
financial benefit prediction, and scope of project. Table 1 shows partial contents of
project charter.
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Factor Evaluation
Six Sigma quality improvement techniques are applied, and the operating procedures
are described as follows:

Process mapping
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Process mapping is used to graphically illustrate the target process for identifying
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input variables (Xs), output variables (Ys), relationships between Xs and Ys, and all
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value-added and NVA process steps. Deficiencies in the lightweight partition walls
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resulted from variation or ineffective control of some factors in the process. Therefore,
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process mapping was used to identify input variables related to key process output
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variables (KPOVs) and to identify the causes of variation. Meanwhile, the
characteristics of input variables, including C, U and S types were displayed in the

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flow chart for further analysis. The meanings of C, U and S are shown below:
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(1) Controlled (C): those that affected KPOVs and were easily controlled;
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(2) Uncontrolled (U): those that affected KPOVs but were difficult to control;
(3) Standard Operation Process (SOP) (S): those in current SOP.
The KPOVs of lightweight partition wall process are cracks, wall body structure
quality, and wall body surface strength. When the flow is analyzed and the
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cause-effect relationship is set up by process mapping, it is shown that the whole
lightweight partition flow consists of seven working procedures. Use of process
mapping to analyze the overall flow and cause-effect relationships showed seven
main working procedures. The forty-nine input variables included thirty-five
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controllable input variables and seven uncontrollable input variables. Of these, ten
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key variables and twenty-seven items had SOPs. It is worth noting that if a
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controllable input variable without SOP was identified as a key variable, the SOP of
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this input variable should be established. When the process mapping has been done
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(Table 2), the next step in the C&E Matrix is used for screening variables.
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C&E Matrix screens critical steps and influencing factors

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The C&E Matrix is then used to select the key input factors that contribute to cracks
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in lightweight partition walls. The project team put the input variables in the left part
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of the table and the KPOV in the upper part of the table. The KPOV was then
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weighted from 1 to 10 according to customer requirements. The relationship between
the input variable and KPOV was then graded as 0, 1, 3 or 9 for (strong, moderate,
weak, and nonexistent correlations, respectively). Based on the C&E Matrix screening
analysis, the project team then selected 5 key input variables: U-runner fixing method,
construct as design drawings, joint spacing between panels, spacing between board
and main structure, spacing between studs. Table 3 shows part of the C&E Matrix.
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Use FMEA to determine the causes affecting the key factors
When using the C&E Matrix to select key input variables, FMEA was performed to
determine the actual causes of key input variables with potential impacts on key output
variables. After the FMEA method identifies potential failures in key variables, it is used to
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reduce or eliminate their occurrence rate. After identifying potential failure modes of key
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variables, FMEA shows the causes of such failures and how they can be eliminated to
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prevent further failures. Table 4 shows part of the FMEA table.
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Factor verification
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Although FMEA showed several directions for improvement, the project team found that
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inspection and spot control mechanisms were insufficient preventive measures. The
project team supposed that two of the variables have great impact on the wall surface
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cracks, which are the joint spacing between panels and the spacing between board and
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main structure. Therefore, the project team used ABAQUS for simulation analysis.
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The process of the simulation analysis is described below:
Model building
Since the self tapping bolts used to install the lightweight partition was 4mm in
diameter, the spacing between each calcium silicate board (dimensions 3m * 0.6m)
was set to 1cm, and the c steel spacing was set to 0.3m. Since the specifications
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required a spacing of at least 1.2cm, each piece was installed at a 15 cm interval. Both
boundaries of this wall body were assumed to be concrete columns to simulate field
conditions. A C-shaped steel frame, horizontal prism, calcium silicate board were used
in this model. Table 5 shows the sizes of C-shaped steel frame and horizontal prism,
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and Table 6 shows the material properties. The ABAQUS business software was used
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for analysis, and a 3D elastic beam element was used when simulating the C-shaped
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steel frame. A standard size calcium silicate board (3m high, 0.6m wide and 9mm
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thick) with 3D board element was simulated. The Center Point Flexure Test suggested
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by the American Society for Testing and Materials (ASTM D3043-95) was used to
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obtain the elastic modulus E of covering material and the force and displacement
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curves. The data obtained in this experiment (Fig. 2) were then analyzed.
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The transverse C steel at the flute on the model top was set as steel body element. A
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uniformly distributed mass M on the upper rigid element of the partition wall was
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assumed when simulating the weight of the upper story. The degree of freedom at the
flute under the steel frame was set as the fixed end state, and an X-direction seismic
force on the ground surface was applied in this model. The designed seismic force
used in this research was maximum up to approximately 0.8g, which was the
aftershock intensity of the Chi-Chi earthquake measured form Provincial Puzih
hospital. Figure 3 shows the designed seismic forces.
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Results Analysis
The model showed that the board yielded under a certain lumped mass. At this point,
the board was mass, at which point the board was destroyed. When the lumped mass
was set to 40000kg, the board yielded. According to the stress distribution of board
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under seismic force, the maximum stress was in the center of the board (Point 1 in Fig.
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4). This stress result was exported to obtain the maximum stress of 5.29MPa at this
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point (Fig. 5). Since the 5.08MPa exceeded the maximum yield stress of the calcium
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silicate board (Table 5), the simulation showed that the board was destroyed. The
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larger exported stress on the C steel is exported to determine whether the steel frame
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would be destroyed. Figure 6 shows the steel frame stress distribution and the output
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stress result. The maximum stress on the C steel was about 55MPa, which did not
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exceed the cold rolled steel yield stress 425 MPa listed in Tables 5 and 6. Therefore,
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in this case, only the board was destroyed.

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The simulation showed that the spacing between the board and main structure would
cause a wall surface crack. In order to validate this deduction, the project team kept
the partition system 1 cm away from concrete columns at both sides, hoping to
improve this condition. Figure 7 is a schematic diagram of the modified lightweight
partition system. Figure 8 shows the stress distribution of the modified lightweight
partition system board under earthquake effect. The stress on the bottom of the board
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(Point 2) differed from that observed in the previous case. Figure 9 shows the results
obtained when the stress was exported. The analytical results showed that stress could
be reduced by separating the partition system from nearby concrete columns by a

distance of 1 cm. Under the same condition, the maximum stress of board has not yet
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reached the yield stress value of calcium silicate board, only half of the yield stress,
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2.5MPa. When the stress value of the position with larger steel frame stress was
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exported (Fig. 10), the maximum stress was 65MPa which exceeded the steel frame
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stress value of unmodified partition system. However, the C steel did not yield.
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These test results confirmed that the design effectively reduces, board destruction.
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The simulation confirmed that wall surface cracks could be reduced by keeping the
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board 1cm away from the main structure, where the spacing between the board and
main structure is a key input variable. Therefore, the project team suggested
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establishing an SOP for applying this approach in future construction processes.

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Control plan
In order to control the variation of various key input variables effectively, the control plan is
established at the end of after completing the analysis process. The control plan was turned
over to the process supervisor after the project so that the process could be used to obtain
improvements in future projects. The two key variables affecting cracks in this project were
the spacing between board and main structure and the cross nailing of U-runner. Therefore,
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the two items must be monitored in the control plan (Table 7). The field director must
carefully monitor aspects of other basic operation so as to effectively reduce the variation
occurrence rate.
CONCLUSIONS
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Six Sigma approach provides business a systematic and logical program to solve
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problems and enhance the quality and efficiency of products and processes. In this
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case study, the Six Sigma Black Belts - the trained engineers in case company
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measure key factors affecting the process by applying process mapping, C&E Matrix ,
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FMEA, logical analysis of screening key factors causing the cracks. The FEA
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simulation software ABAQUS was integrated into Six Sigma approach to help
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verifying key variables. The research results showed that a 1 cm spacing between the
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board and main structure effectively reduced cracks. After applying this innovative
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finding applied and following the control plans, the customer dissatisfaction of case
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company decreased from 87% to 11% accordingly. The annual rework cost for
repairing lightweight partition wall crack is from NTD 1,700,000 down to 94,000
dramatically. A new earthquake-proof construction method has been developed based
on the finding of this research and granted a new patent (M 431196) by Intelligent
Property Office in Taiwan recently.
Although Six Sigma management has been widely used in other industries, it is a
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relatively new quality improvement method in the construction industry. Therefore,
the process of using Six Sigma presented in this study can bring new ideas and quality
improvement methods to many construction companies. The research results of this

study can be used as a reference in the construction industry.
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Andersson, R., Eriksson, H., Torstenssor, H. (2006). “Similarities and differences
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between TQM Six Sigma and lean.” The TQM Magazine, 18(3): 282–296.
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Antony, J, Banuelas R. (2002). “Key ingredients for the effective implementation of
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Antony, J. (2006). “Six sigma for service processes.” Business Process Management
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Brue, G., Launsbry, R. (2003). Design for six sigma. McGraw-Hill, New York.
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Hu M, Barth B, Sears R. (2005). “Leveragining Six Sigma disciplines to drive
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Kumar, U.D., Nowicki D., Ramírez-Márquez, J.E., Verma, D. (2008). “On the optimal
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McCarty, T.D., Fisher, S.A. (2007). “Six sigma: it is not what you think”. Journal of
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Meredith, J., Mantel, S. (2000). Project management. Wiley, New York.
Montgomery, D.C. (2001). Introduction to statistical quality control. Wiley, New
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Montgomery, D.C., Woodall W.H., (2008), “An Overview of Six Sigma.”
International Statistical Review. 76(3): 329-346
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Raisinghani, M.S., Ette, H., Pierce, R., Cannon, G., Daripaly, P. (2005). “Six Sigma:
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Roberts, C.M. (2004). “Six Sigma signals.” Credit Union Magazine, 70(1): 40-43.
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Salzman S, Rabeneck LT, Rabeneck SK. (2002) Comprehensive Six Sigma Reference
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)LJXUH&DSWLRQ/LVW
Figure 1 Construction flow of lightweight partition wall
Figure 2 Calcium silicate board load and displacement diagram
Figure 3 The designed earthquake force

Figure 4 Stress distribution of calcium silicate board under earthquake force
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Figure 5 Stress value of calcium silicate board under earthquake force
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Figure 6 Stress value of C steel under earthquake force
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Figure 7 Schematic diagram of modified lightweight partition system
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Figure 8 Board stress envelope of modified lightweight partition system
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Figure 9 Board stress value of modified lightweight partition system
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Figure 10 C steel stress value of modified lightweight partition system

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Figure1.pdf
Figure 1 Construction flow of lightweight partition wall
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Figure2.pdf
60
40
Force(N)
Calcium silicate board
s1
s2
20
s3
Average
0
0 2 4 6 8 10
Displacement(mm)
Figure 2 Calcium silicate board load and displacement diagram
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Figure3.pdf
0.8
0.4
Acceleration(g)
0.0
-0.4
-0.8
-1.2
0 40 80 120
Time(sec)
Figure 3 The designed earthquake force
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Figure4.pdf
Point 1
Figure 4 Stress distribution of calcium silicate board under earthquake force
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Figure5.pdf
6.0E+6
4.0E+6
Stress(Pa)
2.0E+6
0.0E+0
0 40 80 120
time(sec)
Figure 5 Stress value of calcium silicate board under earthquake force
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Figure6.pdf
6.0E+7
4.0E+7
Stress(Pa)
2.0E+7
0.0E+0
0 40 80 120
time(sec)
Figure 6 Stress value of C steel under earthquake force
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Figure7.pdf
Figure 7 Schematic diagram of modified lightweight partition system
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Figure8.pdf
Figure 8 Board stress envelope of modified lightweight partition system
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Figure9.pdf
3.0E+6
2.0E+6
Stress(Pa)
1.0E+6
0.0E+0
0 40 80 120
time(sec)
Figure 9 Board stress value of modified lightweight partition system
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Figure10.pdf
8.0E+7
6.0E+7
Stress(Pa)
4.0E+7
2.0E+7
0.0E+0
0 40 80 120
time(sec)
Figure 10 C steel stress value of modified lightweight partition system
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7DEOHGRF[
Table 1 the part of project charter
Elements Team charter

Case description Lightweight partition wall surface crack improvement
project
Problem Customers often complain about cracks in the
description lightweight partition wall surface of this company

resulted after construction or an earthquake
Project goal Customer complaint about lightweight partition wall
surface crack
Financial benefit Annual rework cost for repairing lightweight partition
wall crack is NTD 1,700,000
Scope of project Lightweight partition wall construction flow
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Table 2: the part of process mapping table
Output variables
Type Flow
Input variable (quality characteristic)
C U S
Accuracy of Setting out
setting out line √

Set water line and
Scoring error vertical line in field
of infrared partition according to the
laser construction drawing
√ √ approved by architect
The supervisor should Crack
verify the setting out sign Wall structure quality
Proficiency of Wall surface strength
in the construction
personnel
process before
√ √ construction
Operation of
infrared laser √
Use of setting
out tool √ √
Type of
worker √ √
Accepted Manuscript
Not Copyedited
2
J. Manage. Eng.
Table 3: the part of C&E Matrix table
Wall structure
Wall surface
strength
quality
Crack
Process input
Process Step 10 9 8 Score
variables
The first calcium Joint spacing
9 9 9 243
silicate board closing between panels
Spacing between
The first calcium
board and main 9 9 9 243
silicate board closing
structure
Studs and frameworks Spacing between
9 9 9 243
assembly studs
Fix upper and lower U-runner fixing
9 9 9 243
U-runner method
Studs and frameworks Construct as
9 9 9 243
assembly design drawings
Position of grout
Filling mortar 9 9 3 195
hole
Tamping device
Filling mortar 9 9 3 195
type
Studs and frameworks Construct as per
9 3 3 141
assembly design drawings
Accepted Manuscript
Not Copyedited
3
J. Manage. Eng.
Table 4 the part of FMEA table
Key input Failure modes Effects causes Improvement

variables
Joint spacing Too small Wall crack Carelessness Examination at

between spacing of builder random after

panels construction
Spacing
Too large Wall crack Carelessness Examination at
between board
spacing of builder random after
and main
construction
structure
Too small Wall crack Carelessness Examination at

Spacing
spacing of builder random after
between studs
construction
Unstable Swing, wall Straight line Change the

U-runner fixing of surface crack nailing cannot nailing method
fixing method u-runner bear shear (by cross
force. nailing)
Not follow Wall crack Without Establish

design quality post-construction
Construct as drawings inspection quality control
design mechanism mechanism
drawings after according to key
construction quality
characteristics
Accepted Manuscript
Not Copyedited
4
J. Manage. Eng.
Table 5 Numerical simulation model parameters of C-shaped steel frame

Simulatio
beam 3D elastic
n element
Z
W1
Graphic t
represent Y
W3
t
ation W2
t
Young's
210 GPa
modulus
C-shaped steel frame (column)
W1 W2 W3 t
5cm 5cm 6.25cm 1mm
Horizontal prism
wi dt h
Graphic
t
representation
width t
5cm 1.2mm
Accepted Manuscript
Not Copyedited
J. Manage. Eng.
Table 6 Numerical simulation model parameters

Simulatio
3D elastic
n element
Density 9.7g/ cm3
Cold
Elastic modulus 205GPa
rolled
Poisson’s Ratio 0.27
steel
Material Yield strength 425 MPa
properties Density 0.8g/ cm3
Calcium
Elastic modulus 4.767 GPa
silicate
Poisson’s Ratio 0.25
board
Elastic modulus 5.08 MPa
Accepted Manuscript
Not Copyedited
J. Manage. Eng.
Table 7 Control plan
Controlled item Operation Control Sample size Sampling

specification methods frequency
Spacing 1cm Checklist Full inspection Full inspection

between board
and main
structure
U-runner Construct as Checklist Full inspection Full inspection

fixing method u-runner
fixing SOP
Accepted Manuscript
Not Copyedited
J. Manage. Eng.

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Journal of Management in Engineering.

Submitted February 8, 2012; accepted September 12, 2012;

Applying Six Sigma to Quality Improvement in Construction

Department of Industrial Management, Ching Yun University,

Jungli, 320, Taiwan, ROC

*Corresponding author. Tel.: +886-3-4581196; fax: +886-3-4683298.

Taiwan is in a seismically active zone, because it is located in the earthquake-prone

Copyright 2012 by the American Society of Civil Engineers

Keywords: Six Sigma, lightweight partition wall, case study.

Copyright 2012 by the American Society of Civil Engineers

Because of advances in construction engineering technology, trends in building

earthquakes can result in customer complaints. This research demonstrates a Six

quality to minimize cracks was found.

2006), several companies, including, General Electric (GE), Honeywell, Bombardier

Copyright 2012 by the American Society of Civil Engineers

The effectiveness of Six Sigma approach depends on business strategy, top-down

involvement, and customer focus and it has an impact on profits if it is successfully

techniques The techniques employed in Six Sigma projects include project

management tools and methodology, advanced data analytical tools, customer

The define–measure–analyze–improve–control (DMAIC) phases of the Six Sigma

Copyright 2012 by the American Society of Civil Engineers

Management approach provide is a structured problem-solving procedure widely used

identifying potential root-cause and establishing the relationships between different

Copyright 2012 by the American Society of Civil Engineers

Six Sigma methodologies were first applied in manufacturing; however, once

different functional areas such as marketing, engineering, purchasing, servicing, and

administrative support (Henderson and Evans, 2000; Rajagopalan et al., 2004;

of Experiments (DOE), Response Surface Methodology (RSM), Robust Design,

and Effect Analysis (FMEA), Capacity Analysis, Hypothesis Testing, Analysis of

Variance (ANOVA), Regression Analysis, and so on (Hoerl, 2001; Elshennawy, 2004;

Copyright 2012 by the American Society of Civil Engineers

business-improvement related problems such as production and service planning and

scheduling, inventory control and management, supply chain management, operations

scheduling and workforce scheduling. OR/M techniques such as forecasting, queuing,

effectively for continuous quality improvement.

LIGHTWEIGHT PARTITION WALL

Conventional partition walls in Taiwan are mainly constructed from reinforced

Copyright 2012 by the American Society of Civil Engineers

salaries, increased construction costs, and changes in the Taiwan construction

demands. As traditional construction methods require heavy building materials and

framework partition wall.

IMPLEMENTATION OF A SIX SIGMA PROJECT

Copyright 2012 by the American Society of Civil Engineers

Project initiation and definition

earthquakes. The dissatisfaction rate of customer was 87%. Frequent customer

help to prevent cracks in subsequent earthquakes. Therefore, the top management of

Copyright 2012 by the American Society of Civil Engineers

are described as follows:

variables (KPOVs) and to identify the causes of variation. Meanwhile, the

characteristics of input variables, including C, U and S types were displayed in the

(3) Standard Operation Process (SOP) (S): those in current SOP.

Copyright 2012 by the American Society of Civil Engineers

cause-effect relationship is set up by process mapping, it is shown that the whole

lightweight partition flow consists of seven working procedures. Use of process

main working procedures. The forty-nine input variables included thirty-five

C&E Matrix screens critical steps and influencing factors

weighted from 1 to 10 according to customer requirements. The relationship between

Copyright 2012 by the American Society of Civil Engineers

Use FMEA to determine the causes affecting the key factors

The process of the simulation analysis is described below:

Copyright 2012 by the American Society of Civil Engineers

aftershock intensity of the Chi-Chi earthquake measured form Provincial Puzih

hospital. Figure 3 shows the designed seismic forces.

Copyright 2012 by the American Society of Civil Engineers