Вы находитесь на странице: 1из 15
  STD NO.: E-0029 PROJECT PAGE: 1 OF 7 QUALITY APPROVED BY: RLW PLAN ISSUE
 

STD NO.:

E-0029

PROJECT

PAGE:

1 OF 7

QUALITY

APPROVED BY:

RLW

PLAN

ISSUE DATE:

10 Oct 2001

SUPERSEDED BY:

PROJECT QUALITY PLAN

  STD NO.: E-0029 PROJECT PAGE: 2 OF 7 QUALITY APPROVED BY: RLW PLAN ISSUE
 

STD NO.:

E-0029

PROJECT

PAGE:

2 OF 7

QUALITY

APPROVED BY:

RLW

PLAN

ISSUE DATE:

10 Oct 2001

SUPERSEDED BY:

PROJECT QUALITY PLAN

PROJECT: CENTINELA FLOTATION COLUMNS

DESCRIPTION: (2ea) Flotation Column 1.0m dia. X 9.5m

REFERENCE NUMBERS: C.003822

QUALITY REQUIREMENTS:

PER CONTRACT

INDEX   STD NO.: E-0029 PROJECT PAGE: 3 OF 7 QUALITY APPROVED BY: RLW PLAN

INDEX

 

STD NO.:

E-0029

PROJECT

PAGE:

3 OF 7

QUALITY

APPROVED BY:

RLW

PLAN

ISSUE DATE:

10 Oct 2001

SUPERSEDED BY:

PAGE

1.0

Scope

4

2.0

Purpose

4

3.0

Quality Assurance Organization

4

4.0

Organizational Structure

4 - 5

5.0

Contract Review

6

6.0

Design Control

6

7.0

Document Control

6

8.0

Material Identification & Traceability

6

9.0

Inspection & Testing

7

10.0

Equipment Calibration

7

11.0

Inspection & Test Status

7

12.0

Non Conformance items

7

13.0

Corrective Action

7

14.0

Storage, Packaging, & Transporting

7

15.0

Quality Records

7

  STD NO.: E-0029 PROJECT PAGE: 4 OF 7 QUALITY APPROVED BY: RLW PLAN ISSUE
 

STD NO.:

E-0029

PROJECT

PAGE:

4 OF 7

QUALITY

APPROVED BY:

RLW

PLAN

ISSUE DATE:

10 Oct 2001

SUPERSEDED BY:

1.0

SCOPE

It is Metso’s objective to fulfill the specifications and requirements designated by our contracts and obligations.

This Quality Plan describes the procedures for compliance.

2.0

PURPOSE

The purpose of this Quality Plan is to outline a system of controls, which will assure the quality of the products manufactured by Metso Grinding.

3.0

QUALITY ASSURANCE ORGANIZATION

3.1

General

The organizational structure of the Metso Project is illustrated (see Attachment A). This chart depicts communication paths and relationships of the Project Team.

4.0

ORGANIZATIONAL STRUCTURE

4.1

Contract Manager

4.1.1

The Contract Manager is responsible for the Project.

4.1.2

The Contract Manager will direct and control the Project within the limitations imposed by the budget, schedule and Project specifications.

4.1.3

The Contract Manager, in conjunction with Marketing will define the requirements of the contract. The Contract Manager will coordinate contract related activities with relevant department heads contract related activities.

4.1.4

The Contract Manager is responsible for overall business decisions related to the planning and control of the Project.

4.1.5

The Contract Manager will establish communications with the client and report progress within the timeframe specified in the contract.

4.1.6

Obtain and distribute contract documents relevant to Engineering.

4.2

Engineering Manager

4.2.1

The Engineering Manager will provide department resources required to effectively meet the contract requirements.

  STD NO.: E-0029 PROJECT PAGE: 5 OF 7 QUALITY APPROVED BY: RLW PLAN ISSUE
 

STD NO.:

E-0029

PROJECT

PAGE:

5 OF 7

QUALITY

APPROVED BY:

RLW

PLAN

ISSUE DATE:

10 Oct 2001

SUPERSEDED BY:

4.3

Project Design Engineer

4.3.1

The Project Design Engineer will be responsible for those tasks assigned by the Engineering Manager.

4.3.2

Coordinate and monitor the overall design and drawing activities for the project.

4.3.3

Notify the Contract Manager to ensure effective communication by distribution of reports, correspondence and personal contact.

4.3.4

Ensure that Project records are maintained by the established filing system.

4.3.5

Ensure that the design of the equipment is compatible with the agreed contract requirements and is completed within time specified.

4.3.6

Issue engineering and material specifications, including all quality requirements for Purchase Orders.

4.4

Quality Manager

4.4.1

The Quality Manager is responsible for carrying out scheduled Quality Audits.

4.4.2

Establish and maintain the Project Quality Plan.

4.4.3

Communication of quality related information for the Project.

4.4.4

Maintenance of the quality records for the Project.

4.4.5

Coordinate and monitor Quality Assurance activities for the Project.

4.4.6

Issue relevant Quality Inspection Plans (QIPS) for the Project.

4.4.6

Maintain a register of all Deviation Reports.

4.4.7

Arranging, performing, and reporting on inspection activities.

4.5

Purchasing Manager

4.5.1

The Purchasing Manager will coordinate and supervise Project purchasing activities.

4.5.2

Ensure that quotes are reviewed for compliance with scheduling, delivery and budget considerations. Coordinate compliance with technical specifications through Engineering.

4.5.3

Ensure Metso and client quality, technical and commercial requirements for goods and services are passed on to vendors as applicable through purchasing documents.

  STD NO.: E-0029 PROJECT PAGE: 6 OF 7 QUALITY APPROVED BY: RLW PLAN ISSUE
 

STD NO.:

E-0029

PROJECT

PAGE:

6 OF 7

QUALITY

APPROVED BY:

RLW

PLAN

ISSUE DATE:

10 Oct 2001

SUPERSEDED BY:

a) The requirements are adequately defined and documented.

b) Any requirements differing from those in the tender are resolved.

c) The subcontractor has the capability to meet contractual requirements.

d) The subcontractor has a quality system acceptable by Metso for the scope of supply.

5.0

CONTRACT REVIEW

The contract and tender documents will be reviewed to verify concurrence. Any discrepancies will be addressed with the client and resolved. Contract review will be conducted in accordance with Metso STD E-0002 Section 19.0.

6.0

DESIGN CONTROL

6.1

Design and verification activities are planned and will be reviewed during the course of the contract.

6.2

Design changes originating from the Client will be reviewed upon receipt by the relevant personnel.

6.3

Design changes/queries originating from the Project team and/or subcontractors will be addressed to the client through the Contract Manager.

6.4

All design changes will be reviewed and approved by the Project Design Engineer before the change is implemented.

7.0

DOCUMENT CONTROL

7.1

All Project documentation subject to document control will be processed through the Contract Manager.

7.2

Drawings are checked and released under authorization of the Project Design Engineer.

7.3

Drawings released from the York office are issued under cover of a Document Transmittal Form.

8.0

MATERIAL IDENTIFICATION AND TRACEABILITY

8.1

Specific material, which requires identification and traceability, will be marked or tagged.

8.2

On Subcontractors’ and Suppliers’ Premises

Specific material, which requires identification and traceability, will be marked or tagged in accordance with the subcontractors’ procedures.

  STD NO.: E-0029 PROJECT PAGE: 7 OF 7 QUALITY APPROVED BY: RLW PLAN ISSUE
 

STD NO.:

E-0029

PROJECT

PAGE:

7 OF 7

QUALITY

APPROVED BY:

RLW

PLAN

ISSUE DATE:

10 Oct 2001

SUPERSEDED BY:

9.0

INSPECTION AND TESTING

9.1

Quality Inspection Plans (QIPs) will be developed in accordance with requirements of each contract. QIPs will be reviewed by Metso and the client prior to use.

9.2

Inspection surveillance points required by Metso and the customer will be identified on the QIP.

10.0

EQUIPMENT AND CALIBRATION

10.1

All inspection, measuring and test equipment to be used on the Project by Metso will be verified as calibrated in accordance with Metso Procedure E-0002 Section 16 and D-0028.

10.2

All inspection, measuring and test equipment to be used on the Project by subcontractors will be verified as calibrated to recognized national standards and supported by copies of calibration certificates.

11.0

INSPECTION AND TEST STATUS

11.1

Quality Inspection Plans (QIPs) and other quality records will be maintained to provide identification of inspection and test status. The availability and compliance of such documentation will be verified before release of the product.

12.0

NON CONFORMANCE ITEMS

For Discrepancy Reports reference Metso procedure E-0016 and flowchart.

13.0

CORRECTIVE ACTION

13.1

Corrective action relating to product non-conformances will be reviewed by the Quality Assurance Manager and the Engineering Manager.

14.0

STORAGE, PACKAGING, AND TRANSPORTING

Requirements for Storage, Packaging and Transporting, see contract requirements.

15.0

QUALITY RECORDS

15.1

Project records will be stored and retained for 10 years from time of delivery.

  STD NO.: E-0029 ATTACHMENT A 1 OF 1 PROJECT PAGE: QUALITY APPROVED BY:  
 

STD NO.:

E-0029 ATTACHMENT A 1 OF 1

PROJECT

PAGE:

QUALITY

APPROVED BY:

 

RLW

PLAN

ISSUE DATE:

 

10 Oct 2001

SUPERSEDED BY:

PROJECT ORGANIZATION

PROJECT ORGANIZATION MANAGER, OPERATIONS King Lim CONTRACT MANAGER Tracey Lawruk MANAGER OF PROJECTS Jeffery
PROJECT
ORGANIZATION
MANAGER, OPERATIONS
King Lim
CONTRACT MANAGER
Tracey Lawruk
MANAGER OF PROJECTS
Jeffery Claycomb
MANAGER
MANAGER, PROJECT
MANAGER
PURCHASING
ENGINEERING
MANUFACTURING
Jeffery Borger
Robert Hendrix
Darlene Krone
MECHANICAL
ELECTRICAL
ENGR
ENGR
Joshua Wills
David Suskie
STRUCTURAL ANALYSIS
Ken Schultz
CONTRACT
ADMINISTRATION
Annette Wilt
QUALITY ASSURANCE MANAGER
Kevin Betolini
DIVISION CONTROLLER
Ann Winter
Q.A. TECHNICIANS
MANAGER INSTALLATION SERVICES
Keith Hill
INSTALLATION SERVICE
Supplier Quality Audit Questionnaire

Supplier Quality Audit Questionnaire

Company

Bafor

Date of Audit

11.04.2014

Location

Kocaeli, Turkey

 

Audit By

Ali Osman Karsan

Contact Person(s) of the Company

Burak Ergüner

 

Position

QA/QC Manager

 

Telephone

+90 549 262 41 44

 

E-mail

b.erguner@bafor.com.tr

 
 

INTRODUCTION of the COMPANY

 

Bafor Construction, which was started to operate in Izmit bay Industrial Zone in 1994, has undertaken execution of large projects by its customer-focused quality policy and obtained ISO 9001 quality management system certificate in 2003.

It continues to operate in its factory established in Izmit/ Ac su with 6.000 m² indoor and 16.000m² open working area and its expert staff.

The base of Bafor’s quality policy is consist of organizing and using of our sources efficiently to satisfy our customers altering and developing demands and needs on time and in a required manner, being a reliable and constant make by establishing a friendship with our customers, which never ends at the end of the business, maintaining our operation by following the applicable technical standards and codes as well as in a manner that labor health and occupational security and environmental protection requirements are met, recovering our management system structure continuously to adapt to our sector’s altering requirements in the quickest way and keeping a structure, which presents the highest guarantee at every stage of our production and service; and these are declared as an undertaking.

BAFOR aat, considers the people and the environment to be the most valuable asset in all activities. In this respect, in order to minimize loss of any kind regarding our environment, our employees and related parties;

Continuous improvement of HSE targets and HSE performance by reviewing periodically, Complying with all relevant HSE legislation, Providing continuous training to increase employees' awareness of HSE, Providing all of the necessary equipment related with HSE , Controling HSE risks associated with the participation of our employees, is committed.

Created by: Ali Osman Karsan (SQM), 21.02.2014

1/7

Supplier Quality Audit Questionnaire

Supplier Quality Audit Questionnaire

 

GENERAL

Item

Requirement / Query

Circumstance

GEN-1

Has the company got a valid ISO 9001 certification?

Yes, valid till 23rd December 2015.

(if yes, please submit the copy)

GEN-2

Has the company got any manufacturer approval?

ISO 3834-2, Expire date: 13.03.2017 ISO 1090-2: Expire date: 10.06.2015

(if yes, please submit the copy)

 

Has the company got a Quality Manual?

 

GEN-3

(if yes, please submit the copy)

Yes, submitted in Turkish only.

GEN-4

Is the QM rewieved and updated periodically? By Who?

Yes, by Quality System Representative. The position has not occupied since August 2013.

GEN-5

Has the company got organization chart per specified tasks and responsibilities?

Yes, submitted in Turkish only. Also tasks and responsibilities is attached.

(if yes, please submit the copy)

GEN-6

Has the company got training activities regularly?

Yes, 2014 training activities list is attached.

(if yes, please list trainings in last 12 months)

GEN-7

Who is QA / QC manager at the company?

Mr. Burak Ergüner

GEN-8

How many years has QA / QC manager worked for the company? How many year experienced is she / he totally?

He is working at Bafor since 2005, his total experience is 12 years.

GEN-9

Has QA / QC manager reported to whom?

General Manager

GEN-10

How many employees working for QA / QC department?

4 QA/QC personnel + Manager

GEN-11

Has QA / QC department got their own organization chart?

Yes, submitted.

(if yes, please submit the copy)

GEN-12

Has the company got a non-conformance / discrepancy procedure?

It covers by Quality Manual Item 8.3.

(if yes, please submit the procedure, NCR/DR form)

GEN-13

How are failed products defined and seperated?

Each unit has scrap stations for sem-finished items, Assembled parts are corrected at work place.

Created by: Ali Osman Karsan (SQM), 21.02.2014

2/7

Supplier Quality Audit Questionnaire

Supplier Quality Audit Questionnaire

 

INSPECTIONS & INSPECTORS & EQUIPMENTS

Item

Requirement / Query

Circumstance

INS-1

Has the company issued ITP / QIP per projects?

Yes, submitted.

(if yes, please submit a sample)

INS-2

Which inspection processes are availble in the company?

Conventional Measurement Non-destructive Tests (all in-house except RT) Hydrostatic Pressure Test Surface Treatment Inspections (blasting and paint)

INS-3

Has the company got inspector(s) certified by notified body?

One welding engineer per ISO 14731 One inspector for MT, one for UT and VT inspections per ISO 9712. Two inspectors for paint.

(if yes, please list and submit copy certificates)

INS-4

Have the company outsourced inspection services?

For RT, Deka Inspection Co and Imkosan AS For destructive testings, END Inspection Co

(if yes, please list outsourced services and suppliers)

INS-5

Has company got an inspection flow charts?

Inspections be followed up by ITP.

(if yes, please submit)

INS-6

Which inspection equipments the company has got inhouse?

Conventional Measurement Devices Laser Measurement Device Magnetic Particle Inspection Yoke Laser temperature measurement device Comparator plates for blasting inspections Paint thickness measurement devices Higrometer

INS-7

Are measurement and inspection equipments recorded and calibrated properly?

Yes, all calibrated.

INS-8

Who is responsible for follow-up the calibration of equipments?

Mr. Yasin Pekta (QC Inspector)

INS-9

Has the company got a checklist of calibration of equipments?

Yes, submitted.

(if yes, please submit)

INS-10

Who is the responsible for quality documentation preparation and approval?

All QC inspector documents their activities, QA/QC Manager approve them at the end of projects.

INS-11

How long are final quality documents archieved?

10 years.

Created by: Ali Osman Karsan (SQM), 21.02.2014

3/7

Supplier Quality Audit Questionnaire

Supplier Quality Audit Questionnaire

 

PRODUCTION & PROCESSES

Item

Requirement / Query

 

Circumstance

PRO-1

How is tracebility managed at the workshop?

Marking transfer by marker accordingly proper instruction.

PRO-2

Which production processes are available inhouse?

Mechanical Cutting Oxyfuel Cutting Plasma Cutting Plate Bending Plate Rolling Pipe and Beam Bending Machine Welding Edge Bevelling Welding Processes (+ UP / SAW Boom) Local Heat Treatment Machine (6 channel resistant) Beam CNC drilling machine Automatic Blasting Machine Manual Blasting Machine and seperated shop Manual Painting and seperated paint shop

PRO-3

What is the capability of above processes?

Please see attached equipments list.

   

111

- E / SMAW

141

- TIG / GTAW

Which welding processes are in usage at the company?

131

+ 135 - MIG + MAG / GMAW

PRO-4

136

- FCAW

 

121

- UP / SAW

78 - B / SW (Stud weld)

PRO-5

Who is responsible person for the welding work?

Fatih Kam (Welding Engineer) Ayhan Mamak (Welding Foreman)

PRO-6

How is welding documentation managed?

Mapping, welder logs and welding documents per EN 3834-2.

PRO-7

How is requirement of the welding parameters issued to the workshop?

WPSs present on the workshop.

PRO-8

How many percent welders are certified at the company?

100% certified welders / 34 welders totally.

PRO-9

How do welders identified?

Cold stamping.

PRO-10

Please submit the welding documentations?

Submitted.

Created by: Ali Osman Karsan (SQM), 21.02.2014

4/7

Supplier Quality Audit Questionnaire

Supplier Quality Audit Questionnaire

 

PRODUCTION & PROCESSES (cont'd)

Item

Requirement / Query

Circumstance

PRO-11

Who is the responsible person for storage and distrubition of welding consumable?

Storage - Cengiz Akanl (Warehouse responsible)Distrubi

PRO-12

Has the company got an instruction for welding consumable storage and distrubition?

Yes, submitted.

 

How is surface treatment is managed?

 

PRO-13

(please submit the surface treatment procedures if available)

Instruction is submitted.

PRO-14

Who is the responsible for surface treatment processes?

Yusuf Okumu (Painting Foreman)

PRO-15

How is ambient conditions checked?

by Higrometer (temperature, humidity and dew point control)

PRO-16

How is surface preparation checked before painting?

Blasting comparator plates.

PRO-17

How is paint surface quality checked?

by DFT, RAL cartela.

PRO-18

Has the company got packaging instruction?

No, client's requirements / specs are followed.

(if yes, please submit packaging instruction)

 

Are machines overhauled regularly?

 

PRO-19

(if yes, please submit the maintenance list)

Yes, submitted.

PRO-20

Has the company got any supplier outsourcing any production activities?

Galvanization - Marmara Machining - Onur makine, DS Grup

(if yes, please list related processes and suppliers)

PRO-21

Has the company carried out audits at suppliers?

No, the company makes supplier evaluation at the begining and during each outsourced item inspections.

(if yes, please submit reports)

PRO-22

Are any inspection activies done before or after recieving the outsourced items?

Outsourced items be checked at the supplier workshop when delivered.

PRO-23

Who is the responsonbile for these inspections?

QA/QC Management

Created by: Ali Osman Karsan (SQM), 21.02.2014

5/7

Supplier Quality Audit Questionnaire

Supplier Quality Audit Questionnaire

 

HEALTH & SAFETY & ENVIRONMENT

Item

Requirement / Query

Circumstance

HSE-1

Has the company got OHSAS 18001 certification?

Yes, expired till 5th February 2015, submitted. (Also ISO 14001 expired till 23rd December 2015, submitted.)

(if yes, please submit)

 

Has the company got a HSE instruction?

The company doesn't have general HSE instruction. They use proper instructions based on processes.

HSE-2

(if yes, please submit)

HSE-3

Has the company ever passed HSE audit by Ministry of Labour and Social Security?

Yes, report is not submitted.

(if yes, please submit the report)

HSE-4

Has the company got a HSE training program for the employees?

Yes, it covers by general training list (GEN-6).

(if yes, please submit)

HSE-5

Which HSE eqipments for employess are provided by the company?

All required HSE equipments are being provided by Bafor.

HSE-6

Has the company got penalty regulation for the employees don't follow HSE program?

Punishments are being declared to workers by Board.

(if yes, please submit)

Created by: Ali Osman Karsan (SQM), 21.02.2014

6/7

 
  Supplier Quality Audit Questionnaire

Supplier Quality Audit Questionnaire

 

CONCLUSION

General

 

Bafor has started to work with Metso for RCS tanks manufacturing for Process Equipment, Sala at end of 2012. First they made RCS tanks for Garpenberg project. They made very good job in very tight schedule except some minor issues. And then some more RCS tanks for Rotem and El-Halasa projects, process tanks for Majdanpek project, cone thickeners for LKAB which made by duplex stainless steel plates. They are mainly the first choice supplier of Process Equipment, Sala for projects locates close to Turkey. They made one project for Pyro, Danville. It was very urgent order for Russia and a combustion chamber and its ducts completed in very short time. Also Bafor is a approved supplier of System, Macon. They make a flotation column for Mondo project nowadays. As far as Bafor made satisfactory jobs for mentioned PLs above.

Inspection & Inspectors & Equipments

 

- Bafor Quality Control team is very experienced about various production processes.

-

They are familiar work with ASME code criterias besides European standards.

Only enlargement of Quality Team looks necessary for quality. They need to work over capacity during rush periods.

-

Production & Processes

 

- Welding work requirements are met properly.

- Handling of raw material should be improved during assembly work especially.

- Production units must remember the quality requirements during rush time even.

- Blasting and painting quality is improving with seperate shop investment.

- Proper stainless steel shop/area should be considered.

Health & Safety & Environment

 

- Overhead management is respectful to HSE requirements.

- Workshop could be tidier to make more comfortable work place.

Created by: Ali Osman Karsan (SQM), 21.02.2014

7/7