FTA-DOT QA/QC Plan Sample Selected pages (not a complete plan)

Transcription

1 FTA-DOT QA/QC Plan Sample Selected pages (not a complete plan) Part 1: Project Specific Quality Plan Part 2: Quality Manual Part 3: Submittal Forms Contact: FirstTimeQuality Pat [Pick the date]

2 PROJECT QUALITY CONTROL PLAN TABLE OF CONTENTS Background Information... 7 Project name... 7 Project Number... 7 Project location... 7 Project description... 7 Plan Scope... 7 Plan Overview... 7 A. Element 1: Management Responsibility... 9 [CompanyName][CompanySuffix] Quality Policy... 9 Appointment of Project QC Personnel... 9 Personnel Qualifications... 9 Project QC Organization Chart Quality Responsibilities B. Element 2: Documented Quality System Quality Manual Quality System Procedures C. Element 3: Design Control D. Element 4: Document Control Document Controls Document Control Procedure Project Document and Record Control Procedure E. Element 5: Purchasing Qualification of Subcontractors and Suppliers Qualification of Testing Laboratories Purchase Order Requirements Purchase Order Approval F. Element 6: Product Identification and Traceability Identification of Lot Controlled Materials Controlled Use of Materials Material Inspection Inspection and Test Status Marking of Nonconformance Materials G. Element 7: Process Controls Identification of Process Controlled Work Tasks Project Quality Standards Page 5 [ProjectName] - [ProjectNumber]

3 Local Building Codes Process Controls Coordination of Process Controls H. Element 8: Inspection and Testing Identification of Work Tasks for Inspection Required Inspections for each Work Task Preparation of Inspection and Test Plan Daily Quality Control Report Project Completion Inspections I. Element 9: Inspection, Measuring, and Test Equipment J. Element 10: Inspection and Test Status Inspection and Test Status of Quality Controlled Materials Inspection and Test Status of Production Work Tasks Inspection and Test Status K. Element 11: Nonconformance Nonconformance Controls L. Element 12: Corrective Action Corrective Actions Nonconformance Preventive Actions M. Element 13: Quality Records Document Controls Project Quality Record Plan N. Element 14: Quality Audits Project Audit Plan Project Audit Requirements Company Quality Audits O. Element 15 Training Project Quality Training Customer Training on Use and Maintenance P. Additional Quality Control Requirements Page 6 [ProjectName] - [ProjectNumber]

4 G. ELEMENT 7: PROCESS CONTROLS The Project Manager ensures that the information in customer contracts clearly defines customer expectations and that the necessary details are provided to set requirements to carry out the work. The construction process plan defines how project work is to be done and approved for the overall project. The construction process plan is communicated to all key personnel, subcontractors and suppliers in a startup meeting. As the project proceeds, work task plans provide additional details of how each individual work task is carried out. Work tasks planning meetings are used to communicate expectations of the work task plan to key personnel responsible for carrying out the work task. Project phases of work and work tasks subject to process control procedures are listed on the Quality Controlled work tasks form. The form is included as an exhibit in this subsection. Process controls include inspection controls which are described in the subsection of this Quality Assurance/Quality Control Plan. Process controls include the control of nonconforming items is described in subsection of this Quality Assurance/Quality Control Plan. IDENTIFICATION OF PROCESS CONTROLLED WORK TASKS The Quality Manager identifies each phase of construction work task that requires separate quality controls. Each work task triggers a set of requirements for quality control inspections before, during and after work tasks. Additional detail on [CompanyName] policies and procedures for process controls appear in Quality Manual section 2.5 Identification of Quality Controlled Work Tasks. PROJECT QUALITY STANDARDS CONTRACT TECHNICAL QUALITY STANDARDS The Project Manager obtains contract technical specifications from the customer. Page 35 [ProjectName] - [ProjectNumber]

5 H. ELEMENT 8: INSPECTION AND TESTING The Quality Inspection and Test Plan form lists inspections and tests that will be performed on this project. The Quality Inspection and Test Plan exhibit is included as an exhibit in this subsection. A series of inspections will be performed on each work task including Tests specified by contract requirements Material inspections Work task Job-ready inspections Work in process inspections Work task Completion inspections Functional inspections and tests Near project completion [CompanyName] performs a punch-out QC inspection, corrects all deficiencies. If the customer performs a final inspection, [CompanyName] corrects all deficiencies. The customer may verify completion of the project by a final acceptance inspection. Results of inspections and tests will be recorded as follows: Task inspection results will be recorded on the Task Inspection Form. Test results will be recorded on the Inspection and Test Form. Daily inspections of work in process will be recorded on the Daily Quality Control Report. Form exhibits are included as an exhibit in this subsection. [CompanyName][CompanySuffix] will conduct a series of completion inspections near the end of the project to assure that the project is completed to specifications. The inspections consist of a punch-out inspection, pre-final inspection, and final acceptance inspection. A Record of each of the inspections will be maintained on the Project Completion Inspection form. If punch items are discovered during the inspection, a record of the punch items and their correction will be maintained on the Punch List form. Project Completion Inspection and Punch List form exhibits are included as an exhibit in this subsection. IDENTIFICATION OF WORK TASKS FOR INSPECTION Each quality controlled work tasks identified in subsection G Element 7: Process Controls on the Quality Controlled Work Tasks form will be inspected. REQUIRED INSPECTIONS FOR EACH WORK TASK The Quality Manager identifies each Task that is a phase of construction that requires separate quality controls to assure and control quality results. Each Task triggers as set of requirements for quality control inspections before, during and after work tasks. Independent quality audits are conducted to verify that the task quality controls are operating effectively. Construction projects may execute a work task multiple times in a project, in which case a series of quality inspections are required for each work task. Page 41 [ProjectName] - [ProjectNumber]

6 [CompanyName][CompanySuffix] Inspection and Test Report Version Inspection Report ID # Project ID Project Name Preparer Signature Date Work Activity: Ref# [ProjectNumber] Inspection/Test Record (additional items on next page) Inspection/ Test/ ID # Inspection/Test Points/Location Acceptance of completed work activity (sign and date) [ProjectName] Acceptance Criteria / Ref# Item inspected and/or tested: Specification reference documents (titles or description with version/date) Test Result, Nonconformance Non-conformance Disposition rework/reject/nonconformance Report Inspector/Tester Subcontractor and Supplier/Supplier Superintendent Corrections Made / Final Acceptance Initial Date Page 45 [ProjectName] - [ProjectNumber]

7 QUALITY MANUAL TABLE OF CONTENTS 1. Quality System Management and Responsibilities Overview [CompanyName][CompanySuffix] Quality Policy Quality Duties, Responsibilities, and Authority Quality System Performance Measures Customer Satisfaction Performance Measures Exceptions Project Quality Assurance/Quality Control Plan Overview [CompanyName] Project License and Qualification Requirements Project Personnel and Qualifications Project Quality Assurance/Quality Control Plan Identification of Quality Controlled Tasks Project Quality Inspection and Test Plan Project Quality Communications Plan Project Quality Training Plan Customer Training On Operation and Maintenance Project Records and Documentation Plan Project Audit Plan Contract Specifications Overview Contract Technical Specifications Contract Drawings Contract Submittals Customer Submittal Approval Contract Warranty Contract Review and Approval Design Review and Control Overview Design Input Review Project Design Quality Assurance/Quality Control Plan Design Progress Reviews Design Output Verification and Approval Project-Specific Quality Standards Overview Page 2 Quality Manual

8 5.2. Regulatory Codes Industry Quality Standards Material and Equipment Specifications Work Process Specifications Controlled Material Identification and Traceability Measuring Device Control and Calibration [CompanyName] Quality Standards Application of Multiple Sources of Specifications Project Purchasing Overview Qualification of Outside Organizations and Company Departments Quality Responsibilities of Key Subcontractor and Supplier Personnel Requirements for Subcontractor QC Plan Subcontractor and Supplier Quality Policy Project Subcontractor and Supplier List Purchase Order Requirements Project Purchase Order Approvals Process Controls Overview Project Startup and Quality Control Coordination Meeting Preparatory Project Quality Assurance/Quality Control Plan Planning Weekly Quality Planning and Coordination Meetings Process Control Standards Daily Quality Control Report Monthly Quality Control Report Inspections and Tests Overview Required Task Quality Inspections and Tests Material Inspections and Tests Work in Process Inspections Task Completion Inspections Inspection of Special Processes Independent Measurement and Tests Commissioning Functional Acceptance Tests Hold Points for Customer Inspection Quality Inspection and Test Specifications Inspection and Test Acceptance Criteria Inspection and Test Status Independent Quality Assurance Inspections Inspection and Test Records Project Completion and Closeout Inspection Nonconformances and Corrective Actions Page 3 Quality Manual

9 9.1. Overview Nonconformances Corrective Actions Preventive Actions Overview Identify Preventive Actions for Improvement Train Preventive Actions for Improvement Quality System Audits Overview Project Quality System Audit Company-wide Quality System Audit Record and Document Controls Overview Quality System Documents Document Controls Record Controls Appendix Definitions of Terms Page 4 Quality Manual

10 7. PROCESS CONTROLS HOW WORK IS CARRIED OUT 7.1. OVERVIEW The construction process plan defines how project work is to be done and approved for the overall project. The construction process plan is communicated to all key personnel, subcontractors and suppliers in a startup meeting. As the project proceeds, Task plans provide additional details of how each individual Task is carried out. Tasks planning meetings are used to communicate expectations of the Task plan to key personnel responsible for carrying out the Task PROJECT STARTUP AND QUALITY CONTROL COORDINATION MEETING Prior to the commencement of work, the Project Manager holds a meeting to discuss and coordinate how project work will be performed and controlled. Key personnel from [CompanyName], subcontractors and suppliers meet to review expectations for project quality results as well as quality assurance and quality control policies and procedures including: Key requirements of the project The Project Quality Assurance/Quality Control Plan Required quality inspections and tests The project submittal schedule Quality policies and heightened awareness of critical quality requirements Project organization chart and job responsibilities Methods of communication and contact information Location of project documents and records 7.3. PREPARATORY PROJECT QUALITY ASSURANCE/QUALITY CONTROL PLAN PLANNING TASK REQUIREMENTS REVIEW In preparation for the start of an upcoming Task, the Superintendent reviews an integrated and coordinated set of documents that collectively define quality requirements for the Task including: Objectives and acceptance criteria of the Task Quality standards that apply to the Task Work instructions, process steps, and product installation instructions that apply to the Task Shop drawings Submittals Tools and equipment necessary to perform the work License, certification, or other qualification requirements of personnel assigned to work Required records of the process and resulting product The subcontractor contracted to perform the work, if applicable Customer contract requirements Required quality inspections and tests Method for clearly marking nonconformances to prevent inadvertent use Location of quality system records and documents Page 28 Quality Manual

11 Personnel training PREPARATORY SITE INSPECTION The Superintendent also performs a quality inspection of the work area and: Assesses completion of required prior work Verifies field measurements Assures availability and receiving quality inspection status of required materials Identifies any nonconformances to the requirements for the Task to begin Identifies potential problems TASK PREPARATORY QUALITY PLANNING MEETINGS Prior to the start of a Task, the Superintendent conducts a meeting with key company, subcontractor personnel responsible for carrying out, supervising, or inspecting the work, and interested customer representatives. During the meeting, the Superintendent communicates the Task quality requirements and reinforces heightened awareness for critical requirements. Topics for a Task quality plan meeting include: Conflicts that need resolution Required quality documents and a verification of availability to personnel carrying out, supervising, or inspecting the Task Record keeping requirements and the availability of necessary forms Review methods and sequences of installation Special details and conditions Standards of workmanship Heightened awareness of critical quality requirements Quality risks Tasks quality inspection form 7.4. WEEKLY QUALITY PLANNING AND COORDINATION MEETINGS Page 29 Quality Manual

12 Standard Forms: Questions? Call First Time Quality List of Included Forms Point Of Contact List Project Organization Chart Project Quality Communications Plan Quality Manager Appointment Letter Project Manager Appointment Letter Superintendent Appointment Letter Personnel Certifications and Licenses Project Personnel Resumes Project Subcontractor and Supplier List Training Plan Training Log Regulatory Codes and Industry Standards Project Regulatory Building Codes Controlled Materials Form Metals Material Receiving Inspection Report Material Inspection and Receiving Report Inspection and Testing Standards Quality Inspection and Test Plan Test Equipment Calibration Plan and Log Quality Controlled Work Task List Daily Production Report Work Task Inspection Form Nonconformance Report Punch List Project Completion Inspection Form System Document Control Form Project Records Control Form Project Quality System Audit Form

13 [CompanyName][CompanySuffix] Nonconformance Report Version Nonconformance Report Control ID Project ID Project Name [ProjectNumber] Preparer Signature/ Submit Date [ProjectName] Quality Manager Signature / Disposition Date Description of the requirement or specification Description of the nonconformance, location, affected area, and marking Disposition Corrective Actions Preventive Actions Replace Repair Rework Use As-is Approval of disposition required by customer representative? Yes Customer approval signature /date: Corrective actions completed Name/Date: Customer acceptance of corrective actions required? Yes Name/Date: No No Preventive actions completed Name/Date: Page 54 [ProjectName] - [ProjectNumber]

14 Industry-Specific Information Available by Division 03 Concrete 08 Openings 27 Communications 04 Masonry 09 Finishes 28 Electronic Safety and Security 05 Metals 21 Fire Suppression 31 Earthwork 06 Wood Plastic Composite 22 Plumbing 32 Exterior Improvements 07 Thermal and Moisture Protection 23 HVAC 33 Utilities 26 Electrical

15 For More Information: Contact: FirstTimeQuality For More Information, contact: CaldeiraQuality, LLC First TimeQuality