The document describes a Kaizen report from ETA ASCON's Quality department about repairing and eliminating honeycomb defects found in concrete columns at a construction site. An analysis identified issues like improper vibration and pouring techniques, and negligence in design mix considerations as causes. Improvement measures included educating workers, updating pouring standards, and preparing a method statement for repairing honeycomb defects to standardize the process and prevent future issues.

1. Quality Month: May 2011 Kaizen No. Page No.:
KAIZEN REPORT QA/QC/2011-03 1of1
Company logo Company Name Department Section/Process
ETA ASCON QUALITY CONSTRUCTION SITE/PROJECT
Improvement Title: REPAIRING AND ELIMINATING HONEYCOMB DEFECT IN CONCRETE COLUMNS
Category: [x] Quality improvement [ ] Health & Safety [ ] Environment [ x] Productivity [ ] Office processes [ ] Product design improvement [ ] Service improvement
Before Situation Root Cause Improvement After Situation
Analysis Measures
BEFORE KAIZEN 1. Education during tool
1. Improper vibration box talks to the
persons involved at
2. Over vibration concrete pouring
activity.
3. Negligence in
consideration of 2. Taking into account of
aggregate size in design mix as per
design mix. Project specification,
ASTM/BS standards,
4. Improper and structural design
application of drg.
shuttering oil 3. Closing of all
gaps/holes with foam
5. Improper closing of tape to avoid seepage
gap/Holes. of cement slurry
4. Application of
approved concrete
repair as per
Defects before KAIZEN: Honeycomb and segregations found in concrete manufacturing
structure(Column) recommendations
Standard method of repairing
5. Method statement for honeycomb defect and
repairing honeycomb Standard method for concrete pouring
defect was prepared. to avoid honeycomb defect in columns.
Benefits: Participation
1. Better strength of the column structure
2. Better aesthetics 3. cost saving by avoiding defect and hence repair Imran (QA/QC), Satish (Project Engineer), Ayub (Foreman)
Standardization: Horizontal Deployment Opportunities (Replication):
Method statement for concrete pouring was amended to specify correct pouring height. The method statement for concrete pouring can be used for all
Method statement for repair of major honeycombing in column structure has been formulated. concrete structures
Single Point Lesson: Remark / Management Comments: Honey combing defect can be
Ensure reminding of right instruction just before an operation is performed. reduced from 10% of concrete surface area to 0% by following the
method standard at the time of pouring
Sign
Copy Distribution: Date of Starting: Date of Completion: Control No. (by DQG)
01 -may -2011 03-may-2011
Declaration: We are submitting this Kaizen case voluntarily to DQG for participation in Kaizen Blitz competition. We are glad to authorize DQG to share this information with the Business
community at large to promote Continual Improvement and good practices. We confirm that the improvement has been initiated and completed.
Signed by Authorised signatory: _______________________Name:________________________________Designation:_____________________________________ Date: ____/____/________