Problem solving case study

Prepare by:Engr. Khaled M. Al Kolfat

Problem SolvingKey to Continuous Improvement

Case Study

Content List:

1. Researcher Identification.

2. Problem-Solving and Decision Making Steps.

3. Case Study (Marafiq Project) Jubail.

4. What is Cold joint ?

Problem Solving (Case Study ) Engr. Khaled M. Al Kolfat 210/15/2014

Professional experience:

• 2012 Operations Manager

• 2009 Project Manager

• 2008 Project Manager

• 2006 Construction Manager

• 2004 Site Manger

• 2003 Site Engineer

Education:

• Tanta University, BS in civil Engineering

• Helwan University, Pass Prep. MEng with concentration in

project management

Contact:

• e-mail: [email protected]

• Tel: 0508016339

Ras Al Khair - Riyadh Water

Transmission System project

Qassim 9025 380 KV Substation

Marafiq IWPP Jubail

PP PDH plant

Different projects with MODA

Fishing Sea Port in Egypt


mailto:[email protected]

What is a Problem ?

10/15/2014 Problem Solving (Case Study ) Engr. Khaled M. Al Kolfat 4

Anything that Deviates from the Standard or Target

What is a “Problem”

An unfulfilled customer’s need

A Gap between Actual & Desired condition

Problem, Problem Solving and Decision Making

Problem

1. Exists whenever objectives are not being met.

2. What is happening vs. what is wanted to be happen

Problem Solving

1. The process of taking corrective action to meet objectives.

Decision Making

1. The process of selecting an alternative course of action thatwill solve a problem.

2. First decision is whether to take corrective action.


PROBLEM


DURING CONSTRUCTION THE ENGINEERS FACEING PROBLEMS

Running Away From Any Problem Only Increases The Distance From The Solution


The Easiest way to escape from a problem is to solve it

Problem-Solving and

Decision Making Steps


Case Study

Project Bird's Eye View

Al Marafiq Project Location MapMarafiq IWPP Jubail

One special project is the Marafiq IWPP project in

Jubail. Marafiq had

developed its coveted IWPP

project in Jubail Industrial

City on a build, own, operate

and transfer (BOT) basis of

a power generation facility

(2,745 MW) and water

desalination (800,000 cubic

meters per day).

This project is the biggest

project of its kind in the

world, fully constructed and

commissioned and is already

servicing the needs of both

the Jubail Industrial City and

the Eastern Province of Saudi

Arabia as a whole.


7 – Monitor progress and follow up

6 – Implement the Selected Solution

5 – Select the best Alternative

4 – Weigh the Alternative's

3 –Develop Alternatives.

2 – Gather Information's

1 – Define the Problem

Problem-Solving and Decision Making Steps


Define the problem

Time delay between the first and second layer concrete

pouring was more than five hours (concrete pour started at 11:30

and the second layer was not poured until 17:30) which should not

exceed above 60-90 min depending on the ambient temperature.

Concrete was found hard in the first layer due to the time delay as it

already started curing.

1


Creating definite chances for cold joint (vertically). As pouring of

concrete was half completed around the foundation on its first

layer and the other half of pouring had also a delay of 5-6 hours

it also have a high chances for cold joint horizontally between

the two half’s.

Define the problem ) cont.): 1


An undesirable discontinuity between layers of concrete that

occurs when one layer of concrete is allowed to harden before the

rest of the concrete is poured in what is meant to be a single, solid

mass The discontinuity occurs between the layers due to the inability

of the freshly poured, wet concrete to intermix with and bind

properly to the hardened concrete. Such a discontinuity is often the

result of logistical issues such as a contractor’s work schedule or an

unexpected material shortage.

A cold joint is :


Keep Your Boss Informed

You must fully engage and make the greatest efforts to realize the matter and

satisfy.

“PMI Stakeholders Module”


WHY?

They pay the bills.

Gather Information's

• Concreting process reports.

• Fresh concrete test reports.

• After cast test report.

• Designer report.

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Ultrasonic Pulse Velocity test requirements by client / consultant

This test is done to assess the quality of concrete by ultrasonic

pulse velocity method by measuring the time of travel of an

ultrasonic pulse passing through the concrete being tested.

Comparatively higher velocity is obtained when concrete quality is

good in terms of density, uniformity, homogeneity etc.



To Solve the Problem must know the Causes to get the Solution for the Effects.


Sequence of casting

Ice is not sufficient

Additives is not sufficient

Pump car not in proper condition

Vibrators not working properly

Vibrator lead not working

Man Method

Machine Material

Did not perform servicing to vibrators

Wrongly assemble the pump car

Concrete not finished properly

Concrete not vibrated properly Cold joint

Develop Alternatives.3

There are a number of methods for finding solutions. We will

describe five thinking methods below, but we recommend that you use

a number of them in finding solutions. The first four methods described

are nontraditional and more innovative. They allow you the possibility of

arriving at a novel solution. The fifth method is a more typical and

straightforward method.


How to Find Solutions?

This type of thinking is basically a linking process either through

similarity, difference, or contiguity. For example, contiguity finds

solutions from things that are connected through proximity, sequence,

and cause and effect.


1. Association


The process works as follows: List as many parts of the

problem you can think of. Then giving yourself a short time limit, list

as many words or ideas that have either proximity, sequence, or

related cause and effect to the ones you have listed. It brings into

focus options you might not have considered if you stuck to ideas

only directly related to the problem.

1. Association (Cont.)

This thinking method is a type of finding solutions through

comparisons. The process based on comparing the different facets of

the problem with other problems that may or may not have similar

facets.


2. Analogy

This thinking method is based on a

free, non-threatening. You can brainstorm

alone or with a group of people. Most often

a group of people from diverse

backgrounds is preferable. Each member is

encouraged to throw out as many ideas for

solutions as he can think of no matter how

ridiculous or far-fetched they may sound.


3. Brainstorming


All the ideas are discussed among the group, revised, tossed

out, expanded, etc. based on the group's analysis and awareness of

the validation for each idea, the best ones are selected for closer

review.

3. Brainstorming (Cont.)

This mode of thinking is based on sensation. It is not, as some think,

irrational. Intuition are built on a strong foundation of facts and

experiences that are buried somewhere in the subconscious. Use your

intuition as much as possible but check it against the reality of the

situation.


4. Intuition

This thinking method is based on analysis. It is the mostconventional and logical of all the methods and follows a step by step

pattern.


5. Analytical Thinking


a) Examine each cause of the problem. Then for each cause, based

on your direct knowledge and experience, list the solutions that

logically would seem to solve the problem.

b) Check the possible solutions you arrive at with the research you

have compiled on how the problem was solved by others.

5. Analytical Thinking( cont.)

Personal Skills for Developing the Alternative

• At first, consider all alternatives.

• Better alternatives may emerge.

• Look for most interesting aspect.

• Good ideas come from unexpected sources.

• Say ”What I like mostly about this idea is...”.


• Ask often for new ideas

• Clarify – “What do you mean when you say...?”

• Use “open” questions. Avoid “Yes” or “no” answers

• Ask “What..., How..., Why...”?

Personal Skills for Developing the Alternative ( cont.)



Using each thinking technique for finding solutions. Keep a

running list for all of them, even the ones that seem far out, too

simple, or even impossible. The effect of this is to give you a rich pool

of ideas that will lead you to the best solution.

Summary

Generally a crack of cold joint will be chipped out using a concrete

chisel bit to 1" (25mm) wide by 1.5" (37mm) deep. The slot will then

be coated with Concentrate in slurry form and then filled with either

by injection or trowel .

Note that many waterproofing repair professionals will have

variations on this procedure that are acceptable.

Choice-1 “Repair the defected structure”

Develop Alternatives. ( cont.):3


Choice-2 “Demolish by chemical” - Non-Explosive Demolition Agent

Is a powder with amazing 18,000 PSI expansive strength when

mixed with common water. Poured into the same holes where

explosive are traditionally placed in, It breaks reinforced concrete

and rock safely, while providing SILENT cracking.

(1) (3)(2)


Choice-3 “Demolish by wire saw by the company

Demolish Tools :

1. Coring machine.

2. Wall saw machine.

3. Wire saw machine.



Saw blade diameter– range

600 - 900 mm



If the company didn’t have the resources / experience the

company can use the Subcontractor to Demolish the defected

construction elements.

Choice-4 “Demolish by subcontractor.


Client Position For Alternative Corrective Options


Weigh alternatives.

1. Quality of the defected structure

after developing the alternative.

2. Time to implement the alternative.

3. Cost impact of the alternative.

4


Some questions to ask:

1. Will this completely resolve the problem?

2. Will this only satisfy part of the problem?

3. Will this have little or no impact on the problem?

4. Do we have the authority to implement?

5. Do we have the necessary resources?

6. How long will it take to implement?


Don't consider any alternative as "perfect solution."

If there were, there probably wouldn't be a problem in the first place

Consider your intuition

or inner feelings in deciding on a course of action

Return to your trusted outsider

Is there something you missed?

Does he/she see a problem with your solution?

Compromise

Consider compromise when you have a full grasp of the problem, and

your alternatives. Competing solutions may yield a hybrid solution.

Select the best alternative 5


Select the best alternative ( cont.)

Repair the

defected

structure

Choice

1

Demolish by

chemical

Choice 2

Demolish by

wire saw by

the company

Choice 3

Demolish by

subcontractor.

Choice 4

5


Implement the solution

1. Determining problem solution response

activities

2. Gathering and reviewing method statement

of the problem solution

3. Coordinate all problem solution activities

4. Allocate resources

6


6. Specifying internal and external

communications

7. Training staff

8. Establishing working relationships

with external stakeholders

9. Monitor progress and continuing

situation assessment



Prepare by:Engr. Khaled M. Al Kolfat

Problem SolvingKey to Continuous Improvement

Case Study

The second lecture

Building the executing team.

1. To solve problems by drawing onthe talents of variety ofindividuals.

2. To foster togetherness in theworkplace while tackling theproblem.

3. To reduce or eliminate a lack ofcommunication among staffmembers on site .


4. To heighten productivity by encouraging an atmosphere ofcooperation.

5. To achieve a solution that might be unpopular to some but is thedesire of the majority.


Demolition

Cutting Plan


Illustration Elevation.


Illustration Plan.


NUMBER OF BLOCKAS

MARKQUANTITY

UPPER LOWER

G1 28 8

G2 15 6

G3 8 4

G4 6 2

G5 4 2

G6 4 2

G7 6 3

CH1 4

CH2 4

CH3 8

CH4 6

SUB-TOTAL 93 27

TOTAL 120

Working Procedure


Operating Floor Plan


Foundation Section -A


Foundation Section -B


Foundation Section -C


Foundation Section -D


Foundation Section -E


Foundation Section -F


Working Schedule

ID ACTIVITY NAME DURATION

PLAN Oct-08 Nov-08

START END # 25 # 27 # # # 31 1 2 3 4 5

STG4 MARAFIQ IWPP (STG#4 REPAIR) 82 25-Oct-08 15-Jan-09

STG4-1Mobilization Phase 10 25-Oct-08 4-Nov-08

A1000 Wire Saw Cutting Machine 1 25-Oct-08 25-Oct-08

A1010 Drilling Machine 1 26-Oct-08 26-Oct-08

A1020 Trailer Truck 60T 1 1-Nov-08 1-Nov-08

A1030 Mobile Crane 50T 1 1-Nov-08 1-Nov-08

A1040 Lifting Wires 1 1-Nov-08 1-Nov-08

A1050 Mobilization Of Manpower 1 1-Nov-08 1-Nov-08

A1060 Coring Machine 1 2-Nov-08 2-Nov-08

A1070 Wire Saw Concrete Cutter "2No'S" 1 4-Nov-08 4-Nov-08



PLAN Oct-08 Nov-08 Dec-08

START END # 25 # 27 # # # 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 # 21 # # # 25 # 27 # # # 1 2 3 4 5


STG4-2 Demolition Phase 42 27-Oct-08 8-Dec-08

STG4-2-1 Crew1 39 27-Oct-08 5-Dec-08

A1080 Mark-Up Cutting Line And Hole Location 3 27-Oct-08 29-Oct-08

A1090 Drill Hole By Core Drilling Machine 5 30-Oct-08 3-Nov-08

A1100 Insert Diamond Wire Saw Into Drilled Hole And Apply It Upward 2 4-Nov-08 5-Nov-08

A1110 Apply Diamond Wire Saw Horizontally 2 6-Nov-08 7-Nov-08

A1120 Apply Diamond Wire Saw Upward 4 8-Nov-08 11-Nov-08

A1130 Lift Demolition Block And Transport It To Trailer 5 12-Nov-08 16-Nov-08

A1140 Move Demolition Blocks Designated Stock Area 4 17-Nov-08 20-Nov-08


A1160 Cut The Column Head By Diamond Wire Saw Horizontally 4 24-Nov-08 27-Nov-08

A1170 Lift Column Head Demolition Block And Transport To Trailer 4 28-Nov-08 1-Dec-08

A1180Chip The As – Cast Concrete Above Column And Exposed Reinforcement 4 2-Dec-08 5-Dec-08



PLAN Oct-08 Nov-08 Dec-08

START END # 25 # 27 # # # 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 # 21 # # # 25 # 27 # # # 1 2 3 4 5 6 7 8


STG4-2 Demolition Phase 42 27-Oct-08 8-Dec-08

STG4-2-2 Crew2 39 30-Oct-08 8-Dec-08

A1190 Mark-Up Cutting Line And Hole Location 3 30-Oct-08 1-Nov-08

A1200 Drill Hole By Core Drilling Machine 5 2-Nov-08 6-Nov-08

A1210Insert Diamond Wire Saw Into Drilled Hole And Apply It Upward 2 7-Nov-08 8-Nov-08

A1220 Apply Diamond Wire Saw Horizontally 2 9-Nov-08 10-Nov-08

A1230 Apply Diamond Wire Saw Upward 4 11-Nov-08 14-Nov-08


A1250 Move Demolition Blocks Designated Stock Area 4 20-Nov-08 23-Nov-08


A1270 Cut The Column Head By Diamond Wire Saw Horizontally 4 27-Nov-08 30-Nov-08

A1280 Lift Column Head Demolition Block And Transport To Trailer 4 1-Dec-08 4-Dec-08

A1290Chip The As – Cast Concrete Above Column And Exposed Reinforcement 4 5-Dec-08 8-Dec-08


ID ACTIVITY NAME DURATIONPLAN Dec-08 Jan-09

START END 6 7 8 9 10 11 12 13 14 15 16 17 18 19 # 21 # # # 25 # 27 # # # 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

STG4 MARAFIQ IWPP (STG#4 REPAIR) 82 25-Oct-0815-Jan-09

STG4-3 Re-Construction Phase 36 10-Dec-08 15-Jan-09

STG4-3-1 Crew1 33 10-Dec-08 12-Jan-09

A1300Connect New Reinforcement To The Existing Reinforcement By Mechanical Coupler 4 6-Dec-08 9-Dec-08

A1310 Rebar works Installation for Raft Foundation 7 10-Dec-08 16-Dec-08

A1320 Form work / Shuttering for Raft Foundation 7 17-Dec-08 23-Dec-08

A1330 Casting The Reinforced Concrete for Raft Foundation. 1 24-Dec-08 24-Dec-08

A1340 Casting Treatment 15 25-Dec-08 8-Jan-09

A1350 Removal The Shuttering of Raft Foundation 4 9-Jan-09 12-Jan-09

STG4-3-2 Crew2 33 13-Dec-08 15-Jan-09

A1360Connect New Reinforcement To The Existing Reinforcement By Mechanical Coupler 4 9-Dec-08 12-Dec-08

A1370 Rebar works Installation for Raft Foundation 7 13-Dec-08 19-Dec-08

A1380 Form work / Shuttering for Raft Foundation 7 20-Dec-08 26-Dec-08

A1390 Casting The Reinforced Concrete for Raft Foundation. 1 27-Dec-08 27-Dec-08

A1400 Casting Treatment 15 28-Dec-08 11-Jan-09

A1410 Removal The Shuttering of Raft Foundation 4 12-Jan-09 15-Jan-09


Demolition

Sequences


1 – Mark-up Cutting Line and Hole Location as per Drawing

Refer to “ Demolition Cutting Plan 01~ 03”. & “Demolition Hole Location 01 and 02”



3 – Drill Hole By Core Drilling Machine.



4 – Insert Diamond Wire Saw Into drilled Hole and apply it upward.



5 – Apply Diamond Wire Saw Horizontally.



6 – As per Cutting Plan, Apply Diamond Wire Saw Upward.



7 – Lift Demolition Block and transport it to Trailer.



8 – Move Demolition Blocks Designated Stock Area.



10 – Lift Demolition Block and Transport it to Trailer.


LiftingProblem Solving (Case Study ) Engr. Khaled M. Al Kolfat 8210/15/2014

11 – Cut the Column Head By Diamond wire Saw Horizontally as per

Cutting Plan



12 – Lift Column Head Demolition Block and Transport to Trailer.



14 – Chip the As – Cast Concrete above Column and Exposed

Reinforcement.



15 - Connect New Reinforcement to the Existing Reinforcement By

Mechanical Coupler.


Ready to ConnectProblem Solving (Case Study ) Engr. Khaled M. Al Kolfat 9010/15/2014


Mechanical Splice



Monitor progress and follow up7


Issue Resolution/ Decision Implementation plan Implementation notes Followup

Briefly discuss the issue?What you decided to do about

it?Who will do what?

Who did what, what

happened?

Was this satisfactory? What

changes needed to be

made?

How to monitor?


Schedule Monitoring

Start Finish Start Finish

STG4-2 Demolition Phase

STG4-2-1 Crew1

A1110 Mark-Up Cutting Line And Hole Location 3.00 27-Oct-08 29-Oct-08 27-Oct-08 29-Oct-08 completed

A1130 Drill Hole By Core Drilling Machine 5.00 30-Oct-08 3-Nov-08 1-Nov-08 5-Nov-08 completed 1 day delay - resources.

A1140Insert Diamond Wire Saw Into Drilled Hole And

Apply It Upward2.00 4-Nov-08 5-Nov-08 6-Nov-08 7-Nov-08 completed 2 day delay - resources.

A1150 Apply Diamond Wire Saw Horizontally 2.00 6-Nov-08 7-Nov-08 7-Nov-08 9-Nov-08 completed 1 day delay - resources.

Marafiq Project (as of 15-11-2008)

Activity ID Activity Name O. D.

Scheduling MonitoringASC REMARKSPlanned Dates Actual Dates

Status


Quantity Monitoring

STG4-2 Demolition Phase

STG4-2-1 Crew1

A1110 Mark-Up Cutting Line And Hole Location 3.00 L.m 500.00 500.00 0.00 0.00 completed

A1130 Drill Hole By Core Drilling Machine 5.00 No. 279.00 210.00 0.00 69.00 completed 1 day delay - resources.

A1140Insert Diamond Wire Saw Into Drilled Hole And

Apply It Upward2.00 L.m 500.00 500.00 0.00 0.00 completed 2 day delay - resources.

A1150 Apply Diamond Wire Saw Horizontally 2.00 l.m 500.00 500.00 0.00 0.00 completed 1 day delay - resources.

Remaining

QuantitiesStatus

Marafiq Project (as of 15-11-2008)

Activity ID Activity Name O. D.

Quantities MonitoringASC REMARKS

UnitTotal Quantity

for each item

Done till date

(Previous)

Daily /Weekly

this period


ReconstructionProblem Solving (Case Study ) Engr. Khaled M. Al Kolfat 9810/15/2014



Please Explain


Team Work Result


Bibliography / References

• ASC Project Lesson Learned. “www.assadsaid.com”

• Hiliti Co. “www.hiliti.com”

• IWPP Specifications “www.marafiq.com.sa”

• PMI Stakeholders Module www.pmi.org

• www.bizmove.com

• www.slideshare.net

• ar.wikipedia.org


Problem Solving.pptx



http://www.pmi.org/

http://www.bizmove.com/

http://www.slideshare.net/


Problem solving case study

Leadership & Management