Assembly-line bugs…by definition…are problems and mistakes that are difficult to discover ahead of time.
Because no one person in construction knows everything…every person out in the field is at a different point on the learning curve. Some people know about and guard against certain construction problems, while other people know and guard against others. The only way for everyone to be equally informed is to collect all the combined experience and knowledge from past projects and apply them as a whole to each new project.
The first step toward achieving this goal is for company owners and managers to assign someone within the company this task.
Over the years I have attended many construction meetings held in corporate main offices. I have heard owners and managers plead, threaten, rant and rave, pound tables with their fists, and offer all sorts of incentive bonuses for faster construction an improved quality.
It took me years to realize that what these owners and managers were asking for was within their reach all the time. The basic research information…all of which is non-technical…to identify the bugs that cause schedule delays, budget overruns, nightmarish field problems, stressed-out jobsites, personnel turnover, and unhappy homebuyers…was all obtainable from the field at any time.
They just needed to look.
Why should owners invest the time and resources upfront to discover and prevent design and construction bugs? Why not wait until bugs materialize during the construction before trying to solve them case by case after-the-fact? Isn’t that why field people are on the jobsite? Isn’t that part of their job description?
The answer to these questions is the same reason why so much effort is spent upfront debugging the traditional mass-production assembly-line.
The debugging of an assembly-line before full-scale production begins…benefits each and every product assembled thereafter. When the time, effort, and costs of the initial debugging operation are spread-out over a large number of the same identical products…then the costs of that debugging operation become lower per item.
It makes economic sense to confine the discovery and elimination of bugs to the initial trial-run period of the mass-production assembly-line…because any remaining bugs slow down or temporarily stop each subsequent production cycle.