Quality Control Manual DOCUMENT NUMBER 15

Transcription

1 Quality Control Manual DOCUMENT NUMBER 15

2 Table of Contents 1. Distribution Scope Definitions Principal Characteristics of the Quality Management System Quality Policy Primary Activities Documented Procedures Product Realisation Responsibility and Authority Organisational Structure Monitor, Measure and Analyse the Processes for Service Provision (ISO 9001 Section 8) Continued Improvement of these Processes Amendment Record Records... 7 Document Owner: Quality Department Page 1 of 7

3 1. Distribution This document is distributed in hardcopy and is available to all NOVA Plant Services employees. Electronic copies of this document will be made available in.pdf form. 2. Scope This Quality Manual provides a central layout of the Quality Management System for NOVA Plant Services and a reference to all the components and aspects not contained in this document. It fulfils the requirements of Section of ISO 9001 upon which this system is based. The management, control and coordination of work requests placed on NOVA Plant Services in respect of industrial insulation, corrosion prevention (Painting), scaffolding and heat tracing. The specific aspects covered are listed below: Generation of Job Card (JCE) Preparation of quotation Allocation of work to subcontractor Final inspection and confirmation of satisfactory completion Closure of job card and invoice generation Submitting invoice Administering payment confirmation and payment of subcontractor Exclusions: Design and development All services provided and managed by NOVA Plant Services are designed by the customer who prescribes all requirements and specifications. These are reviewed and affirmed annually when the service contract is renewed. 3. Definitions Client s Agent Job Cost Estimate Management Quality Control Program Quality Inspector Self-Bill Invoice The person appointed by the client who is duly authorised to generate Job Cost Estimates and allocate such requests to NOVA Plant Services for attention. Costing request created by the client on their commercial program required for generating a purchase order This includes all line managers from Supervisors through to Directors. Each category acts and input at their respective level A program developed in terms of the Quality Control Program Instruction. This document governs the interaction between NOVA Plant Services, the client and all third parties and specifies the hold-points, authorities for release and final acceptance requirements The person appointed by NOVA Plant Services to inspect and verify the workmanship and conformance to requirements of insulation and painting work performed by NOVA Plant Services Invoice created by the client on their commercial program to ensure electronic payment Document Owner: Quality Department Page 2 of 7

4 4. Principal Characteristics of the Quality Management System The Quality Management System consists of a basic 3-tier documented system. The system is logically structured to ensure ease of access to obtain relevant information and to aid in the automatic flow of actions and paperwork, resulting in conformance and customer satisfaction. The documented system is set up as follows: Top Level o This level of documents consist of the Quality Manual, Quality Policy and Procedures. These documents define the core of the relevant quality management principles and generally require top management to implement, manage and amend the aspects governed by it. It also provides the frameworks within which the next level of quality control measures are defined Middle o This level of documents consists of the instructions and records. These documents define the specifics of how the job is done and what information and parameters are captured to verify performance and conformance. Middle management normally implements, manage and amend the aspects governed by it. Base Level o This level of documents consists of guidelines and supplementary information pieces. These documents are normally more detailed and may include other information relating to aspects such as safety and explanations of sub-procedures. o Where work is sub-contracted, the minimum requirements for quality service provisions are provided to the sub-contractor in a guideline. 5. Quality Policy The Quality Policy and the Quality Objectives are defined and set out in the Quality Policy. Management commitment to uphold this policy is also defined in the Quality Policy. 6. Primary Activities The main processes of NOVA Plant Services are listed below. The sequence and interaction of these processes are illustrated in Appendix 1. The relevant criteria and methods needed to ensure that both the operation and control of these processes are effective are defined in the procedures, instructions and guidelines developed in terms of the Document Control Procedure. Scaffolding o General scaffolding o Specialised scaffolding Insulation o Hot insulation o Cold insulation o Sheet metal fabrication o Specialised insulation Painting o As per client specification Document Owner: Quality Department Page 3 of 7

5 o Specialised painting Sandblasting o Grit blasting o Shot blasting o Glass blasting o Micro blasting Heat Tracing o Electrical heat tracing on piping and vessels Administration o Processing request for quote (RFQ) o Preparation of Job Cost Estimate (JCE) o Processing order execution and controlling the process o Closing out the job and generating invoices o Processing payments (DT & CT)o 7. Documented Procedures The structure of the documentation for this Quality Management System is discussed in Section 4 of this document Where to look and find the procedures on how to do things o All controlled documents are managed in terms of the Document Control Procedure. Each document has a Distribution Register which clearly indicates where all controlled copies of those documents are kept. Generally the relevant documentation is available from the line manager who manages the work governed by the relevant document. Records required by this International Standard (4.2.4.) o All records that need to be completed when one performs controlled work are indicated by the relevant procedures, instructions, orders and QCP s governing and related to that job. The application and sequence of completion is given in the section providing the administration requirements. Communicating to the organisation the importance of meeting customer as well as statutory and regulatory requirements o Each individual undergoes Quality induction when NOVA Plant Services employs them. Two induction modules are available, one targeted at supervisory personnel and one at worker level. Managers undergo training in all aspects of the Quality Management System. All line managers confirm their awareness and understanding of the Quality Management System by signing the Commitment Statement provided in the Quality Policy. Document Owner: Quality Department Page 4 of 7

6 8. Product Realisation Planning (ISO 9001 Section 7.1) o These requirements of the standard are defined in the Quality Control Program Instruction which is clearly referred to in all the relevant work instructions Customer related processes (ISO 9001 Section 7.2) o These requirements of the standard are defined in the Quality Control Program Instruction which is clearly referred to in all the relevant work instructions Design and development (ISO 9001 Section 7.3) o NOVA Plant Services does not design or develop any products and services independently. As a rule, the customer prescribes the specifications, procedures and methods. The design and development in which NOVA Plant Services a part is limited to the application and implementation of said prescribed specifications. These aspects are covered in the Quality Control Program Instructions Procurement (ISO 9001 Section 7.4) o These requirements of the standard are defined in the Procurement Instruction which is clearly referred to in all the relevant work instructions. Service provision (ISO 9001 Section 7.5) o Control over service provision is governed by the three tier documented Quality Management System which spells out the planning and management parameters. The specifics of each job are defined during the pricing process (JCE and Quotation) and execution constraints and requirements are defined in the Plant Access and Work Permits issued by the client (Section 7.5.1) o The validation process of the service provision is defined in the relevant Quality Control Program and is executed as the service is provided (Section 7.5.2) o All documents and records are recorded in indexes and logs and are cross-referenced to ensure that the complete history and validation records are traceable. Where products are pre-fabricated, such as sheet metal parts, it is clearly marked and/or tagged with the relevant equipment identification number, to ensure correct installation (Section 7.5.3) o Where customer property is handled, care is taken that it is clearly tagged and identified. Identification is the responsibility of the customer. This property is recorded on the relevant work log and QCP. (Section 7.5.4) o Any damage and non-conforming products are handled in terms of the Control of Non-Conformances (Section 7.5.4, & 8.5.3) o Placing products and materials in clearly demarcated laydown areas, controls product preservation. All such areas meet the requirements as agreed with the customer to ensure acceptable preservation. (Section 7.5.5) 9. Responsibility and Authority The structure of the organisation is presented in Appendix 2 which presents the lines of command. The general responsibilities for individual positions are given in the Job Descriptions while specific appointments are made in terms of legislative requirements and internal procedures Document Owner: Quality Department Page 5 of 7

7 10. Organisational Structure To ensure the availability of resources necessary to support the operation and monitoring of these processes the following has been put in place. Human Resources o See organisational chart outlining the permanent positions (Appendix 2). During the executions of large projects, additional personnel are contracted to meet the increased demands. The organogram outlining that specific requirements are included in the quotation/tender for that project. Infrastructure o NOVA Plant Services has all the office space, storage facilities and workshop facilities it requires to perform the work it undertakes. These are equipped with all the equipment and machinery required to ensure that the work performed meets the requirements agreed on. A maintenance plan and qualified personnel ensure that this equipment is kept in a serviceable condition at all times. Work Environment o NOVA Plant Services ensures that the requirements for suitable work environments are met by subscribing and maintaining the IRCA Safety Management system which governs these aspects. 11. Monitor, Measure and Analyse the Processes for Service Provision (ISO 9001 Section 8) Each and every job is monitored and measured in terms of the requirements and validations required by the relevant records. On final completion of each job, the client confirms conformance by signing off the required paperwork. (Section 8.1 (a), & 8.2.4) The conformance of the Quality Management System is verified by means of self- and independent auditing. Internal Audits, Job Observations and Activity Sampling are performed as prescribed in procedures. (Section 8.1 (b), & 8.2.3) The measure of conformance to the continued improvement of the Quality Management System can be taken from the number of Document Change Forms processed and implemented. (Section 8.1 (c) & 8.5.1) These requirements regarding the analysis of data are defined in the Data Processing Instruction (Section 8.4) 12. Continued Improvement of these Processes The organisation continuously improves the effectiveness of the QMS through the use of: Quality Policy Quality Objectives Audit Results Analysis of Data Corrective and Preventive Actions Management Review 13. Amendment Record Revision Number: Page: Status Change Date: Document Owner: Quality Department Page 6 of 7

8 00 ALL New Document January ALL Amendment and Review Records Identification: Storage: Retention Time: Disposition: Responsible Person: Obsolete Documents Obsolete File 5 Years Shred System Administrator Document Owner: Quality Department Page 7 of 7