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WHICH IS BETTER QUALITY ?

To buy for our customer XYZ a


mercedes or hyundai car ???

WHAT DO YOU THINK ????

mercedes

HYUNDAI

Mercedes

Hyundai

Customer Requirements

Meet requirement Meet requirement

6 cylinders
Having AC

Yes
Yes

Yes
Yes

Having GPS
At least 5 seaters

Yes
Yes

Yes
Yes

Having air bags


HP Engine is not less than 300

Yes
Yes

Yes
Yes

Color is blue

No

Yes

Maintainence fee is less than 500


SAR per month

No

Yes

Yes

Yes

No

Yes

Antilock Braking System (ABS)


The cost of spare parts are
economical

The Answer is .

HYUNDAI
Because it meets the Customer
requirements !!
The Conclusion is .
YOU SHALL BE FULLY AWARE OF
CUSTOMER REQUIREMENTS BEFORE
YOU DECIDE

WHICH IS CONFORMING
WORK?
A OR B

ANSWER IS

REQUIREMENTS
The bottle of water shall be installed
vertically and the top part (Blue Cap)
shall touch the bottom of the floor

FULLFILLING THE PROJECT


QUALITY REQUIREMENTS
1. COMPLIANCE WITH THE APPROVED PROJECT
QUALITY PLAN(SchQ and ISO9000)
2. COMPLIANCE WITH THE SCHEDULE Q
3. COMPLIANCE WITH THE PROJECT
INSPECTION
REQUIREMENTS (SATIP / ITP)
4. COMPLIANCE WITH THE APPROVED METHOD
OF
STATEMENTS AND SPECIAL PROCESS

LET US UNDERSTAND
SOME IMPORTANT
QUALITY TERMINOLOGY
QUALITY ASSURANCE
QUALITY CONTROL

ISO 9000

QUALITY MANGEMENT SYSTEM

QUALITY POLICY

QUALITY OBJECTIVE

What is Quality Assurance


(QA)?
Quality Assurance (QA) is the activity of providing evidence
needed to establish confidence among all concerned, that
quality-related activities are being performed effectively.

What is Quality Control (QC)?


Quality Control (QC) is a procedure or set of procedures
intended to ensure that a manufactured product or perform
service adheres to a defined set of quality criteria or meets
the requirements of the client or customer. QC is similar to,
but not identical with Quality Assurance.
Assurance.

What is Quality
Management System?
- Quality Management System (QMS) can be
defined
as a set of policies, process and procedures
required for planning and execution
(production /
development / service) in the core business
area of
- an
It directs
organization.
and controls an organization with
regard
to quality.(Quality objectives and Quality
policy)

What is
ISO?

ISO (International Organization for Standardization) is a worldwide federation


of national standards bodies (ISO member bodies). The work of preparing
International Standards is normally carried out through ISO technical
committees.

The ISO 9000 Family of


Standards
ISO 9000
-

Describes fundamental of quality management systems.

ISO 9001

Specifies requirements for a quality management system where an


organization needs to demonstrate its ability to provide products that
fulfill customer.

ISO 9004

Provides guidelines.

ISO 9011

Provides guidance on auditing quality and environmental


management systems.

What is Quality Policy?


- Overall intentions and direction of an organization related to quality as
formally expressed by the top management.
- The quality policy provides a framework for establishing and reviewing quality
objectives.

What is Quality Objective?


-

Something sought, or aimed for, related to quality.

- The quality objective need to be consistent with the quality policy and the
commitment to continual improvement, and their achievement needs to
measurable .

Project Quality Plan

Project Quality Plan can be defined as a set of activities planned


at the beginning of the project that helps achieve Quality in the
Project being executed.

The Purpose of the Project Quality Plan is to give the


methodology for managing the quality in a specific project site.

Project Quality Plan identifies which Quality Standards are


relevant to the project and determines how can they be satisfied.

Typical Project Quality Plan Index


1.0

PROJECT QUALITY POLICY STATEMENT

1.1
1.2

Scope & Objectives of Project Quality Plan


Authority & Responsibility for amendment
changes
Authority for change of control to documents

1.3
2.0

NESMA & PARTNERS I.S.O. 9001 & ASME A


& PP CERTIFICATES

3.0

QA SPECIFICATION

3.1
3.2

Reference & Standards


Definition

4.0

BRIEF SCOPE OF WORKS

5.0

RESPONSIBILITIES

5.1
5.2
5.3
5.4
5.5
5.6

Project Manager
QA/QC & Safety Manager (H.O.)
Construction Manager
Project QA/QC Manager
Discipline QA/QC Engineer
Document & Data Controller

6.0

ORGANISATION CHARTS

6.1

QA/QC Organisation Chart

7.0

QUALITY CONTROL PROCESS

7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
7.13
7.14
7.15
7.16
7.17
7.18
7.19

Management Responsibilities
Project Quality System
Quality Planning
Contract Review
Concessions
Quality Reporting
Document Control
Procurement Control
Process Control
Inspection and Testing
Inspection, Measuring and Test Equipment Control
Material and Equipment Handling & Storage
Control of Non Conformance and Corrective Action
Preventive Action
Quality Records
Audit/Surveillance
Project Handover Documentation
Project Submissions
Training

8.0

REGISTER OF TYPICAL INSPECTION & TEST


PLANS

9.0

LIST OF QUALITY SYSTEM PROCEDURES

10.0

LIST OF PROJECT QUALITY SYSTEM FORMS

11.0

KEY PERSONNEL

12.0

AUDIT SCHEDULE

LIST OF QUALITY SYSTEM PROCEDURES


HEAD OFFICE QUALITY MANAGEMENT SYSTEM PROCEDURES
QA/QAD/01
QA/QAD/03
QA/QAD/04
QA/QAD/05
QA/QAD/08
QA/EST/04
QA/PRO/03
QA/PRO/04
Schedule
QA/PRO/05
QA/PRO/06
QA/ENG/03
QA/ENG/04
QA/ENG/05
QA/ENG/06
QA/ENG/07
QA/ENG/08
QA/ENG/09
QA/ENG/10
QA/ENG/11
QA/ENG/12
QA/ENG/13
QA/ENG/14
QA/HRT/05
QA/ITS/03
QA/STO/03

Operation & Control of the Procedure Manual


Internal Quality Audits
Management Review Meetings
Library Control
Quality Records Retention
Contract Review
Supplier and Sub Contractor Control
Procedure for Preparing, Updating & Controlling of Proc.
Purchase Order Control
Material Submittal Procedure
Project Design Unit and Initial Planning
Client Design Review Meetings
Design Co-ordination Meetings
Design and Discipline check
Architectural Material Approvals
Drawing Presentation
Site Surveillance Visits
RFI and Questions/Answers
Design by External Organization
Standards Library
Technical Submission
As-Built Drawings
Training / Performance Appraisal Review
Electronic Media Virus Control
Calibration of Measuring & Test Equipment

PROJECT QUALITY MANAGEMENT SYSTEM PROCEDURES


QA/CON /01 Operation of Project Quality System

QA/CON /14Material Receipt and Control

QA/CON /02 Project Management Review Meeting

QA/CON /15 Non Conforming Material

QA/CON /03 Control of Authorized Signatures

QA/CON /16 Handling and Storage

QA/CON /04 Project Quality Audits

QA/CON /17 Stock Records

QA/CON /05 Sub-contractor Control

QA/CON /18 Customer Supplied Material

QA/CON /06 Process Control

QA/CON /19 Non Conformance & Corrective Action

QA/CON /07 Quality Records

QA/CON /20 Customer Complaints

QA/CON /08 Site Works Inspection

QA/CON /21 Concreting Procedure

QA/CON /09 Completion Inspections

QA/CON /22 Incoming Drawing Control

QA/CON /10 Project Handover / Completion

QA/CON /23 Plant and Equipment Commissioning

QA/CON /11 Material Testing

QA/CON /24 Site Calibration Procedure

QA/CON /12 Material Scheduling

QA/CON /25 Control of Documentation & Archiving

QA/CON /13 Approved Material Control

QA/CON /26 Customer Satisfaction

Scope of the Project Quality Plan

Meet the Project Quality System and product


requirements
for Saudi Aramco.
It will be prepared in accordance with Saudi Aramco
quality
and ISO 9000 requirements.

QUALITY OBJECTIVES

Acceptance of RFI rate shall be over 95%.

All measuring and test equipment shall be maintained and


calibrated efficiently.

Close out of Non-conformance reports within the stipulated time


given.

PQI > 90%.

External

NCR to Internal NCR ratio should be 1/7.

SCHEDULE Q
It describes SAUDI ARAMCOs minimum
requirements for NESMAs Quality
Management System.

SCHEDULE Q
QUALITY MANAGEMENT SYSTEM
REQUIREMENTS:
NESMA shall implement for the Contract a
Quality
Management
System
in
accordance with the latest version of ISO
9001 (Quality Management Systems
Requirements), which is incorporated by
reference and the Schedule Q.

SCHEDULE Q
DOCUMENTATION REQUIREMENTS:
NESMA shall plan, organize, control
and execute all WORK in accordance
with
NESMAs
Quality
Plan(s),
Inspection and Test Plans (ITPs) and
documented procedures.
NESMA will adopt the SAUDI ARAMCO
Typical Inspection Plans (SATIP) and
SAUDI ARAMCO Inspection Checklists
(SAIC) in its Quality Plan, it shall
include a list of applicable SATIPs for
execution of the scope of the WORK in
accordance with Schedule B of the
Contract.

SCHEDULE Q
SAMPLE COPY OF TYPICAL INSPECTION PLAN
(SATIP)

SAMPLE COPY OF TYPICAL INSPECTION PLAN


(SATIP)

SAMPLE COPY OF SAUDI ARAMCO INSPECTION CHECKLIST (SAIC)

SCHEDULE Q
MANAGEMENT RESPONSIBILITY:
In accordance with ISO 9001, NESMAs
Senior Management shall review the
project specific Quality System every
six months to ensure that the system
is suitable, adequate and effective.
Within two (2) weeks after the
scheduled review date, NESMA shall
advise
the
Saudi
Aramco
Representative in writing of the
results and recommended actions of
such review.

SCHEDULE Q

RESOURCE MANAGEMENT:

NESMA shall designate the Quality Assurance


Manager for the Contract within seven (7)
calendar days of the effective date of
Contract.
NESMA shall designate the Quality Control
Manager for the Contract one month prior to
start of fabrication.
Procurement Quality Control Manager or
Supervisor shall be assigned to the WORK
within one month of the effective date of
contract and shall WORK through Project
Completion.
NESMA,
subcontractors and third party
agency Quality personnel assigned to WORK
shall
meet
the
minimum
qualification
requirements of Attachment I of the Schedule
Q.

SCHEDULE Q

RESOURCE REQUIREMENTS &


REPORTING:
NESMAs quality personnel shall have sufficient and

well
defined
responsibilities,
qualifications,
authority, and organizational freedom to identify
quality problems.
NESMA
shall
submit
to
Saudi
Aramco
Representative as part of the monthly Quality
Management Report as listing / sorted by discipline
of:

Quality personnel forecast to be mobilized in the next sixty (60)


days.

Quality personnel forecast to be demobilized in the next sixty


(60) days.

NESMA shall make quality personnel changes


required due to vacations, illness, temporary
assignments, emergency leave, resignations or
other reasons as necessary to maintain required
Quality coverage and shall advise Saudi Aramco
Representative of such personnel and quality
coverage at least thirty (30) calendar days in
advance of scheduled absences or changes.

SCHEDULE Q
PROJECT REALIZATION /
EXECUTION:
DESIGN PHASE QUALITY
ACTIVITIES:

NESMA shall comply with the Design Phase


requirements of NESMAs approved Quality
Plan and the Schedule Q.
DESIGN PHASE QUALITY
ACTIVITIES:

NESMA shall comply with the Construction


Quality requirements of NESMAs approved
Quality Plan and Attachment IV of the
Schedule Q.

Inspection & Test Plan


The

purpose is to ensure conformance to quality planned requirements of all executed


works on site.

A document setting out the specific quality practices, resources, and sequence of
activities relevant to a particular product, project or contract.

Surveillance: Saudi Aramco to monitor work in progress without notice from Nesma.

Witness: Saudi Aramco shall be notified of the timing of Inspection or test In advance.
However, the inspection or test shall be performed as scheduled if Saudi
Aramco representative is not present.

Hold: Saudi Aramco shall be notified by Nesma of the timing of inspection or test in
advance. Inspection or test shall not be carried out without Saudi Aramco
representative in attendance.

Inspection & Test Plan Sample

Checklist / Quality Record

The checklist can be used throughout the construction


process
to establish, maintain and ensure a minimum quality
requirements have been achieved .

The checklist can be used to inform construction crews


of the
steps that are necessary to reach quality standards and
ensure
that all groups involved have the same information
about the
work site.

Inspection Checklist Sample

QUALITY SYSTEM AUDITS


Systematic, independent and documented
process for obtaining audit evidence and
evaluating it objectively to determine the
extent to which audit criteria are fulfilled
Audits are planned and carried out in
accordance with the project Audit Schedule.
Independent
surveillance audits will be
carried out every six month by Nesmas Lead
Auditor.

What is Non
Conformance ?

- Non-fulfillment of a requirement.
The product which does not conform to
product
requirements shall be identified and
controlled
to prevent its intended use or delivery.

NCR FORM

Car didnt start.


Battery is dead
Alternator does not meet the specification.
The wrong one has been installed.
Improper control of identification and
traceability process of materials in the
assembly shop.
Concerned staff is not fully aware of the
applicable procedure

Cracks are observed on the foundation


Improper curing.
Not enough water is being reached at site for
all foundations.
Not Enough water tankers are available on site
Improper planning of the required resources for
the relevant site activities.

What is Corrective
- The action to eliminate
Action?
of
a

the cause

of
a
detected non-conformance in order
to
prevent recurrence.
Toolbox
should
be always conducted to all
concerned
to ensure they do understand
the concept of root cause, remedial
action and corrective action.

SCHEDULE Q

INTERNAL
NESMA shall conduct internal audits covering
AUDITS
:
Contracts
with duration
of six months or longer.

WORK Phases or
This shall include
audits of the NESMAs quality function and obligations as
described in the SAUDI ARAMCO approved quality plans, the
Contract and ISO 9001.

NESMA shall submit a quality audit schedule to the Saudi Aramco


Representative for review and approval within twenty one (21)
calendar days from the effective date of Contract.

All audits shall be executed by quality system auditors (qualified


in accordance with Attachment I of the Schedule Q).

NESMA shall submit to Saudi Aramco Representative a copy of


each audit report within fourteen (14) calendar days of its
completion.

Saudi Aramco Representative or his nominee shall be invited to


participate in all audits.

SCHEDULE Q

CONTROL OF NONCONFORMANCE
:
NESMA shall
include in the quality Plans
procedures to prevent

inadvertent use of design documents, materials, parts,


components, services or workmanship not conforming to
requirements of the Contract.

NESMA shall investigate the root cause of non-conformities and


initiate Corrective Actions to prevent recurrence of nonconformities maximum seven (7) days of the issue date.

NESMA shall maintain a summary of the open non-conformities.

NESMA shall respond to all non-conformities issued by SAUDI


ARAMCO in writing within 48 hours of receiving notification of
non-conformance.

Saudi Aramco Representative or his nominee shall be invited to


participate in all audits.

SCHEDULE Q
WAIVERS:
NESMA shall not waive the requirements of
any NESMA Quality Plan or Inspection and
Test Plan previously accepted by Saudi
Aramco Representative without the express
written
consent
of
Saudi
Aramco
Representative.

NESMA shall also maintain a log detailing all


waivers to SAUDI ARAMCO standards
obtained during all phases.

ATTACHMENTS TO SCHEDULE
Q

ATTACHMENT I

ATTACHMENT II
ATTACHMENT III
ATTACHMENT IV
ATTACHMENT V
ATTACHMENT VI

ATTACHMENT I:

It defines NESMA and Subcontractor Quality Personnel


Qualification requirements.

Quality personnel employed by NESMA and its


subcontractors to perform the WORK described in the
Contract shall meet, as a minimum, the qualification and
experience requirements.

ATTACHMENT II:

It defines SAUDI ARAMCO Standards and Procedures


containing Quality requirements.

NESMA shall comply with all applicable SAUDI ARAMCO


Material System Specifications (SAMSS), COMPANY
Engineering Standards (SAES), and other SAUDI
ARAMCO standards and specifications.

ATTACHMENT III:

It defines the Quality requirements for NESMA


supplied materials.

NESMA shall provide and document Quality services


in the procurement of equipment and material to be
used or installed during the construction and
installation
of
facilities
as
specified
in
the
requirements of the Contract.

ATTACHMENT IV:
QUALITY REQUIREMENTS FOR THE CONSTRUCTION
PHASE
CONTROL OF CONSTRUCTION ACTIVITIES:
Unless submitted with the Project Quality Plan in accordance
with paragraph 3.2 of Schedule Q, one month prior to the start
of the applicable WORK, NESMA shall submit for review and
approval a detailed Inspection and Test Plan (ITP) along with
related procedures / work instructions for all construction
processes to be executed by NESMA or subcontractor.
VALIDATION OF CONSTRUCTION
The PROCESSES:
special processes require SAUDI ARAMCOs review and / or
approval of work procedures, personnel qualifications, or
personnel qualification procedures. NESMA shall ensure that
these special processes are accomplished under controlled
conditions as specified in all applicable standards and
specifications. All process parameters shall be identified with
acceptance criteria specified and monitored. All Procedures and
Personnel Qualifications shall be submitted for review and / or
approval at least twenty one (21) calendar days prior to the start
of WORK.

Work
Procedure
Approval (A)
or Review (R)
Required

Personnel
Qualifications
Procedure
Approval
Required (Yes /
No)

Personnel
Qualificatio
n Approval
Required
(Yes / No)

No

No

Concrete Finishing

Yes

Yes

Concrete and Asphalt Mix

No

No

Welding / Brazing

Yes

Yes

Nondestructive Testing (NDT)

Yes (Note 1)

Yes

Positive Material Identification (PMI) & Color-Code Verification

No

Yes

Heat Treatment & associated Hardness Testing

No

No

Hydrostatic Pressure Testing

No

No

Valve Testing and Installation

No

No

Coating & Lining

No

Yes

Gasket Installation & Bolt Tightening

No

No

Gap Control (Socket welds, thread engagement, back welding of threaded joints)

No

No

Hot Taps (Calcs) & Tie-ins

No

No

Refractory Installation

No

No

HVAC Testing & Balancing

No

No

RTR Pipe work

No

Yes

Special Process (Note 1)

Field Engineering Change Control


Civil Processes

Mechanical Processes

Electrical, Instrumentation & Communication Processes


High / Medium Voltage (HV / MV) Cable Splicing / Termination

No

Yes

Electric Power Systems Energization

No

No

Fiber Optic Cable Installation / Termination

No

No

Cable Gland / Seal & Conduit Seal Installation

No

Yes

ATTACHMENT V:
SUMMARY OF QUALITY SYSTEM
DELIVERABLES
No.

Title

First Submittal to COMPANY

Subsequent submittal to COMPANY

Quality Plan: Paragraph 3.2 of Schedule Q

Twenty one (21) calendar days after the effective


date of Contract and for any significant changes

Within 7 calendar days of each revision


requirement

Organization Chart(s) Paragraph 5.12 of


Schedule Q

With Quality Plan submittal

When changes occur

Personnel Qualifications: Paragraph 5.6 of


Schedule Q

Prior to assignment of personnel on the project

Prior to bringing new Quality personnel on


the project

Quality Audit Schedule: Paragraph 7.3.2 of


Schedule Q

Within twenty one (21) calendar days of the


effective date of the Contract

Within 7 calendar days of revision

Audit Report: Paragraph 7.3.5 of Schedule


Q

Within fourteen (14) calendar days of completion


of the audit and re-audit.

CONTRACTOR, Vendor and Subcontractor


non-conformities: Paragraph 7.5.3 of Schedule
Q

Within forty eight (48) hours of reporting each


non-conformance

Notification of clearance required

Non-conformance Summary: Paragraph 7.5.5


of Schedule Q

After the first non-conformance is issued

Weekly for the Project Progress Meeting

Management Review results: Paragraph 4 of


Schedule Q

Within two (2) weeks after scheduled review

Quality Management Report: Paragraph 7.7 of


Schedule Q

Sixty (60) calendar days after the effective date of


the Contract

10

Evidence of manufacturer prequalification:


Paragraph 1.2.1 of Attachment III

Two (2) weeks prior to placement of purchase


order.

11

Inspection / Fabrication Status Report:


Paragraph 2.4 of Attachment III

One week after the first purchase order is awarded


for the Contract

Monthly
Weekly

ATTACHMENT VI:

Project Specific Quality Requirements.


Procurement Phase Project Specific Quality
Requirements:
Minimum inspection levels for NESMA supplied
equipment and materials are indicated in SAEP-1151.
NESMA shall submit its supplier inspection and test
plans according to these minimum inspection levels.

Inspection levels specified in Attachment VI shall not


be any lower than the level of inspection specified in
SAEP-1151.

QA/QC and Construction should work as


a team

Walk the talk .

The Success of any is a success of the other.

The failure of any is a failure of the other.

Blame culture should be replaced by a problem solving Culture.

When a non-conformity happens on site, the question is "How did


that happen and what can we do about it? And not Who did the
mistake.

If you dont
please ask

know,

Dont assume because


assumption
is
the
mother
of
all
screwups

THANK YOU