Checking of Design | Design Checking | Design Checklist

What is Design Checking?

Design Checking or checking of design is a process of validating a design and/or a design calculation to ensure that it is error-free and of good quality and is good for engineering and/or fabrication or whatever the end-use of it is.

Checking is also a process of value addition in terms of applying good engineering practices, aesthetics, reduction in cost and thereby providing better value to the client.

A design checklist is prepared for each important design process to aid in the design checking process.

Why design checking is required?

A quality check in design is required to

• Ensure that the engineering deliverables (drawing, calc, etc.) are error-free.
• Ensure that it is in line with the appropriate design standards and codes
• Ensure that there is consistency in the design approach and aesthetics across units in the design
• Ascertain optimization with respect to design and cost.
• Reduce field rework

What do we check against?

• Check calculations against applicable codes and standards
• Check design against control documents (P&IDs, Line List, General Arrangement Drawings, vendor drawings, design standards, checklists, etc.)
• Controlled issues of stress isometrics
• Statutory norms and regulations, eg. OISD, IBR, etc.
• Design safety, HSE, and constructability factors

Minimum Quality Plan for design Checking

• Follow appropriate color codes for checking.
• Use appropriate checklists. Signed and dated.
• Continual review of design/model is a must
• List items requiring special attention or independent review
• Conduct design safety and constructability reviews
• Mandatory to conduct inter-squad checks on design documents prior to the final check and issue
• Conduct formal stage-wise collaborative design review/model review sessions

What do we check for?

• The Deliverable is error-free with respect to the inputs provided
• Ease of fabrication, shipping, and erection
• Reduction in material and fabrication costs. Value+++
• Build some flexibility into the design, especially for critical items
• Ensure a consistent design approach for similar pieces of equipment and/or unit area piping
• Aesthetics

Responsibility Matrix for design check

• Every individual is responsible and accountable for checking his deliverable to ensure quality and error-free design.
• Every individual checks, signs, date, and then pass it on to the next individual.
• Calculations/drawings received for checking by the next individual, without a sign and date, shall not be entertained/accepted!!!
• Back-ups of holds and assumptions, if any, are maintained in an orderly manner before the issue
• A signed and dated checklist, completely filled out is a must for any checked document as this is a quality record
• The ultimate responsibility of quality and correctness lies with the lead as he is the one who enforces teams conformance to quality procedures
• Checking is a collaborative effort. Every individual owns and is accountable for an error-free and quality product

Why Design Checking Adds Value

• Owning responsibility and following good practices and procedures results in overall quality
• The use of checklists ensures important points needing check are not missing out
• Design reviews & inter-squad checks ensure interdisciplinary aspects are addressed in the design
• Safety and constructability reviews ensure good overall layout, approach, constructability, maintenance, and operability
• Incorporating fabrication/contractor-specific details and/or preferences into the design helps in easier and faster fabrication and lesser errors
• Facilitates a once-through approach from start to finish thereby saving on time and schedule
• Minimizes rework in design and at the field

Where do we stand today?

• Ownership and accountability by individuals missing. “Next person will check”!!!
• Do not prioritize tasks to ensure project schedules and goals are met
• Work hard but do not “Work Smart”
• Perform checking using either incomplete and/or superseded inputs
• Do not capture design changes and revisions properly. Do not use revision notes.
• Do not follow proper checking procedures, checklists, and colors from the initial stages. Keep this aside only for the final IFC check stage. Too late….!
• Do not check important items/spelling. More focused on irrelevant aspects
• Do not clarify checking procedures, standards, guidelines, checklists, etc. in the job notes upfront
• Do not obtain early client approval on checking procedures and expectations
• Do not have a checking and approval matrix for approval of various deliverables
• Do not maintain discipline holds summary
• Team and team leaders are often not aligned regarding the requirements/expectations of the project
• Final number-crunching during the IFC issue period often affects productivity, and efficiency and lowers team morale

What Needs Improvement?

• Follow a holistic approach toward checking
• Approach and expectations shall be clarified upfront through job notes and induction sessions
• Obtain client approvals and finalize checklists upfront
• Pay attention to minor details. Spell check is also important
• Work smart, prioritize, and be focused
• Checklists and proper procedures shall be used religiously – this is mandatory
• Always check against the latest documents to avoid rework.
• Always start the final check process against a frozen and dated set of documents like P&IDs, LL, etc.
• Lead to incorporate lessons learned in design into checklists as a process of procedural improvement
• Lead to make expectations known to the team, fix individual responsibility and enforce accountability
• Assign the right work to the right individual
• The team is to be told that this is not an individual activity but a team effort. We sail or sink together!

Synopsis

• Effective checking is integral to project success
• Translates into quality, cost, and schedule advantage. Value+++
• Checking is an innovative process, to find the best approach. One hat does not fit all!
• We need to challenge a situation to come out as a winner. Think “out of the box”!