Quality System Requirements
QUALITY SYSTEM
The Project Quality System is established and documented as a means of ensuring that the materials, Installation, Testing &
Commissioning activities of this Project conform to the specified requirements of the Employer.
It comprises of:
1. Project Quality Plan
2. Inspection and Test Plan
3. Quality Control Procedures
4. Forms
SUB CONTRACT REVIEW
The following abbreviations are applicable, where used, in this Project
Quality Plan:
AVL: Approved Vendor’s List
ISO: International Standard Organization
ITP: Inspection & Test Plan
LPO: Local Purchase Order
MTR: Material Test Report
NCCAR: Non-Conformance and Corrective Action
Report PO: Purchase Order
PQP: Project Quality Plan
QA: Quality Assurance
QC: Quality Control
WO: Work Order
QCP: Quality Control Procedure
QMP: Quality Management Procedure
DESIGN CONTROL
The Project Manager is responsible for ensuring that design activities are being performed correctly to meet the specified
requirements.
All design changes and modifications shall be identified, documented, reviewed and approved by authorized personnel
before their implementation.
DOCUMENT AND DATA CONTROL
Documents and data related to the project shall be controlled properly to ensure the availability of the latest issue of documents and data for the reference of Project Staff for Design, Installation, Testing and Commissioning.
The documents and data covered in this Section includes:
● Project Quality System Documents External Documents
● Electrical Data
PURCHASING
Evaluation of Supplier / Sub- contractors:
Supplier or sub-sub-contractor shall be selected on the basis of their ability to meet the specified requirements including the quality system and any quality assurance requirements.
The authorized Suppliers of acceptable Manufacturer, as mentioned on Project Specification, shall be considered with top priority.
The pre-qualification documents and proposed material catalogues (which are confirmed as suitable by the Project coordinator) Supplier or Sub-subcontractor shall be submitted for Employer’s Representative’s review and approval. Only the Employer’s Representative approved Sub- Contractors and Suppliers shall be selected for performing the specified job or supplying the specified materials. The site Quality Supervisor shall maintain an approved Vendor’s List.
Purchasing Data
Purchase Orders and Local Purchase Orders shall contain data clearly describing the material or services ordered, including:
● The type, Class, Grade or other precise identification.
● The title or other positive identification and applicable issues of specifications, drawings, material submittal approvals, process
requirements, inspection requirements, inspection instructions, packing and marking requirements, factory test certificates,
warranty certificates, certificate of origin, operation & maintenance manuals, installation drawings and other relevant technical data.
● The title, number and issue of the quality system standard to be applied.
CONTROL OF EMPLOYER SUPPLIED PRODUCTS
General
The Site Engineer and / or Storekeeper shall be responsible for receiving, handling and storing Employer – supplied product.
The Site Manager shall be responsible for co-ordination with the Contractor and conveying the requirements of the Employer’s Representative to the concerned Site Engineers.
Receipt and Verification
The Contractor shall inform the Site Manager when the material is ready for delivery to the Sub-contractor.
Employer’s Representative, Contractor and Sub-contractor shall jointly inspect the received materials, to verify the quantity and compliance with the specified requirements.
Handling and Storage
A dedicated location shall be allocated for the storage of Employersupplied materials. The contractor shall provide the Manufacturer’s and
/or Employer’s Representative’s instructions regarding handling and Storage of Materials. The Site Engineer and Storekeeper shall ensure the
strict implementation of these instructions.
Any Employer-supplied product that is lost, damaged or is otherwise unsuitable for use shall be recorded and reported to the Contractor.
PRODUCT IDENTIFICATION AND TRACEABILITY
The Quality Supervisor is responsible for the inspection & test status of materials and installation activities.
The Storekeeper is responsible for proper identification of materials stored in warehouse for trace ability.
The materials shall be properly identified by suitable means from receipt through to all stages of storage, issuance and installation. Accepted
materials or services during receiving or in-process inspection shall be identified with ‘ACCEPTED’ Tag. Rejected materials or services shall be
identified with ‘REJECTED’ Tag. Materials or services, for which final decision to be taken at higher Management or Engineer’s Representative,
shall be identified with ‘HOLD FOR DISPOSITION’.
PROCESS CONTROL
The Site Manager and Site Quality Supervisor are responsible for identifying and planning the process, which directly affect quality and to ensure that these processes are carried out under controlled conditions.
The design, materials purchasing, receiving, installation and servicing
processes shall be carried out under following controlled conditions:
● Documented Inspection and Test Plans and QC Procedures where the
absence of which could adversely affect quality.
● Use of suitable installation and servicing equipment and suitable working
environment.
● Compliance with contract documents, Project Quality Plans and
Inspection & Test Plan.
● Monitoring and Control of suitable process parameters and product
characteristics through the use of Inspections and Test Plan.
● Approval of processes and equipment by Quality Supervisor and Senior
Engineers.
● Suitable maintenance of equipment to ensure continuing process
capability.
Special Processes
Where the results of processes cannot be fully verified by subsequent
inspection and testing of the product and where, for example, processing
deficiencies may become apparent only after the product is in service, the
processes shall be carried out by qualified operators and / or shall require
continuous monitoring and control of process parameters to ensure that the
specified requirements are met. Such process requiring pre-qualification of
their process capability are called as special processes. Examples for special
processes are Welding, Brazing, H.V Cable Jointing & Termination, etc.
INSPECTION AND TESTING
General
All the materials and processes related to this project shall be inspected and/ or tested as per contract document requirements in order to confirm that the specified requirements for the material or process are met.
The required inspection, tests, and records shall be detailed in the Project Quality Plan, Inspection and Test Plan or QC Procedures.
The Quality Supervisor is responsible for performing the receiving and inprocess inspection. Sub-sub-contractor shall be responsible for
performing all final test as per Contract requirements.
Receiving Inspection and Testing
Incoming product shall not be used until it has been subjected to a receiving inspection to verify conformance with the specified requirements of the contract specifications, approved material submittals, approved samples and / or Purchase Order.
Incoming product shall not be released for urgent production purposes; positive recall shall not be instituted by Sub- contractor.
In determining the amount and nature of receiving inspection, consideration shall be given to the control exercised at the Supplier and / or Sub-sub-contract premises. Documented evidence of quality conformance must be provided by the supplier and / or Sub-subcontractor.
CONTROLL OF INSPECTION, MEASURING & TEST EQUIPMENT
The Site Quality Supervisor shall be responsible for ensuring that only calibrated equipment shall be used in this project. Any uncalibrated
equipment or equipment with expired calibration dates shall be removed from Site and sent for calibration.
INSPECTION AND TEST STATUS
The Site Engineers and Quality Supervisor shall ensure that the Inspection and Test Status of material or activity shall be identified by suitable means, which indicate the conformance or non-conformance of materials or activity with regard to inspection or test preformed, in order to avoid unintended use of non-conforming products.
The Inspection and Test Status of a product is identified by using marking, tags, labels, ITP, inspection records or other suitable means.
The Inspection and Test Status shall be maintained throughout material storage, issuance, installation and servicing of the product to ensure that only a product that has passed the required inspections and test is dispatched and installed.
Records shall identify the inspection authority, who is responsible for the release of conforming product and status of inspection (accepted / rejected / hold). Inspection and Test Status Records shall comprise of any one or more of the following.
a) Inspection and Test Plan.
b) Goods Receiving Report / Delivery Note / Packing Slip.
c) Inspection / Test Reports
d) Inspection / Test Reports
e) Non-conformance and Corrective Action Reports.
CONTROL OF NON-CONFORMING PRODUCTS
The Site Quality Supervisor shall be responsible for monitoring the proper identification, documentation, evaluation, segregation (if possible) and disposition of a non-conforming product to ensure that the product that does not conform to specified requirements is prevented from unintended use or installation.
During the receiving, in-process or final inspection and testing, if any product does not conform to the specified requirements, the Quality
Supervisor shall ensure that:
● The product shall be identified with ‘REJECTED’ tag (if the product
cannot be repaired) or “HOLD FOR DISPOSTION’ tag:
● Prepare Non-conformance and Corrective Action Report.
● For Non-conforming materials, instruct the Storekeeper to store the item
in dedicated location for non-conforming products.
● For non-conforming activities, inform the concerned Site Engineer to hold
the said activities until further notice.
● Inform the Site Manager, Senior Engineers and concerned Supplier or
Sub-sub-contractor for further action and disposition.
CORRECTIVE AND PREVENTIVE ACTIONS
The Site Manager and Quality Supervisor shall be responsible for taking necessary corrective or preventive action to eliminate the causes of actual or potential non-conformities.
Non-conformance corrective actions and preventive actions shall be identified, documented, implemented and verified as per following
Procedures.
Corrective Action shall be identified, recorded, implemented and verified to ensure the following.
a) Effective Handling of Customer Complaints.
b) Reporting of Product Non-conformities
c) Investigation of the cause of non conformities relating to product, process and quality system and recording the result of the investigation.
d) Determination of the Corrective Action needed to eliminate the cause of non-conformities.
e) Application of controls to ensure that corrective action is taken and that it is effective.
The Preventative Actions shall be identified, recorded, implemented and verified to ensure the following:
a) The use of appropriate sources of information such as processes and work operations, concessions, audits, quality records, service
reports and customer complaints to detect, analyze and eliminate potential causes of non-conformities.
b) Determination of the steps needed to deal with any problems requiring preventative action.
c) Initiation of preventative action and application of controls to ensure that it is effective.
d) Ensuring that relevant, information on actions taken is submitted for management review.
HANDLING, STORAGE, PACKAGING, PRESERVATION & DELIVERY
The Storekeeper shall ensure that the materials and equipment are properly handled, stored, packed and preserved during receipt, storing and delivery.
The materials shall be handled properly to prevent damage or deterioration.
Designated Storage Areas or Stock Rooms shall be used to prevent damages or deterioration of materials or equipment stored for future use.
Storekeeper shall maintain authorized records of receipt of materials and delivery of materials to / from Site store.
Materials or equipment in stock shall be checked monthly to detect deterioration, if any.
CONTROL OF QUALITY RECORDS
The Project Co-Ordinator is responsible for the maintenance of the project records, from project completion date until the completion of retention period (as per sub-contractor’s quality system and contract requirements), at Sub-contractor’s Head Office.
Quality Records
The Project Quality Records, which shall be maintained as per this
procedure, are as follows:
Technical / Engineering Records:
a) Design Submittals.
b) Drawings (All revisions & Employer’s Representatives comments)
c) Quotations & Product Catalogues
d) Material Technical Submittals & Samples (All Revision and Employer’s Representative’s Comments).
e) Contract Documents
f) As-built Drawings & Contract Documents
g) Request for Information and Employer’s Representative’s response.
Construction Records:
a) Purchase Orders
b) Contract Amendments / Variations / Change Orders
c) Correspondence with Contractor
d) Minutes of Weekly Project Co-ordination Meeting
e) Minutes of Technical Meeting
f) Correspondence with Suppliers
g) Warranty Certificates, Certificates of Origin , Factory
Test Certificates, Delivery Notes, Packing Lists, etc.…
h) Sub-sub-contract Documents
i) Goods Receiving Reports & Goods Issue Reports
j) Site Instructions
k) Operation and Maintenance Manuals
l) Training Records
INTERNAL QUALITY AUDITS
The Sub-contractor’s QA Dept. at Head Office is responsible for planning and implementing Internal Quality Audits to verify whether quality activities and related results comply with planned arrangements and to determine the effectiveness of the Project Quality System.
TRAINING
The Site Manager and Senior Engineers shall identify training needs and provide training for all personnel performing activities affecting quality.
The Site Engineers shall ensure that personnel performing specific assigned tasks shall be qualified on the basis of appropriate education,
training and / or experience, as required.
SERVICING
All the servicing requirements as per project contract documents shall be performed and documented.
The Site Manager shall ensure that qualified and experienced personnel shall be assigned to perform equipment servicing.
STATISTICAL TECHNIQUES
The Senior Engineer shall identify the need for statistical techniques required for establishing, controlling and verifying process capability and product characteristics.