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PROJECTS DEPARTMENT
SPECIFICATION
TITLE
NON CONFORMANCE
REPORTING PROCEDURE
DOCUMENT NUMBER
REV
DATE
PAGE
84501-9200-9P-009
1 Mar 03
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DATE ISSUED
PREPARED
REVIEWED
APPROVED
COMMENTS
1 October 2002
B. Burn
R.Ford
A.McIntosh
1 March 2003
B. Burn
C.Binks
A.McIntosh
Department Name
Change
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TABLE OF CONTENTS
1.
INTRODUCTION.....................................................................................................4
2.
SCOPE ...................................................................................................................4
3.
RESPONSIBILITIES...............................................................................................5
4.
5.
6.
PROCEDURE .........................................................................................................7
7.
REVISIONS .......................................................................................................... 10
8.
APPENDICES..................................................................................................10-14
1.
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INTRODUCTION
The purpose of this DOCUMENT is to ensure the control of Non-Conformance of
material and manufacturing processes.
Quality Assurance / Quality Control on the Project is the contractual responsibility
of the EPCI Contractor who must put into place a quality system that complies
with the requirements of ISO 9000 standard and identifies, marks and segregates
(whenever applicable) items that do not conform to specified requirements and
prevents their inadvertent use on the Project.
These non-conforming items are recorded, reviewed, dispositions decided and
approved by designated Company personnel.
Remedial actions are taken and recurrence prevented.
The Company QC Department and Project Team must ensure that these steps
are carried out and that all necessary actions required to ensure the control of
non-conforming products, i.e. materials, processes, procedures and actions, are
utilized.
In addition, this procedure will define the methodology in issuing, handling and
filing of non-conformance reports within the Specific project
An integrated team approach with EPCI Contractor will be taken to avoid
duplication of effort and eliminate inefficiencies.
2.
SCOPE
The scope of this procedure is to describe the systems for identification,
reporting, evaluation and disposition of non-conformance in relation to materials,
procedures, actions, processes and products that will be actioned during the
fabrication, construction and installation of the Specific project
The procedure identifies in detail the necessary actions to be followed and the
associated responsibilities for taking remedial action and maintaining records of
all non-conformances and documentation.
Design changes arising from non conformance activities are not covered under
this scope and are subject to a site query system or a design change control
system.
3.
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RESPONSIBILITIES
The application of this procedure shall be the responsibility of the Company
Project QC department within the Company Project Team.
This procedure is relevant to material, process, fabrication, installation, precommissioning and commissioning of all works executed on the Specific project
Non-conformance can be identified during receipt of material, process,
construction, installation, pre-commissioning and commissioning of work. The
Company QC Department will interface with the EPCI QA/QC Department to
identify and control non-conformances.
It is the responsibility of all Project personnel in the above areas to assist in the
identification of possible non-conformances and to promptly notify their
departmental head/section lead and to the EPCI QA/QC personnel in charge of
the inspection of a particular activity.
The EPCI QA/QC personnel in charge of the area or activity where the nonconformance is discovered will be responsible for the preparation of a NonConformance Report (NCR) or a Material Non-Conformance Report (MNCR). If
necessary, the Company QC Department personnel may assist in preparing the
report and the development of proposals for remedial action and ways to stop
recurrence of the problem.
Company QC Personnel Responsibilities
During fabrication and construction activities regular inspections will take place
and it will be the responsibility of the Company QC department inspectors to
ensure that the contractor highlights, informs, records and documents any non
conformances against an applicable material, process, procedure or activity.
This does not free the Contractor of any of his contractual responsibilities.
A copy of all MNCR/NCRs will be maintained at site and copies will be sent to
Company Project QC Manager. The original is to be held by EPCI Contractors
QA/QC Manager.
Contractors approved documentation, such as MNCR and NCR forms, will be
utilized to avoid duplication of paperwork.
The Project and/or EPCI QC inspector responsible for the activity will be
responsible for performing the re-inspection of the non-conformity and reporting
of such re-inspection activities.
It is the responsibility of the designated Company QC department to ensure that
a record of all inspection related non-conformance reports are held and
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subsequent actions are recorded, distributed and retained within the Company
QC Department.
Project Engineering Section
It is the responsibility of the appropriate discipline engineers in the Project to
oversee the EPCI Engineering department and ensure that the construction
drawings, specifications, procedures and data sheets conform to contract
requirements.
Project QC Manager
It is the responsibility of the Companys Project QC Manager to liaise with the
Contractor to report the applicable MNCRs or NCRs and their dispositions
It is the responsibility of the Companys Project QC Chief Inspector to ensure that
a record of all MNCRs & NCRs and their dispositions are retained within the
project filing system.
4.
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6.
PROCEDURE
6.1
6.2.1 Contractor is contractually responsible to implement a documented nonconformance reporting and corrective action system.
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Authorized personnel implement approved disposition and the reinspection shall be carried out to original requirements.
Records are to be maintained which readily and positively identify the nonconforming item or material and specify the nature and extent of the nonconformance. Records shall also contain evidence that the repaired or
rectified item / material have been re-inspected in accordance with the
approved methods.
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that this would be a one off waiver and not a general relaxation of the
specification.
6.2
6.2.1 When initiating a non-conformance report the originator shall ensure that the
following information is included in the report.
6.3
6.4
Disposition of Non-Conformity
Each MNCR or NCR shall receive one of the following dispositions:
6.5
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Final Documentation
6.5.1 All original process- or production-related NCRs and the NCR status log shall be
retained in the Contractors QA/QC Department. Copies of all documentation
related to the issue and resolution of NCRs shall be placed in the project asbuilt
dossier or data book.
6.5.2 On a monthly basis, the Company Project QC Manager will review the nonconformance report status and its dispositions in order to identify any significant
trends. Corrective actions taken shall be assessed in order to prevent the
recurrence of non-conformities. QA/QC reports from Contractors production and
fabrication/construction facilities shall include a summary of NCRs raised or in
process.
The Project QC Manager shall appraise all data on non-conforming material or
process and the results will be presented at management review meetings.
6.6
The clearance of any disposition by the Company does not relieve the Contractor
of any of his obligations and responsibilities under the contract.
7.
REVISIONS
This Procedure may not be revised unless approved by the Company Project
Manager.
8.
APPENDICES
The following Appendix is an integral part of this procedure
Sample MNCR Report
Sample NCR Report
Sample NCR Log
Sample NCR Flow Sheet
84501-9200-9P-009
Revision
Date:
Contractor
PO No
MATERIAL
DESCRIPTION
PO Item No
Units
PROPOSAL
A = Accept As Is
B = Repair
C = Rejected
No further Action
Subject to corrective action
New Material to be procured
REMARKS
PROPOSED BY
APPROVED BY
Original
Copy
TPA
Name:
Signature
Date
Copy
Stores
Project
Copy
TPA
Quantity
84501-9200-9P-009
Revision
Date:
Contractor
PO No
DESCRIPTION
PO Item No
Units
PROPOSAL
A = Accept As Is
B = Repair
C = Rejected
No further Action
Subject to corrective action
New Material to be procured
REMARKS
PROPOSED BY
APPROVED BY
Original
Copy
TPA
Name:
Signature
Date
Copy
Stores
Project
Copy
TPA
Quantity
84501-9200-9P-009
PROJECT NONCONFORMANCE
REPORT LOG
NON CONFORMANCE
REPORT (NCR) LOG
NCR ORIGINATOR
NO.
AUDIT
REF.
NCR
ISSUE
DATE
NCR
ISSUED TO
DEFICIENCY
AGREED
COMPLETION
DATE
ACTUAL
CORRECTIVE
ACTION
COMPLETION
DATE
NCR
CLOSED
DATE
Contractor QA/QC
CII QA/QC
CII PROJECT
ENGINEER
Give instruction to QC
Department
On receipt
refer to
engineering if
applicable.
Act on
received
advice from
engineering
YES
Discipline
Eng
Project
Eng
Prepare answer to
NCR/MNCR c/w
Action Plan
Record NCR/
MNCR and
their
disposition.
Transmit to
Contractor
Contractor carries
out remedial work
Gain
approval
for
action or
"Accept
as is"
Clear NCR/
MNCR
84501-9200-9P-009