Reducing Welding Defects in Turnaround Projects: A Lean Six Sigma Case Study

ABSTRACT

In the construction industry, successful project completion leads to customer satisfaction. Schedule delays, however, may be caused by unexpected downtime due to rework/repair. This case study describes how one specialty construction company used the Lean Six Sigma methodology to reduce welding defects in turnaround projects. As a result, they improved project performance and identified solutions that were implemented company-wide. From a broader perspective, this research demonstrates how Lean Six Sigma can be applied in service-based environments such as turnaround projects. It also provides evidence of the tangible benefits that can be achieved within specialty construction operations using process improvement strategies.

KEYWORDS:

• case study
• DMAIC
• Lean Six Sigma
• turnaround/construction projects
• welding defects

ACKNOWLEDGMENTS

The authors thank the following representatives from JVIC who supported this project from beginning to end: Jeremy Grace, Doyle Cassity, Tony Barraza, and Christina Walden. Without their support, this project would not have been possible.

Notes

Color versions of one or more of the figures in the article can be found online at www.tandfonline.com/lqen.