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CONTENTS
1 - SCOPE 2 - APPLICATION 3 - INTRODUCTION OF THE WORK 4 - MANAGEMENT COMMITMENT 5 - ORGANIZATION 6 COMMUNICATION 7 ENGINEERING AND DESIGN 8 - DRAWING AND DOCUMENT CONTROL 9 PURCHASING 10 MANUFACTURING PROCESS 11 - SPECIAL PROCESSES 12 PRODUCT IDENTIFICATION AND TRACEABILITY 13 MARKING AND CUTTING PROCESS 14 BULD UP MEMBER AND FITTING PROCESS 15 WELDING PROCESS 16 FINISHING PROCESS 17 BLASTING PAINTING PROCESS 18 INSPECTION AND TESTING 19 CONTROL OF NONCONFORMING PRODUCT 20 CORRECTIVE AND PREVENTIVE ACTION 21-STORAGE, PACKING, AND DELIVERY 22 -QUALITY RECORDS

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0. REVISION STATUS

Rev
No

Description of Change
Initial release Additional processes and Organizational chart

Effective Date

0 1 2 3 4 5 6

20.08.08

Prepared by:

Cc to: CUST. SERV. DEPT Nanda Kumar 23rd of Oct. 08

Approved by: DIRECTOR Adib Kouteili 23rd of Oct. 08

Department
Name Date Signature

QUALITY DEPT. Mark Nofuente 23rd of Oct. 08

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1.

SCOPE This quality plan describes the manufacturing details of pre-engineering structures and the quality control requirements where all the respective departments of PEB Steel Buildings Co., Ltd. need to demonstrate their ability to consistently provide the service that meet customers and applicable regulatory requirements.

2-

APPLICATION This quality plan is intended to be applicable to all the respective departments of the manufacturing process of the PEB Steel Buildings Co., Ltd.

3-

INTRODUCTION OF THE WORK CUSTOMER NAME OF PROJECT JOB SITE LOCATION : : :

DESCRIPTION OF ITEMS: WORK VOLUME: PERIOD OF MANUFACTURING:

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4.

MANAGEMENT COMMITMENT The management of PEB Steel Buildings Co. Ltd. has fully committed to meeting all the specified requirements on time with high degree of quality. The manufacturing and quality system requirement described in this quality plan is based on PEB STEEL and international standards, design and technical specification, and other contractual requirements. All our employees are responsible for comply with this quality plan and for the quality of work carried out on the manufacturing process of structures, services and performance. Operation Director, Mr. Adib Kouteili is responsible and has the authority to organize, maintain and administer this quality plan and to ensure its effective implementation. Further all other key staff of our factory is given the responsibility and authority to identify any problem and implement solutions to those problems and to control the product quality at all stages of manufacturing. This includes preventing dispatch defective, nonconforming and unsatisfactory products to customer until satisfactory corrective action has been taken. Each process group is required to implement this quality plan in each area of their responsibility.

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5.

ORGANIZATION
ENGINEERING MANAGER
SUPERVISORS

QUALITY DEPT. HEAD

QC SUPERVISOR & INSPECTORS

LOGICSTIC & PURCHASING MANAGER

SHIPPING /PURCHASING SUPERVISOR & FOREMAN

DIRECTOR

CUSTOMER SERVICE MANAGER

CUSTOMER SERVICE ENGINEER/SUPERVISOR

Mr. ADIB KOUTEILI


CHIEF ACCOUTANT
ACCOUNTANT

ADMIN & HR

H.R.ASSISTANT

PLANT MANAGER MR. NABIL KHALAF

PRODUCTION/PLANNING ENGINEERING/SUPERVIS OR

PROJ. MGMT. MANAGER

SITE ENGINEERS / EREC. COOR.

IT SUPERVISOR

IT TECHNICIANS

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6-

COMMUNICATION 6.1 Management has ensured that the appropriate communication process by defining interrelations between the departments within the organization by means of documented internal communication instructions. It shall ensure the effective communications take place regarding the effectiveness of the quality control and manufacturing system. 6.2 All the communication shall be addressed to: Mr.Adib Kouteili Director Ho Chi Minh City Office Unit 701, 7th Floor, City Plaza, 60A Truong Son St., Tan Binh Dist, HCMC Tel: (84) 8 847 5475 / 997 5975 Fax: (84) 8 847 6476 / 9975157 Vung Tau City Office PEB Steel Buildings Co., Ltd. Dong Xuyen Industrial zone, Ward 10, Vung Tau city Viet Nam Tel: (84) 64 613 124 / 613126 Fax: (84) 64 613 125 Mobile: (84) 903 353 335 E-mail: adib@pebsteel.com.vn

77.1

ENGINEERING AND DESIGN PEB design department shall take the responsibility of the following related to: a. Design development b. Identifying and documenting any statutory and regulatory requirements c. Review of the selection of design input requirements d. Resolving incomplete, ambiguous or conflicting requirements e. Documenting the design output f. Design calculations

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g. Design analysis h. Design reviews i. Design verification j. Design validation 7.2 Acceptance criteria and identifying any crucial design requirements for the main frame and other structures shall be the responsibility of customer. Any design modification required by design department or customer during the manufacturing process, a written instruction shall need to be issued through PEBs Customer Service Department so that the modification can be embodied in the final product.

7.3

8. 8.1

DRAWING AND DOCUMENT CONTROL Planning Engineer shall establish and maintain a project document list showing the latest revision status of the documents and it shall be readily available to preclude the use of invalid/superseded documents. Any superseded document retained for reference by the user and it shall be communicated to the Planning Engineer. Planning Engineer shall identify those documented to clearly differentiate from current version of documents by means of stamp SUPERSEDED and RETAINED BY USER. All the engineering documents which include PEB design, drawing and detailed engineering drawings, connection details, engineering specifications and product drawing or shop drawings shall be reviewed, controlled, managed, maintained, issued revised and recalled by the Panning Engineer. Design drawing list shall be based on drawing number and showing the status of revision and date of receipt from the PEBs Customer service department. The Engineer in-charge shall ensure that all the information provided in the design drawings is very clear, complete and legible.

8.2

8.3

8.4

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8.5

If any unclear, portion of the design drawing shall be clouded and marked as HOLD in design drawing. No engineering work shall be carried out on HOLD until it is released by PEBs design dept. with appropriate information. Upon receipt of revised design drawing from PEBs design dept. the Planning Engineer shall update the drawing list for new revision and he will ensure that the revised portions have been clouded clearly, having the revision mark in a triangle at every place of revision. The new revised information shall be compared with existing drawing to identify the changes or modification. If any discrepancy or conflict is found, it shall be reported to PEBs design dept. immediately. Upon receipt of new revision, the existing drawing shall be SUPERSEDED and the new revision drawings shall be distributed to all the processes area concerned and the old revision drawing shall be withdrawn from all the process concern. If any design revision received after issue of shop drawing to the production process, the Planning Engineer shall communicate this information to the production process and request them to hold the production process of such items.

8.6

8.7

8.8

8.9

9.

PURCHASING OF MATERIAL, CONSUMABLES AND PAINTING MATERIAL Purchasing department of PEB shall ensure all the materials, welding consumables and paint material purchased from approved manufacturer/supplier to confirm the specified requirements of design drawing and international standards. All of the steel materials shall be procured for the main frame structure by PEB STEEL purchasing department and delivered to the factory at Vung Tau city. Purchasing department in-charge in Factory will coordinate with Head office to procure other consumables such as: Welding electrode & Wire, Paint and thinner, Tools, Safety devices and accessories etc.

9.1

9.2

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9.3 Purchase order/Sales contracts shall be described and defined clearly the material to be purchased. All the purchasing information shall be defined and documented in the purchase order/sales contract. 9.4 Prior to order being placed to any supplier or manufacturer, purchasing department Head shall ensure the adequacy of the specified purchase requirement by communicating with the supplier or manufacturer. 9.5 Prior to release purchase order/sales contract to the supplier, the purchasing Documents shall be verified by the end user in the company who made the Requests and it shall be reviewed by the Planning. 9.6 All the materials, consumables and paints from the supplier or manufacturer shall be verified and inspected to ensure that the materials meet specified purchase requirements. All the verifications and inspection activities shall be in accordance with the company in-coming material receiving inspection and test procedure. 10. MANUFACTURING PROCESS The company has identified various processes that involve in the manufacturing of mainframe structures: Marking / cutting Build up of members Fitting / assembly Final Welding Secondary and Sundry Parts Sheeting, Panel and Trims Surface Treatment and Painting Buyouts Loading /Delivery

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11.

SPECIAL PROCESSES The following processes are considered as special processes where conformity of product is totally depend upon the capability of personnel, equipment and facilities used and where the resulting output cant be fully verified by subsequent inspection and testing and where the deficiencies become apparent only after the product is used: Welding Surface treatment and painting NDT

12. 12.1. 12.2

PRODUCT IDENTIFICATION AND TRACEABILITY Identification of parts shall be followed in accordance with PEB STEEL design and shop detail drawings. Planning and Production Manager in consultation with other concern departments shall establish the identification of each item based on design and contract requirement. Upon completion of marking and prior to start cutting every parts, the identification number of the particular parts shall be written by means of crayons/paint in accordance with drawing and part list. Prior to start blasting of items, blasting team shall prepare the metal tags with hard punched identification number of the particular items and hang on the product by mean of steel wire to avoid missing of the tags during blasting. Identification of completed product and logo of company shall be stenciled by paint on the surface of connecting parts so that it will not appear on the final l structure.

12.3

12.4

12.5

13. 13.1

MARKING AND CUTTING PROCESS Prior to marking, bend or deformation of the material shall be corrected by mechanical method or heat-cooling methods. On the heat-cooling method, the heating temperature should be less than 4500C

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13.2

Prior to start marking, cutting plan showing allotment of the component on the ordered materials shall be made to minimize the losses and surpluses. Application to the center punch in the marking shall be minimized except for those areas where marking can be completely erased afterwards by means of drilling, coping or welding. As much as possible, original heat number which is stamped by mill must be retained and marking should be avoided on the identification numbers. Only on un-avoidable circumstances, the original plate heat numbers shall be transferred by means of hard punch at unusable corner of the material. The cutting face of each member shall be perpendicular to the axis line unless otherwise specified on the drawing. Cut face shall be free from remarkable uneven notch or slag attachment. In case of occurrence of notch, such part shall be welded and finished to flatness by means of grinder.

13.3

13.4

13.5

13.6

14. 14.1

BULD UP MEMBER AND FITTING PROCESS Fitter shall inspect the items visually for any surface damages, bends and deformation. If so, it shall be properly corrected in accordance with shop detail drawings. It is the responsibility of fitter/QC Supervisor to verify the size, thickness, hole details, hole diameter, spacing and number of holes. The contact surfaces of the components shall be free of burrs and foreign materials that would prevent solid seating of the part. All the edge preparation and site assembly profile on both main members and components shall be carried out prior to start fitting and in accordance with shop drawing. Assembly work shall be carried out with suitable tools and equipment, such as surface plate, positioners, jacks, lever blocks, chain blocks and strong backs.

14.2

14.3

14.4

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14.5

All full penetration weld joints of fitting shall have minimum root gap of 3mm and the edge preparation strictly in accordance with shop drawing.

14.6 The fitter performing the tack welding shall be qualified for the process in accordance with the applicable welding procedure specification. 14.7 Electrode for tack welding shall be in accordance with the specification and as per the approved welding procedure.

15. 15.1

WELDING PROCESS All the welding process shall be in accordance with the approved welding procedure specification (WPS) and procedure qualification record (PQR). All the welders to be engaged in this work should have approved welder performance qualification test certificates. Prior to the welding, all welding joint surfaces shall be clean and dry condition. Rust, paint, dust, grease or any other foreign particles shall be cleaned by mechanically using wire brush or grinding. When the pre-heat is required as per WPS, pre-heating temperature of the base metal shall be of 100-1200C and shall be checked by temperature crayon. Welding gaps or bevels must be accurately controlled over the entire joint during welding operation. Control prior to welding

15.2

15.3

15.4

15.5

15.6

15.6.1 Consumables such welding electrodes, flux etc. to be used shall be as per standards. Deteriorated or spoiled consumables should not be used. 15.6.2 Welding equipment should be in satisfactory working condition and be able to product right quality welds. 15.6.3 Weld testing equipment should be in good operating condition and be handled by the well trained staff.

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15.7 15.7.1

Control during welding The weld groove should be free from dirt, rust, oil, slag or any other foreign particles which affect the quality of the weld. Job edge preparation should be as per approved welding procedure The fit-up, gap, orientation, welding position, method and sequence of assembly all should be as per approved welding procedure. Tack welds should be of adequate size, length and pitch. Fittings, clamps, fixtures, etc. should not interfere with welding Methods should be adopted to minimize distortion Slag should be thoroughly removed from each pass in multi-pass arc welds and spot welding electrodes should be dresses periodically. Control after welding Cleaning and visual inspection of welding includes: Final weld appearance, final weld size, extent of welding, dimensional of accuracy, amount of distortion, surface cracks, undercut, overlap, exposed porosity, unacceptable weld profile, and roughness of the weld face. Check the welding conformity to the drawings and specification.

15.7.2 15.7.3 15.7.4 15.7.5 15.7.6 15.7.7

15.8 15.8.1

15.8.2

16. 16.1 16.2

FINISHING PROCESS Welding slag and spatter must be cleaned properly and use wire brush or power brush as post cleaning operation. If any undercutting or porosity found during cleaning, mark the spot by means of crayons and report to welding supervisor for repair and ensure the repair has been done in accordance with the standard and acceptable level. If any crater observed, note down the welder identification number which is written near the welding and call the same welder for repair.

16.3

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16.4 16.5 16.6 16.7

All the bolt holes must be clean and trimming by means of grinder, round file and reamer if in case necessary. All the cutting edges must be grind smooth and all the sharp edges must be radius and smooth. All the gas notches must be rebuilt by (touch up) qualified welders and grind smooth. Any bend, deflection and deformation of member out of tolerance should be corrected by means of heating and cooling methods.

17. 17.1

BLASTING PAINTING PROCESS Prior to start painting blasted surface shall be cleaned by dry compressed air and ensure the surface is dust free.

17.2

The following area shall be covered by masking tape to avoid painting: The parts to be metal to metal contact Embedded steel in contact with concrete The parts where field welding is to be applied

17.3

Each container of paint shall be clearly marked or labeled to show paint identification date of manufacture, batch number, analysis of contents, identification of all toxic substance and special instruction.

17.4 All ingredients in any container of paint shall be thoroughly mixed before use and shall be agitated often enough during application to keep the paint uniform. 17.5 The type of thinner shall comply with paint manufacturers instructions. Correct amount of thinner to be added to particular application when the use of thinner is permissible, thinner shall be added slowly to paint during mixing process.

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17.6 The equipment used for painting application shall be suitable for the appropriate purpose and coating system and shall be capable of properly atomizing the paint to be applied. 17.7 All the paint pot shall be equipped with suitable pressure regulators and gauges. 17.8 Paint shall be applied in a uniform layer with overlapping at the edges of the pattern. During application, the painting spray gun shall be held perpendicular to the surface which will ensure that a wet layer of paint is deposited on the surface. The trigger of the gun should be released at the end of each stroke. 17.9 The air caps, nozzles and needles shall be those recommended by the paint manufacturers of material being sprayed and equipment being used. 17.10 Traps or separators shall be provided to remove oil and condensed water from air. The traps or separators must be of adequate size and must be drained periodically during operations. 17.11 The pressure on the material in the pot and of the air at the gun shall be adjusted for optimum spraying effectiveness. 17.12 The pressure on the material in the pot shall be adjusted when necessary for changes in elevation of the gun above the pot. The atomizing air pressure At the gun shall be high enough to properly atomize the paint. 17.13 When spraying the spray gun should be held from 250 mm to 350 mm from the surface and maintained perpendicular to the surface throughout the stroke. At the end of each pass, the gun trigger should be released. 17.14 For airless application, the distance should be from each spray pass should overlap the previous one by 50%, and where possible, a cross hatch technique

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should be used. This requires a duplicate series of pass at 90o to the first to ensure complete and uniform coverage. 17.15 Paint shall not be applied when the temperature of steel or the paint is below 4o C. 17.16 Paint shall not be in rain, wind, fog, mist or when the steel surface temperature is less than 3o C above the dew point. 17.17 Paint shall not be applied when the relative humidity is above 80%. The manufacturers instructions shall be followed regarding the acceptable humidity range for the particular paint. 17.18 Paint thickness shall be in accordance with the customer requirements. 18. 18.1 INSPECTION AND TESTING Material receiving inspection

18.1.1 All the materials shall be inspected against the specified material specification and the mill certificate. 18.1.2 Upon receipt of materials/products, storekeeper shall verify the quantity, number of packing, type of materials, general appearance of materials and conformance against the requisition order, purchase documents, packing list and delivery order. He shall also make arrangements to request Q.C Inspector for receiving inspection. 18.1.3 Q.C Inspector shall carry out the following visual inspection upon receipt Of materials: General appearance Corrosion or pitting conditions Conformance to the purchase order Material identification (heat number) conformance to the Mill certificate.

18.1.4 All the welding consumables shall be in inspected before use.

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18.1.5 Material shall not be used for production until it has been inspected or verified as conforming to specified requirements. 18.2 In-process inspection and testing

18.2.1 In-process inspection shall be carried out in all stages of process in order to verify the conformance of the product against drawings and technical specification. 18.2.2 Product shall be hold until the required in process and test have been completed and shall be released for next process, only after acceptance by QC inspector. 18.2.3 If any part or item found nonconformity during in-process inspection and test shall be identified, segregated and hold until the items to be re-inspected and accepted by QC inspector. 18.2.4 Marking and cutting process a) b) The in- process inspection during marking and cutting process shall include: Checking of full scale template Verification of marking against the required dimension including any cutting allowance Verification of part number Transfer of heat number, when necessary Edge preparation in accordance to the drawing In-process inspection during marking and cutting shall be carried out by the marking/cutting group leader and the Q.C Supervisor / Engineer may witness the transfer of heat number when necessary.

18.2.5 Fit up process a) b) In process inspection during the fitting and assembly of the items Any non-conformance observed during inspection, QC supervisor shall fix a HOLD label and subsequently NCR to be raised.

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c)

Appropriate corrective action shall be carried out within the period stated in the NCR reports. Upon completion of satisfactory corrective action, the same item shall be re-inspected again in accordance with the requirements. If any items are not in conformance with the requirements after necessary repair and re-inspection, QC Engineer shall fix REJECT label and separate the item from the assembly line and further investigation to be conducted for the failure.

d)

18.2.6 Welding process a) QC Engineer shall verify the following conditions for conformity to the applicable specification, AWS D1.1 Edition 2008. b) Review of the welding procedure specification (WPS) Review of welding procedure qualification record (PQR) Review of welders performance test records Verification of the welders against their qualification badge number Verification of joint preparation, dimensions against design drawing and cleanliness Alignment and fit up of the pieces being welded. Welding process and consumables Condition of welding equipment and power sources Preheat temperature Condition of tack welding

QC Engineer/welding Supervisor shall inspect the following aspect during the welding process Treatment of tack welding Verification of corrective usage of electrodes and classification Verification of welder identification number written near the weld joint Inspection of quality of the root pass and the succeeding weld layers Ensure the sequence of welding

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Ensure the adequate cleaning of welding

Verify the root pass penetration prior to welding a second side and ensure the back chipping/grinding in accordance with the welding procedure specification. c) Any welding defect noticed by the QC Engineer who shall mark the defective area and subsequently the welding supervisor shall take necessary corrective action.

18.2.7 Non-destructive Inspection As applicable for jobs NDT inspection shall be carried out by subcontractor. Any non-conformance found through NDT test reports and the defects shall be identified by the paint/chalk and subsequently HOLD label shall be fixed to the defective area and NCR to be raised for necessary corrective action. 18.2.8 Painting inspection a) QC Engineer shall perform random inspection on the profile of the surface preparation. Surface profile comparator shall be used to verify the surface profile conformance. The following shall be inspected upon completion of painting: Required dry film thickness Dryness of the paint Completeness of coverage Brush mark, run sags etc. Adhesion of dry paint Specified number of coats Blisters, pores etc.

b)

18.2.9 Final inspection and testing a) The equipment shall not be dispatched or handed over to customer until all the activities specified in this work plan/quality plan, inspection & test plan including applicable records and documents have been satisfactorily completed.

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b) The final inspection activities shall include: Ensure all the previous inspection and tests have been performed The as-built configuration is the same as the issued status of all parts, sub assemblies, specified by the design standard. All the documented non-conformities have been resolved and remedial action taken and verified All customers and Engineers concession if any, has been approved. All the inspection and test records have been collected and complete the final inspection records and documentation. Any inspection and test result beyond the specified limit is either subject to an approved concession, an approved specification change or re-inspection which shows conformance with the requirements.

19. 19.1

CONTROL OF NONCONFORMING PRODUCT QC Engineer shall be responsible for review and disposition of non-conforming report. Al the non-conforming product shall be segregated from the routine process or from the conforming items. If the parts or items are heavy and too big, a HOLD label shall be fixed until the appropriate corrective action taken. Any item or part number that has been repaired, reworked and modified shall be re-inspected prior to it being released to further process or dispatch. Reinspection and test records shall indicate the original rejection, disposition and the result of the re-inspection. Upon completion of correction action, QC Engineer shall verify the effectiveness of the corrective action and records in the non-conformance report. NCR shall be closed once the corrective action is completed and satisfied. QC Engineer shall ensure that product which does not conform to the specified requirements is prevented from further processing or dispatch to the customer.

19.2

19.3

19.4

19.5

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20. 20.1

CORRECTIVE AND PREVENTIVE ACTION The QC Engineer shall be responsible for the execution of proposed corrective action for any customers complaint or comments and he is also responsible to submit the appropriate corrective action reports to customers representative when required. Corrective action shall include the documenting/recording both cause and proposed appropriate corrective action needed to eliminate the cause of nonconformities. The concerned action party shall report when the corrective action has been completed and the QC Engineer shall verify it. If QC Engineer determines the non-conformance is minor and the effect of nonconformities does not affect the performance of the product, it shall be recommended to use as it is without any corrective action. In case of product non-conformity is considered as major the QC Engineer shall recommend for repair the product to meet the requirements. In such case, the repair method and acceptance criteria shall be documented in the nonconformance report.

20.2

20.3

20.4

20.5

21. 21.1

STORAGE, PACKING, PRESERVATION AND DELIVERY Storage

21.1.1 Appropriate designated storage areas for raw materials and the equipment shall be planned in advance in order to prevent damage or deterioration. 21.1.2 After painting, the product shall be kept in open yard on the stable steel skid beams and there shall not be any deflection in the middle. 21.2. Preservation (protection)

21.2.1. Machined surfaces shall be coated with rust preventive grease

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21.2.2. All threads of bolt and nuts including any exposed parts should be coated with rust preventive grease or oil to prevent corrosion during storage. 21.3 Packing and marking Marking and identification shall be done clearly on the equipment and other packages and shall be in accordance with requirements, which is stated in contract or technical specification. 21.4 Delivery

21.4.1 Products shall be delivered to the Project site based on schedule and instruction to delivery from Customer Service Department (PEB STEEL). 21.4.2 Delivery/shipping documents as required shall be prepared by the Shipping Manager, Reviewed by Factory Manager and submit to CSD for review and final submission to customers/client.

22. 22.1

QUALITY RECORDS The following records shall be maintained to demonstrate to conformance of the goods to the requirements: Material Mill Certificate ( from the Manufacturer) Appropriate Welding Procedure Specification (WPS) Appropriate Procedure Qualification Record (PQR) List of Qualified Welder Involved in Welding Process Approved Welder Performance Qualification. Incoming Material Inspection Report In Process and Final Dimensional Inspection Report Secondary Inspection Report Final Welding Inspection Record Appropriate NDT Inspection Report

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22.2

Surface Preparation Inspection Report Painting Inspection Report Appropriate Non-conformance Report Pre Shipment Inspection Report Final Release Inspection Report

All the quality records shall be stored in the place having the facilities that provide a suitable environment to prevent damage or deterioration and to prevent loss.

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