Friday, August 07, 2009

Quality Assurance Plan 6 of 6

14.1. General
This section covers the control procedure of the non-conformity treatment and corrective action to prevent mis-use and recurrence.

14.2. Control of Non-conforming Items and Services
14.2.1. When any deviation from the requirement is detected or reported, CONTRACTOR shall confirm the status and direct to withhold the process and to identify the product by marking or affixing a hold tag to preclude inadvertent use or installation.

14.2.2. If the Non-conformity is of such a major grade as the disposition can be decided by CONTRACTOR’S Inspector, he will direct Vendor/ Subcontractor of the treatment.

14.2.3. In the event that the non-conformity is major as to fall into one or more of the following items, the Non-conformity report shall be prepared by the Inspector or Vendor/ Subcontractor, and be sent to QA/QC Manager with details sufficient to pass a fair judgment, as required.
The following non-conformity is defined to be major:
- Where the non-conformity deviates from statutory or contractual requirements.
- Where requested by OWNER
- Where it cause design changes, including the case to use-as-is
- Where it has significant effects on schedule and cost.

14.2.4. QA/QC Manager shall circulate the non-conformity report to Engineering Manager, Project Manager, Project Engineer, and Construction Manager. QA/QC Manager shall discuss it with key personnel of the relevant organization (DE, EM, PE, and the special on the matter, where necessary) to decide the disposition. When PM considers necessary, he reports to OWNER to obtain his approval and direction.

14.3. Disposition Plan Order

14.3.1. The disposition is classified basically into “Use-as-is”, “Repair” or “Rework” and “Reject”.

14.3.2. The final disposition shall be notified through QA/QC Manager to Vendor/ Subcontractor with a copy of the report.

14.3.3. When the non-conformity item is accepted as “Use-as-is” the responsible organization shall revise the relevant drawings (make as-built drawing) and/or documents.

14.3.4. When the non-conformity is accepted as “Repair” or “Rework”, the responsible organization shall prepare the repair or rework procedure for review and approval by PM and QA/QC Manager prior to the start of the work.

14.3.5. When non-conformity is decided as “Reject” the product shall be scrapped (regarded for alternative application, depending upon the conditions).

14.3.6. The results shall be confirmed, entered in the confirmation column, and reported by the responsible organization to OWNER, PM, and QA Manager.

14.4. Corrective Action
For the purpose of precluding recurrence of similar non-conformance, the information pertaining to the non-conformance is investigated, analyzed and made known to relevant engineers.

14.4.1. Preparation of Feedback Data Sheet
Information of outstanding trouble, which occurs during and after the plant construction, shall be directed to QA Manager through relevant engineers using Feedback Data Sheets in accordance with CONTRACTOR’S internal system.

14.4.2. QA Manager will examine the data sheet, and distribute them with comments on the cause and the corrective actions to the relevant groups who perform similar work.

14.4.3. Group Manager who has received Feedback Data Sheet will review the contents and initiate corrective actions to eliminate potential cause with the relevant engineers, and reflect them into the group procedure instruction, as appropriate, to make all his members know.
The result of corrective actions shall be evaluated for the effectiveness.

14.4.4. Data Sheets and the analyzed data are categorized into appropriate factors (e.g. kinds of equipment, materials, and plants) for the record maintenance.


15.1. General
This section covers the control procedure for the preparation and maintenance of the evidence of quality.

15.2. Identification,Collecting and Filling
15.2.1. Records required to be turned over to OWNER shall be defined at an early stage of the work by mutual agreement between OWNER and CONTRACTOR.

15.2.2. Records shall be classified into the following categories:
- General Documents : QA Documents, Project Documents
- Engineering Documents: Design Document, including Vendor Documents
- Procurement Documents: Requisition, PO (Un-price)
- Shop Quality Records : Manufacturing Record, Inspection and Test Record.
- Construction Records : Site Construction & Installation Record.
- Commissioning : Operation records

15.2.3. The size of record, format of record, content of file shall also be defined.

15.2.4. Records shall be legible with approved signs and the identification.

15.3. Storage, maintenance and Issuance of records
15.3.1. Records shall be identifiable, easy retrievable, and be stored in a manner and at the location to prevent to prevent deterioration or loss.

16.1. General
This section covers the procedure for audit to ensure the proper execution of quality related activities and to evaluate the effectiveness of QA Program.

16.2. Audit Procedure
16.2.1. External Audit QA Manager shall establish an external audit plan for plan of Vendor, giving consideration to the importance of items and service for which they received orders and to their past performance.
With the agreement of PM, QA manager will designate audit personnel out of his QA Staff. Audits are performed in accordance with appropriate procedures, schedules and checklists by audit personnel.

16.2.2. Internal Audit
Internal audit are performed in accordance with the predetermined schedule, which includes audits for the site work at appropriate stages. In the event that QA Manager deems necessary through routine monitoring of QA/QC activities as required by the contract, additional internal audits are to be selected.
Audits will be performed by QA Manager or personnel designated by him on the particular areas.

16.3. Audit Finding and corrective Action
Audit results shall be recorded in Audit Check List, and reported to QA manager together with Audit Summary Report. These shall be reviewed by QA Manager and sent to the audited organizations and PM with the recommendation for the corrective actions.
Corrective actions for the pointed out items shall be taken by the organization, and followed up by an auditor, where necessary.


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