QA Programme Rev.3 ,TERF

8/1/2019 QA Programme Rev.3 ,TERF

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QA Programme Construction of Transportation Engineering Projects

GENERAL QA Programme

for

Construction of Transportation Engineering

Projects

Doc. No. : TERF-001Prepare : Program Manager Review : Sr Program Manager

Approve : Program Director

3

2

1

0 DD/MM/YYYY Initial Release

Index Date Revisions Prepared Reviewed Approved


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Table of Contents

Chapter 1. Management Responsibility

Chapter 2. Quality System

Chapter 3. Document and Data Control

Chapter 4. Material Identification and Traceability

Chapter 5. Inspection and Testing

Chapter 6. Control of Nonconforming Products

Chapter 7. Corrective Action

Chapter 8. Handling, Storage and Preservation

Chapter 9. Control of Quality Records

Chapter 10. Internal Audits

Chapter 11. Training

Chapter 12. Standard Forms Indexing System

Chapter 13. Control of Inspection, Measuring & Test Equipment


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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


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Flow Chart Management by Objectives Chapter 1

Scope

All activities of the project

Procedure

Activity R A DCorresponding

Document1 Define targets and make known to all staff PM Overall Target

Schedule2 Define sub targets All Staff Work Schedule per

Department3 Strive to achieve targets All Staff

4 Evaluate target achievement All Staff Compare Planned/Actual schedule

5 Corrective action >>>continue with Chapter7

All Staff PM

6 Revise targets >>>continue with 1 PM

R = Responsible / A = Assists / D = Decides, ApprovesPM = Project Manager

Project Specific Targets

Item Target Controlling Instrument Interval Responsible

1 Costs

Meet Estimated Budgets Performance Report + Cost

Control

Monthly Planning Manager

2 Dates

Meet Programme /milestone

Updated Time Schedule Monthly Planning Manager

Weekly Reports Weekly Planning Manager

Monthly Reports Monthly Planning Manager

3 Quality

Meet Requirement ofSpecification & Drawing

Method Statement ConstructionManager / WorksManager

Reduce Inferiority Inspection and Test Plan QA Manager

4 Safety on Site

Reduce Accident List of Sick LeavesList of Accumulated

Accidents

Safety Manager

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


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1.2 Organisation

1.2.1 Organisation of the project

1.2.1.1 Organisation Chart

Figure 1.1: Organization Chart

1.2.1.2 Coordination Committee


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

1.2.2 Organization of the Site Management

Plant Manager

Document Controller

QC Engineers

Bridge Co-ordinator

Q/S

Contract Manager

contractor

Survey Engineers

Admin. Manager

Planning Engineers Field Engineers

Design ManagerPlanning Manager Construction Manager

Chief-Procurement

Admin. Staff Design Engineers


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1.2.3. Responsibilities of the Site Management

The Site Management shall act in accordance with the contract Agreement and the ContractDocuments.The Site Management shall be responsible for the due execution of the works as defined by thecontract.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. Heis responsible for ensuring the execution and the maintenance of the works according tocontractual specifications, drawings and programme of work. He is responsible for the properexecution 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 Managerhas the responsibility to

- assist the Project Manager for achieving and improving quality.

1.2.3.3 QA Managerhas 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 Managerare 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.


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QA Programme Construction of Transportation Engineering Project

1.2.3.5 Construction Engineer / Works Engineerhas 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 Managerhas 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 Managerhas the responsibility for

- 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.

1.2.3.9 Administration Managerhas 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 Managerhas the responsibility for

- Supporting the purchasing of new equipment,- Maintenance of all equipment (service and repair),- Maintenance and operation of all equipment at site.


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1.2.3.11 Safety Managerhas 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 Managerhas the responsibility to

1.2.4 Scope of Work

Sl.no. Section Contractor Scope Sub contractor Scope

1 Section-1

2 Section-2

3 Section-3

4 Section-4

5 Miscellaneous


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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 andTesting) for at least every title where quality tests are required by the contractualspecifications. The Inspection and Test Plan has to be set up by the QA Manager withsupport of organization who is in charge of the work (i.e. Construction Manager, WorksManager, 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.


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2.3 System Improvement.

If a product does not meet the contractual specifications, (also calledNonconforming Product) it must be guaranteed, that the product will meet therequirements by repairing or similar. The manner is ruled by the chapter 6 (Control ofNonconforming Products).

If there is the possibility that any mistake is repeated,

- In case of technical problems: Corrective actions have to be carried out byalteration of the regarding Method Statement and / or

- In case of organizational problems: Corrective actions have to be carried out byalteration of the regarding chapters.

Besides the issuing of corrective action requests upon detectednonconformance 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 ofquality system, the items of low level documents shall be consistent with requirementsof high level documents.

Level I

Level II

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

QA Plan

Method Statements

Including Quality / Work *Procedure,

Inspection & Test Plan


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Chapter 3 Document and Data Control

1. Purpose : To define a system for the control of document approval, issue and changes /modification.

2. Scope : 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.

3. Reference : Chapter 12 - Standard Forms Indexing System

4. Definitions :

4.1 Documents

Any written information describing requirements of activities affecting quality.Documents shall include QA Programme, Method Statement, Inspection & Test Plan andEngineering and Technical Documents. If correspondence (e.g. letter, memo etc.) mentionedserious 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 activitiesrelevant 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. Scope of Work2. References3. Description of the Work4. Responsibility5. Plant and Equipment

6. Inspection, Testing and Survey7. Safety8. Appendices

4.5 Inspection & Test Plan

Documents which contain hold point, witness point, acceptance criteria and document requiredaccording to sequence of inspection to ascertain quality.


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4.6 Controlled Copy

An identifiable copy of the QA Programme or its supporting Quality procedures and ITP which isdistributed, revised or replaced through a written Document Control Procedure that assures thedocument 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 currentrequirements. These shall be for information only and shall not be used as reference to performwork.

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., QAProgramme, 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 exceptdrawing, 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 indexingsystem.

6.1.1.1 The QA Programme shall be indexed as follows :

TEQA-XXX

TEQA = Transportation Engineering QA ProgrammeXXX = 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 = Quality Procedures / Work ProcedureXXX = 3 Digit Running Procedure Number


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6.1.1.3 The supportive Form for QP / WP shall be indexed as follows :

QP-XXX-YY / Z (e.g. QP-001-01/A). WP-XXX-YY / Z (e.g. WP-001-01/A)

QP-XXX = Quality Procedures NumberWP-XXX = Work Procedures Number

YY = 2 Digit Running Form Number / Z = Alphabet Numbering for Continuation Sheet (if there)

6.1.1.4 The Method Statement shall be indexed as follows :

CPS-X-MSP-YYY.

CPS = Construction Plan and SpecificationX = Module Number (0 for two or more modules)MSP = Method StatementYYY = 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 = Construction Plan and SpecificationX = Module Number (0 for two or more modules)MSP = Method StatementYYY = 3 Digit Running Method Statement NumberZZZ = 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 = Inspection & Test PlanXXX = 3 Digit Running ITP Number

6.1.1.7 The Internal Drawing shall be indexed as follows :

TE-SX-YY-ZZZ

TE= Transportation EngineeringSX = section 0

YY = TD : Temporary DrawingSK : SketchCS : Construction DrawingAB : As-Built Drawing

ZZZ = 3 Digit Running Drawing Number

6.1.1.8 The Calculations shall be indexed as follows :

CPS-X-CLC-YYY

CPS = Construction Plan SpecificationX = Module Number (0 for two or more modules)CLC = CalculationYYY = 3 Digit Running Calculation Number


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6.1.1.9 For sub-title and sub-paragraph, use

1. 1.1 1.2 1.3 ...2. 2.1 2.2 2.3 ...3. 3.1 3.2 3.3 ...

6.1.1.10 The document indexing system for standard forms shall be followed inaccordance 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-ZZZTE = Transportation EngineeringDML = Document Master ListMX = Module Number (0 for two or more modules)YYY = Document Type (as QAP, QPS, MSP, TCR, ITP, Etc.)ZZZ = 3 Digit Running Documents Master List Number

6.1.2.2 The Drawing Master List shall be indexed as follows :

TE-DWL-MX-YY-ZZZTE = Transportation EngineeringDWL = Drawing Master ListMX = Module Number (0 for two or more modules)YY = TD : Temporary Drawing

SK : SketchCS : Construction DrawingAB : As-Built Drawing

ZZZ = 3 Digit Running Drawing Master List Number

6.1.3 Preparation, Review and Approval

All Documents must be reviewed and approved by the respective department priorto issue.

6.1.3.1 QA Programme must be prepared by QA Manager, reviewed by PlanningManager and approved by Project Manager.

6.1.3.2 Quality Procedures must be prepared by QA Manager, reviewed byPlanning Manager and approved by Project Manager.

6.1.3.3 Method Statement / Work Procedure must be prepared by Construction

Manager or Works Manager, reviewed by Planning Manager andapproved by Project Manager .

6.1.3.4 Inspection & Test Plan must be prepared by QA Manager (or QCEngineer for HCCs independent work), reviewed by Planning Managerand approved by Project Manager.

6.1.3.5 Drawings must be prepared by Design Manager, reviewed by PlanningManager and approved by Project Manager.As built drawing control procedure (work procedure) must beprepared by design manager reviewed by planning manager andapproved by project manager.Calculations must be prepared by Design Engineer, reviewed by DesignManager and approed by Planning Manager.


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6.1.4 Distribution

6.1.4.1 The Project Manager shall mark the Document Distribution Sheet fordistribution.

6.1.4.2 After approval of Document Distribution Sheet with documents by the ProjectManager, full set of documents are filed in Master File Shelf.

6.1.4.3 All following process shall be done in accordance with Annex 1 .

6.1.5 Documents Master List

6.1.5.1 All internal and external document except drawings shall be listed up in theform of Documents Master List for identification of latest status ofdocuments.

6.1.5.2 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

6.1.5.3 The Documents Master List may be prepared for each type of documents.

6.1.5.4 The Documents Master List shall be submitted to the Engineer 2 days beforeeach Site Meeting at least.

6.1.6 Revision Control

6.1.6.1 Change to documents shall be performed by department that carried outoriginal preparation unless specifically designated otherwise.

6.1.6.2 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.

6.1.6.3 The approved revised documents shall be controlled in accordance withabove paragraph 6.1.3, 6.1.4, & 6.1.5.

6.2 External Documents

6.2.1 Receipt

6.2.1.1 Upon receipt of document, the Document Controller shall check the following :

(a) Document bear the name and approved authorities;

(b) Correct document number, revision and pages;

(c) Legibility of the document.

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


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6.2.2Review

6.2.2.1 Project Manager shall review the incoming document and comments at remarkon the column.

6.2.2.2 Document reviewed will be distributed to various department as per ANNEX 1attached.

6.2.2.3 Person who received the copied incoming document shall take an actionaccording to the comments by Project Manager.

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 MasterFiling System in Annex 2 of this chapter.

6.2.4.2 The list-up of external documents shall be done in accordance with aboveparagraph 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) List in Correspondence Logging Book(b) Submit to Planning Manager for review

6.3.1.2 Planning Manager shall perform the following :

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

6.3.1.3 Design Engineer shall perform the following :

(a) Check the correct drawing number, revision and pages(b) List in Drawing Master List(c) 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 DesignEngineer 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


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

6.3.3Distribution

6.3.3.1 The received drawings are distributed to Construction Manager / WorksManager 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 forsubcontractor. (if there)

6.3.3.4 When receive the Master Drawing List from Design Manager, this lists shall becopied by Construction Manager / Works Manager and distributed tosubcontractor for cross checking the latest status.

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

6.3.4 Control of Obsoleted Drawings

6.3.4.1 When receive the revised drawings, the Design Engineer shall check therevision status.

6.3.4.2 If there are revised drawing , the obsolete drawings in Master Drawings shall bestamped "Void" and separate storage.

6.3.4.3 When receive the revised drawings from Design Manager, the ConstructionManager / Works Manager promptly destroy the obsolete drawings afterreplacing them with revised ones to assure the latest drawings are used.

6.3.4.4 Where the Construction Manager / Works Manager require obsolete drawingsfor their retention, this may be permitted but it shall be clearly identified with theVoid stamp.

6.3.4.5 The Construction Manager / Works Manager shall perform the checking at alltimes that subcontractors are using latest drawing.

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.

6.3.5.2 The Design Manager is responsible to check for discrepancies / compliance tospecification and consultant drawings.

6.3.5.3 The Planning Manager is responsible to submit drawing to The Engineer forapproval. He shall obtain The Engineers approval letter or endorsement.

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


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ANNEX 1 - FLOW CHART OF DOCUMENT CONTROL

INTERNAL DOCUMENTS

No. ACTIVITY CONTENT OF ACTION ACTIONED BY

STEP

1.

1. Issue, Review in organization Relevant Engineer or

Personnel / ManagerDepartment Engineer

STEP

2.

1. Submit to Planning Manager for review

2. Submit to Project Manager

Document Controller

Planning Manager

STEP

3.

1. Review the content and approval

2. Assign the ref. Number taken from CorrespondenceLogging Book (Outgoing).

3. Issue for Outgoing

Project Manager

Document Controller

Document Controller

STEP

4.

1. Direct to Copy & distribute to Relevant Organisation

2. Copy & distribute to relevant organization

2. Filing at Master File Shelf

Planning Manager

Document Controller

Document Controller

BEFORE HAND OVERTO PLANNINGMANAGER

SUBMIT TO PROJECTMANAGER& ISSUE

RECEIVE THEDOCUMENTS TO BE

OUTGOING

DISTRIBUTION TORELEVANT

ORGANIZATION


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EXTERNAL DOCUMENTS

No. ACTIVITY CONTENT OF ACTION ACTIONED BY

ST

EP

1.

1. Chopping the Stamp for Circulation

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

Document Controller

Document Controller

Document Controller

Planning Manager

Planning Manager

STEP

2.

1. Review the content

2. Return to Planning Manager to circulate

3. Copy to relevant department

4. Filing at Master File Shelf

Project Manager

Project Manager

Document Controller

Document Controller

STEP

3.

1. Review the Content

2. Circulate within Department

3. Action if required

Department Manager

Department Manager

Department Engineer

RECEIPTION

SUBMIT TO PROJECTMANAGER

DISTRIBUTE TORELEVANT

DEPARTMENT


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ANNEX 2 - MASTER FILING SYSTEM

FILE NUMBERING SYSTEM

AAA - XXX - YY / ZZ

2 Digit Running File Number

ISSUED FM = From company toTO = FromMT = Maintain Document

Type of DocumentsCOR = General Correspondence (Letter)DWG = DrawingCLC = CalculationIND = The Engineers Instruction / DirectionCOV = Confirmation of Verbal Instruction / DirectionDML = Document Master ListDWL = Drawing Master ListQAP = QA ProgrammeMSP = Method StatementsQPS = Quality ProcedureITP = Inspection and Test PlanTCR = Test Certificate ReportCLC = CalculationsNCR = Nonconformance ReportWPS = Work ProcedureI & TP = Inspection & Test Procedure

COMPANY CODE , Alphabetic 3~4 CharacterNHA = National Highways Authority of India / Employer

If the type of documents or company Code are required increasing or decreasing, the new Codes will assigned byPlanning Manager.


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ANNEX 3 - SAMPLE STAMP

For Document

For Drawing

Project Name

- - 200

PMPLANADMINCONSTDESIGNW/SHOP

Project Name .

PL

AN

ENGR. SR.ENGR. MGR PM

CON

ADMN

ASST STAFF MGR

VOID

For Reference For Approval For Construction

VOID Preliminary


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QA Programme Construction of Transportation Engineering project

Chapter 4 Material Identification and Traceability

1. Purpose : To define a system for the identification and traceability of materials during all stages ofconstruction.

2. Scope : This chapter applies to the Identification and traceability of materials.

3. Reference : Table 1 - Material Identification & traceability Requirement

4. Responsibility

The Planning Manager and / or Construction Manager / Works Manager are responsible for theidentification and traceability of materials.

5. Procedure :

5.1 General Requirement

5.1.1 Material Identification

5.1.1.1 Material for permanent constructionThe project staff shall ensure the materials received at site are identical to approvedspecifications, 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 inPurchase Order for identification of Material by Planning Manager.

5.1.1.3 All materials shall be identified and segregated using label, tagging, marking orpost in warehouse or storage area.

5.1.1.4 The identification of completed works (material) is provided by the Drawings(such as Module Number, Drawing Nos., Block Nos.,) during and final

construction.

5.1.2 Document Traceability

5.1.2.1 When the Traceability is a specified requirements for specific materials, followingactivities 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 followinginformations 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 thehistory and location of materials or activities.


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TABLE 1 - DOCUMENT IDENTIFICATION & TRACEABILITY REQUIREMENTS

Item No. Document Name Required Identification

A Project Files and relevant documents /correspondence inside the file

Project Name Reference No. Issuing Date

B Supplier File (P.O. / Agreement) Project Name Name of Supplier Purchase Agreement Number

C Subcontractor File (P. O. / Agreement) Project Name Name of Subcontractor Purchase Agreement Number

D QA Programme / Method Statement/ Quality Procedure / Work Procedure

Project Name Date of Release Name of Person for

preparation Name of Person for review

E Inspection / Test Reports Project Name Type / Reference Number Location Date Name, Title and Signature of

Inspector


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TABLE 2 - MATERIAL IDENTIFICATION & TRACEABILITY REQUIREMENTS

Item No. Material Required Identification

1 Cement Batch No on bag / MTC / D.O(indicating MTC No.)

2 Coarse Aggregate Lab. Certificate3 Sand Lab. Certificate

4 Reinforcement MTC / D.O (indicating MTC No.)5 Stainless Steel MTC / D.O

6 Bearings MTC / Inspection Release Note /Tag. No. with Bearing

7 Expansion Joint MTC / D.O

8 Concrete Admixtures Supplier / Manufacturer Name /Brand Name /Batch No. on containers / MTC

9 Structural Steel MTC / D.O (indicating MTC No.)

10 Reinforced Cement Concrete Pipe MTC / Inspection Release Note

11 Epoxy Mortar MTC for each batch

12 Anchor Bolt & Nut MTC / D.O

13 Connection Bolt & Nut MTC / D.O

14 Ladder, Handrail, Material accessFacilities

MTC of basic material / D.O

15 Steel Pipe MTC / D.O (Indicating MTC No.)

16 Prestressed Steel Reinforcement Test Certificate

17 Anchorages & Tendon Couplers Test Certificate

18 Equipment Calibration CertificateTag No. with validity date

19 Concrete Concrete Requisition Slip /Delivery Slip (indicating location,starting time and delivery time) /Grade of Concrete / Slump

20 Grouting Material Batch No. on bag. /MTC / D.O (indicating Batch No.)

21 Paint MTC / D.O

22 Welding Electrode MTC / D.O

23 Bitumen MTC / D.O


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MTC = Mill Test Certificate

D.O = Delivery Order


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Chapter 5 Inspection and Testing

1. Purpose : To define the system for the inspection and testing of materials / works to specifyrequirements and the necessary controls to achieve and maintain the requiredstandard.

2. Scope : This chapter applies to the Transportation Engineering project for Inspection & Test

activities.

3. Reference : chapter 4 - Material Identification and traceabilitychapter 6 - Control of nonconforming Productschapter 7 - Corrective Action.Applicable Method statement.

4. Responsibility

4.1 The QA Manager is responsible to ensure that materials / works are duly inspected and tested tospecified requirements, and necessary controls are taken to achieve and maintain the requiredstandard as per contractual specification.

4.2 The QC Engineer is responsible for the proper identification of inspection and test status andensuring that only materials that has passed the required inspection and test are dispatched orused.

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 aremet.

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 thesubcontractor. Construction Manager / Works Manager will request the subcontractor to complywith the QA programme and:

4.6.1Subcontractor should be responsible for their own testing and inspection. Report and findingsof 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 thatsubcontractor 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 The QA Manager shall ensure that Inspections & Tests, including those submitted bysubcontractors, are carried out in accordance with the Inspection & Test Plan [ITP].

5.1.2 The QA Manager shall ensure that all relevant contractual specifications and methodstatement 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 receivinginspection.

5.1.4 The Project Manager shall check the above prior to approving the Inspection & Test Plan.


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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 thatthe 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 thecontractor for record and monitoring. QA Manager will carry out periodic check toensure 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 andtested 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 totheir 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, areinspected in accordance with the Inspection & Test Plan. He shall also ensure thespecified records are maintained.

b) No works shall be released until all the activities specified in the Inspection & TestPlan for Materials and Works have been satisfactorily completed and the associatedrecords 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 testreports for all materials and completed works, including those of thesubcontractors.

5.3.2 The test reports shall be reviewed based on the acceptance criteria set in theInspection & Test Plan.

5.3.3 The QA Manager / QC Engineer shall endorse on all test reports, including those ofthe subcontractors, that have been reviewed.

5.3.4 If the materials / works fail to meet the criteria, chapter 6 shall apply.

5.4 Use Of Un-inspected Materials

5.4.1 In the event, materials are not inspected due to urgent production purposes, theProject Manager shall authorize the QA Manager to draw samples and the lots shallbe positively identified. The location where the materials are used shall berecordedin 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 worksshall be put on hold pending decision by Material Review Meeting. Reference shallbe made to according the chapter 6 control of nonconforming Product.


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5.5 Summary Of Inspection & Test Responsibility

StageInspection

ItemRef. Quality Plan

ResponsiblePerson

Quality Records

R.I Material - PurchasingSpec.

- ITP for Material

QC Engineer Delivery Order withAccepted / RejectedMarks

I. I Works inProgress

ITP for Works QC Engineer Inspection / TestReports

F. I FinishedWorks

ContractSpecification

QA Manager /QC Engineer /subcontractor

Inspection / TestReports

R. I = Receiving InspectionI. 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 Accepted Rejected

A. ReceivingInspection

Materials are placed onthe location indicated inthe project facilitieslayout plan

Tag a Rejected sign orsegregated rejectedarea

B. ConstructionProcess

Mark X on rejected areaon relevant layoutdrawings

C. Finished Works No defects listed in unitlayout plan

Described on Punch list


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Chapter 6 Control of Nonconforming Products

1. Purpose : To define a control and review system to prevent the inadvertent use or release ofnonconforming materials / works and to reach a consensus on the disposition of them.

2. Scope : This chapter applies to the Transportation Engineering Project to the materials,

intermediary and final works.

3. Reference : chapter 5 - Inspection & Testing

4. Responsibility

4.1 The QC Engineer shall be responsible for the control of nonconforming materials / works andpreventing the inadvertent use or release of nonconforming materials / works.

4.2 The QA Manager that manages the respective inspection and test of materials, intermediary andfinal works shall ensure that the identification, segregation and documentation of nonconformingmaterials / 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 SegregationThe nonconforming materials / works shall be identified as per chapter5 (Inspection andTesting).

5.1.2 DocumentationThe descriptions and data of the nonconforming materials / works shall be recorded in theNonconformance Report.

5.1.3 NotificationRecommended corrective action will be initiated by the QA Manager and taken by theorganisation responsible for the nonconforming materials / works.

5.2 Review and Disposition

5.2.1 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.

5.2.2 Roles and Authorities

Each member with practical expertise in his discipline is authorized to make decisionwithin his discipline.

5.2.2.1 Project Manager shall advise on the feasibility of rework, the impact on projectschedule and storage issues. He shall make the final decision on disposition of allnonconformances.

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 onthe cost impact, specification and contract implications. He shall liaise with the

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Engineer and / or the supplier / subcontractor on the nonconformances fornecessary 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 correctingthe nonconformance, if the materials or works are determined to be satisfactory fortheir intended purpose and such use is acceptable to the Engineer.

(b) Repair

To carry out minor rectifications / repair work on nonconformity, it shall be inspectedby 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. (Reworkedmaterials / 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 giveaccurate and practical advice. A group consensus on the disposition and correctiveaction shall be reached. In the event of any dispute, the matter shall be referred tothe Project Manager.

5.2.4 Documentation

The "Nonconformance Report" shall be prepared by personnel who foundnonconformance. The Project Manager shall ensure that reason to justify the groupdecision on the disposition to "use as it is" is documented in the report. Thenonconformance report shall be submitted to the Engineer for approval of proposeddisposition immediately.

5.2.5 Corrective Action

5.2.5.1 The Project Manager shall ensure that corrective action is taken by theorganisation (i.e. Vendor or staff etc.) who is responsible for thenonconforming 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 tothe 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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QA Programme Construction of Concrete Cable Stayed Bridge across River Yamuna atAllahabad/Naini

Chapter 7 Corrective Action

1. Purpose : To define a Corrective Action System to ensure that the root cause ofnonconformance is promptly analyzed and effective corrective actions are takento prevent recurrence.

2. Scope : This chapter applies to all organizations.

3. Reference : chapter 3 - Document & Data Controlchapter 6 - Nonconforming Product Controlchapter 10 - Internal Quality Audit

4. Procedure

4.1 Responsibility

4.1.1 The responsible department manager for the nonconforming product shall ensure thatroot cause of nonconforming product is promptly analyzed and effective corrective

actions are taken to prevent recurrence.

4.1.2 All staff has the responsibility to identify any potential product quality problem and initiatepreventive actions to prevent its occurrence.

4.2 The Engineer Complaint / Corrective Action

4.2.1 The Project Manager shall be responsible to take the appropriate action upon receipt ofcomplaint / feedback from the Engineer either in writing or verbal. In case of verbalcompliant from the Engineer, the The Engineer Complaint Report to be initiated by whoreceived complaint from the Engineer. Either way, the complaints shall be reported to

the responsible department manager.

4.2.2 Responsible department manager shall report to Project Manager or his related and holdthe meeting with related functional Department Manager, if required.

4.2.3 Responsible department manager shall participate jointly with other related functionaldepartments in identifying the root cause to the complaint and initiating correctiveactions of the problem.

4.2.4 If the root cause of the nonconformity shows that it was originated from the suppliedmaterial, clause 4.3 of this chapter shall follow.

4.2.5 The responsible department manager shall take necessary actions promptly and ensurethat the corrective actions are effective to prevent recurrence of the problem.

4.2.6 The Project Manager or his delegate shall follow-up on the corrective actioncommitment, verify the implementation.

4.2.7 The responsible department manager shall feedback to the Engineer, the correctiveaction taken if requested by the Engineer.

4.2.8Upon receipt of the Engineer positive reaction to the feedback given, the Project Manager orhis delegate shall close the case. For verbal complaint, Project Manager or his delegateshall complete the The Engineer Complaint Report. For written complaint, ProjectManager or his delegate shall write back to the Engineer to report completion ofrectification works.


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Chapter 8 Handling, Storage and Preservation

1. Purpose : To define methods or system for handling, storage and preservation of products toprevent damage, deterioration, or loss and final inspection and hand over ofcompleted project.

2. Scope : This chapter applies to Transportation Engineering Project.

3. Reference : Applicable method statement.

4. Responsibility

4.1 The Construction Manager / Works Manager is responsible for the proper handling andprotection of materials / works at all stages.

4.2 The Field Engineer is responsible to ensure material in such a way that they do notsuffer damage, deterioration or loss.

4.3 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.

5. Procedure :

5.1 Handling

5.1.1 All operators of handling equipment, that is, excavator/crane, etc. shall beexperienced

in the proper use of the equipment. Field Engineer shall ensure that workers involvedin handling and transportation activities observe the applicable method statement.

5.1.2 The following table shows the Handling Precautions (Dos & Dont):

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.

Material/Product

HandlingEquipment

Precaution(Dos & Dont)

Re-bar

Bag Cement

Pipe

Equipment

The Others

crane

Forklift, crane

Crane

Crane/Lift

Manufacturersinstruction

1. During hoisting, ensure proper balancing2. & securing of the load

3. Do not wet the bags4. Do not burst/puncture the bags

5. Bundle tightly

6. Bundle tightly

Follow Manufacturers instruction toprevent damage


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5.2.3 The QC Engineer shall conduct a monthly assessment of the stock condition. He shalluse the Stock Condition Assessment Checklist / Report to perform the assessment

The following table shows the Storage Precautions (Dos & Dont) :

Material /Product

StoragePrecautions (Dos & Dont)

Location Method

Re-bar Open store on timber runners or concretebar

Do not mix difference dias.Cover with canvas in bad weatherDo not block access to vehicles

BagCement

Sheltered Store Placed on palletslifted 300mm aboveground

Do not allow contact with moistureDo not exceed 10 bags stacking

Pipes Open on timber runners Ensure that wooden frames at eachend are secured for thin walled pipes

TheOthers

Manufacturersinstruction

Manufacturer'sinstruction

Follow Manufacturers instruction toprevent damage

5.3 Packaging and Preservation

5.3.1 The Construction Manager / Works Manager or his delegate (e.g. Field Engineer, orsubcontractor) shall ensure that the completed project / works and completed worksby subcontractors are protected to ensure conformance to customer.

5.3.2 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 fromunauthorized use, damage and deterioration.

5.3.3 Additional protection measures arising from or required to meet contractualrequirements shall be observed.

5.3.4 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.

5.4 Delivery

5.4.1 The Project Manager or his delegate shall plan and coordinate the final inspection /testing of all services and facilities by relevant authorities.

5.4.2 The Project Manager or his delegate shall assign the Engineer / QC Engineer tocarry out final defect checking with respective subcontractors. The Punch List shallbe prepared. The Project Manager or his delegate shall verify and carry out randomcheck on the inspected units.

5.4.3 Punch list shall be rectified by the responsible organisation. All defects due tosubcontractors shall be rectified by the respective subcontractors.

5.4.4 The defective areas shall be re-checked by the Field Engineer and subcontractor toensure the defect has been rectified.


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5.4.5 The QA Manager or his delegate for the Engineers representative to inspect theworks, it shall be done after defective areas have been rectified.

5.4.6 The Project Manager or his delegate shall prepare and compile the necessary documentssuch as Warranty Certificate / Test Certificates for the Engineer.

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


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Chapter 9 Control of Quality Records

1. Purpose : To define controls for the identification, collection, indexing, filing, storage,maintenance and disposition of quality records.

2. Scope : This chapter applies to the Project.

3. Reference : chapter 3 - Document & Data Control

4. Responsibility

4.1 The Managers (See table 1) are responsible to provide instruction for the completion andstorage of quality records that must be kept for historical purposes. He is to ensure qualityrecords are legible and identifiable to the products and every alteration made on the qualityrecord 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 ofQuality 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 readilyavailable 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 Accessing of Quality records shall be approved by the Authorized staff and recorded inthe record accessing log.

5.1.3 Records shall be segregated, logged and boxed as of the last working date of the fiscalyear, or their warrant periods.

5.1.4 Records shall be stored and maintained in facilities that allow easy retrieval and providesuitable environment to minimize deterioration or damage and to prevent loss.

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

5.1.6 Subcontractor will be contacted regarding disposition of their records when specified inthe contract.


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Table 1 - List of Quality Records

Index of FormNumber

Description of Quality Records / Form Retention Time Location & Responsiblemanager of File

QP-009-01 Minutes of Meeting - Management Review Until finish theProject

Planning

QP-009-26QP-009-28

Audit PlanAudit Summary Report

Until finish theProject QA

QP-009-20QP-009-21

The Engineer Complaint ReportInternal Corrective Action Request

Until finish theProject QA

QP-009-05

QP-009-07

Documents Master List

Drawing Master List

Until finish the

Project

QA

Design

- Inspection and Test Report Until finish theProject

QA / QC

QP-009-18 Nonconformance Report Until finish theProject

QA

QP-009-32QP-009-33

Training PlanTraining Attendance Record

Until finish theProject

QA

-----

QA ProgrammeQuality / Work ProcedureMethod StatementCalculationTest Certificate Report


QA

- DrawingsUntil finish theProject

Design

- Contract Specification(including Technical Spec.)


Planning


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Chapter 10 Internal Quality Audits

1. Purpose : To define a system for the conduct of Internal Quality Audit to verify whether qualityactivities and related results comply with planned arrangements and to evaluate theeffectiveness of the implementation of the Quality System.

2. Scope : This chapter applies to the Transportation Project.

3. Reference : Nil

4. Definitions

4.1 Audit Team Member is a person who has the qualification and is authorized to perform aQuality System audit.

4.2 Audit Team Leader is a person who has the qualification and is authorized to manage a teamof Auditors.

4.3 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 HeadOffice Audit Team is not available for the site, the Project Manager shall appoint PlanningManager (for QA Department) and QA Manager (for the other organization) as Auditor. In thiscase, forms for audit may be used standard forms in Transportation Engineering Projectprocedure (Standerd forms for QA procedure : QP-009).

5.2 The QA Manager

- 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 HeadOffice Audit Team is not available for the site).

5.3 The Audit Team Leader shall oversee the internal quality audit activities and enforce theimplementation of outstanding corrective actions. He shall report to the Project Manager on thefindings of each auditing cycle.

5.4 The Audit Team Member is to carry out the instructions as layout by the Audit Team Leader.

5.5 The individual Department Manager responsible for the area audited shall review, agree andcorrect the Audit Finding items. He shall ensure the effectiveness of the corrective actions.


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6. Procedure :

6.1 The detail procedure of Internal Quality Audits shall be done in accordance with latest versionof Head office Internal quality audit procedure.

6.2 The Department Manager shall take action on the Audit Finding Report until the

recommended date in those request sheet.

6.3 After completion of Audit Finding Report, the Project Manager shall review and signed onthose report and this report sent to Head Office.

6.4 The QA Manager is responsible to ensure that the Quality System of the Project is implementedand maintained.

6.5 All copy of reports related to the Internal Quality Audit shall kept (filing) by QA Manager forusing the back-data of Coordinate Committee Review.


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Chapter 11 - Training

1. Purpose : To define the system for identifying the training needs and providing for thetraining of all personnel performing activities affecting quality.

2. Scope : This chapter applies to the Transportation Engineering Project overseeing thetraining need of staff performing activities affecting quality.

3. Reference : Nil

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 trainingrecords.

5. Training needs identified :

TrainingCourse no.

Description Training Training Method Remark

1 New System Introduced All staff Education

2

Use new tech. & methodCube test control

Con. staff Education or OJT orExercise

3New recruitmentImplementation of Regulation- Safety course

RecruitmentAll worker

OJT (On-Job-Training)Training on commission


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Chapter 12 Standard Forms Indexing System

1. Purpose : To define the system for identifying the indexing system for standard forms.

2. Scope : This chapter applies to the Transportation Engineering Project.

3. Reference : QP-009 Standard forms for QA (Quality Assurance)

4. 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 = 1 Digit Running Module Number (0 for two or more modules)YYY = 3 Digit Running FCN (FCR) Number

5.2 Punch List for Hand-Over

PNC-MX-YYY

MX = 1 Digit Running Module Number (0 for two or more modules)YYY = 3 Digit Running Punch List Number

5.3 Nonconformance Report

CPS-X NCR-YY

X = 1 Digit Running Module Number (0 for two or more modules)YY = 2 Digit Running NCR Number

5.4 The Engineer Complaint Report

ECR-MX-YYY

MX = 1 Digit Running Module Number (0 for two or more modules)YYY = 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


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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 = 2 Digit Running ACAR Number

5.9 Memo

TERF X / YYY

X = First Letter of Department(e.g D : Design, C : Construction, P : Planning, A : Admin etc)

YYY = 3 Digit Running Memo Number


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Chapter 13 Control of Inspection, Measuring & Test Equipment

1. Purpose : To define a system for the calibration of inspection, measuring and test equipment.

2. Scope : This chapter applies to the inspection, measuring and test equipment used by TEProject. The applicable equipment are those listed in the "Master list of

Inspection / Measuring / Test Equipment" (see Attachment 6.1).

3. Reference : Not Applicable

4. Responsibility

The QC Engineer shall have the main responsibility to supervise and co-ordinate all calibrationservices 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 assurethat each equipment meets the specification and performance test.

5.1.2 He shall ensure that the equipment is logged in the Master list of Inspection /Measuring / Test Equipment and arrange for external calibration as appropriate.

5.2 Existing Equipment Control

5.2.1 The QC Engineer shall ensure that the Master list of Inspection / Measuring / TestEquipment is generated for review monthly (on the first week of each month) and eachitem on the list shall be physically identified and traceable to the list.

5.2.2 He shall decide the frequency of calibration, review the master list for any equipmentcurrently in use which is due for calibration and arrange for external or internalcalibration as appropriate.

5.2.3 He shall ensure that only calibrated equipment shall be used.

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 foridentification purposes. Equipment that does not bear a serial number is assigned aidentification 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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5.3.4 Equipment Calibration Procedures

For routine measuring equipment, such as steel rulers and measuring tapes, areexempted from calibration.

5.3.4.1 For task identified in the QA Plan as requiring controlled measuring or testequipment, 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 acceptablestate of calibration. All such equipment shall be labelled, marked or engraved.Non-controlled equipment is identified by the absence or such label, mark orengraving.

5.3.5 Calibration Reports / Certificates

The QC Engineer shall ensure the external and internal calibration reports / certificatesare 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 environmentalcondition, in accordance with manufacturer's recommendation (if any) and wherenecessary in a dry, clean and cool place free from mechanical damage, impact andshock. User shall not adjust or temper with the calibrated equipment to invalidate thecalibration settings.

5.3.7 Measurement Accuracy and Precision

The user and / or his superior shall ensure that the inspection / measuring / testequipment 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 thefault 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 iscompletely repaired / calibrated prior to further use. He shall review the need to revisethe frequency of calibration of such equipment and ensure that the calibration is carriedout 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) The works measured by the faulty equipment shall be identified.

(b) Their parameters shall be re-validated starting from the latest by another piece ofequipment certified to be of good condition. The re-validation will stop at theworks that show satisfactory results.


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(c) If necessary, a meeting shall be held amongst the QC Engineer, to discuss thedisposition of the non-conforming works.

The affected works shall be verified with the client to determine if :

(i) Works still within design requirement;(ii) Works comply with requirements with recommended improvements;

(iii) Works must be reconstructed.

QA Programme Rev.3 ,TERF

Documents

Transcript of QA Programme Rev.3 ,TERF