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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 Yes Yes
Having AC Yes Yes
Having GPS Yes Yes
At least 5 seaters Yes Yes
Having air bags Yes Yes
HP Engine is not less than 300 Yes Yes
Color is blue No Yes
Maintainence fee is less than 500
No Yes
SAR per month
Antilock Braking System (ABS) Yes Yes
The cost of spare parts are
No Yes
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 B
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 7.0 QUALITY CONTROL PROCESS

7.1 Management Responsibilities


1.1 Scope & Objectives of Project Quality Plan 7.2 Project Quality System
1.2 Authority & Responsibility for amendment 7.3 Quality Planning
changes 7.4 Contract Review
1.3 Authority for change of control to documents 7.5 Concessions
7.6 Quality Reporting
2.0 NESMA & PARTNERS I.S.O. 9001 & ASME A 7.7 Document Control
& PP CERTIFICATES 7.8 Procurement Control
7.9 Process Control
3.0 QA SPECIFICATION 7.10 Inspection and Testing
7.11 Inspection, Measuring and Test Equipment Control
3.1 Reference & Standards 7.12 Material and Equipment Handling & Storage
3.2 Definition 7.13 Control of Non Conformance and Corrective Action
7.14 Preventive Action
4.0 BRIEF SCOPE OF WORKS 7.15 Quality Records
7.16 Audit/Surveillance
5.0 RESPONSIBILITIES 7.17 Project Handover Documentation
7.18 Project Submissions
5.1 Project Manager 7.19 Training
5.2 QA/QC & Safety Manager (H.O.)
5.3 Construction Manager 8.0 REGISTER OF TYPICAL INSPECTION & TEST
5.4 Project QA/QC Manager PLANS
5.5 Discipline QA/QC Engineer
5.6 Document & Data Controller 9.0 LIST OF QUALITY SYSTEM PROCEDURES

6.0 ORGANISATION CHARTS 10.0 LIST OF PROJECT QUALITY SYSTEM FORMS

6.1 QA/QC Organisation Chart


11.0 KEY PERSONNEL

12.0 AUDIT SCHEDULE


LIST OF QUALITY SYSTEM PROCEDURES
HEAD OFFICE QUALITY MANAGEMENT SYSTEM PROCEDURES

QA/QAD/01 Operation & Control of the Procedure Manual


QA/QAD/03 Internal Quality Audits
QA/QAD/04 Management Review Meetings
QA/QAD/05 Library Control
QA/QAD/08 Quality Records Retention
QA/EST/04 Contract Review
QA/PRO/03 Supplier and Sub Contractor Control
QA/PRO/04 Procedure for Preparing, Updating & Controlling of Proc.
Schedule
QA/PRO/05 Purchase Order Control
QA/PRO/06 Material Submittal Procedure
QA/ENG/03 Project Design Unit and Initial Planning
QA/ENG/04 Client Design Review Meetings
QA/ENG/05 Design Co-ordination Meetings
QA/ENG/06 Design and Discipline check
QA/ENG/07 Architectural Material Approvals
QA/ENG/08 Drawing Presentation
QA/ENG/09 Site Surveillance Visits
QA/ENG/10 RFI and Questions/Answers
QA/ENG/11 Design by External Organization
QA/ENG/12 Standards Library
QA/ENG/13 Technical Submission
QA/ENG/14 As-Built Drawings
QA/HRT/05 Training / Performance Appraisal Review
QA/ITS/03 Electronic Media Virus Control
QA/STO/03 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 the cause
Action?
of
of aa
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
WORK Phases or
AUDITS
Contracts :
with duration of six months or longer.
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 NON-
CONFORMANCE
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 non-
conformities 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.
Personnel
Work Personnel
Qualifications
Procedure Qualificatio
Procedure
Special Process (Note 1) Approval (A) n Approval
Approval
or Review (R) Required
Required (Yes /
Required (Yes / No)
No)
Field Engineering Change Control A No No
Civil Processes
Concrete Finishing A Yes Yes
Concrete and Asphalt Mix A No No
Mechanical Processes
Welding / Brazing A Yes Yes
Nondestructive Testing (NDT) A Yes (Note 1) Yes
Positive Material Identification (PMI) & Color-Code Verification A No Yes
Heat Treatment & associated Hardness Testing A No No
Hydrostatic Pressure Testing A No No
Valve Testing and Installation A No No
Coating & Lining A No Yes
Gasket Installation & Bolt Tightening A No No
Gap Control (Socket welds, thread engagement, back welding of threaded joints) A No No
Hot Taps (Calcs) & Tie-ins A No No
Refractory Installation R No No
HVAC Testing & Balancing A No No
RTR Pipe work A No Yes
Electrical, Instrumentation & Communication Processes
High / Medium Voltage (HV / MV) Cable Splicing / Termination R No Yes
Electric Power Systems Energization R No No
Fiber Optic Cable Installation / Termination R No No
Cable Gland / Seal & Conduit Seal Installation R No Yes
ATTACHMENT V:
SUMMARY OF QUALITY SYSTEM
DELIVERABLES
No. Title First Submittal to COMPANY Subsequent submittal to COMPANY

Twenty one (21) calendar days after the effective Within 7 calendar days of each revision
1 Quality Plan: Paragraph 3.2 of Schedule Q
date of Contract and for any significant changes requirement

Organization Chart(s) Paragraph 5.12 of


2 With Quality Plan submittal When changes occur
Schedule Q

Personnel Qualifications: Paragraph 5.6 of Prior to bringing new Quality personnel on


3 Prior to assignment of personnel on the project
Schedule Q the project

Quality Audit Schedule: Paragraph 7.3.2 of Within twenty one (21) calendar days of the
4 Within 7 calendar days of revision
Schedule Q effective date of the Contract

Audit Report: Paragraph 7.3.5 of Schedule Within fourteen (14) calendar days of completion
5 -
Q of the audit and re-audit.

CONTRACTOR, Vendor and Subcontractor


Within forty eight (48) hours of reporting each
6 non-conformities: Paragraph 7.5.3 of Schedule Notification of clearance required
non-conformance
Q

Non-conformance Summary: Paragraph 7.5.5


7 After the first non-conformance is issued Weekly for the Project Progress Meeting
of Schedule Q

Management Review results: Paragraph 4 of


8 Within two (2) weeks after scheduled review -
Schedule Q

Quality Management Report: Paragraph 7.7 of Sixty (60) calendar days after the effective date of
9 Monthly
Schedule Q the Contract

Evidence of manufacturer prequalification: Two (2) weeks prior to placement of purchase


10 -
Paragraph 1.2.1 of Attachment III order.

Inspection / Fabrication Status Report: One week after the first purchase order is awarded
11 Weekly
Paragraph 2.4 of Attachment III for the Contract
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 know,
please ask

Dont assume because


assumption is the
mother of all
screwups
THANK YOU