| S.No. | Checkpoint | IS Requirement | Status |
|---|---|---|---|
| IDENT. CAR Identification & Problem Summary | |||
| IDENT_01 | CAR Title / Brief Description Acceptance: e.g., 'Establish concrete cure time monitoring procedure', 'Implement rebar spacing verification checklist', 'Recertify welders in structural welding', 'Calibrate concrete batch plant' | Concise title for this corrective action | |
| IDENT_02 | Problem Statement / Summary of Non-Conformance Acceptance: e.g., 'Concrete surface honeycombing detected in foundation slab. Root cause: Shuttering removed before 28-day cure completed due to schedule pressure. Occurred 3 times in past 2 weeks.' | What was the original defect or issue? | |
| IDENT_03 | Frequency of Occurrence Acceptance: e.g., 'First occurrence (one incident)', 'Recurring (3 incidents in 2 weeks)', 'Sporadic (5 incidents over 3 months)', 'Trending upward/downward' | How often has this problem occurred? | |
| IDENT_04 | Impact Assessment (Safety / Schedule / Cost / Quality) Acceptance: Safety: 'No safety impact' / 'Minor risk' / 'Major hazard'. Schedule: 'No delay' / '2-3 day delay' / 'Significant delay'. Cost: 'Minimal (<5% scope)' / 'Moderate (5-15%)' / 'High (>15%)'. Quality: 'Cosmetic' / 'Functional impact' / 'Structural risk' | Assess consequence if problem continues | |
| CAUSE. Root Cause Analysis | |||
| CAUSE_01 | RCA Method Used Acceptance: 5-Why Analysis: Depth of questioning to reach root cause. Fishbone/Ishikawa: Factors categorized (People, Process, Materials, Equipment, Environment). Pareto Analysis: 80/20 rule — vital few causes. Fault Tree Analysis: Top-down logical breakdown. | Systematic analysis technique applied | |
| CAUSE_02 | ROOT CAUSE (Why did this happen?) Acceptance: e.g., 'Schedule pressure prioritized completion over cure time requirements', 'No formal procedure to track shuttering cure duration', 'Worker training lacked emphasis on IS 456 cure time requirements', 'Lack of supervision / quality gate before shuttering removal' | Underlying systemic reason for problem | |
| CAUSE_03 | Contributing Factors (Environment, People, Process, Materials, Equipment) Acceptance: People: 'Supervisor not trained on cure requirements', 'Worker fatigue due to overtime'. Process: 'No written procedure', 'Inspection not scheduled'. Materials: 'Defective cement causing weak hydration'. Equipment: 'No timers/alarms to remind cure time'. Environment: 'Hot weather accelerating apparent set' | Secondary factors that enabled root cause | |
| CAUSE_04 | Why did it reach site? (Systemic Breakdown) Acceptance: e.g., 'Pre-activity checklist not mandatory before shuttering removal', 'ITP did not define cure time hold point', 'QC checkpoint missing between shuttering and removal', 'Approval authority not consulted' | System-level reason defect was not caught | |
| CORRPLAN. Corrective Action Plan | |||
| CORRPLAN_01 | Immediate Containment Action (short-term stopgap) Acceptance: e.g., 'STOP all shuttering removal until procedure approved', 'Inspect all recently removed shuttering', 'Notify all teams of 28-day cure requirement', 'Place hold on schedule compression requests' | Stop the problem from getting worse NOW | |
| CORRPLAN_02 | Long-term Corrective Action (permanent fix for root cause) Acceptance: e.g., 'Establish written 'Concrete Cure & Shuttering Removal Procedure' with clear timelines', 'Implement daily cure time tracking checklist', 'Add 'cure time verification' as ITP hold point', 'Require QC sign-off before any shuttering removal' | Eliminate the underlying problem | |
| CORRPLAN_03 | Preventive Action (prevent similar issues in other activities) Acceptance: e.g., 'Conduct toolbox talk on cure requirements for all workers', 'Update method statement template to include cure time requirements', 'Revise ITP template to include cure time hold point', 'Monthly training for new workers on IS 456 requirements' | System-wide improvement to prevent recurrence | |
| CORRPLAN_04 | Action 1: Description, Responsible Person, Target Date Acceptance: What: e.g., 'Draft and circulate procedure'. Who: 'QC Manager, Shri X, Tel: 9xxx'. When: 'By 2026-04-10'. Status: Pending/In Progress/Complete | First specific action item | |
| CORRPLAN_05 | Action 2: Description, Responsible Person, Target Date Acceptance: What: e.g., 'Conduct toolbox talk'. Who: 'Site Supervisor, Shri Y'. When: 'By 2026-04-12' | Second specific action item | |
| CORRPLAN_06 | Action 3: Description, Responsible Person, Target Date Acceptance: What: e.g., 'Implement daily checklist in ITP'. Who: 'Consultant QC Engineer'. When: 'By 2026-04-15' | Third specific action item (if needed) | |
| CORRPLAN_07 | Budget / Resource Impact (if any) Acceptance: e.g., 'No additional cost', 'Requires 2 days for training (~Rs. 2000)', 'Requires new monitoring equipment (~Rs. 5000)', 'Minimal impact expected' | Identify resource requirements | |