Construction small-projects rework reduction for capital facilities

Rework is a persistent problem in construction. Reducing field rework is widely regarded as an effective way of improving construction performance in terms of productivity, cost, and schedule. Although much literature exists concerning rework reduction, there is a need for further analysis, validation, and improvement of rework reduction methods. This paper presents a generalized model for a rework reduction program (RRP), which is intended to reduce rework by managing a continuous improvement loop with four functional processes: (1) rework tracking and cause classification, (2) evaluation of rework and its causes, (3) corrective action planning, and (4) integration of changes into the total management system. Analysis is conducted to examine and verify the functional mechanisms and effectiveness of the generalized model, by investigating a rework reduction program implemented in practice for a series of dozens of small projects executed by three contractors that represents the generalized model, and by analyzing the impact trends on rework in terms of frequency, cost, and labor hours over a considerable time period. The paper's primary contribution to the overall body of knowledge is that it provides statistical evidence that the occurrence and impact of rework can be reduced significantly with such a program.