QUALITY CONTROL PRACTICE / SYSTEM
QUALITY CONTROL
PRACTICE / SYSTEM
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QUALITY CONTROL PRACTICE / SYSTEM
CONTENTS
1.0 Introduction
1.1 Definitions / Abbreviations
2.0 Project Description
3.0 Purpose & Scope
3.1 Supplementary Documentation
4.0 References
5.0 Organization & Responsibility
5.1 General
5.2 Site Management Responsibility
5.3 Management Review
6.0 Contract Review & Variations to Contract
7.0 Design & Design Change Control
8.0 Document & Data Control
9.0 Procurement
10.0 Process Control
11.0 Inspection & Testing
12.0 Non‐conformance, Corrective & Preventive Action
13.0 Handling & Storage
14.0 Quality Assurance ‐ Quality Control, Audits & Monitoring
15.0 Quality Records
16.0 Data Dossier
17.0 Training
18.0 Safety , Health and Environment
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QUALITY CONTROL PRACTICE / SYSTEM
INTEGRATED MANAGEMENT SYSTEM (IMS)
QUALITY, HEALTH & SAFETY
POLICY STATEMENT
SYME Mechanical Contracting SPC, has established, implemented and maintains an Integrated Management
System (IMS) within the frame work of Quality Management System –
ISO 9001:2008 and Occupational Health & Safety Management System – OHSAS 18001:2007, for the provision
of Civil, Mechanical and Stainless Steel Contracts works:
The Management of SYME is committed to the following:
Document, implement and maintain the Integrated Management System as per ISO 9001:2008 &
OHSAS 18001:2007 requirements and continually improve its effectiveness and performance.
To offer best quality projects/products, understand and achieve customer requirements, their
expectation & utmost satisfaction.
To observe all relevant statutes, regulations and codes of practice and will take appropriate steps with
its authority.
To prevent from injury/incident and ensure all reasonably practicable efforts are made to safeguard
of our employees, customers, visitors, contractors and members of the public who may affect by its
activities and operations.
Regular reviews to measure and improve the Integrated Management System.
Review the Policy periodically to ensure that it remains relevant and appropriate to the organization.
This Policy shall be communicated to all employees, customers, suppliers and those who works for the
organization and shall be made available to public.
____________________
Divakaran Ashok Kumar
Managing Director Date: 01 September 2014
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1.0 Introduction
This Quality control practice & Systems explains about the quality practice and control systems that in
general SYME take care of while carrying out projects in fields of civil and mechanical.
SYME has implemented an Integrated Management System looking forward for ISO certification hence the
requirements of ISO 9001:2008, ISO 14001:2004, OHSAS: 18001:2007 are taken care of while adopting
quality systems.
1.1 Definitions / Abbreviations
QMS ‐ Quality Management System ‐ documented system that details the organizational
structure, procedures, process and resources needed to implement quality management.
QP ‐ Quality Procedure ‐ A document that clearly stated the established manner or method of
executing a process or course of action for a defined purpose.
PQP ‐ Project Quality Plan / contractor Quality Control (CQC) Plan Document that provided an
overview of the controls and requirements for the quality management of the project. The PQP
describes project complain to ISO 9001:2008
CQP ‐ Construction Quality Plan ‐ Sub‐tier to the PQP, and defines how specific processes or
activities will be managed and controlled.
MS ‐ Method Statement ‐ Sub‐tier the PQP or CQP, and describe the parameters, operational
processes and resources to complete the process or activity.
QCP ‐ Quality Control Plan ‐ Document detailing verification documentation, inspection and
testing requirements for specific activities.
ITP ‐ Inspection & Test Plan ‐ Document identifying inspection and testing criteria and details
including hold, witness and inspection points.
QA/QC ‐ Quality Assurance / Quality Control
SHE ‐ Safety, Health and Environment
SYME ‐ Syme Mechanical Contracting SPC
2.0 Project Description
The works for projects consists of the scope of works as per drawings and detailed bill of quantities as
described in the contract documents
While executing the works, following shall be taken care of:
Full compliance with the contract environmental, health and safety requirements
Execution of works as per Scope of Works and Drawings with all quality criteria
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3.0 Purpose & Scope
The Project Quality Plan (PQP) is intended to provide the basis for the project management and ongoing
controls to ensure compliance to the contract and internal Quality Assurance requirements. The plan
describes the overall management structure and methodologies required for the project and shall be read
in conjunction with the requirements of Contract Documents.
The PQP is applicable to all quality related activities required for the successful completion of the project.
The control of these activities shall be based on the requirements of the standards set on.
3.1 Supplementary Documentation
Supplementary Construction Quality Plans (CQPs) shall be developed to identify the key stages of
construction, the processes to be performed, including the applicable standards and specification,
the inspection and test procedures and equipment, the control and verification documents to be
used, the acceptance criteria, and the quality record to be generated. The CQPs shall be
augmented as necessary by subsidiary method statements for individual parts of the works. The
CQPs and method statements shall be submitted to the Engineer for review / approval prior to
commencing the works.
The Method Statement / Construction Procedure / Working Drawings shall be submitted in line
with the Program requirement and the time limit for approval of the same shall be allowed.
Method Statements shall be developed to provide detail for specific activities. Each method
statement will deal with a specific activity / area of the works and is linked to the overall PQP and
CQPs and together provides a coherent system to ensure that the overall objectives of the
processes necessary to complete the activity, and shall include the associative quality assurance,
safety, health and environmental control procedures to be followed to ensure compliance to
contract requirements. Method statement shall identify the personnel, and their responsibilities,
specific tools and equipment, as well as inspection and testing procedures required for each
activity.
Risk associated with the specific activity shall be identified and assessed as part of the job Hazard
Analysis.
Specific project Quality Procedures will be developed, where required to deal the quality assurance and quality
control procedures that shall be employed during the execution of the project.
Quality Control Plans (QCPs) shall be developed to identify that required control documents, responsibilities
and verifying documents for processes or activities, as required.
Inspection and Test Plants (ITPs) shall be developed for various activities, as required. to identify inspection
and testing criteria and details, including hold, witness and inspection points the applicable standards and
specifications, the inspection and test procedures, and equipment, the control and verification documents to
be used, the acceptance criteria, the frequency of testing and the quality records to be generated.
Various processes carried out by SYME office, including human resource management, general administration,
top management commitment and review, commercial evaluation of purchased product, execution of
purchase orders, etc. will be controlled as per organization's standard quality procedures. These processes
are not described in this document.
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Where any process is outsources, the control of this process shall be identified and the requirement stipulated
in the respective CQP or method statement.
The works will be separated into primary areas of activity. CQPs will be developed for these activities, as
follows:
Site Mobilization ‐ including the fabrication and installation of the site offices, workshops, lay down areas,
material stores, QA/QC store, welfare facilities, Safety / first Aid room, access road and parking areas,
fencing and security facilities.
Construction of and later removal of the temporary works
Other required areas as stipulated in the contract terms
The permanent works items may be grouped and described in combined or separate CQPs as required.
4.0 References
ISO 9001:2008 ‐ Quality Management Systems ‐ Requirements
ISO 14001: 2004 ‐ Environmental Management Systems ‐ Requirements
OHSAS 18001: 2007 ‐ Occupational Health & Safety Management Systems ‐ Requirements
Contract Documents and Specification of respective works
5.0 Organization & Responsibility
5.1 General
Top Management will appoint a Project Manager who shall be fully responsible for the overall
performance of the works and will report to the Contracts Manager / Supervisory Board. Project
Manager shall be responsible for executing and carrying out the works, in accordance with the
project requirements. The Project Manager, or his nominated representative, shall be
responsible for document submission to and correspondence with the Engineer.
The project organization and responsibility structure will be in accordance with the general
organization chart suitable for each project
List of project functional responsibilities for the development and / or control, as appropriate, of
quality documentation shall be matching with project volume. This will be prepared based on the
requirements of each projects.
5.2 Site Management Responsibility
Contracts Manager ‐ has overall responsibility and control over the project
Project Manager ‐ shall ensure that assigned, responsible and competent persons implement this
PQP, throughout project operations
Commercial & Construction Managers ‐ are responsible to the Project Manager and shall ensure
implementation of the PQP by all personnel and subcontractors operating under their control.
This shall be managed, audited and reviewed by the Commercial Construction Manager, as
appropriates, ensuring that ll documentation related to quality completed and filed as required.
Site Engineers and Supervisors / Foreman ‐ are responsible to the Construction Manager and
shall ensure that operations on site are performed according to set procedures and quality
standards.
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Sr. QA/QC Engineers (i.e. QA / QC Management) ‐ are responsible to the Sr. QA/SHE Engineer,
who is in turn responsible to the Project Manager, as shown in the organization chart contained in
Appendix 1. QA/QC Management shall ensure that project quality requirement are identified,
inspected, completed and monitored in accordance with the Contract Documents, PQPs,
procedures, ITPs, checklists, etc.
Inspection test plan for all major activities (ITPs) will be prepared incorporating the role of Design
consultant in terms of Surveillance, Hold Point, Witness, etc.
QA/QC Management shall review and all 'submittal for approval' prior to forwarding submittals to
the Engineer.
The QA/QC Management shall be responsible for identifying and reporting non‐conformances
and thereafter initiating, recommending and providing solutions to these non‐conformances.
They shall also be responsible for implementing corrective and preventive action.
Dedicated QA/QC inspectors, responsible to the QA/QC Management, will be appointed to ensure
that the control of project requirements is maintained for specific activities.
Project Personnel ‐ All project personnel shall be responsible for identifying and reporting
deficiencies and non‐conformances.
5.3 Management Review
The Status and adequacy of the quality management system shall be reviewed periodically as per
the planned schedule, throughout the duration for the project by the Contracts Manager, project
Manager, Construction Managers, QA/QC Managers and other senior management. Records of
these reviews shall be maintained.
In addition to the above, Quality Management System shall be audited by the main office Quality
Manager.
The items to be reviewed are, as minimum, as follows:
Results of audit (review of audit reports);
Customer (Employer or Engineer) feedback, complaints, claims; the importance of meeting customer,
statutory and regulatory requirements;
Process performance and product conformity (non‐conformance reports); need for product improvement
relating to requirements;
Status of corrective and preventive action;
Follow up action from previous reviews;
New trends / technology or changes that could affect the QMS;
Resources requirements and training needs;
The suitability, adequacy, effectiveness and recommendations need for improvement of the IMS and its
processes.
6.0 Contract Review & Variations to Contract
All contracts including those awarded by SYME shall be reviewed to ensure that
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Contract requirements are determined i.e. clearly defined and documented, including any
requirements for delivery or post delivery service;
Any requirements not stated by the Employer but necessary for specified or intended use, are
determined;
Any statutory and regulatory requirements relating to the scope of works are determined;
Contract differences are resolved and documented;
SYME or the subcontractor / service provider has the capability to meet contract requirements; and
Amendments to contracts are administered, documented, auctioned and records maintained.
Variations identified during the duration of the contract, shall be reviewed by the SYME Project Manager to
ensure that the variation is adequately defined and documented, and that adequate resources are available
to complete the work described in the variation.
Where changes or proposed changed to approved details or designs originate from teh Employer, Engineer
or the SYME Project team, and have a cost implication i.e. re‐design and drawing revision, or material or
resource cost implication, or similar document, and submitted to the Engineer for review and approval.
Records of the results of the reviews and action arising from the reviews shall be maintained.
Unless alternative designs are submitted, general contract permanent works design, Design development is
not included in the scope of works except as noted below. All contract design activities shall be controlled
through the Engineer's / consultant's design office.
8.0 Document & Data Control
All quality related documents and data shall be managed and controlled in accordance with Contract
Documents and Project Procedure Document Control. The procedure shall cover the following items /
activities:
A documented procedure is available for control of documents
All the document are approved, stamped prior to use
Document are reviewed and updated as necessary and re‐approved as well
Identify changes and current revision
Ensure right documents are at right place at right time
Documents of external origin are identified
Obsolete documents are kept and they are identified suitably
The management and control of electric data, including network security, computer backup, achieving,
retention time and computer virus control shall be in accordance with the specific Project Procedure.
Project filing system shall be established and maintained.
9.0 Procurement
Procurement / purchasing processes carried out by the SYME site offices i.e. final commercial evaluation of
product, execution of purchase orders (LPOs), will be controlled in main office and are not described in this
document.
The Project Manager or his nominated representative will be responsible for communication with the main
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office and ensure that all materials or services comply with Contract and IMS requirements.
All procurement will be carried out in accordance with the requirements of the Contract Documents and
shall ensure that:
Controls are developed to ensure that purchased product conforms to intended and specified
requirements;
Requisitions / Purchase Orders contain sufficient information to clearly describe the product or service
ordered and shall include specified requirements such as specifications, standards, testing and
acceptance criteria, safety, technical and quality requirements, ITPs, expected delivery dates, and
handling storage and shipping requirement, as applicable;
Requisitions / Purchase Order are reviewed and approved, as applicable;
Copies of agreements, subcontractors and purchase orders for materials and sources obtained from
others will be submitted to the Engineer as soon as such agreements are entered. These shall include
the provision that the Engineer shall be give free access to the manufacturing, fabrication and assembly
facilities of the various vendors to witness any test of materials and to monitor the progress of the
work.
Material and test certificates, Inspection Release Certificates and Certificates Conformance /
compliance, as required, are provided with, or prior to, delivery and will be forwarded to the Engineer.
Principal suppliers and contractors / subcontractors shall be assessed, as necessary, to ensure that they have
the capability to meet the required specification prior to product supply or work commencement. Preference
shall be given to ISO 9001 or equivalent standard, certified companies.
It shall be the responsibility of the site QA / QC Management to evaluate and assess the proposed company, to
verify that all of the essential (quality related) criteria have and can be met by the company and that the
necessary management controls such as quality plans, resources, personnel qualification, material controls
and process procedures as appropriate, are in place prior to purchase order or contract placement. The
degree of evaluation shall be entirely at the discretion of the QA/QC Management. Technical, financial or
other specialists may support the evaluation, as the QA/QC Management deems necessary. Quality, timescale
and cost shall be considered in the evaluation, where appropriate.
Material Approval Certificates (MAC) and Supplier Approval Certificates (SAC) will be submitted to the
Engineer for evaluation and approval. Where the source of a particular material is not stated, sample technical
catalogues will be submitted to the Engineer for approval before the placing of bulk orders.
All Employer supplied product or property shall be identified, verified, protected and safeguarded. If any
property is lost, damaged or otherwise found unsuitable for use, this shall be reported to the Employer and
records are to be maintained.
10.0 Process Control
All processes including fabrication, inspection, testing, material and product traceability, etc. with each area
of activity, shall be in accordance with the requirements of the Contract Documents and will be controlled
in accordance with project CQPs, ITPs, checklists and / or method statements. These processes shall be
planned and carried out under controlled conditions.
The process control documentation that will be developed for the various primary areas of activity shall be
prepared, as appropriate.
A master program of works and various short‐term programs shall be developed, updated regularly and
submitted to the Engineer for review and approval.
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11.0 Inspection & Testing
The responsible person for the tools and equipment control shall maintain a file or record which list each
piece of equipment that needs to be calibrated, its unique identification number, the frequency of
calibration, who performed the calibration (name of the person if performed by SYME employee or the
name of the company that performed by an outside company or organization) and date of the next
calibration.
The responsible person for the tools and equipments in communication with the buyer shall ensure that
only companies that appear on the SYME contracting site team approval suppliers list and has been
accredited with "Third Party" inspection authority to be allowed to calibrate testing equipment.
The responsible person for the SYME contracting site Stores shall assign each item of inspection, measuring
and testing equipment, a unique identification number i.e. Serial Number been etched or stamped or the
item, and shall ensure that the calibration status has been indicated by a sticker or any other means of
identification.
Documentation certifying calibration shall be retained on file by tools & equipment controller and shall be
made available for perusal by the customer and / or inspection authority.
When inspection, measuring and testing equipment is used for site, the tools and equipment controller
shall ensure that it is correctly certified copy of the relevant calibrations certificate accompanies the
equipment.
Inspection measuring tools are been rented from outside companies shall conform to the same calibration
requirements as far as the SYME contracting site equipment. The Stores controller for SYME stores or the
applicable project manager shall ensure that a valid calibration certificate with the required inspection,
measuring and testing equipment.
The stores controller shall notify the parties responsible for having the calibration performed reasonably in
advance of the due date of the next scheduled calibration.
All calibrations shall be conducted using equipment or instruments of higher accuracy which is traceable to
recognized national or international standards.
Any equipment requiring calibration which cannot be confirmed as to identification or calibration status, or
is found to be out of calibration, shall be removed from service and returned to the place of issue. Such
equipment shall only be placed back into service after the identification or calibration status has been
verified and either cleared or corrected and previous inspection and test results are verified.
Inspection, measuring and testing equipment shall be stored and handled such that accuracy and fitness for
use is maintained.
All special testing shall be carried out in an approved Third Party Laboratory.
12.0 Non‐conformance, Corrective & Preventive Action
Nonconforming product shall be controlled in accordance with the requirements of the Contract
Documents and Project Procedure control of Non‐conforming Product, Corrective and Preventive Action,
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and shall ensure that:
Products or services that do not conform to specified requirements are identified and prevented from
un‐intended use or delivery;
Disposition of nonconforming products is dealt with a defined manner;
Customer complaints are reviewed and resolved;
Corrective and preventive action is carried out in order to prevent or eliminate the causes of actual or
potential nonconformance;
All personnel shall support and take necessary corrective and preventive actions for the resolution of
identical problems.
The Sr. QA / QC Engineer / Site Quality Manager shall maintain records of all non‐conformances and
concession requests, and shall investigate and report, to the Project Manager, on the cause of the deficiency
and the action taken to prevent recurrence.
13.0 Handling & Storage
All handling and storage of materials will be managed and controlled in accordance with the requirements
of the Contract Documents, the manufacturer's requirements. ITPs and standard rigging and lifting
practices as applicable. The procedures shall ensure that:
The handling of materials is carried out by competent persons and by the use of proven lifting
equipment. Lifting equipment falling into the category of legislative control shall be suitably certified;
Designated storage areas are identified and used to prevent possible damage or deterioration to
materials and products;
Materials are segregated where required, e.g. inflammable materials.
14.0 Quality Assurance ‐ Quality Control, Audits & Monitoring
Site operations will be managed within the Project Quality Management System and the requirement of the
Contract Documents. Site QA/QC Management shall ensure that project quality requirements are
identified, monitored, inspected and completed in accordance with the project procedures, checklists and
method statements, in each primary area of operational activity.
Site quality related activities shall be monitored and audited by the QA/QC Management to ensure that the
quality system activities and procedures are effective and are being implemented in conformance with the
documented system. Auditors shall not audit their own work.
Internal audits shall be carried out as per the audit schedule, in accordance with the requirement contained
in the project procedure under 'Internal Audits'
Copies of Audit reports shall be sent to the Contracts Manager and Project Manager for review.
15.0 Quality Records
In addition to the identified project quality documents i.e. Quality Plans, method statements, project
procedures, CQPs, ITPs, checklists, all contract documents, material certificates, design briefs, design
calculations and associated documentation, drawings, document control registers and audit reports and all
progress reports, programs etc. as required in the Contract Documents shall be retained as quality records
and controlled to ensure these records are indexed, filed, stored and protected from loss or damage and
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made available as required.
All checklists and specific project procedures shall be referenced with the respective construction quality
plans.
16.0 Data Dossier
The data dossier will have details of the handover project completion documentation. The final list and
format of the packages shall be developed in conjunction with the Engineer during the progress of works as
required. This shall be in accordance with contract requirements as noted in the Contract Documents.
17.0 Training
The Project Manager shall ensure that:
All personnel are competent and adequately trained for their job activities. Personnel CV shall be made
available to the Engineer if required as per the Contract Documents.
Where training need are identified, such needs are programmed and implemented. These needs shall
be identified to those having the discipline authority for th work to be performed.
The detailed records of education skill, experience etc are maintained in the SYME Personnel Dept.
18.0 Safety , Health and Environment
All contract and site related Safety, Health and Environment (SHE) requirement will be controlled, managed
and regularly reported on, in accordance with approved Safety Procedures; by the appointed site Safety
Representatives or other identified parties.
A sit Safety, Health and Environment Plan will be developed in accordance with the requirements of the
contract documents and the Kingdom of Bahrain safety regulations, including those contained in the
document 'State of Bahrain, Ministry of Labour and Social Affairs, The Labour Law for the Private Sector,
1976 and Legislation Relating Thereto'.
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