QA Programme Construction of Transportation Engineering Projects

GENERAL QA Programme

for

Construction of Transportation Engineering Projects

Doc. No. Prepare Review Approve

: : : :

TERF-001 Program Manager Sr Program Manager Program Director

3 2 1 0 Index DD/MM/YYYY Initial Release Date Revisions Prepared Reviewed Approved

QA Programme Construction of Transportation Engineering Projects

Table of Contents

Chapter 1. Chapter 2. Chapter 3. Chapter 4. Chapter 5. Chapter 6. Chapter 7. Chapter 8. Chapter 9. Chapter 10. Chapter 11. Chapter 12. Chapter 13.

Management Responsibility Quality System Document and Data Control Material Identification and Traceability Inspection and Testing Control of Nonconforming Products Corrective Action Handling, Storage and Preservation Control of Quality Records Internal Audits Training Standard Forms Indexing System Control of Inspection, Measuring & Test Equipment

QA Programme Construction of Transportation Engineering Projects

Chapter 1 Management Responsibility

1.1 Quality Policy This general QA Programme represents quality assurance policy and requirements for the construction of Transportation Engineering projects . The QA Programme is to provide objective evidence that the projects mission will be effectively completed. This will be accomplished by an integrated systems approach to quality assurance and quality control, based on ISO 9002 quality management system. The ultimate goal is to achieve projects successful completion with quality engineering, procurement, construction, commissioning and all of which is adequately documented. In this respect, this QA Programme is to be used as a standard and this policy shall be understood, implemented, and maintained at all levels in the organizations engaged in or concerned with the project execution in accordance with the requirements of the contract documents. For the overall implementation of the QA Programme, it also defines the fundamental organizational structure and aims to complete the project work to the Engineers satisfaction. All personnel including subcontractors shall faithfully observe all plans, specification, schedules, instructions and recommendations provided or made by Contractor, for carrying out the project work. The Project Manager has the primary responsibility for project quality as delegated by the Employer organisation.

----------------------------------------Director Employer

QA Programme Construction of Transportation Engineering Projects

Flow Chart Management by Objectives Chapter 1 Scope All activities of the project Procedure
Activity 1 2 3 4 5 6 Define targets and make known to all staff Define sub targets Strive to achieve targets Evaluate target achievement Corrective action >>>continue with Chapter 7 Revise targets >>>continue with 1 R PM All Staff All Staff All Staff All Staff PM PM A D Corresponding Document Overall Target Schedule Work Schedule per Department Compare Planned/ Actual schedule

R = Responsible / A = Assists / D = Decides, Approves PM = Project Manager Project Specific Targets

Item 1 2 Target Costs Meet Estimated Budgets Dates Meet Programme /mile stone Quality Meet Requirement of Specification & Drawing Reduce Inferiority Safety on Site Reduce Accident Controlling Instrument Performance Report + Cost Control Updated Time Schedule Weekly Reports Monthly Reports Method Statement Inspection and Test Plan List of Sick Leaves List of Accumulated Accidents Interval Monthly Monthly Weekly Monthly Responsible Planning Manager Planning Manager Planning Manager Planning Manager Construction Manager / Works Manager QA Manager Safety Manager

Remarks: These targets are made known to all staff on site, fulfillment or non-fulfillment of targets is made known to all staff on site.

QA Programme Construction of Transportation Engineering Projects

1.2 1.2.1 1.2.1.1

Organisation Organisation of the project Organisation Chart Figure 1.1: Organization Chart

1.2.1.2

Coordination Committee

QA Programme Construction of Concrete Cable Stayed Bridge across River Yamuna at Allahabad/Naini 1.2.2 Organization of the Site Management
QC Engineers

contractor

Admin. Manager

Planning Manager

Design Manager

Construction Manager

Admin. Staff

Planning Engineers

Design Engineers

Field Engineers

Chief-Procurement

Document Controller

Survey Engineers

Contract Manager

Plant Manager

Q/S

Bridge Co-ordinator

QA Programme Construction of Transportation Engineering Projects

1.2.3.

Responsibilities of the Site Management The Site Management shall act in accordance with the contract Agreement and the Contract Documents. The Site Management shall be responsible for the due execution of the works as defined by the contract. The following descriptions are the main tasks and responsibilities of the Site Management.

1.2.3.1

Project Manager The Project Manager is the leading authority on site and responsible for all activities on site. He is responsible for ensuring the execution and the maintenance of the works according to contractual specifications, drawings and programme of work. He is responsible for the proper execution of the following: Approve QA Programme, Method Statement and Inspection & Test Plan (ITP), Define and document quality policy, Take corrective action on the finding of internal quality audit, General technical administration, Define the structure of his team and control its composition, Manage relations with the Engineer / Employer, Select subcontractors and suppliers and sign subcontracts and purchase orders (or authorise signature), Manage subcontractors and suppliers, Implement a management system for costs, time, technics, safety and quality, Supervise administrative and financial management of the project, Supervise the management of the personnel placed under his control.

1.2.3.2

Deputy Project Manager has the responsibility to assist the Project Manager for achieving and improving quality.

1.2.3.3

QA Manager has the responsibility to Manage Quality Assurance and Quality Control activities, Prepare and control the QA Programme and Inspection & Test Plan (ITP), Manage submission of QA documents to the Engineer, Maintain the quality record.

1.2.3.4 -

Construction Manager / Works Manager are responsible, within their scope of works, for ; Communication with the Engineer, Preparation of method statement (with the support of the Department Managers), Execution of temporary and permanent works, Follow up of purchasing of all necessary goods and materials for the execution of the works, Management of subcontractors works, including preparation of subcontracts and orders, with the support of the relevant department, if necessary, Monitoring the progress of the works, Executing the work in accordance with the Contract.

QA Programme Construction of Transportation Engineering Project

1.2.3.5

Construction Engineer / Works Engineer has the responsibility for Preparation of Daily Reports, Counter-checking alignments/levels by surveyor, Monitoring work progress and quality control, Planning ahead on construction materials ordering, hiring/buying machinery equipment and tools for site issue, - Recording daily work (including subcontractors daily work), - Planning ahead of daily work, - Safety of their works. -

1.2.3.7

Planning Manager has the responsibility for - Planning, - Review of QA Programme, Method Statement and Inspection & Test Plan (ITP), - Preparation of Project Construction Schedule Updates, - Monitoring of Progress against Construction Schedule and Clause 14 Programmes, - Claim Preparation, - Assistance to Administration Manager in Cash Flow Forecast Preparation.

1.2.3.8

Design Manager has the responsibility for -

1.2.3.9

Design Temporary Works, Preparation of Shop Drawings, Support the Construction Manager / Works Manager for preparation of Method Statements, Review or Calculations for works, Maintenance of drawings, Preparation of inquiries and obtaining and comparing quotations. Preparation and Review of as built drawings.

Administration Manager has the responsibility for - General commercial administration, - Cash flows, - Financial matters, - Insurance matters, - Banking, - Taxes and levies, - Accounting, - Personnel, - Purchasing, - Medical service, - Camp.

1.2.3.10

Plant Manager has the responsibility for Supporting the purchasing of new equipment, Maintenance of all equipment (service and repair), - Maintenance and operation of all equipment at site.

QA Programme Construction of Transportation Engineering Project

1.2.3.11

Safety Manager has the responsibility to Manage site safety activities according to safely procedure (separate volume), Education of new workers, Keep safety requirements of specific method statement, Look after the personnel in illness and hurt.

1.2.3.12 Quality Control Manager has the responsibility to 1.2.4 Scope of Work

Sl.no. 1 2

Section Section-1 Section-2

Contractor Scope

Sub contractor Scope

Section-3

Section-4

Miscellaneous

QA Programme Construction of Transportation Engineering Project

Chapter 2 - Quality System

The Quality Assurance System consists of: - the description of organizational processes (QA documentation), - the continuous supervision of the system, - permanent improvement. 2.1 QA Documentation The QA documentation is made up as follows: -

QA Programme Method Statements Quality Procedure / Work Procedure Inspection & Test Plan

Inspection & Test Plans shall be provided according to the chapter 5 (Inspection and Testing) for at least every title where quality tests are required by the contractual specifications. The Inspection and Test Plan has to be set up by the QA Manager with support of organization who is in charge of the work (i.e. Construction Manager, Works Manager, subcontractor). 2.2 System Control The System Control is made up by Internal Quality Auditing, Quality Control.

Internal Quality Auditing has to ensure that all persons - know their responsibilities, - are familiar with their QA Plan, pay attention to the QA Plan, will help the QA Manager to improve and update the QA Plan for a better quality and effectiveness on site. Quality Control has to ensure that all works are carried out according to the contractual specifications, the corresponding standards, the method statements, the inspection & test plan.

QA Programme Construction of Transportation Engineering Project

2.3

System Improvement. If a product does not meet the contractual specifications, (also called Nonconforming Product) it must be guaranteed, that the product will meet the requirements by repairing or similar. The manner is ruled by the chapter 6 (Control of Nonconforming Products). If there is the possibility that any mistake is repeated, - In case of technical problems: Corrective actions have to be carried out by alteration of the regarding Method Statement and / or - In case of organizational problems: Corrective actions have to be carried out by alteration of the regarding chapters. Besides the issuing of corrective action requests upon detected nonconformance there is the preventive possibility for detected improvements - In technical - Organizational regulations, where also corrective action requests can be issued. The issuing and introduction of corrective actions is described in the chapter 7 (Cor-rective Actions).

2.4

Structure of Quality System The quality system document hierarchy is same as below. In document structure of quality system, the items of low level documents shall be consistent with requirements of high level documents.

QA Plan

Level I
Method Statements Including Quality / Work * Procedure, Inspection & Test Plan

Level II

*These documents are may be prepared and submitted separately, if necessary.

QA Programme Construction of Transportation Engineering Project

Chapter 3 Document and Data Control

1. Purpose : To define a system for the control of document approval, issue and changes / modification. : This chapter applies to all documents used in Transportation Engineering Project. such as Quality Programme, Quality Procedure, Method Statement, Inspection & Test Plan and Engineering and Technical Documents. Chapter 12 - Standard Forms Indexing System

2.

Scope

3. 4.

Reference : Definitions : 4.1 Documents

Any written information describing requirements of activities affecting quality. Documents shall include QA Programme, Method Statement, Inspection & Test Plan and Engineering and Technical Documents. If correspondence (e.g. letter, memo etc.) mentioned serious subject about Quality or Technical data, it shall be maintained as document. 4.2 QA Programme (QAP) Document setting out the specific quality implementation, resources and sequence of activities relevant to an product, project or contract. 4.3 Quality Procedure / Work Procedure A document that specifies or describes how an activity is to be performed for quality / work. 4.4 Method Statement Working Method for Tradesman and Workers to follow when they perform a specific job. As a minimum, the following points shall be included: 1. 2. 3. 4. 5. 6. 7. 8. Scope of Work References Description of the Work Responsibility Plant and Equipment Inspection, Testing and Survey Safety Appendices

4.5 Inspection & Test Plan Documents which contain hold point, witness point, acceptance criteria and document required according to sequence of inspection to ascertain quality.

QA Programme Construction of Transportation Engineering Project

4.6 Controlled Copy An identifiable copy of the QA Programme or its supporting Quality procedures and ITP which is distributed, revised or replaced through a written Document Control Procedure that assures the document reflects all current requirements. 4.7 Uncontrolled Copy An identifiable copy of the QA Programme or document that is distributed through a Document and Data Control Procedure with no assurance that later, the document reflects all current requirements. These shall be for information only and shall not be used as reference to perform work. 4.8 Engineering and Technical Documentation- Specification - Drawings - Calculations (CLC) - Test Certificate Report (TCR) - Engineers Instruction / Direction - Confirmation of Verbal Instruction / Direction 5. Responsibility : 5.1 The Project Management shall be overall responsible for the control of Documents. (i.e., QA Programme, Quality Procedure / Work Procedure, Method Statement, Inspection & Test Plan, Drawings and Calculations)
5.2 The responsibility for each stage of the control of documents are defined in Annex 1.

5.3 QA Manager is responsible for taking out a unique document number of QA documents except drawing, and Design Manager is responsible for taking out unique drawing number. 6. Procedure : 6.1 Internal Documents
6.1.1Document Indexing System

Prepared documents by subcontractor may be indexed according to its own indexing system. 6.1.1.1 The QA Programme shall be indexed as follows : TEQA-XXX TEQA XXX = = Transportation Engineering QA Programme 3 Digit Running Section Number

6.1.1.2 The Quality Procedure / Work Procedure shall be indexed as follows : QP-XXX / WP-XXX QP / WP = XXX = Quality Procedures / Work Procedure 3 Digit Running Procedure Number

QA Programme Construction of Transportation Engineering Project

6.1.1.3 The supportive Form for QP / WP shall be indexed as follows : . QP-XXX WP-XXX YY /Z QP-XXX-YY / Z (e.g. QP-001-01/A) WP-XXX-YY / Z (e.g. WP-001-01/A) = = = = Quality Procedures Number Work Procedures Number 2 Digit Running Form Number Alphabet Numbering for Continuation Sheet (if there)

6.1.1.4 The Method Statement shall be indexed as follows : CPS-X-MSP-YYY . CPS X MSP YYY = = = = Construction Plan and Specification Module Number (0 for two or more modules) Method Statement 3 Digit Running Method Statement Number

6.1.1.5 The supportive Form for Method Statement shall be indexed as follows : CPS-X-MSP-YYY-ZZZ (e.g. CPS-1-MSP-001-001) . CPS X MSP YYY ZZZ = = = = = Construction Plan and Specification Module Number (0 for two or more modules) Method Statement 3 Digit Running Method Statement Number 3 Digit Running Serial Number for Continuation Sheet (if there)

6.1.1.6 The Inspection & Test Plan shall be indexed as follows : ITP-XXX . ITP XXX = = Inspection & Test Plan 3 Digit Running ITP Number

6.1.1.7 The Internal Drawing shall be indexed as follows : TE-SX-YY-ZZZ TE= SX YY Transportation Engineering = section 0 = TD : Temporary Drawing SK : Sketch CS : Construction Drawing AB : As-Built Drawing 3 Digit Running Drawing Number

ZZZ

6.1.1.8 The Calculations shall be indexed as follows : CPS-X-CLC-YYY CPS X CLC YYY = = = = Construction Plan Specification Module Number (0 for two or more modules) Calculation 3 Digit Running Calculation Number

QA Programme Construction of Transportation Engineering Project

6.1.1.9 For sub-title and sub-paragraph, use 1. 1.1 2. 2.1 3. 3.1 1.2 2.2 3.2 1.3 2.3 3.3 ... ... ...

6.1.1.10 The document indexing system for standard forms shall be followed in accordance with chapter 12 (Standard forms indexing system). 6.1.2 List Indexing System 6.1.2.1 The Documents Master List shall be indexed as follows : TE DML MX YYY ZZZ TE-DML-MX-YYY-ZZZ = Transportation Engineering = Document Master List = Module Number (0 for two or more modules) = Document Type (as QAP, QPS, MSP, TCR, ITP, Etc.) = 3 Digit Running Documents Master List Number

6.1.2.2 The Drawing Master List shall be indexed as follows : TE DWL MX YY TE-DWL-MX-YY-ZZZ = Transportation Engineering = Drawing Master List = Module Number (0 for two or more modules) = TD : Temporary Drawing SK : Sketch CS : Construction Drawing AB : As-Built Drawing = 3 Digit Running Drawing Master List Number

ZZZ 6.1.3

Preparation, Review and Approval All Documents must be reviewed and approved by the respective department prior to issue.
6.1.3.1 QA Programme must be prepared by QA Manager, reviewed by Planning

Manager and approved by Project Manager. 6.1.3.2 6.1.3.3 Quality Procedures must be prepared by QA Manager, reviewed by Planning Manager and approved by Project Manager. Method Statement / Work Procedure must be prepared by Construction Manager or Works Manager, reviewed by Planning Manager and approved by Project Manager . Inspection & Test Plan must be prepared by QA Manager (or QC Engineer for HCCs independent work), reviewed by Planning Manager and approved by Project Manager. Drawings must be prepared by Design Manager, reviewed by Planning Manager and approved by Project Manager. As built drawing control procedure (work procedure) must be prepared by design manager reviewed by planning manager and approved by project manager. Calculations must be prepared by Design Engineer, reviewed by Design Manager and approed by Planning Manager.

6.1.3.4

6.1.3.5

QA Programme Construction of Transportation Engineering Project

6.1.4

Distribution
6.1.4.1

The Project Manager shall mark the Document Distribution Sheet for distribution. After approval of Document Distribution Sheet with documents by the Project Manager, full set of documents are filed in Master File Shelf. All following process shall be done in accordance with Annex 1 .

6.1.4.2

6.1.4.3

6.1.5

Documents Master List 6.1.5.1 All internal and external document except drawings shall be listed up in the form of Documents Master List for identification of latest status of documents. The Documents to be listed in Documents Master List are as follows. - Documents as mentioned above definition No. 4.2, 4.3, 4.4, 4.5 & 4.8 (except drawing) - Appointed by Planning Manager The Documents Master List may be prepared for each type of documents. The Documents Master List shall be submitted to the Engineer 2 days before each Site Meeting at least.

6.1.5.2

6.1.5.3 6.1.5.4

6.1.6

Revision Control 6.1.6.1

6.1.6.2

Change to documents shall be performed by department that carried out original preparation unless specifically designated otherwise. Revised portion shall be marked by typing them in bold and Italic letters. Cloud mark with revision number shall be used for revised portion of drawing, and cloud mark shall be used for revised portion of form. The approved revised documents shall be controlled in accordance with above paragraph 6.1.3, 6.1.4, & 6.1.5.

6.1.6.3

6.2

External Documents Receipt 6.2.1.1 Upon receipt of document, the Document Controller shall check the following : (a) (b) (c) Document bear the name and approved authorities; Correct document number, revision and pages; Legibility of the document.

6.2.1

6.2.1.2 All documents received shall be controlled in accordance with ANNEX 1 of this chapter.

QA Programme Construction of Transportation Engineering Project 6.2.2Review 6.2.2.1

Project Manager shall review the incoming document and comments at remark on the column. Document reviewed will be distributed to various department as per ANNEX 1 attached. Person who received the copied incoming document shall take an action according to the comments by Project Manager.

6.2.2.2

6.2.2.3

6.2.3

Distribution All documents received shall be distributed in accordance with ANNEX 1 of this chapter.

6.2.4

Filing & Master Listing

6.2.4.1

All documents received shall be filed at Master File Shelf according to Master Filing System in Annex 2 of this chapter.

6.2.4.2 The list-up of external documents shall be done in accordance with above paragraph 6.1.5
6.3Drawing Control

6.3.1

Receipt 6.3.1.1 Upon receipt of drawing, Document Controller shall perform the following :
(a)

(b)
6.3.1.2

List in Correspondence Logging Book Submit to Planning Manager for review

Planning Manager shall perform the following : (a) (b) (c) Review the drawing received Submit to Project Manager for review and comment Hand-over to Design Engineer

6.3.1.3

Design Engineer shall perform the following :

(a) (b) (c)

Check the correct drawing number, revision and pages List in Drawing Master List Submit to Design Manager to review and take an action

6.3.2

Registration 6.3.2.1 After checking and stamping of received drawings, the Design Engineer shall list-up the received drawings in Drawing Master List.
6.3.2.2.

The information of registration of drawing are as follows Drawing No. Drawing Title Revision No. Revision Date Issued Date

QA Programme Construction of Transportation Engineering Project 6.3.2.3

Drawing Master List shall be distributed periodically by Design Engineer to the relevant departments for cross checking the latest status.

6.3.3Distribution

6.3.3.1 The received drawings are distributed to Construction Manager / Works Manager by the Design Manager. 6.3.3.2 A Master Set of Drawings of this Project shall be kept by Design Manager. 6.3.3.3 The Construction Manager / Works Manager shall make the copies for subcontractor. (if there) 6.3.3.4 When receive the Master Drawing List from Design Manager, this lists shall be copied by Construction Manager / Works Manager and distributed to subcontractor for cross checking the latest status.
6.3.3.5

The Drawing Master List shall be submitted to the Engineer 2 days before each Site Meeting at least.

6.3.4

Control of Obsoleted Drawings

6.3.4.1

When receive the revised drawings, the Design Engineer shall check the revision status. If there are revised drawing , the obsolete drawings in Master Drawings shall be stamped "Void" and separate storage. When receive the revised drawings from Design Manager, the Construction Manager / Works Manager promptly destroy the obsolete drawings after replacing them with revised ones to assure the latest drawings are used. Where the Construction Manager / Works Manager require obsolete drawings for their retention, this may be permitted but it shall be clearly identified with the Void stamp. The Construction Manager / Works Manager shall perform the checking at all times that subcontractors are using latest drawing.

6.3.4.2

6.3.4.3

6.3.4.4

6.3.4.5

6.3.5

Control of Internal Drawings

6.3.5.1

The Design Engineer is responsible to collect relevant information from vendor / subcontractor in order to prepare shop drawings/ coordination drawings. The Design Manager is responsible to check for discrepancies / compliance to specification and consultant drawings. The Planning Manager is responsible to submit drawing to The Engineer for approval. He shall obtain The Engineers approval letter or endorsement.

6.3.5.2

6.3.5.3

6.3.5.4 All process of internal drawings are same as Annex 1 of Outgoing.

QA Programme Construction of Transportation Engineering Project

ANNEX 1 - FLOW CHART OF DOCUMENT CONTROL INTERNAL DOCUMENTS

No. S T E P 1. S T E P 2. S T E P 3. 1. Submit to Planning Manager for review 2. Submit to Project Manager Document Controller Planning Manager ACTIVITY BEFORE HAND OVER TO PLANNING MANAGER CONTENT OF ACTION 1. Issue, Review in organization ACTIONED BY Relevant Engineer or Personnel / Manager Department Engineer

RECEIVE THE DOCUMENTS TO BE OUTGOING

1. Review the content and approval

SUBMIT TO PROJECT MANAGER & ISSUE

Project Manager Document Controller Document Controller

2. Assign the ref. Number taken from Correspondence

Logging Book (Outgoing). 3. Issue for Outgoing 1. Direct to Copy & distribute to Relevant Organisation

S T E P 4.

Planning Manager Document Controller

DISTRIBUTION TO RELEVANT ORGANIZATION

2. Copy & distribute to relevant organization 2. Filing at Master File Shelf Document Controller

QA Programme Construction of Transportation Engineering Project

EXTERNAL DOCUMENTS
No. ACTIVITY CONTENT OF ACTION 1. Chopping the Stamp for Circulation S T E P 1. RECEIPTION ACTIONED BY Document Controller Document Controller Document Controller Planning Manager Planning Manager Project Manager Project Manager Document Controller Document Controller Department Manager Department Manager Department Engineer

2. Listed in Correspondence Logging Book (Incoming)

3. Submit to Planning Manager for review 4. Review the content 5. Submit to Project Manager for review

S T E P 2.

SUBMIT TO PROJECT MANAGER

1. Review the content

2. Return to Planning Manager to circulate 3. Copy to relevant department 4. Filing at Master File Shelf

S T E P 3.

DISTRIBUTE TO RELEVANT DEPARTMENT

1. Review the Content

2. Circulate within Department

3. Action if required

QA Programme Construction of Transportation Engineering Project

ANNEX 2 - MASTER FILING SYSTEM

FILE NUMBERING SYSTEM
AAA - XXX YY / ZZ 2 Digit Running File Number ISSUED FM = From company to TO = From MT = Maintain Document = = = = = = = = = = = = = = = = General Correspondence (Letter) Drawing Calculation The Engineers Instruction / Direction Confirmation of Verbal Instruction / Direction Document Master List Drawing Master List QA Programme Method Statements Quality Procedure Inspection and Test Plan Test Certificate Report Calculations Nonconformance Report Work Procedure Inspection & Test Procedure

Type of Documents COR DWG CLC IND COV DML DWL QAP MSP QPS ITP TCR CLC NCR WPS I & TP

COMPANY CODE , Alphabetic 3~4 Character NHA = National Highways Authority of India / Employer If the type of documents or company Code are required increasing or decreasing, the new Codes will assigned by Planning Manager.

QA Programme Construction of Transportation Engineering Project

ANNEX 3 - SAMPLE STAMP

For Document
Project Name . SR.ENGR. MGR

Project Name PM PLAN ADMIN CONST DESIGN W/SHOP - 200

P L A N C O N A D M N

ENGR.

PM

ASST

STAFF

MGR

VOID

For Drawing

For Reference

For Approval

For Construction

VOID

Preliminary

QA Programme Construction of Transportation Engineering project

Chapter 4 Material Identification and Traceability

1. 2. 3. 4. Purpose Scope : : To define a system for the identification and traceability of materials during all stages of construction. This chapter applies to the Identification and traceability of materials. Table 1 - Material Identification & traceability Requirement

Reference : Responsibility

The Planning Manager and / or Construction Manager / Works Manager are responsible for the identification and traceability of materials. 5. Procedure : 5.1 General Requirement 5.1.1 Material Identification 5.1.1.1 Material for permanent construction The project staff shall ensure the materials received at site are identical to approved specifications, drawings or catalogues (Brand, Model, Dimension, Specification). 5.1.1.2 When prepare the Purchasing data, Identification requirements [making of Heat / Batch / Lot No., Dimension, type, related Code No., etc.] shall be included in Purchase Order for identification of Material by Planning Manager.
5.1.1.3

All materials shall be identified and segregated using label, tagging, marking or post in warehouse or storage area. The identification of completed works (material) is provided by the Drawings (such as Module Number, Drawing Nos., Block Nos.,) during and final construction.

5.1.1.4

5.1.2

Document Traceability
5.1.2.1

When the Traceability is a specified requirements for specific materials, following activities should be done by QA Manager. Set-up the Material list for Traceability (See Table 2) Prepare the document for Traceability before the material is used on site. Prepare the Inspection / Test report form for Traceability

5.1.2.2 The Inspection & Test Reports for required traceability shall include the following informations for traceability : Description of inspected / tested materials Inspected / Tested date Description of the identification marking Inspected / Tested location or Agency name.

5.1.2.3 Working daily reports and other type of construction reports are used for trace the history and location of materials or activities.

QA Programme Construction of Transportation Engineering project

TABLE 1 - DOCUMENT IDENTIFICATION & TRACEABILITY REQUIREMENTS

Item No. A

Document Name Project Files and relevant documents / correspondence inside the file

Required Identification Project Name Reference No. Issuing Date Project Name Name of Supplier Purchase Agreement Number Project Name Name of Subcontractor Purchase Agreement Number Project Name Date of Release Name of Person for preparation Name of Person for review Project Name Type / Reference Number Location Date Name, Title and Signature of Inspector

Supplier File (P.O. / Agreement)

Subcontractor File (P. O. / Agreement)

QA Programme / Method Statement / Quality Procedure / Work Procedure

Inspection / Test Reports

QA Programme Construction of Transportation Engineering project

TABLE 2 - MATERIAL IDENTIFICATION & TRACEABILITY REQUIREMENTS

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Material Cement Coarse Aggregate Sand Reinforcement Stainless Steel Bearings Expansion Joint Concrete Admixtures Structural Steel Reinforced Cement Concrete Pipe Epoxy Mortar Anchor Bolt & Nut Connection Bolt & Nut Ladder, Handrail, Material access Facilities Steel Pipe Prestressed Steel Reinforcement Anchorages & Tendon Couplers Equipment Concrete

Required Identification Batch No on bag / MTC / D.O (indicating MTC No.) Lab. Certificate Lab. Certificate MTC / D.O (indicating MTC No.) MTC / D.O MTC / Inspection Release Note / Tag. No. with Bearing MTC / D.O Supplier / Manufacturer Name / Brand Name / Batch No. on containers / MTC MTC / D.O (indicating MTC No.) MTC / Inspection Release Note MTC for each batch MTC / D.O MTC / D.O MTC of basic material / D.O MTC / D.O (Indicating MTC No.) Test Certificate Test Certificate Calibration Certificate Tag No. with validity date Concrete Requisition Slip / Delivery Slip (indicating location, starting time and delivery time) / Grade of Concrete / Slump Batch No. on bag. / MTC / D.O (indicating Batch No.) MTC / D.O MTC / D.O MTC / D.O

20 21 22 23

Grouting Material Paint Welding Electrode Bitumen

QA Programme Construction of Transportation Engineering project

MTC D.O

= =

Mill Test Certificate Delivery Order

QA Programme Construction of Transportation Engineering Project

Chapter 5 Inspection and Testing

1. Purpose : To define the system for the inspection and testing of materials / works to specify requirements and the necessary controls to achieve and maintain the required standard. This chapter applies to the Transportation Engineering project for Inspection & Test activities. chapter 4 - Material Identification and traceability chapter 6 - Control of nonconforming Products chapter 7 - Corrective Action. Applicable Method statement.

2. 3.

Scope

Reference :

4.

Responsibility 4.1 The QA Manager is responsible to ensure that materials / works are duly inspected and tested to specified requirements, and necessary controls are taken to achieve and maintain the required standard as per contractual specification. 4.2 The QC Engineer is responsible for the proper identification of inspection and test status and ensuring that only materials that has passed the required inspection and test are dispatched or used. 4.3 The QC Engineer who manage the respective inspection and test of incoming materials, intermediary and completed works shall ensure that the following identification requirements are met.
4.4 The QC Engineer holds the responsibility and authority for the release of conforming materials /

works.
4.5 QA Manager is responsible to prepare the ITP before start of Inspection & Test. 4.6 In case the work involve subcontractors, Contractor programme will be issued to the

subcontractor. Construction Manager / Works Manager will request the subcontractor to comply with the QA programme and:
4.6.1Subcontractor should be responsible for their own testing and inspection. Report and findings

of the inspection should be submitted to contractor for record and monitoring purpose.
4.6.2QA Manager will conduct a periodic check on subcontractors site work to ensure that

subcontractor is complying with the quality requirement. 5. Procedure : 5.1 Inspection and Test Plan The followings shall be apply to both Contractor ITP and subcontractors ITP: 5.1.1 5.1.2 The QA Manager shall ensure that Inspections & Tests, including those submitted by subcontractors, are carried out in accordance with the Inspection & Test Plan [ITP]. The QA Manager shall ensure that all relevant contractual specifications and method statement are clearly stated when preparing the Inspection & Test Plan.

5.1.3 All construction materials that will affect the work quality shall be performed with the receiving inspection. 5.1.4 The Project Manager shall check the above prior to approving the Inspection & Test Plan.

QA Programme Construction of Transportation Engineering Project

5.2

Inspection and Test

Reference should be made with the Inspection & Test Plan for Works and Material. 5.2.1 Receiving Inspection & Testing a) QC Engineer shall ensure that the material / supplies are inspected and tested as planned and in accordance with the Inspection & Test Plan. He shall also ensure that the specified records are maintained. b) For subcontractor, subcontractor is responsible for their own material inspection & testing. All inspection and testing record and findings to be submitted to the contractor for record and monitoring. QA Manager will carry out periodic check to ensure all materials of the subcontractor are comply to standard. 5.2.2 Inspection & Testing during Construction a) QC Engineer shall ensure the intermediary and completed works are Inspected and tested as planned and in accordance with the Inspection & Test Plan. He shall also ensure that the specified records are maintained. b) Subcontractors own QC will carry out their own inspection and testing according to their own ITP. QA Manager will carry out periodic check to ensure work quality. 5.2.3 Final Inspection a) QC Engineer shall ensure the works, including those done by the subcontractor, are inspected in accordance with the Inspection & Test Plan. He shall also ensure the specified records are maintained. b) No works shall be released until all the activities specified in the Inspection & Test Plan for Materials and Works have been satisfactorily completed and the associated records are available and authorized by Construction Manager and Works Manager. 5.3 Review and Interpretation of Test Reports 5.3.1 The QA Manager / QC Engineer is responsible to review and interpret the test reports for all materials and completed works, including those of the subcontractors. The test reports shall be reviewed based on the acceptance criteria set in the Inspection & Test Plan. The QA Manager / QC Engineer shall endorse on all test reports, including those of the subcontractors, that have been reviewed. If the materials / works fail to meet the criteria, chapter 6 shall apply.

5.3.2 5.3.3 5.3.4

5.4 Use Of Un-inspected Materials 5.4.1 In the event, materials are not inspected due to urgent production purposes, the Project Manager shall authorize the QA Manager to draw samples and the lots shall be positively identified. The location where the materials are used shall be recordedin the Remarks column of the Store Record Sheet. The samples shall be inspected at a later stage and in the case when materials failed, the affected works shall be put on hold pending decision by Material Review Meeting. Reference shall be made to according the chapter 6 control of nonconforming Product.

QA Programme Construction of Transportation Engineering Project

5.5 Summary Of Inspection & Test Responsibility Stage R.I Inspection Item Material Ref. Quality Plan - Purchasing Spec. - ITP for Material I. I F. I Works in Progress Finished Works ITP for Works Contract Specification QC Engineer QA Manager / QC Engineer / subcontractor Inspection / Test Reports Inspection / Test Reports Responsible Person QC Engineer Quality Records Delivery Order with Accepted / Rejected Marks

R. I = Receiving Inspection I. I = In-process Inspection F. I = Final Inspection 5.6 Inspection & Test Status The results of each stage of Inspection & Tests are identified as follows
Stage A. Receiving Inspection Accepted Materials are placed on the location indicated in the project facilities layout plan Rejected Tag a Rejected sign or segregated rejected area

B. Construction Process C. Finished Works No defects listed in unit layout plan

Mark X on rejected area on relevant layout drawings Described on Punch list

QA Programme Construction of Transportation Engineering Project

Chapter 6 Control of Nonconforming Products

1. 2. 3. 4. Purpose Scope : To define a control and review system to prevent the inadvertent use or release of nonconforming materials / works and to reach a consensus on the disposition of them. : This chapter applies to the Transportation Engineering Project to the materials, intermediary and final works. chapter 5 - Inspection & Testing

Reference : Responsibility

4.1 The QC Engineer shall be responsible for the control of nonconforming materials / works and preventing the inadvertent use or release of nonconforming materials / works. 4.2 The QA Manager that manages the respective inspection and test of materials, intermediary and final works shall ensure that the identification, segregation and documentation of nonconforming materials / works are properly made. 4.3 The Project Manager shall be responsible for decision on disposition of nonconforming materials / works. 5. Procedure : 5.1 General Requirements 5.1.1 Identification and Segregation The nonconforming materials / works shall be identified as per chapter 5 (Inspection and Testing). Documentation The descriptions and data of the nonconforming materials / works shall be recorded in the Nonconformance Report. Notification Recommended corrective action will be initiated by the QA Manager and taken by the organisation responsible for the nonconforming materials / works.

5.1.2

5.1.3

5.2 Review and Disposition 5.2.1 5.2.2 When the nature of nonconformity is beyond the decision of Project Manager, he should open a Review Meeting. The meeting shall be delegated by the respective organisation. Roles and Authorities Each member with practical expertise in his discipline is authorized to make decision within his discipline. 5.2.2.1 Project Manager shall advise on the feasibility of rework, the impact on project schedule and storage issues. He shall make the final decision on disposition of all nonconformances. 5.2.2.2 QA Manager shall also advise on the contractual specification pertaining to the use or rework of the nonconformances for necessary action. 5.2.2.3 Planning Manager and Construction Manager / Works Manager shall advise on the cost impact, specification and contract implications. He shall liaise with the
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QA Programme Construction of Transportation Engineering Project

Engineer and / or the supplier / subcontractor on the nonconformances for necessary action. 5.2.3 Disposition Options and Conditions (a) Use As It Is (Use for Same Process) To accept materials or works with a minor nonconformance for use without correcting the nonconformance, if the materials or works are determined to be satisfactory for their intended purpose and such use is acceptable to the Engineer. (b) Repair To carry out minor rectifications / repair work on nonconformity, it shall be inspected by the Engineer during work. (c) Rework To subject to a process which restores nonconforming materials or works to full conformance to contractual requirements, specifications and drawings. (Reworked materials / works shall be re-inspected in accordance with the applicable ITP). (d) Reject To return to supplier as materials are not useable. (e) Scrap To dispose the materials which are not consumable. The members must give accurate and practical advice. A group consensus on the disposition and corrective action shall be reached. In the event of any dispute, the matter shall be referred to the Project Manager. 5.2.4 Documentation The "Nonconformance Report" shall be prepared by personnel who found nonconformance. The Project Manager shall ensure that reason to justify the group decision on the disposition to "use as it is" is documented in the report. The nonconformance report shall be submitted to the Engineer for approval of proposed disposition immediately. 5.2.5 Corrective Action 5.2.5.1 The Project Manager shall ensure that corrective action is taken by the organisation (i.e. Vendor or staff etc.) who is responsible for the nonconforming materials or works. 5.2.5.2 Nonconformance Report shall be issued to the respective organisation. After completion of nonconformance, the respective organisation shall notify to the personnel who found nonconformance for verification. 5.2.5.3 If the results are satisfactory, the QA Manager shall close out the NCR. 5.2.5.4 The closed out NCR shall be controlled in accordance with chapter 9 (control of quality records).

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Chapter 6 Control of Nonconforming Products

QA Programme Construction of Concrete Cable Stayed Bridge across River Yamuna at Allahabad/Naini

Chapter 7 Corrective Action

1. Purpose : To define a Corrective Action System to ensure that the root cause of nonconformance is promptly analyzed and effective corrective actions are taken to prevent recurrence. This chapter applies to all organizations. chapter 3 chapter 6 chapter 10 - Document & Data Control - Nonconforming Product Control - Internal Quality Audit

2. 3.

Scope

Reference :

4.

Procedure 4.1 Responsibility 4.1.1 The responsible department manager for the nonconforming product shall ensure that root cause of nonconforming product is promptly analyzed and effective corrective actions are taken to prevent recurrence. All staff has the responsibility to identify any potential product quality problem and initiate preventive actions to prevent its occurrence.

4.1.2

4.2 The Engineer Complaint / Corrective Action 4.2.1 The Project Manager shall be responsible to take the appropriate action upon receipt of complaint / feedback from the Engineer either in writing or verbal. In case of verbal compliant from the Engineer, the The Engineer Complaint Report to be initiated by who received complaint from the Engineer. Either way, the complaints shall be reported to the responsible department manager. Responsible department manager shall report to Project Manager or his related and hold the meeting with related functional Department Manager, if required. Responsible department manager shall participate jointly with other related functional departments in identifying the root cause to the complaint and initiating corrective actions of the problem. If the root cause of the nonconformity shows that it was originated from the supplied material, clause 4.3 of this chapter shall follow. The responsible department manager shall take necessary actions promptly and ensure that the corrective actions are effective to prevent recurrence of the problem. The Project Manager or his delegate shall follow-up on the corrective action commitment, verify the implementation. The responsible department manager shall feedback to the Engineer, the corrective action taken if requested by the Engineer. his delegate shall close the case. For verbal complaint, Project Manager or his delegate shall complete the The Engineer Complaint Report. For written complaint, Project Manager or his delegate shall write back to the Engineer to report completion of rectification works.

4.2.2 4.2.3

4.2.4 4.2.5 4.2.6 4.2.7

4.2.8Upon receipt of the Engineer positive reaction to the feedback given, the Project Manager or

QA Programme Construction of Concrete Cable Stayed Bridge across River Yamuna at Allahabad/Naini

4.3 Supplier / Subcontractor Corrective Action 4.3.1 The respective responsible Managers or his delegate having a material / workmanship quality problem shall notify the content of nonconformity to the supplier or subcontractor respectively by means of site memorandum, nonconformance report or letter according to a degree appropriate to the magnitude of problems and complexity. responds with a detailed corrective action plan within the stipulated date. If required, submit the corrective action plan for the Engineers / Design Managers approval. 4.3.3 The responsible Manager or his delegate shall review the suppliers / subcontractors response, and, either close the case if the response is acceptable, or follow-up the case if the response is unacceptable.

4.3.2The responsible Manager or his delegate shall ensure that the supplier / subcontractor

4.4 Project (Works) Corrective Action 4.4.1 Project corrective action may be issued by any department whose function is affected by the nonconforming product, practices or services of another Department. This shall be documented in an Nonconformance Report Form in the chapter 6 (Control of nonconforming products). The responsible Department for action to correct the nonconformity shall reply within one week unless it is justifiable that more time is needed due to complexity of the problem.

4.4.2

4.5 System Corrective Action Nonconformity detected during Internal Quality Audits should be recorded and closed-out by the QA Manager. 4.6 Corrective Action Status Log A Corrective Action Request Log shall be maintained by the QA Manager. 4.7 The responsible Department Manager shall implement and record any change in chapter resulting from corrective actions. This shall be carried out in accordance with the chapter 3 Document & Data Control. 4.8 Follow-up of Corrective Action All corrective action issued as per clause 4.2, 4.3, 4.4 and 4.5 shall be verified-out by the QA Manager, and if necessary, a follow-up visit is to evaluate the effectiveness of its implementation.

QA Programme Construction of Transportation Engineering Project

Chapter 8 Handling, Storage and Preservation

1. Purpose : To define methods or system for handling, storage and preservation of products to prevent damage, deterioration, or loss and final inspection and hand over of completed project. This chapter applies to Transportation Engineering Project. Applicable method statement.

2. 3. 4.

Scope

Reference : Responsibility
4.1

The Construction Manager / Works Manager is responsible for the proper handling and protection of materials / works at all stages. The Field Engineer is responsible to ensure material in such a way that they do not suffer damage, deterioration or loss. The Project Manager is responsible for the planing and coordination of final inspection and hand over of the completed project to the Employer after final inspection and test.

4.2

4.3

5.

Procedure : 5.1 Handling

5.1.1

All operators of handling equipment, that is, excavator/crane, etc. shall be experienced in the proper use of the equipment. Field Engineer shall ensure that workers involved in handling and transportation activities observe the applicable method statement. The following table shows the Handling Precautions (Dos & Dont): Material/ Product Re-bar Bag Cement Pipe Equipment The Others Handling Equipment crane Forklift, crane Crane Crane/Lift Manufacturers instruction Precaution (Dos & Dont) 1. During hoisting, ensure proper balancing 2. & securing of the load 3. Do not wet the bags 4. Do not burst/puncture the bags
5. 6.

5.1.2

Bundle tightly Bundle tightly Follow Manufacturers instruction to prevent damage

5.2 Storage 5.2.1 The materials shall be stored in accordance to the storage locations identified. 5.2.2 Materials shall be issued on a First-In First-Out basis.

QA Programme Construction of Transportation Engineering Project

5.2.3

The QC Engineer shall conduct a monthly assessment of the stock condition. He shall use the Stock Condition Assessment Checklist / Report to perform the assessment The following table shows the Storage Precautions (Dos & Dont) :

Material / Product Re-bar

Storage Location Open Method store on timber runners or concrete bar Placed on pallets lifted 300mm above ground on timber runners Manufacturer's instruction

Precautions (Dos & Dont) Do not mix difference dias. Cover with canvas in bad weather Do not block access to vehicles Do not allow contact with moisture Do not exceed 10 bags stacking Ensure that wooden frames at each end are secured for thin walled pipes Follow Manufacturers instruction to prevent damage

Bag Cement Pipes The Others

Sheltered Store

Open Manufacturers instruction

5.3 Packaging and Preservation

5.3.1

The Construction Manager / Works Manager or his delegate (e.g. Field Engineer, or subcontractor) shall ensure that the completed project / works and completed works by subcontractors are protected to ensure conformance to customer. All internal areas and facilities within the building and all external areas and facilities shall be cleaned, locked or barricaded and / or cleared of debris and prevented from unauthorized use, damage and deterioration. Additional protection measures arising from or required to meet contractual requirements shall be observed. In General - Patch up chipped surface and touch-up using similar paint color. - Barricade and lock up all the access to prevent unauthorized entry for internal area. - Lock up all windows, main doors and gates of internal area.

5.3.2

5.3.3 5.3.4

5.4 Delivery 5.4.1

5.4.2

The Project Manager or his delegate shall plan and coordinate the final inspection / testing of all services and facilities by relevant authorities. The Project Manager or his delegate shall assign the Engineer / QC Engineer to carry out final defect checking with respective subcontractors. The Punch List shall be prepared. The Project Manager or his delegate shall verify and carry out random check on the inspected units. Punch list shall be rectified by the responsible organisation. All defects due to subcontractors shall be rectified by the respective subcontractors. ensure the defect has been rectified.

5.4.3

5.4.4 The defective areas shall be re-checked by the Field Engineer and subcontractor to

QA Programme Construction of Transportation Engineering Project 5.4.5

The QA Manager or his delegate for the Engineers representative to inspect the works, it shall be done after defective areas have been rectified. such as Warranty Certificate / Test Certificates for the Engineer.

5.4.6 The Project Manager or his delegate shall prepare and compile the necessary documents

5.4.7 Any defects found by the Engineers representative shall be rectified and recorded.

QA Programme Construction of Transportation Engineering Project

Chapter 9 Control of Quality Records

1. Purpose : To define controls for the identification, collection, indexing, filing, storage, maintenance and disposition of quality records. This chapter applies to the Project. chapter 3 Document & Data Control

2. 3. 4.

Scope

Reference : Responsibility

4.1 The Managers (See table 1) are responsible to provide instruction for the completion and storage of quality records that must be kept for historical purposes. He is to ensure quality records are legible and identifiable to the products and every alteration made on the quality record is to be counter signed by the Originator or by his immediate Superior. 4.2 The Managers (See table 1) are responsible for the identification, collection, indexing, filing, accessing storage, maintenance and disposition of quality records. Refer to Table 1 - List of Quality Records. 5. Procedure : 5.1 Accessing, Storage, Maintenance and Disposition of Records (Active & Inactive)
5.1.1Records including those submitted by pertinent subcontractors shall be made readily

available for review at the request of the Engineer or other responsible organisation. Records shall be listed in Records Master List which includes as a minimum, - Records title - Records I/D No. - Storage Location or box, file No. 5.1.2 5.1.3 5.1.4 Accessing of Quality records shall be approved by the Authorized staff and recorded in the record accessing log. Records shall be segregated, logged and boxed as of the last working date of the fiscal year, or their warrant periods. Records shall be stored and maintained in facilities that allow easy retrieval and provide suitable environment to minimize deterioration or damage and to prevent loss. Engineer. 5.1.6 Subcontractor will be contacted regarding disposition of their records when specified in the contract.

5.1.5Records shall be stored by receipt of Certificate of Practical Completion from the

QA Programme Construction of Transportation Engineering Project

Table 1

List of Quality Records

Index of Form Number QP-009-01 QP-009-26 QP-009-28 QP-009-20 QP-009-21

Description of Quality Records / Form Minutes of Meeting - Management Review Audit Plan Audit Summary Report The Engineer Complaint Report Internal Corrective Action Request

Retention Time Until finish the Project Until finish the Project Until finish the Project

Location & Responsible manager of File Planning

QA

QA

QP-009-05 QP-009-07 QP-009-18 QP-009-32 QP-009-33 -

Documents Master List Drawing Master List Inspection and Test Report Nonconformance Report Training Plan Training Attendance Record QA Programme Quality / Work Procedure Method Statement Calculation Test Certificate Report Drawings Contract Specification (including Technical Spec.)

Until finish the Project Until finish the Project Until finish the Project Until finish the Project

QA Design QA / QC QA QA

Until finish the Project

QA

Until finish the Project Until finish the Project

Design Planning

QA Programme Construction of Transportation Engineering Project

Chapter 10 Internal Quality Audits

1. Purpose : To define a system for the conduct of Internal Quality Audit to verify whether quality activities and related results comply with planned arrangements and to evaluate the effectiveness of the implementation of the Quality System. This chapter applies to the Transportation Project. Nil

2. 3. 4.

Scope

Reference : Definitions 4.1 4.2 4.3

Audit Team Member is a person who has the qualification and is authorized to perform a Quality System audit. Audit Team Leader is a person who has the qualification and is authorized to manage a team of Auditors. Auditee is the person being audited.

5.

Responsibility 5.1 The Internal Quality Audit shall be performed by qualified auditor in Head Office. If the Head Office Audit Team is not available for the site, the Project Manager shall appoint Planning Manager (for QA Department) and QA Manager (for the other organization) as Auditor. In this case, forms for audit may be used standard forms in Transportation Engineering Project procedure (Standerd forms for QA procedure : QP-009). The QA Manager -

5.2

Establish the Annual Quality Audit Program This program shall confirm with Manager of Quality Assurance Office in Head Office for smooth progress of Internal Quality Audit. Review the Quality Audit Results performed by the Internal Quality Audit Team Report to Project Manager on the effectiveness of the Quality System. Audit organisation except QA Department in according to Head Office internal audit procedure. (if the Head Office Audit Team is not available for the site).

5.3 The Planning Manager

-

Audit QA Department in according to Head Office internal audit procedure (if the Head Office Audit Team is not available for the site). The Audit Team Leader shall oversee the internal quality audit activities and enforce the implementation of outstanding corrective actions. He shall report to the Project Manager on the findings of each auditing cycle. The Audit Team Member is to carry out the instructions as layout by the Audit Team Leader. The individual Department Manager responsible for the area audited shall review, agree and correct the Audit Finding items. He shall ensure the effectiveness of the corrective actions.

5.3

5.4
5.5

QA Programme Construction of Transportation Engineering Project

6.

Procedure :
6.1

The detail procedure of Internal Quality Audits shall be done in accordance with latest version of Head office Internal quality audit procedure. The Department Manager shall take action on the Audit Finding Report until the recommended date in those request sheet. After completion of Audit Finding Report, the Project Manager shall review and signed on those report and this report sent to Head Office. The QA Manager is responsible to ensure that the Quality System of the Project is implemented and maintained. All copy of reports related to the Internal Quality Audit shall kept (filing) by QA Manager for using the back-data of Coordinate Committee Review.

6.2

6.3

6.4

6.5

QA Programme Construction of Transportation Engineering Project

Chapter 11 - Training
1. Purpose : To define the system for identifying the training needs and providing for the training of all personnel performing activities affecting quality. This chapter applies to the Transportation Engineering Project overseeing the training need of staff performing activities affecting quality. Nil

2.

Scope

3.

Reference :

4.

Responsibility 4.1 The Project Manager is responsible for approving of yearly training schedule. 4.2 QA Manager is responsible for the execution of the training and maintain the training records.

5.

Training needs identified

Training Course no. 1 2 Description

:
Training All staff Con. staff Training Method Education Education or OJT or Exercise OJT (On-Job-Training) Training on commission Remark

New System Introduced Use new tech. & method Cube test control New recruitment Implementation of Regulation - Safety course

Recruitment All worker

QA Programme Construction of Transportation Engineering Project

Chapter 12 Standard Forms Indexing System

1. 2. 3. 4. Purpose Scope : : To define the system for identifying the indexing system for standard forms. This chapter applies to the Transportation Engineering Project. QP-009 Standard forms for QA (Quality Assurance)

Reference : Responsibility

4.1 The QA Manager is responsible for monitoring of documents indexing system. 4.2 Relevant Department Manager is responsible for the execution of document indexing system. 5. Indexing System 5.1 Field Change Notice / Request FCN (FCR)-MX-YYY MX YYY = = 1 Digit Running Module Number (0 for two or more modules) 3 Digit Running FCN (FCR) Number

5.2 Punch List for Hand-Over PNC-MX-YYY MX YYY = = 1 Digit Running Module Number (0 for two or more modules) 3 Digit Running Punch List Number

5.3 Nonconformance Report CPS-X NCR-YY X YY = = 1 Digit Running Module Number (0 for two or more modules) 2 Digit Running NCR Number

5.4 The Engineer Complaint Report ECR-MX-YYY MX YYY = = 1 Digit Running Module Number (0 for two or more modules) 3 Digit Running ECR Number

5.5 Internal Corrective Action Request ICAR-XXX XXX = 3 Digit Running ICAR Number

5.6 Supplier / Subcontractor Corrective Action Request

QA Programme Construction of Transportation Engineering Project

SCAR-XXX XXX = 3 Digit Running SCAR Number

5.7 Audit Plan AP-XX XX = 2 Digit Running AP Number

5.8 Audit Corrective Action Request ACAR-XX XX 5.9 Memo TERF X / YYY X YYY = = First Letter of Department (e.g D : Design, C : Construction, P : Planning, A : Admin etc) 3 Digit Running Memo Number = 2 Digit Running ACAR Number

QA Programme Construction of Transportation Engineering Project

Chapter 13 Control of Inspection, Measuring & Test Equipment

1. 2. Purpose Scope : : To define a system for the calibration of inspection, measuring and test equipment. This chapter applies to the inspection, measuring and test equipment used by TE Project. The applicable equipment are those listed in the "Master list of Inspection / Measuring / Test Equipment" (see Attachment 6.1). Not Applicable

3. 4.

Reference

Responsibility The QC Engineer shall have the main responsibility to supervise and co-ordinate all calibration services of all inspection, measuring and test equipment.

5.

Procedure : 5.1 New Equipment Control

5.1.1

The QC Engineer or his delegates shall check the new equipment prior to use to assure that each equipment meets the specification and performance test. He shall ensure that the equipment is logged in the Master list of Inspection / Measuring / Test Equipment and arrange for external calibration as appropriate.

5.1.2 5.2

Existing Equipment Control 5.2.1 The QC Engineer shall ensure that the Master list of Inspection / Measuring / Test Equipment is generated for review monthly (on the first week of each month) and each item on the list shall be physically identified and traceable to the list. He shall decide the frequency of calibration, review the master list for any equipment currently in use which is due for calibration and arrange for external or internal calibration as appropriate. He shall ensure that only calibrated equipment shall be used.

5.2.2

5.2.3 5.3

Control Elements 5.3.1 Standards Traceability The calibration standards shall be traceable to national metrology laboratories in developed industrialised countries such as USA, UK, Australia, Japan, West Germany, India and France. 5.3.2 Identification of Equipment Equipment manufacturer's serial number or identification number is used for identification purposes. Equipment that does not bear a serial number is assigned a identification number. 5.3.3 Equipment Calibration Schedule The calibration schedule in the Master list of Inspection / Measuring / Test Equipment is updated, immediately, whenever there is a change.

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Chapter 13 Control of Inspection, M & TE

QA Programme Construction of Transportation Engineering Project

5.3.4

Equipment Calibration Procedures For routine measuring equipment, such as steel rulers and measuring tapes, are exempted from calibration. 5.3.4.1 For task identified in the QA Plan as requiring controlled measuring or test equipment, the QC Engineer shall ensure that only properly controlled inspection or measuring equipment is used. 5.3.4.2 The QC Engineer shall show that all controlled equipment is in an acceptable state of calibration. All such equipment shall be labelled, marked or engraved. Non-controlled equipment is identified by the absence or such label, mark or engraving.

5.3.5

Calibration Reports / Certificates The QC Engineer shall ensure the external and internal calibration reports / certificates are reviewed. The equipment is released to the User only if the result is in order.

5.3.6

Equipment Care The equipment are calibrated, used, handled and stored in suitable environmental condition, in accordance with manufacturer's recommendation (if any) and where necessary in a dry, clean and cool place free from mechanical damage, impact and shock. User shall not adjust or temper with the calibrated equipment to invalidate the calibration settings.

5.3.7

Measurement Accuracy and Precision The user and / or his superior shall ensure that the inspection / measuring / test equipment used for a verification activity is suitable for the necessary accuracy and precision.

5.4

Action To Be Taken When Calibration Results Are Unsatisfactory 5.4.1 Reporting Procedure When a measuring equipment is found to be out of calibration, the User shall report the fault to the QC Engineer. The QC Engineer shall investigate and confirm the fault. Once the fault is confirmed, he shall stop the measurement task. 5.4.2 Disposition of Faulty Equipment The faulty equipment usage shall be prohibited immediately and an "Out of Service" label shall be affixed to it by QC Engineer. He shall ensure that the faulty equipment is completely repaired / calibrated prior to further use. He shall review the need to revise the frequency of calibration of such equipment and ensure that the calibration is carried out on prescribed intervals. 5.4.3 Disposition of Products Measured by the Faulty Equipment The QC Engineer shall ensure that the following are carried out : (a) (b) The works measured by the faulty equipment shall be identified. Their parameters shall be re-validated starting from the latest by another piece of equipment certified to be of good condition. The re-validation will stop at the works that show satisfactory results.

QA Programme Construction of Transportation Engineering Project

(c)

If necessary, a meeting shall be held amongst the QC Engineer, to discuss the disposition of the non-conforming works. The affected works shall be verified with the client to determine if : (i) (ii) (iii) Works still within design requirement; Works comply with requirements with recommended improvements; Works must be reconstructed.