The purpose of this procedure is to establish the system for initiating, processing, and controlling Nonconformance Reports and Stop Work Notices.

Transcription

1 Project Procedure 09/21/2012 PAGE 1 OF PURPOSE The purpose of this procedure is to establish the system for initiating, processing, and controlling Nonconformance Reports and Stop Work Notices. 2.0 SCOPE This procedure applies to both Pike and subcontracted work. 3.0 REFERENCES 3.1 Project Procedure P 1 7, Technical Document Control (Construction Site) 4.0 DEFINITIONS 4.1 Unsatisfactory: Any item, condition, or material that deviates from contractual documents, engineering drawings or specifications, but that can be corrected within the scope of such documents. 4.2 Nonconformance: Any item, condition, or material that deviates from contractual documents, engineering drawings, or specifications and that cannot be corrected within the scope of such documents or otherwise requires input from the Project Management or Design and Engineering to resolve. 5.0 RESPONSIBILITIES 5.1 The Project Manager or the Construction Site Supervisor is responsible for the following: Approval of dispositions for nonconformances Authorization for Stop Work Notices 5.2 The QA/QC Manager or the Site Quality Control Manager is responsible for the following: Determine, in coordination with the Project Management, when a problem constitutes an unsatisfactory or nonconformance condition.

2 PAGE 2 OF 5 Initiate Nonconformance Reports (NCR) and Stop Work Notices (SWN) (see Section 8.0 for forms) as conditions warrant. Identify in conjunction with engineers, inspectors, and craft supervision nonconforming material, parts, components, or installations at the construction site. Initiate closure inspection of nonconformance reports to verify corrective actions have been completed in accordance with approved disposition instructions. 5.3 The Project Engineer or the Project Manager is responsible for the following: Determine and assign dispositions for nonconformances. Maintain site files for required NCR and SWN records. 5.4 The Construction Site Supervisor is responsible for the following: Determine and assign dispositions for nonconformances (with input from the design engineering agency, where applicable). Maintain site files for required NCR and SWN records. 6.0 PROCEDURE 6.1 SUBCONTRACTED WORK The Site Quality Control Manager shall assure performance of inspections and verifications to ensure Subcontractor work complies with the engineering design and the Contract requirements. Upon notice of an unacceptable condition, the Site Quality Control Manager shall determine, in conjunction with the Construction Site Supervisor and the Subcontractor, whether the condition warrants a NCR If the condition is determined to be an Unsatisfactory (i.e., correctable within the scope of existing requirements), the Site Quality Control Manager shall advise the Subcontractor to correct the problem and record the action taken in accordance with the Subcontractor s approved procedures If the condition is determined to be a nonconformance, the item shall be processed for resolution in accordance with Section 6.3, Nonconformances. 6.2 DIRECT HIRE WORK Upon identification of an unsatisfactory item or condition, or notification from the QA/QC Manager or the Site Quality Control Manager of an unsatisfactory item or condition, the responsible Engineer or Construction Supervisor shall take appropriate actions to correct the problem.

3 PAGE 3 OF The resolution of unsatisfactory items or conditions shall be noted on (or as an attachment to) the associated Quality Form found in Section 8.0 (e.g., QF 1 6 A, Nonconformance Report and QF 1 6 C, Stop Work Notice). Items or conditions that cannot be corrected within existing design requirements shall be processed for resolution in accordance with Section 6.3, Nonconformances. 6.3 NONCONFORMANCES When an item or completed work is presented for inspection and determined to be a nonconformance, the QA/QC Manager or the Site Quality Control Manager or qualified designee shall originate an NCR (Form QF 1 6 A), and apply a Reject Inspection Tag (Form QF 1 6 B), where practical. After completing the required data, the NCR shall be forwarded to Project Management and the Construction Site Supervisor Project Management and the Construction Site Supervisor or designee shall process the NCR for resolution as follows: a. The NCR shall be reviewed with the originator for completeness and applicability and an NCR number assigned. b. Project Management and the Construction Site Supervisor or designee shall maintain Form QF 1 6 D, NCR log (see Form 8.4), indicating the status of NCRs in process and a file of open reports. c. Project Management and the Construction Site Supervisor shall complete the instructions for disposition of the nonconforming condition and obtain concurrence from the design engineering agency for NCR dispositions of accept as is or repair. d. Upon review and acceptance, the NCR log shall be updated with the disposition assigned date and identification of the individual to whom the disposition action is assigned. The original NCR shall be retained in the Open file and copies provided to the Project Management, Construction Site Supervisor, the Site Quality Control Manager, and others, as required Upon completion of the disposition instructions (corrective action), the party responsible for the correction shall notify Project Management and the Construction Site Supervisor, who will sign and date the original in the open file, update the NCR log, and forward a copy of the completed NCR to the Site Quality Control Manager for verification and close out The QA/QC Manager and/or the Site Quality Control Manager shall initiate a reinspection to verify satisfactory completion of the disposition of the NCR, sign off the

4 PAGE 4 OF 5 original NCR if the remedial work is satisfactory, remove the Reject Inspection Tag (if applied), update the NCR files, and make a copy of the NCR and file the copy with the quality control records. Note: If construction activities are controlled under a Subcontractor s quality control program, a system may be established, prior to the Subcontractor starting work, to use the Subcontractor s NCR form (or equivalent document) to resolve nonconforming conditions. This system shall be identified in the Project Execution Plan or site memorandum. 6.4 STOP WORK NOTICES In situations where the Project Management, Quality Control Inspector, Construction Site Supervisor, or Site Quality Control Manager determines that continued work would cause damage, jeopardize the safety of personnel, preclude subsequent inspection, or make corrective action ineffective, the Project Manager and the Construction Site Supervisor shall be advised of the condition and an authorization requested to issue a Stop Work Notice (SWN) (see Form QF 1 6 C in Section 8.0). Note: When a potential stop work condition or situation is observed that, in the judgment of the Project Management, Quality Control Inspector, Construction Site Supervisor, or Site Quality Control Manager warrants direct action and the Project Manager and the Construction Site Supervisor are unavailable, a verbal stop work order may be issued immediately and be subsequently followed up with the written SWN and concurrence of the Project Manager and the Construction Site Supervisor The Construction Site Supervisor or the Site Quality Control Manager shall initiate the SWN, providing details concerning specific work activities that are to cease; the area, location, boundaries, and components to which the stop work action applies; and the reason(s) for the action. After the SWN is approved, copies shall be distributed to affected parties. Once issued, activities noted on the SWN shall cease immediately. These activities shall not be resumed until the SWN is rescinded When the resolution of the stop work condition has been effected, via the SWN, the Site Quality Control Manager shall assure that the details of the disposition are understood by the responsible personnel and, with the concurrence of the Construction Site Supervisor, rescind the SWN. Upon completion of the disposition action, the Site Quality Control Manager shall close out the SWN in accordance with Section 6.3, Nonconformances.

5 PAGE 5 OF ATTACHMENTS None 8.0 FORMS The following forms are quality records and shall be maintained in the Project file. 8.1 Quality Form QF 1 6 A, Nonconformance Report 8.2 Quality Form QF 1 6 B, Reject Inspection Tag (typical example) 8.3 Quality Form QF 1 6 C, Stop Work Notice 8.4 Quality Form QF 1 6 D, Nonconformance Report/Stop Work Notice Log 9.0 REVISIONS AND APPROVALS Revision Level Revision Revision Description Department Head (Approver) 0 01/15/2010 Original Issue Brian R. Hay 1 07/26/2011 Updated logo and company name N/A 2 09/21/2012 General updating and editing Brian R. Hay

6 FORM 8.1 PAGE 1 OF 1 NONCONFORMANCE REPORT Project: Job Number: NCR No.: Client: Description: Data Sheet/Rev.: System No.: Location: Sub System No.: Drawing/Rev.: Sub System Description: : Vendor Name: P.O. No.: Shop Field Other Specification Nonconformance Issue Drawing Nonconformance Issue Vendor Const. Code Nonconformance Name I Section Vendor I Para Mark No. Reject Tag Initiator Request Disposition From Completion Deadline Condition Details Approved NCR CONDITION Condition Details (use separate sheet if necessary) DISPOSITION Disposition Assigned To Action Accept As Is Scrap Rework Repair Return to Vendor Disposition Details (use separate sheet if necessary) Project Engineer or Resident Engineer Project Manager or Construction Site Supervisor Other Planned Completion Rework Complete Signature NCR Closed Site Quality Control Manager Client Quality Form QF 1 6 A, Rev. 1 Last Revised: 07/26/2011 Project Number: Project Procedure P 1 6 Page 1 of 1

7 FORM 8.2 PAGE 1 OF 1 Project Job No. REJECT INSPECTION TAG Item Identification/Description NCR No. Signature Quality Form QF 1 6 B, Rev. 1 Last Revised: 07/26/2011 Project Procedure P 1 6 Project Number: TYPICAL EXAMPLE

8 FORM 8.3 PAGE 1 OF 1 STOP WORK NOTICE Project: Job Number: SWN No.: Client: Description: Data Sheet/Rev.: System No.: Location: Sub System No.: Drawing/Rev.: Sub System /Time: Description: Contractor: Contract No.: You are directed to Stop Work immediately on: (use separate attached sheet if necessary) For the following reasons: (use separate sheet if necessary) Project Manager or Construction Supervisor and Engineer or Site Quality Control Manager Construction Manager and Time Problem Resolution Work Resumption Authorization Project Manager or Construction Supervisor and Engineer or Site Quality Control Manager Construction Manager (Client) Distribution Quality Form QF 1 6 C, Rev. 1 Last Revised: 07/26/2011 Project Number: Project Procedure P 1 6 Page 1 of 1

9 FORM 8.4 PAGE 1 OF 1 NONCONFORMANCE REPORT/STOP WORK NOTICE LOG Project: Job Number: Location: Client: NCR/SWN Number Issue Issued By Subject/Item Number Closed Remarks Quality Form QF 1 6 D, Rev. 1 Last Revised: 07/26/2011 Project Number: Project Procedure P 1 6 Page 1 of 1