Improving Quality Control and Reducing Inspection Failures with Active Oversight

The Challenge

Precision Construction was challenged with building nearly 340 similar residential units delivering 20-30 units per month. Inconsistent construction processes and a lack of quality management led the project to experience an average of 200 failed inspection items per unit. These failures resulted in schedule delays, costly rework, and missed client deadlines for delivery.

The Solution

Vertex Innovations crafted a QMP (Quality Management Plan) based on the types of units and the floorplans. Once we understood the key metrics the client was looking for, we introduced Active Oversight (AO), a quality management system designed to streamline workflows, eliminate guesswork, and provide a consistent process for field staff and trades. The key aspects of Active Oversight that drove improvement included:

• Standardized Workflow: A unified process for construction and QA/QC inspections, ensuring consistency across teams.
• Real-Time Data Tracking: The system provided live updates on inspection progress, allowing Precision and their client to address quality concerns immediately.
• Insightful Analytics: Active Oversight helped identify recurring quality issues, particularly those related to drywall, paint, and doors, enabling targeted attention.

The Results

After implementing Active Oversight, Precision Construction saw a dramatic improvement in inspection results. The average number of failed inspection items dropped from 200 failures prior to implementing AO to just 40 failures per project in less than a year. This marked an 80 percent improvement in quality following the use of Active Oversight.

Key Outcomes:

• Reduction in Failed Inspections: The number of failed inspections dropped significantly, reducing delays and rework.
• Focus on High-Risk Areas: Data pinpointed problem areas like door installs and plumbing, allowing for proactive interventions.
• Proactive Quality Control: Real-time tracking enabled teams to address issues before they became costly.
• Improved Focus for Future Projects: Active Oversight provided actionable insights into which trades or scopes needed improvement, helping guide future training and project planning.

Through detailed analysis of inspection failures, it became evident that regular site inspections were key to minimizing issues at project completion. A crucial insight was that conducting quality inspection/site walks at six weeks into construction and again at handoff would have likely minimized the number of failed inspections at completion. This highlighted the importance of periodic oversight and early intervention to prevent costly issues at project completion.

Vertex Innovations helped implement Active Oversight, tailoring workflows and checklist templates to Precision’s needs. While Vertex also offered QA/QC inspection services, Active Oversight was designed to enable teams to use the tool independently for ongoing projects.

The success of Active Oversight in this project demonstrates its ability to significantly improve quality management. By providing clear workflows, real-time data, and actionable insights, the tool helped Precision Construction reduce inspection failures, minimize rework, and stay on schedule. Ultimately, Active Oversight helped deliver a higher-quality project and set a foundation for even better outcomes in future projects.