In order to validate the tools developed as part of the Construction Product Quality Planning (CPQP) framework, the Construction Innovation Hub worked with specialist modular building manufacturer ilke Homes to demonstrate the benefits of following the framework when developing new construction products.
CPQP is a quality assurance framework for the construction industry which sets out a best practice approach for manufacturers to follow during the creation of new platform systems and offsite construction products.
CPQP includes a five-phase process, ranging from product definition to product launch, and the creation of a ‘live’ risk and control document which provides a digital audit trail for building safety cases.
A set of documents has been made available which includes the CPQP Guide, the Construction Product Approval Process (CPAP) Handbook and nine supporting guidelines which provide templates for the completion of crucial aspects of the quality assurance process.
ilke Homes is revolutionising the way in which high-quality, energy-efficient homes are delivered across the country. The modular housing provider is the first in the UK to develop and manufacture a mainstream zero-carbon home. It has the capacity to deliver 2,000 homes per year, with six units complete per day.
The CPQP project team supported ilke Homes in the development of its new Product Introduction Programme. Benchmarking against the CPQP framework revealed the need to focus on capturing customer needs as well as product risk assessment and prioritization. These align with phases one and two of the CPQP framework:
The Hub helped form a multidisciplinary team within ilke Homes and delivered bespoke training and guidance material to help them understand the principles set out in the CPQP framework. A Gap Analysis was then undertaken to identify where the CPQP framework could be of most value.
Following this work, the project team were able to see the benefits ofthe ‘Quality Function Deployment’ tool available in the CPQP toolset to facilitate the translation of the Voice of the Customer into actionable product design requirements including technical design specifications, critical product characteristics and critical process characteristics.
Next, the Hub team guided the adoption and population of both a Design and a Process failure mode and effect analysis (DFMEA and PFMEA). DFMEA is a structured approach used by engineers to identify potential failures that could occur in the design of a product.
CPQP is an adaptation of Advanced Product Quality Planning (APQP), which is employed throughout manufacturing industries, such as aviation and automotive, to effectively ‘build in’ quality when developing new products.
The Construction Playbook and Transforming Infrastructure Performance Roadmap to 2030 have both set out a vision for a manufacturing-led construction sector. New products and platforms are needed to achieve this and drive progress against value, quality and Net Zero targets.
CPQP is part of a suite of tools that the Hub has developed to meet these ambitions. Specifically, it aims to ensure innovative new products meet and exceed existing quality standards in traditional construction projects.
The aim of CPQP is to ensure that quality is built into the manufacturing process and final product from the start and that any new construction products meet performance requirements from day one and throughout their lifecycle. This helps businesses move away from defect detection and toward a culture of defect prevention.
In the case of ilke Homes, big wins included the ability to quickly detect and address possible product failures and the development of a bespoke quality standard for the company.
The process of identifying critical and significant risks and embedding FMEA’s into ilke’s new product introduction programme helps to ensure all new and current products have design and process risks evaluated to a demonstrably high standard.. A new post has also been created to integrate CPQP into the NPI programme going forward, creating a clear line of responsibility.
"Our customers deserve the highest quality. Adopting the CPQP principles alongside our existing processes ensures that we can maintain the highest standards as we continue to develop and deliver more complex projects.
CPQP has helped us to build in additional quality at the product stage, rather than relying on quality control at the end of manufacturing. Essentially, it moves the quality element further back in the process.”