Non-conformances in infrastructure engineer-to-order production systems

Peter E. D. Love, Jane Matthews and Hadi Mahamivanan

International Journal of Production Research, 2025, vol. 63, issue 21, 7753-7776

Abstract: Non-conformances can adversely impact the productivity, performance, and safety of infrastructure engineer-to-order (ETO) production systems. However, we have a limited understanding of their actual costs, causes, severity, and remedial actions, as access to such data is rarely available for analysis. Using an illustrative case study, we provide insights into the nature of non-conformances from 14 projects totalling $2.34 billion, forming part of a programme of work in an infrastructure mega project. We analyse 1097 non-conformances and determine their costs, causes, severity, and the remedial actions undertaken. Key findings include: (1) a mean non-conformance cost of 0.41% of a project’s contract value; (2) a mean rework cost of 0.30% of a project’s contract value; (3) the root causes of non-conformance were processes and methods not being followed and defective materials (e.g. concrete); and (4) 41% of non-conformances are repeated. An interpretive analysis of several rework events is undertaken to understand their causation and the learning culture enacted to adapt, respond and manage their occurrence. The theoretical and practical implications of our analysis are discussed, which provide insights for practitioners and stimulate new lines of inquiry to understand better how quality can be better managed in an infrastructure ETO production system.

Date: 2025
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DOI: 10.1080/00207543.2025.2505156

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