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QA Programme – Construction of Transportation Engineering Projects

GENERAL QA Programme

for

Construction of Transportation Engineering

Projects

Doc. No. : TERF-001


Prepare : Program Manager
Review : Sr Program Manager
Approve : Program Director

0 DD/MM/YYYY Initial Release

Index Date Revisions Prepared Reviewed Approved


QA Programme – Construction of Transportation Engineering Projects
QA Programme – Construction of Transportation Engineering Projects

Table of Contents

Chapter 1. Management Responsibility

Chapter 2. Quality System

Chapter 3. Document and Data Control

Chapter 4. Material Identification and Traceability

Chapter 5. Inspection and Testing

Chapter 6. Control of Nonconforming Products

Chapter 7. Corrective Action

Chapter 8. Handling, Storage and Preservation

Chapter 9. Control of Quality Records

Chapter 10. Internal Audits

Chapter 11. Training

Chapter 12. Standard Forms Indexing System

Chapter 13. Control of Inspection, Measuring & Test Equipment


QA Programme – Construction of Transportation Engineering Projects

Chapter 1 – Management Responsibility

1.1 Quality Policy

This general QA Programme represents quality assurance policy and requirements for the
construction of Transportation Engineering projects .

The QA Programme is to provide objective evidence that the project’s mission will be effectively
completed. This will be accomplished by an integrated systems approach to quality assurance
and quality control, based on ISO 9002 quality management system.

The ultimate goal is to achieve project’s successful completion with quality engineering,
procurement, construction, commissioning and all of which is adequately documented. In this
respect, this QA Programme is to be used as a standard and this policy shall be understood,
implemented, and maintained at all levels in the organizations engaged in or concerned with the
project execution in accordance with the requirements of the contract documents.

For the overall implementation of the QA Programme, it also defines the fundamental
organizational structure and aims to complete the project work to the Engineer’s satisfaction.

All personnel including subcontractors shall faithfully observe all plans, specification, schedules,
instructions and recommendations provided or made by Contractor, for carrying out the project
work.

The Project Manager has the primary responsibility for project quality as delegated by the
Employer organisation.

-----------------------------------------
Director
Employer
QA Programme – Construction of Transportation Engineering Projects

Flow Chart Management by Objectives Chapter 1

Scope

All activities of the project

Procedure

Corresponding
Activity R A D
Document
1 Define targets and make known to all staff PM Overall Target
Schedule
2 Define sub targets All Staff Work Schedule per
Department
3 Strive to achieve targets All Staff
4 Evaluate target achievement All Staff Compare Planned/
Actual schedule
5 Corrective action >>>continue with Chapter All Staff PM
7
6 Revise targets >>>continue with 1 PM

R = Responsible / A = Assists / D = Decides, Approves


PM = Project Manager

Project Specific Targets

Item Target Controlling Instrument Interval Responsible


1 Costs
Meet Estimated Budgets Performance Report + Cost Monthly Planning Manager
Control
2 Dates
Meet Programme /mile Updated Time Schedule Monthly Planning Manager
stone Weekly Reports Weekly Planning Manager
Monthly Reports Monthly Planning Manager
3 Quality
Meet Requirement of Method Statement Construction
Specification & Drawing Manager / Works
Manager
Reduce Inferiority Inspection and Test Plan QA Manager
4 Safety on Site
Reduce Accident List of Sick Leaves Safety Manager
List of Accumulated
Accidents

Remarks:
These targets are made known to all staff on site, fulfillment or non-fulfillment of targets is made known to
all staff on site.
QA Programme – Construction of Transportation Engineering Projects

1.2 Organisation

1.2.1 Organisation of the project

1.2.1.1 Organisation Chart

Figure 1.1: Organization Chart

1.2.1.2 Coordination Committee


QA Programme – Construction of Concrete Cable Stayed Bridge across River Yamuna at Allahabad/Naini

1.2.2 Organization of the Site Management


QA Programme – Construction of Transportation Engineering Projects

1.2.3. Responsibilities of the Site Management

The Site Management shall act in accordance with the contract Agreement and the Contract
Documents.
The Site Management shall be responsible for the due execution of the works as defined by the
contract.
The following descriptions are the main tasks and responsibilities of the Site Management.

1.2.3.1 Project Manager

The Project Manager is the leading authority on site and responsible for all activities on site. He
is responsible for ensuring the execution and the maintenance of the works according to
contractual specifications, drawings and programme of work. He is responsible for the proper
execution of the following:

- Approve QA Programme, Method Statement and Inspection & Test Plan (ITP),
- Define and document quality policy,
- Take corrective action on the finding of internal quality audit,
- General technical administration,
- Define the structure of his team and control its composition,
- Manage relations with the Engineer / Employer,
- Select subcontractors and suppliers and sign subcontracts and purchase orders
(or authorise signature),
- Manage subcontractors and suppliers,
- Implement a management system for costs, time, technics, safety and quality,
- Supervise administrative and financial management of the project,
- Supervise the management of the personnel placed under his control.

1.2.3.2 Deputy Project Manager


has the responsibility to

- assist the Project Manager for achieving and improving quality.

1.2.3.3 QA Manager
has the responsibility to

- Manage Quality Assurance and Quality Control activities,


Prepare and control the QA Programme and Inspection & Test Plan (ITP),
- Manage submission of QA documents to the Engineer,
- Maintain the quality record.

1.2.3.4 Construction Manager / Works Manager


are responsible, within their scope of works, for ;

- Communication with the Engineer,


- Preparation of method statement (with the support of the Department Managers),
- Execution of temporary and permanent works,
- Follow up of purchasing of all necessary goods and materials for
the execution of the works,
- Management of subcontractors works, including preparation of subcontracts
and orders, with the support of the relevant department, if necessary,
- Monitoring the progress of the works,
- Executing the work in accordance with the Contract.
QA Programme – Construction of Transportation Engineering Project

1.2.3.5 Construction Engineer / Works Engineer


has the responsibility for

- Preparation of Daily Reports,


- Counter-checking alignments/levels by surveyor,
- Monitoring work progress and quality control,
- Planning ahead on construction materials ordering, hiring/buying machinery equipment
and tools for site issue,
- Recording daily work (including subcontractors’ daily work),
- Planning ahead of daily work,
- Safety of their works.

1.2.3.7 Planning Manager


has the responsibility for

- Planning,
- Review of QA Programme, Method Statement and Inspection & Test Plan (ITP),
- Preparation of Project Construction Schedule Updates,
- Monitoring of Progress against Construction Schedule and Clause 14 Programmes,
- Claim Preparation,
- Assistance to Administration Manager in Cash Flow Forecast Preparation.

1.2.3.8 Design Manager


has the responsibility for

- Design Temporary Works,


- Preparation of Shop Drawings,
- Support the Construction Manager / Works Manager for preparation of Method Statements,
- Review or Calculations for works,
- Maintenance of drawings,
- Preparation of inquiries and obtaining and comparing quotations.
- Preparation and Review of as built drawings.

1.2.3.9 Administration Manager


has the responsibility for

- General commercial administration,


- Cash flows,
- Financial matters,
- Insurance matters,
- Banking,
- Taxes and levies,
- Accounting,
- Personnel,
- Purchasing,
- Medical service,
- Camp.

1.2.3.10 Plant Manager


has the responsibility for

- Supporting the purchasing of new equipment,


- Maintenance of all equipment (service and repair),
- Maintenance and operation of all equipment at site.
QA Programme – Construction of Transportation Engineering Project

1.2.3.11 Safety Manager


has the responsibility to

- Manage site safety activities according to safely procedure (separate volume),


- Education of new workers,
- Keep safety requirements of specific method statement,
- Look after the personnel in illness and hurt.

1.2.3.12 Quality Control Manager


………has the responsibility to

1.2.4 Scope of Work

Sl.no. Section Contractor Scope Sub contractor Scope


1 Section-1

2 Section-2

3 Section-3

4 Section-4

5 Miscellaneou
s
QA Programme – Construction of Transportation Engineering Project

Chapter 2 - Quality System

The Quality Assurance System consists of:

- the description of organizational processes (QA documentation),


- the continuous supervision of the system,
- permanent improvement.

2.1 QA Documentation

The QA documentation is made up as follows:

- QA Programme
- Method Statements
- Quality Procedure / Work Procedure
- Inspection & Test Plan

Inspection & Test Plans shall be provided according to the chapter 5 (Inspection and
Testing) for at least every title where quality tests are required by the contractual
specifications. The Inspection and Test Plan has to be set up by the QA Manager with
support of organization who is in charge of the work (i.e. Construction Manager,
Works Manager, subcontractor).

2.2 System Control

The System Control is made up by

- Internal Quality Auditing,


- Quality Control.

Internal Quality Auditing has to ensure that all persons

- know their responsibilities,


- are familiar with their QA Plan,
- pay attention to the QA Plan,
- will help the QA Manager to improve and update the QA Plan for a better quality
and effectiveness on site.

Quality Control has to ensure that all works are carried out according to

- the contractual specifications,


- the corresponding standards,
- the method statements,
- the inspection & test plan.
QA Programme – Construction of Transportation Engineering Project

2.3 System Improvement.

If a product does not meet the contractual specifications, (also called


”Nonconforming Product”) it must be guaranteed, that the product will meet the
requirements by repairing or similar. The manner is ruled by the chapter 6 (Control
of Nonconforming Products).

If there is the possibility that any mistake is repeated,

- In case of technical problems: Corrective actions have to be carried out by


alteration of the regarding Method Statement and / or
- In case of organizational problems: Corrective actions have to be carried out by
alteration of the regarding chapters.

Besides the issuing of corrective action requests upon detected


nonconformance there is the preventive possibility for detected improvements

- In technical
- Organizational

regulations, where also corrective action requests can be issued.

The issuing and introduction of corrective actions is described in the chapter


7 (Cor-rective Actions).

2.4 Structure of Quality System

The quality system document hierarchy is same as below. In document structure of


quality system, the items of low level documents shall be consistent with requirements
of high level documents.

QA Plan
Level I

Method Statements
Level II Including Quality / Work *
Procedure,
Inspection & Test Plan

*These documents are may be prepared and submitted separately, if necessary.


QA Programme – Construction of Transportation Engineering Project

Chapter 3 – Document and Data Control

1. Purpose : To define a system for the control of document approval, issue and changes /
modification.

2. Scope : This chapter applies to all documents used in Transportation Engineering Project.
such as Quality Programme, Quality Procedure, Method Statement, Inspection &
Test Plan and Engineering and Technical Documents.

3. Reference : Chapter 12 - Standard Forms Indexing System

4. Definitions :

4.1 Documents

Any written information describing requirements of activities affecting quality.


Documents shall include QA Programme, Method Statement, Inspection & Test Plan and
Engineering and Technical Documents. If correspondence (e.g. letter, memo etc.) mentioned
serious subject about Quality or Technical data, it shall be maintained as document.

4.2 QA Programme (QAP)

Document setting out the specific quality implementation, resources and sequence of activities
relevant to an product, project or contract.

4.3 Quality Procedure / Work Procedure

A document that specifies or describes how an activity is to be performed for quality / work.

4.4 Method Statement

Working Method for Tradesman and Workers to follow when they perform a specific job.
As a minimum, the following points shall be included:

1. Scope of Work
2. References
3. Description of the Work
4. Responsibility
5. Plant and Equipment
6. Inspection, Testing and Survey
7. Safety
8. Appendices

4.5 Inspection & Test Plan

Documents which contain hold point, witness point, acceptance criteria and document required
according to sequence of inspection to ascertain quality.
QA Programme – Construction of Transportation Engineering Project
4.6 Controlled Copy

An identifiable copy of the QA Programme or its supporting Quality procedures and ITP which
is distributed, revised or replaced through a written Document Control Procedure that assures
the document reflects all current requirements.

4.7 Uncontrolled Copy

An identifiable copy of the QA Programme or document that is distributed through a Document


and Data Control Procedure with no assurance that later, the document reflects all current
requirements. These shall be for information only and shall not be used as reference to
perform work.

4.8 Engineering and Technical Documentation-

- Specification
- Drawings
- Calculations (CLC)
- Test Certificate Report (TCR)
- Engineer’s Instruction / Direction
- Confirmation of Verbal Instruction / Direction

5. Responsibility :

5.1 The Project Management shall be overall responsible for the control of Documents. (i.e., QA
Programme, Quality Procedure / Work Procedure, Method Statement, Inspection & Test Plan,
Drawings and Calculations)

5.2 The responsibility for each stage of the control of documents are defined in Annex 1.

5.3 QA Manager is responsible for taking out a unique document number of QA documents except
drawing, and Design Manager is responsible for taking out unique drawing number.

6. Procedure :

6.1 Internal Documents

6.1.1 Document Indexing System

Prepared documents by subcontractor may be indexed according to its own indexing


system.

6.1.1.1 The QA Programme shall be indexed as follows :

TEQA-XXX

TEQA = Transportation Engineering QA Programme


XXX = 3 Digit Running Section Number

6.1.1.2 The Quality Procedure / Work Procedure shall be indexed as follows :

QP-XXX / WP-XXX

QP / WP = Quality Procedures / Work Procedure


XXX = 3 Digit Running Procedure Number
QA Programme – Construction of Transportation Engineering Project

6.1.1.3 The supportive Form for QP / WP shall be indexed as follows :

QP-XXX-YY / Z (e.g. QP-001-01/A)


. WP-XXX-YY / Z (e.g. WP-001-01/A)

QP-XXX = Quality Procedures Number


WP-XXX = Work Procedures Number
YY = 2 Digit Running Form Number
/Z = Alphabet Numbering for Continuation Sheet (if there)

6.1.1.4 The Method Statement shall be indexed as follows :

CPS-X-MSP-YYY
.
CPS = Construction Plan and Specification
X = Module Number (‘0’ for two or more modules)
MSP = Method Statement
YYY = 3 Digit Running Method Statement Number

6.1.1.5 The supportive Form for Method Statement shall be indexed as follows :

CPS-X-MSP-YYY-ZZZ (e.g. CPS-1-MSP-001-001)


.
CPS = Construction Plan and Specification
X = Module Number (‘0’ for two or more modules)
MSP = Method Statement
YYY = 3 Digit Running Method Statement Number
ZZZ = 3 Digit Running Serial Number for Continuation Sheet
(if there)

6.1.1.6 The Inspection & Test Plan shall be indexed as follows :

ITP-XXX
.
ITP = Inspection & Test Plan
XXX = 3 Digit Running ITP Number

6.1.1.7 The Internal Drawing shall be indexed as follows :

TE-SX-YY-ZZZ

TE = Transportation Engineering
SX = section 0

YY = TD : Temporary Drawing
SK : Sketch
CS : Construction Drawing
AB : As-Built Drawing
ZZZ = 3 Digit Running Drawing Number

6.1.1.8 The Calculations shall be indexed as follows :

CPS-X-CLC-YYY

CPS = Construction Plan Specification


X = Module Number (‘0’ for two or more modules)
CLC = Calculation
YYY = 3 Digit Running Calculation Number
QA Programme – Construction of Transportation Engineering Project

6.1.1.9 For sub-title and sub-paragraph, use

1. 1.1 1.2 1.3 ...


2. 2.1 2.2 2.3 ...
3. 3.1 3.2 3.3 ...

6.1.1.10 The document indexing system for standard forms shall be followed in
accordance with chapter 12 (Standard forms indexing system).

6.1.2 List Indexing System

6.1.2.1 The Documents Master List shall be indexed as follows :

TE-DML-MX-YYY-ZZZ
TE = Transportation Engineering
DML = Document Master List
MX = Module Number (‘0’ for two or more modules)
YYY = Document Type (as QAP, QPS, MSP, TCR, ITP, Etc.)
ZZZ = 3 Digit Running Documents Master List Number

6.1.2.2 The Drawing Master List shall be indexed as follows :

TE-DWL-MX-YY-ZZZ
TE = Transportation Engineering
DWL = Drawing Master List
MX = Module Number (‘0’ for two or more modules)
YY = TD : Temporary Drawing
SK : Sketch
CS : Construction Drawing
AB : As-Built Drawing
ZZZ = 3 Digit Running Drawing Master List Number

6.1.3 Preparation, Review and Approval

All Documents must be reviewed and approved by the respective department


prior to issue.

6.1.3.1 QA Programme must be prepared by QA Manager, reviewed by Planning


Manager and approved by Project Manager.

6.1.3.2 Quality Procedures must be prepared by QA Manager, reviewed by


Planning Manager and approved by Project Manager.

6.1.3.3 Method Statement / Work Procedure must be prepared by Construction


Manager or Works Manager, reviewed by Planning Manager and
approved by Project Manager .

6.1.3.4 Inspection & Test Plan must be prepared by QA Manager (or QC


Engineer for HCC’s independent work), reviewed by Planning Manager
and approved by Project Manager.

6.1.3.5 Drawings must be prepared by Design Manager, reviewed by Planning


Manager and approved by Project Manager.
As built drawing control procedure (work procedure) must be
prepared by design manager reviewed by planning manager and
approved by project manager.
Calculations must be prepared by Design Engineer, reviewed by Design
Manager and approed by Planning Manager.
QA Programme – Construction of Transportation Engineering Project

6.1.4 Distribution

6.1.4.1 The Project Manager shall mark the “Document Distribution Sheet” for
distribution.

6.1.4.2 After approval of Document Distribution Sheet with documents by the Project
Manager, full set of documents are filed in Master File Shelf.

6.1.4.3 All following process shall be done in accordance with Annex 1 .

6.1.5 Documents Master List

6.1.5.1 All internal and external document except drawings shall be listed up in the
form of “Documents Master List” for identification of latest status of
documents.

6.1.5.2 The Documents to be listed in “Documents Master List” are as follows.


- Documents as mentioned above definition No. 4.2, 4.3, 4.4, 4.5 & 4.8
(except drawing)
- Appointed by Planning Manager

6.1.5.3 The “Documents Master List” may be prepared for each type of documents.

6.1.5.4 The “Documents Master List” shall be submitted to the Engineer 2 days
before each Site Meeting at least.

6.1.6 Revision Control

6.1.6.1 Change to documents shall be performed by department that carried out


original preparation unless specifically designated otherwise.

6.1.6.2 Revised portion shall be marked by typing them in bold and Italic letters.
Cloud mark with revision number shall be used for revised portion of
drawing, and cloud mark shall be used for revised portion of form.

6.1.6.3 The approved revised documents shall be controlled in accordance with


above paragraph 6.1.3, 6.1.4, & 6.1.5.

6.2 External Document s

6.2.1 Receipt

6.2.1.1 Upon receipt of document, the Document Controller shall check the following :

(a) Document bear the name and approved authorities;

(b) Correct document number, revision and pages;

(c) Legibility of the document.

6.2.1.2 All documents received shall be controlled in accordance with ANNEX 1 of this
chapter.
QA Programme – Construction of Transportation Engineering Project

6.2.2 Review

6.2.2.1 Project Manager shall review the incoming document and comments at remark
on the column.

6.2.2.2 Document reviewed will be distributed to various department as per ANNEX 1


attached.

6.2.2.3 Person who received the copied incoming document shall take an action
according to the comments by Project Manager.

6.2.3 Distribution

All documents received shall be distributed in accordance with ANNEX 1 of this


chapter.

6.2.4 Filing & Master Listing

6.2.4.1 All documents received shall be filed at Master File Shelf according to Master
Filing System in Annex 2 of this chapter.

6.2.4.2 The list-up of external documents shall be done in accordance with above
paragraph 6.1.5

6.3 Drawing Control

6.3.1 Receipt

6.3.1.1 Upon receipt of drawing, Document Controller shall perform the following
:

(a) List in Correspondence Logging Book


(b) Submit to Planning Manager for review

6.3.1.2 Planning Manager shall perform the following :

(a) Review the drawing received


(b) Submit to Project Manager for review and comment
(c) Hand-over to Design Engineer

6.3.1.3 Design Engineer shall perform the following :

(a) Check the correct drawing number, revision and pages


(b) List in Drawing Master List
(c) Submit to Design Manager to review and take an action

6.3.2 Registration

6.3.2.1 After checking and stamping of received drawings, the Design


Engineer shall list-up the received drawings in “Drawing Master List”.

6.3.2.2. The information of registration of drawing are as follows

- Drawing No.
- Drawing Title
- Revision No.
- Revision Date
- Issued Date
QA Programme – Construction of Transportation Engineering Project

6.3.2.3 Drawing Master List shall be distributed periodically by Design Engineer to the
relevant departments for cross checking the latest status.

6.3.3 Distribution

6.3.3.1 The received drawings are distributed to Construction Manager / Works


Manager by the Design Manager.

6.3.3.2 A Master Set of Drawings of this Project shall be kept by Design Manager.

6.3.3.3 The Construction Manager / Works Manager shall make the copies for
subcontractor. (if there)

6.3.3.4 When receive the Master Drawing List from Design Manager, this lists shall be
copied by Construction Manager / Works Manager and distributed to
subcontractor for cross checking the latest status.

6.3.3.5 The “Drawing Master List” shall be submitted to the Engineer 2 days before
each Site Meeting at least.

6.3.4 Control of Obsoleted Drawings

6.3.4.1 When receive the revised drawings, the Design Engineer shall check the
revision status.

6.3.4.2 If there are revised drawing , the obsolete drawings in Master Drawings shall
be stamped "Void" and separate storage.

6.3.4.3 When receive the revised drawings from Design Manager, the Construction
Manager / Works Manager promptly destroy the obsolete drawings after
replacing them with revised ones to assure the latest drawings are used.

6.3.4.4 Where the Construction Manager / Works Manager require obsolete drawings
for their retention, this may be permitted but it shall be clearly identified with
the “Void” stamp.

6.3.4.5 The Construction Manager / Works Manager shall perform the checking at all
times that subcontractors are using latest drawing.

6.3.5 Control of Internal Drawings

6.3.5.1 The Design Engineer is responsible to collect relevant information from vendor
/ subcontractor in order to prepare shop drawings/ coordination drawings.

6.3.5.2 The Design Manager is responsible to check for discrepancies / compliance to


specification and consultant drawings.

6.3.5.3 The Planning Manager is responsible to submit drawing to The Engineer for
approval. He shall obtain The Engineer’s approval letter or endorsement.

6.3.5.4 All process of internal drawings are same as Annex 1 of Outgoing.


QA Programme – Construction of Transportation Engineering Project

ANNEX 1 - FLOW CHART OF DOCUMENT CONTROL

INTERNAL DOCUMENTS

No. ACTIVITY CONTENT OF ACTION ACTIONED BY

S BEFORE HAND OVER 1. Issue, Review in organization Relevant Engineer or


T TO PLANNING Personnel / Manager
E MANAGER Department Engineer
P

1.

S 1. Submit to Planning Manager for review Document Controller


T RECEIVE THE
E DOCUMENTS TO BE 2. Submit to Project Manager Planning Manager
P OUTGOING

2.

S 1. Review the content and approval Project Manager


T
E SUBMIT TO PROJECT 2. Assign the ref. Number taken from Correspondence Document Controller
P MANAGER Logging Book (Outgoing).
& ISSUE
3. 3. Issue for Outgoing Document Controller

S 1. Direct to Copy & distribute to Relevant Organisation Planning Manager


T DISTRIBUTION TO
E 2. Copy & distribute to relevant organization
RELEVANT
P Document Controller
ORGANIZATION
2. Filing at Master File Shelf
4. Document Controller
QA Programme – Construction of Transportation Engineering Project

EXTERNAL DOCUMENTS

No. ACTIVITY CONTENT OF ACTION ACTIONED BY

1. Chopping the Stamp for Circulation Document Controller


S
T 2. Listed in Correspondence Logging Book (Incoming) Document Controller
RECEIPTION
E
P 3. Submit to Planning Manager for review Document Controller

1. 4. Review the content Planning Manager

5. Submit to Project Manager for review Planning Manager

S 1. Review the content Project Manager


T SUBMIT TO PROJECT
E MANAGER 2. Return to Planning Manager to circulate Project Manager
P
3. Copy to relevant department Document Controller
2.
4. Filing at Master File Shelf Document Controller

S DISTRIBUTE TO 1. Review the Content Department Manager


T RELEVANT
E DEPARTMENT 2. Circulate within Department Department Manager
P
3. Action if required Department Engineer
3.
QA Programme – Construction of Transportation Engineering Project

ANNEX 2 - MASTER FILING SYSTEM

FILE NUMBERING SYSTEM

AAA - XXX - YY / ZZ

2 Digit Running File Number

ISSUED FM = From company to


TO = From
MT = Maintain Document

Type of Documents
COR = General Correspondence (Letter)
DWG = Drawing
CLC = Calculation
IND = The Engineer’s Instruction / Direction
COV = Confirmation of Verbal Instruction / Direction
DML = Document Master List
DWL = Drawing Master List
QAP = QA Programme
MSP = Method Statements
QPS = Quality Procedure
ITP = Inspection and Test Plan
TCR = Test Certificate Report
CLC = Calculations
NCR = Nonconformance Report
WPS = Work Procedure
I & TP = Inspection & Test Procedure

COMPANY CODE , Alphabetic 3~4 Character


NHA = National Highways Authority of India / Employer
 If the type of documents or company Code are required increasing or decreasing, the new Codes will assigned by
Planning Manager.
QA Programme – Construction of Transportation Engineering Project

ANNEX 3 - SAMPLE STAMP

For Document

Project Name .
Project Name SR.ENGR
P ENGR. MGR PM
L .
- - 200 A
N
PM
PLAN C
ADMIN O
N
CONST
DESIGN A ASST STAFF MGR
W/SHOP D
M
N
VOID

For Drawing

For Reference For Approval For Construction

VOID Preliminary
QA Programme – Construction of Transportation Engineering project
QA Programme – Construction of Transportation Engineering project

Chapter 4 – Material Identification and Traceability

1. Purpose : To define a system for the identification and traceability of materials during all stages
of construction.

2. Scope : This chapter applies to the Identification and traceability of materials.

3. Reference : Table 1 - Material Identification & traceability Requirement

4. Responsibility

The Planning Manager and / or Construction Manager / Works Manager are responsible for the
identification and traceability of materials.

5. Procedure :

5.1 General Requirement

5.1.1 Material Identification

5.1.1.1 Material for permanent construction


The project staff shall ensure the materials received at site are identical to
approved specifications, drawings or catalogues (Brand, Model, Dimension,
Specification).

5.1.1.2 When prepare the Purchasing data, Identification requirements [making of Heat /
Batch / Lot No., Dimension, type, related Code No., etc.] shall be included in
Purchase Order for identification of Material by Planning Manager.

5.1.1.3 All materials shall be identified and segregated using label, tagging, marking or
post in warehouse or storage area.

5.1.1.4 The identification of completed works (material) is provided by the Drawings


(such as Module Number, Drawing Nos., Block Nos.,) during and final
construction.

5.1.2 Document Traceability

5.1.2.1 When the Traceability is a specified requirements for specific materials, following
activities should be done by QA Manager.

- Set-up the Material list for Traceability (See Table 2)


- Prepare the document for Traceability before the material is used on site.
- Prepare the Inspection / Test report form for Traceability

5.1.2.2 The Inspection & Test Reports for required traceability shall include the following
informations for traceability :

- Description of inspected / tested materials


- Inspected / Tested date
- Description of the identification marking
- Inspected / Tested location or Agency name.

5.1.2.3 Working daily reports and other type of construction reports are used for trace
the history and location of materials or activities.
QA Programme – Construction of Transportation Engineering project

T ABLE 1 - DOCUMENT IDENTIFICATION & TRACEABILITY REQUIREMENTS

Item No. Document Name Required Identification

A Project Files and relevant documents /  Project Name


correspondence inside the file  Reference No.
 Issuing Date

B Supplier File (P.O. / Agreement)  Project Name


 Name of Supplier
 Purchase Agreement
Number

C Subcontractor File (P. O. / Agreement)  Project Name


 Name of Subcontractor
 Purchase Agreement
Number

D QA Programme / Method Statement  Project Name


/ Quality Procedure / Work Procedure  Date of Release
 Name of Person for
preparation
 Name of Person for
review

E Inspection / Test Reports  Project Name


 Type / Reference Number
 Location
 Date
 Name, Title and
Signature of Inspector
QA Programme – Construction of Transportation Engineering project

TABLE 2 - MATERIAL IDENTIFICATION & TRACEABILITY REQUIREMENTS

Item No. Material Required Identification


1 Cement Batch No on bag / MTC / D.O
(indicating MTC No.)
2 Coarse Aggregate Lab. Certificate
3 Sand Lab. Certificate
4 Reinforcement MTC / D.O (indicating MTC No.)
5 Stainless Steel MTC / D.O
6 Bearings MTC / Inspection Release Note /
Tag. No. with Bearing
7 Expansion Joint MTC / D.O
8 Concrete Admixtures Supplier / Manufacturer Name /
Brand Name /
Batch No. on containers / MTC
9 Structural Steel MTC / D.O (indicating MTC No.)
10 Reinforced Cement Concrete Pipe MTC / Inspection Release Note
11 Epoxy Mortar MTC for each batch
12 Anchor Bolt & Nut MTC / D.O
13 Connection Bolt & Nut MTC / D.O
14 Ladder, Handrail, Material access MTC of basic material / D.O
Facilities
15 Steel Pipe MTC / D.O (Indicating MTC No.)
16 Prestressed Steel Reinforcement Test Certificate
17 Anchorages & Tendon Couplers Test Certificate
18 Equipment Calibration Certificate
Tag No. with validity date
19 Concrete Concrete Requisition Slip /
Delivery Slip (indicating location,
starting time and delivery time) /
Grade of Concrete / Slump
20 Grouting Material Batch No. on bag. /
MTC / D.O (indicating Batch No.)
21 Paint MTC / D.O
22 Welding Electrode MTC / D.O
23 Bitumen MTC / D.O

MTC = Mill Test Certificate


D.O = Delivery Order
QA Programme – Construction of Transportation Engineering Project

Chapter 5 – Inspection and Testing

1. Purpose : To define the system for the inspection and testing of materials / works to specify
requirements and the necessary controls to achieve and maintain the required
standard.

2. Scope : This chapter applies to the Transportation Engineering project for Inspection & Test
activities.

3. Reference : chapter 4 - Material Identification and traceability


chapter 6 - Control of nonconforming Products
chapter 7 - Corrective Action.
Applicable Method statement.

4. Responsibility

4.1 The QA Manager is responsible to ensure that materials / works are duly inspected and tested
to specified requirements, and necessary controls are taken to achieve and maintain the
required standard as per contractual specification.

4.2 The QC Engineer is responsible for the proper identification of inspection and test status and
ensuring that only materials that has passed the required inspection and test are dispatched or
used.

4.3 The QC Engineer who manage the respective inspection and test of incoming materials,
intermediary and completed works shall ensure that the following identification requirements are
met.

4.4 The QC Engineer holds the responsibility and authority for the release of conforming materials /
works.

4.5 QA Manager is responsible to prepare the ITP before start of Inspection & Test.

4.6 In case the work involve subcontractors, Contractor programme will be issued to the
subcontractor. Construction Manager / Works Manager will request the subcontractor to comply
with the QA programme and:

4.6.1 Subcontractor should be responsible for their own testing and inspection. Report and
findings of the inspection should be submitted to contractor for record and monitoring
purpose.
4.6.2 QA Manager will conduct a periodic check on subcontractor’s site work to ensure that
subcontractor is complying with the quality requirement.

5. Procedure :

5.1 Inspection and Test Plan

The followings shall be apply to both Contractor ITP and subcontractors ITP:

5.1.1 The QA Manager shall ensure that Inspections & Tests, including those submitted by
subcontractors, are carried out in accordance with the Inspection & Test Plan [ITP].

5.1.2 The QA Manager shall ensure that all relevant contractual specifications and method
statement are clearly stated when preparing the Inspection & Test Plan.

5.1.3 All construction materials that will affect the work quality shall be performed with the
receiving inspection.

5.1.4 The Project Manager shall check the above prior to approving the Inspection & Test Plan.
QA Programme – Construction of Transportation Engineering Project

5.2 Inspection and Test

Reference should be made with the Inspection & Test Plan for Works and Material.

5.2.1 Receiving Inspection & Testing

a) QC Engineer shall ensure that the material / supplies are inspected and tested as
planned and in accordance with the Inspection & Test Plan. He shall also ensure
that the specified records are maintained.

b) For subcontractor, subcontractor is responsible for their own material inspection &
testing. All inspection and testing record and findings to be submitted to the
contractor for record and monitoring. QA Manager will carry out periodic check to
ensure all materials of the subcontractor are comply to standard.

5.2.2 Inspection & Testing during Construction

a) QC Engineer shall ensure the intermediary and completed works are Inspected and
tested as planned and in accordance with the Inspection & Test Plan. He shall also
ensure that the specified records are maintained.

b) Subcontractor’s own QC will carry out their own inspection and testing according to
their own ITP. QA Manager will carry out periodic check to ensure work quality.

5.2.3 Final Inspection

a) QC Engineer shall ensure the works, including those done by the subcontractor, are
inspected in accordance with the Inspection & Test Plan. He shall also ensure the
specified records are maintained.

b) No works shall be released until all the activities specified in the Inspection & Test
Plan for Materials and Works have been satisfactorily completed and the
associated records are available and authorized by Construction Manager and
Works Manager.

5.3 Review and Interpretation of Test Reports

5.3.1 The QA Manager / QC Engineer is responsible to review and interpret the test
reports for all materials and completed works, including those of the
subcontractors.

5.3.2 The test reports shall be reviewed based on the acceptance criteria set in the
Inspection & Test Plan.

5.3.3 The QA Manager / QC Engineer shall endorse on all test reports, including those
of the subcontractors, that have been reviewed.

5.3.4 If the materials / works fail to meet the criteria, chapter 6 shall apply.

5.4 Use Of Un-inspected Materials

5.4.1 In the event, materials are not inspected due to urgent production purposes, the
Project Manager shall authorize the QA Manager to draw samples and the lots
shall be positively identified. The location where the materials are used shall be
recordedin the Remarks column of the “Store Record Sheet”. The samples shall
be inspected at a later stage and in the case when materials failed, the affected
works shall be put on hold pending decision by Material Review Meeting.
QA Programme – Construction of Transportation Engineering Project

Reference shall be made to according the chapter 6 – control of nonconforming


Product.

5.5 Summary Of Inspection & Test Responsibility

Inspection Ref. Quality Responsible


Stage Quality Records
Item Plan Person
R.I Material - Purchasing QC Engineer Delivery Order with
Spec. Accepted / Rejected
Marks
- ITP for
Material

I. I Works in ITP for Works QC Engineer Inspection / Test


Progress Reports

F. I Finished Contract QA Manager / Inspection / Test


Works Specification QC Engineer / Reports
subcontractor

R. I = Receiving Inspection
I. I = In-process Inspection
F. I = Final Inspection

5.6 Inspection & Test Status

The results of each stage of Inspection & Tests are identified as follows

Stage Accepted Rejected

A. Receiving Materials are placed on Tag a ‘Rejected’ sign or


Inspection the location indicated in segregated “rejected”
the project facilities area
layout plan

B. Construction Mark ‘X’ on rejected area


Process on relevant layout
drawings

C. Finished Works No defects listed in unit Described on Punch list


layout plan
QA Programme – Construction of Transportation Engineering Project

Chapter 6 – Control of Nonconforming Products

1. Purpose : To define a control and review system to prevent the inadvertent use or release of
nonconforming materials / works and to reach a consensus on the disposition of
them.

2. Scope : This chapter applies to the Transportation Engineering Project to the materials,
intermediary and final works.

3. Reference : chapter 5 - Inspection & Testing

4. Responsibility

4.1 The QC Engineer shall be responsible for the control of nonconforming materials / works and
preventing the inadvertent use or release of nonconforming materials / works.

4.2 The QA Manager that manages the respective inspection and test of materials, intermediary and
final works shall ensure that the identification, segregation and documentation of nonconforming
materials / works are properly made.

4.3 The Project Manager shall be responsible for decision on disposition of nonconforming materials
/ works.

5. Procedure :

5.1 General Requirements

5.1.1 Identification and Segregation


The nonconforming materials / works shall be identified as per chapter 5 (Inspection and
Testing).

5.1.2 Documentation
The descriptions and data of the nonconforming materials / works shall be recorded in
the “Nonconformance Report”.

5.1.3 Notification
Recommended corrective action will be initiated by the QA Manager and taken by the
organisation responsible for the nonconforming materials / works.

5.2 Review and Disposition

5.2.1 When the nature of nonconformity is beyond the decision of Project Manager, he should
open a Review Meeting. The meeting shall be delegated by the respective organisation.

5.2.2 Roles and Authorities

Each member with practical expertise in his discipline is authorized to make decision
within his discipline.

5.2.2.1 Project Manager shall advise on the feasibility of rework, the impact on project
schedule and storage issues. He shall make the final decision on disposition of
all nonconformances.

5.2.2.2 QA Manager shall also advise on the contractual specification pertaining to the
use or rework of the nonconformances for necessary action.

Doc. No. : YBQA-001 Rev. No. : 3 Page No : 31/47 Chapter 6 – Control of Nonconforming
Products
QA Programme – Construction of Transportation Engineering Project

5.2.2.3 Planning Manager and Construction Manager / Works Manager shall advise on
the cost impact, specification and contract implications. He shall liaise with the
Engineer and / or the supplier / subcontractor on the nonconformances for
necessary action.

5.2.3 Disposition Options and Conditions

(a) Use As It Is (Use for Same Process)

To accept materials or works with a minor nonconformance for use without correcting
the nonconformance, if the materials or works are determined to be satisfactory for
their intended purpose and such use is acceptable to the Engineer.

(b) Repair

To carry out minor rectifications / repair work on nonconformity, it shall be inspected


by the Engineer during work.

(c) Rework

To subject to a process which restores nonconforming materials or works to full


conformance to contractual requirements, specifications and drawings. (Reworked
materials / works shall be re-inspected in accordance with the applicable ITP).

(d) Reject

To return to supplier as materials are not useable.

(e) Scrap

To dispose the materials which are not consumable. The members must give
accurate and practical advice. A group consensus on the disposition and corrective
action shall be reached. In the event of any dispute, the matter shall be referred to
the Project Manager.

5.2.4 Documentation

The "Nonconformance Report" shall be prepared by personnel who found


nonconformance. The Project Manager shall ensure that reason to justify the group
decision on the disposition to "use as it is" is documented in the report. The
nonconformance report shall be submitted to the Engineer for approval of proposed
disposition immediately.

5.2.5 Corrective Action

5.2.5.1 The Project Manager shall ensure that corrective action is taken by the
organisation (i.e. Vendor or staff etc.) who is responsible for the
nonconforming materials or works.

5.2.5.2 “Nonconformance Report” shall be issued to the respective organisation.


After completion of nonconformance, the respective organisation shall notify
to the personnel who found nonconformance for verification.

5.2.5.3 If the results are satisfactory, the QA Manager shall close out the NCR.

5.2.5.4 The closed out NCR shall be controlled in accordance with chapter 9
(control of quality records).

Doc. No. : YBQA-001 Rev. No. : 3 Page No : 32/47 Chapter 6 – Control of Nonconforming
Products
QA Programme – Construction of Concrete Cable Stayed Bridge across River Yamuna at
Allahabad/Naini

Chapter 7 – Corrective Action

1. Purpose : To define a Corrective Action System to ensure that the root cause of
nonconformance is promptly analyzed and effective corrective actions are
taken to prevent recurrence.

2. Scope : This chapter applies to all organizations.

3. Reference : chapter 3 - Document & Data Control


chapter 6 - Nonconforming Product Control
chapter 10 - Internal Quality Audit

4. Procedure

4.1 Responsibility

4.1.1 The responsible department manager for the nonconforming product shall ensure that
root cause of nonconforming product is promptly analyzed and effective corrective
actions are taken to prevent recurrence.

4.1.2 All staff has the responsibility to identify any potential product quality problem and
initiate preventive actions to prevent its occurrence.

4.2 The Engineer Complaint / Corrective Action

4.2.1 The Project Manager shall be responsible to take the appropriate action upon receipt
of complaint / feedback from the Engineer either in writing or verbal. In case of verbal
compliant from the Engineer, the “The Engineer Complaint Report” to be initiated by
who received complaint from the Engineer. Either way, the complaints shall be
reported to the responsible department manager.

4.2.2 Responsible department manager shall report to Project Manager or his related and
hold the meeting with related functional Department Manager, if required.

4.2.3 Responsible department manager shall participate jointly with other related functional
departments in identifying the root cause to the complaint and initiating corrective
actions of the problem.

4.2.4 If the root cause of the nonconformity shows that it was originated from the supplied
material, clause 4.3 of this chapter shall follow.

4.2.5 The responsible department manager shall take necessary actions promptly and
ensure that the corrective actions are effective to prevent recurrence of the problem.

4.2.6 The Project Manager or his delegate shall follow-up on the corrective action
commitment, verify the implementation.

4.2.7 The responsible department manager shall feedback to the Engineer, the corrective
action taken if requested by the Engineer.

4.2.8 Upon receipt of the Engineer positive reaction to the feedback given, the Project
Manager or his delegate shall close the case. For verbal complaint, Project Manager or
his delegate shall complete the “The Engineer Complaint Report”. For written
complaint, Project Manager or his delegate shall write back to the Engineer to report
completion of rectification works.
QA Programme – Construction of Concrete Cable Stayed Bridge across River Yamuna at
Allahabad/Naini

4.3 Supplier / Subcontractor Corrective Action

4.3.1 The respective responsible Managers or his delegate having a material / workmanship
quality problem shall notify the content of nonconformity to the supplier or
subcontractor respectively by means of site memorandum, nonconformance report or
letter according to a degree appropriate to the magnitude of problems and complexity.

4.3.2 The responsible Manager or his delegate shall ensure that the supplier / subcontractor
responds with a detailed corrective action plan within the stipulated date. If required,
submit the corrective action plan for the Engineer’s / Design Manager’s approval.

4.3.3 The responsible Manager or his delegate shall review the supplier’s / subcontractor’s
response, and, either close the case if the response is acceptable, or follow-up the
case if the response is unacceptable.

4.4 Project (Works) Corrective Action

4.4.1 Project corrective action may be issued by any department whose function is affected
by the nonconforming product, practices or services of another Department. This shall
be documented in an “Nonconformance Report” Form in the chapter 6 (Control of
nonconforming products).

4.4.2 The responsible Department for action to correct the nonconformity shall reply within
one week unless it is justifiable that more time is needed due to complexity of the
problem.

4.5 System Corrective Action

Nonconformity detected during Internal Quality Audits should be recorded and closed-out by
the QA Manager.

4.6 Corrective Action Status Log

A “Corrective Action Request Log” shall be maintained by the QA Manager.

4.7 The responsible Department Manager shall implement and record any change in chapter
resulting from corrective actions. This shall be carried out in accordance with the chapter 3 -
Document & Data Control.

4.8 Follow-up of Corrective Action

All corrective action issued as per clause 4.2, 4.3, 4.4 and 4.5 shall be verified-out by the QA
Manager, and if necessary, a follow-up visit is to evaluate the effectiveness of its
implementation.
QA Programme – Construction of Transportation Engineering Project

Chapter 8 – Handling, Storage and Preservation

1. Purpose : To define methods or system for handling, storage and preservation of products
to prevent damage, deterioration, or loss and final inspection and hand over of
completed project.

2. Scope : This chapter applies to Transportation Engineering Project.

3. Reference : Applicable method statement.

4. Responsibility

4.1 The Construction Manager / Works Manager is responsible for the proper handling
and protection of materials / works at all stages.

4.2 The Field Engineer is responsible to ensure material in such a way that they do not
suffer damage, deterioration or loss.

4.3 The Project Manager is responsible for the planing and coordination of final inspection
and hand over of the completed project to the Employer after final inspection and test.

5. Procedure :

5.1 Handling

5.1.1 All operators of handling equipment, that is, excavator/crane, etc. shall be
experienced
in the proper use of the equipment. Field Engineer shall ensure that workers
involved in handling and transportation activities observe the applicable method
statement.

5.1.2 The following table shows the Handling Precautions (Do’s & Don’t):

Material/ Handling Precaution


Product Equipment (Do’s & Don’t)

Re-bar crane 1. During hoisting, ensure proper balancing


2. & securing of the load

Bag Cement Forklift, crane 3. Do not wet the bags


4. Do not burst/puncture the bags

Pipe Crane 5. Bundle tightly

Equipment Crane/Lift 6. Bundle tightly

The Others Manufacturer’s Follow Manufacturer’s instruction to


instruction prevent damage

5.2 Storage

5.2.1 The materials shall be stored in accordance to the storage locations identified.

5.2.2 Materials shall be issued on a “First-In First-Out” basis.


QA Programme – Construction of Transportation Engineering Project

5.2.3 The QC Engineer shall conduct a monthly assessment of the stock condition. He
shall use the “Stock Condition Assessment Checklist / Report” to perform the
assessment

The following table shows the Storage Precautions (Do’s & Don’t) :

Material / Storage
Precautions (Do’s & Don’t)
Product
Location Method

Re-bar Open store on Do not mix difference dias.


timber runners or Cover with canvas in bad
concrete bar weather
Do not block access to
vehicles

Bag Sheltere Placed on Do not allow contact with


Cement d Store pallets lifted 300mm moisture
above ground Do not exceed 10 bags
stacking

Pipes Open on timber Ensure that wooden frames


runners at each end are secured for thin
walled pipes

The Manufacturer’s Manufacturer's Follow Manufacturer’s instruction to


Others instruction instruction prevent damage

5.3 Packaging and Preservation

5.3.1 The Construction Manager / Works Manager or his delegate (e.g. Field Engineer, or
subcontractor) shall ensure that the completed project / works and completed works
by subcontractors are protected to ensure conformance to customer.

5.3.2 All internal areas and facilities within the building and all external areas and
facilities shall be cleaned, locked or barricaded and / or cleared of debris and
prevented from unauthorized use, damage and deterioration.

5.3.3 Additional protection measures arising from or required to meet contractual


requirements shall be observed.

5.3.4 In General

- Patch up chipped surface and touch-up using similar paint color.


- Barricade and lock up all the access to prevent unauthorized entry for internal area.
- Lock up all windows, main doors and gates of internal area.
5.4 Delivery

5.4.1 The Project Manager or his delegate shall plan and coordinate the final inspection /
testing of all services and facilities by relevant authorities.

5.4.2 The Project Manager or his delegate shall assign the Engineer / QC Engineer to
carry out final defect checking with respective subcontractors. The “Punch List” shall
be prepared. The Project Manager or his delegate shall verify and carry out random
check on the inspected units.

5.4.3 Punch list shall be rectified by the responsible organisation. All defects due to
subcontractors shall be rectified by the respective subcontractors.
QA Programme – Construction of Transportation Engineering Project

5.4.4 The defective areas shall be re-checked by the Field Engineer and subcontractor to
ensure the defect has been rectified.

5.4.5 The QA Manager or his delegate for the Engineer’s representative to inspect the
works, it shall be done after defective areas have been rectified.

5.4.6 The Project Manager or his delegate shall prepare and compile the necessary
documents such as Warranty Certificate / Test Certificates for the Engineer.

5.4.7 Any defects found by the Engineer’s representative shall be rectified and recorded.
QA Programme – Construction of Transportation Engineering Project

Chapter 9 – Control of Quality Records

1. Purpose : To define controls for the identification, collection, indexing, filing, storage,
maintenance and disposition of quality records.

2. Scope : This chapter applies to the Project.

3. Reference : chapter 3 - Document & Data Control

4. Responsibility

4.1 The Managers (See table 1) are responsible to provide instruction for the completion and
storage of quality records that must be kept for historical purposes. He is to ensure quality
records are legible and identifiable to the products and every alteration made on the quality
record is to be counter signed by the Originator or by his immediate Superior.

4.2 The Managers (See table 1) are responsible for the identification, collection, indexing, filing,
accessing storage, maintenance and disposition of quality records. Refer to Table 1 - List of
Quality Records.

5. Procedure :

5.1 Accessing, Storage, Maintenance and Disposition of Records (Active & Inactive)

5.1.1 Records including those submitted by pertinent subcontractors shall be made readily
available for review at the request of the Engineer or other responsible organisation.
Records shall be listed in Records Master List which includes as a minimum,
- Records title
- Records I/D No.
- Storage Location or box, file No.

5.1.2 Accessing of Quality records shall be approved by the Authorized staff and recorded
in the record accessing log.

5.1.3 Records shall be segregated, logged and boxed as of the last working date of the
fiscal year, or their warrant periods.

5.1.4 Records shall be stored and maintained in facilities that allow easy retrieval and
provide suitable environment to minimize deterioration or damage and to prevent
loss.

5.1.5 Records shall be stored by receipt of “Certificate of Practical Completion” from the
Engineer.

5.1.6 Subcontractor will be contacted regarding disposition of their records when specified
in the contract.
QA Programme – Construction of Transportation Engineering Project

Table 1 - List of Quality Records

Index of Form Description of Quality Records / Form Retention Time Location & Responsible
Number manager of File

QP-009-01 Minutes of Meeting - Management Review Until finish the Planning


Project

QP-009-26 Audit Plan Until finish the


QP-009-28 Audit Summary Report Project QA

QP-009-20 The Engineer Complaint Report Until finish the


QP-009-21 Internal Corrective Action Request Project QA

QP-009-05 Documents Master List Until finish the QA


QP-009-07 Drawing Master List Project Design

- Inspection and Test Report Until finish the QA / QC


Project

QP-009-18 Nonconformance Report Until finish the QA


Project

QP-009-32 Training Plan Until finish the QA


QP-009-33 Training Attendance Record Project

- QA Programme
- Quality / Work Procedure
Until finish the
- Method Statement QA
Project
- Calculation
- Test Certificate Report

Until finish the


- Drawings Design
Project

- Contract Specification Until finish the Planning


(including Technical Spec.) Project
QA Programme – Construction of Transportation Engineering Project

Chapter 10 – Internal Quality Audits

1. Purpose : To define a system for the conduct of Internal Quality Audit to verify whether quality
activities and related results comply with planned arrangements and to evaluate the
effectiveness of the implementation of the Quality System.

2. Scope : This chapter applies to the Transportation Project.

3. Reference : Nil

4. Definitions

4.1 Audit Team Member is a person who has the qualification and is authorized to perform a
Quality System audit.

4.2 Audit Team Leader is a person who has the qualification and is authorized to manage a team
of Auditors.

4.3 Auditee is the person being audited.

5. Responsibility

5.1 The Internal Quality Audit shall be performed by qualified auditor in Head Office. If the Head
Office Audit Team is not available for the site, the Project Manager shall appoint Planning
Manager (for QA Department) and QA Manager (for the other organization) as Auditor. In this
case, forms for audit may be used standard forms in Transportation Engineering Project
procedure (Standerd forms for QA procedure : QP-009).

5.2 The QA Manager

- Establish the Annual Quality Audit Program


- This program shall confirm with Manager of Quality Assurance Office in Head Office for
smooth progress of Internal Quality Audit.
- Review the Quality Audit Results performed by the Internal Quality Audit Team
- Report to Project Manager on the effectiveness of the Quality System.
- Audit organisation except QA Department in according to Head Office internal audit
procedure. (if the Head Office Audit Team is not available for the site).

5.3 The Planning Manager

- Audit QA Department in according to Head Office internal audit procedure (if the Head
Office Audit Team is not available for the site).

5.3 The Audit Team Leader shall oversee the internal quality audit activities and enforce the
implementation of outstanding corrective actions. He shall report to the Project Manager on
the findings of each auditing cycle.

5.4 The Audit Team Member is to carry out the instructions as layout by the Audit Team Leader.

5.5 The individual Department Manager responsible for the area audited shall review, agree and
correct the Audit Finding items. He shall ensure the effectiveness of the corrective actions.
QA Programme – Construction of Transportation Engineering Project

6. Procedure :

6.1 The detail procedure of Internal Quality Audits shall be done in accordance with latest version
of Head office Internal quality audit procedure.

6.2 The Department Manager shall take action on the “Audit Finding Report” until the
recommended date in those request sheet.

6.3 After completion of “Audit Finding Report”, the Project Manager shall review and signed on
those report and this report sent to Head Office.

6.4 The QA Manager is responsible to ensure that the Quality System of the Project is
implemented and maintained.

6.5 All copy of reports related to the Internal Quality Audit shall kept (filing) by QA Manager for
using the back-data of Coordinate Committee Review.
QA Programme – Construction of Transportation Engineering Project

Chapter 11 - Training

1. Purpose : To define the system for identifying the training needs and providing for the
training of all personnel performing activities affecting quality.

2. Scope : This chapter applies to the Transportation Engineering Project overseeing


the training need of staff performing activities affecting quality.

3. Reference : Nil

4. Responsibility

4.1 The Project Manager is responsible for approving of yearly training schedule.

4.2 QA Manager is responsible for the execution of the training and maintain the training
records.

5. Training needs identified :

Training Description Training Training Method Remark


Course no.

1 New System Introduced All staff Education

2 Use new tech. & method Con. staff Education or OJT or


Cube test control Exercise

New recruitment Recruitment OJT (On-Job-Training)


3 Implementation of Regulation All worker Training on commission
- Safety course
QA Programme – Construction of Transportation Engineering Project

Chapter 12 – Standard Forms Indexing System

1. Purpose : To define the system for identifying the indexing system for standard forms.

2. Scope : This chapter applies to the Transportation Engineering Project.

3. Reference : QP-009 – Standard forms for QA (Quality Assurance)

4. Responsibility

4.1 The QA Manager is responsible for monitoring of documents indexing system.

4.2 Relevant Department Manager is responsible for the execution of document indexing system.

5. Indexing System

5.1 Field Change Notice / Request

FCN (FCR)-MX-YYY

MX = 1 Digit Running Module Number (‘0’ for two or more modules)


YYY = 3 Digit Running FCN (FCR) Number

5.2 Punch List for Hand-Over

PNC-MX-YYY

MX = 1 Digit Running Module Number (‘0’ for two or more modules)


YYY = 3 Digit Running Punch List Number

5.3 Nonconformance Report

CPS-X –NCR-YY

X = 1 Digit Running Module Number (‘0’ for two or more modules)


YY = 2 Digit Running NCR Number

5.4 The Engineer Complaint Report

ECR-MX-YYY

MX = 1 Digit Running Module Number (‘0’ for two or more modules)


YYY = 3 Digit Running ECR Number

5.5 Internal Corrective Action Request

ICAR-XXX

XXX = 3 Digit Running ICAR Number

5.6 Supplier / Subcontractor Corrective Action Request


QA Programme – Construction of Transportation Engineering Project

SCAR-XXX

XXX = 3 Digit Running SCAR Number

5.7 Audit Plan

AP-XX

XX = 2 Digit Running AP Number

5.8 Audit Corrective Action Request

ACAR-XX

XX = 2 Digit Running ACAR Number

5.9 Memo

TERF – X / YYY

X = First Letter of Department


(e.g D : Design, C : Construction, P : Planning, A : Admin etc)
YYY = 3 Digit Running Memo Number
QA Programme – Construction of Transportation Engineering Project

Chapter 13 – Control of Inspection, Measuring & Test Equipment

1. Purpose : To define a system for the calibration of inspection, measuring and test
equipment.

2. Scope : This chapter applies to the inspection, measuring and test equipment used by
TE Project. The applicable equipment are those listed in the "Master list of
Inspection / Measuring / Test Equipment" (see Attachment 6.1).

3. Reference : Not Applicable

4. Responsibility

The QC Engineer shall have the main responsibility to supervise and co-ordinate all calibration
services of all inspection, measuring and test equipment.

5. Procedure :

5.1 New Equipment Control

5.1.1 The QC Engineer or his delegates shall check the new equipment prior to use to
assure that each equipment meets the specification and performance test.

5.1.2 He shall ensure that the equipment is logged in the “Master list of Inspection /
Measuring / Test Equipment” and arrange for external calibration as appropriate.

5.2 Existing Equipment Control

5.2.1 The QC Engineer shall ensure that the “Master list of Inspection / Measuring / Test
Equipment” is generated for review monthly (on the first week of each month) and
each item on the list shall be physically identified and traceable to the list.

5.2.2 He shall decide the frequency of calibration, review the master list for any equipment
currently in use which is due for calibration and arrange for external or internal
calibration as appropriate.

5.2.3 He shall ensure that only calibrated equipment shall be used.

5.3 Control Elements

5.3.1 Standards Traceability

The calibration standards shall be traceable to national metrology laboratories in


developed industrialised countries such as USA, UK, Australia, Japan, West Germany,
India and France.

5.3.2 Identification of Equipment

Equipment manufacturer's serial number or identification number is used for


identification purposes. Equipment that does not bear a serial number is assigned a
identification number.

5.3.3 Equipment Calibration Schedule

The calibration schedule in the “Master list of Inspection / Measuring / Test Equipment”
is updated, immediately, whenever there is a change.

Doc. No. : YBQA-001 Rev. No. : 3 Page No : 45/47 Chapter 13 – Control of Inspection, M & TE
QA Programme – Construction of Transportation Engineering Project

5.3.4 Equipment Calibration Procedures

For routine measuring equipment, such as steel rulers and measuring tapes, are
exempted from calibration.

5.3.4.1For task identified in the QA Plan as requiring controlled measuring or test


equipment, the QC Engineer shall ensure that only properly controlled
inspection or measuring equipment is used.

5.3.4.2The QC Engineer shall show that all controlled equipment is in an acceptable


state of calibration. All such equipment shall be labelled, marked or engraved.
Non-controlled equipment is identified by the absence or such label, mark or
engraving.

5.3.5 Calibration Reports / Certificates

The QC Engineer shall ensure the external and internal calibration reports /
certificates are reviewed. The equipment is released to the User only if the result is in
order.

5.3.6 Equipment Care

The equipment are calibrated, used, handled and stored in suitable environmental
condition, in accordance with manufacturer's recommendation (if any) and where
necessary in a dry, clean and cool place free from mechanical damage, impact and
shock. User shall not adjust or temper with the calibrated equipment to invalidate the
calibration settings.

5.3.7 Measurement Accuracy and Precision

The user and / or his superior shall ensure that the inspection / measuring / test
equipment used for a verification activity is suitable for the necessary accuracy and
precision.

5.4 Action To Be Taken When Calibration Results Are Unsatisfactory

5.4.1 Reporting Procedure

When a measuring equipment is found to be out of calibration, the User shall report
the fault to the QC Engineer. The QC Engineer shall investigate and confirm the fault.
Once the fault is confirmed, he shall stop the measurement task.

5.4.2 Disposition of Faulty Equipment

The faulty equipment usage shall be prohibited immediately and an "Out of Service"
label shall be affixed to it by QC Engineer. He shall ensure that the faulty equipment
is completely repaired / calibrated prior to further use. He shall review the need to
revise the frequency of calibration of such equipment and ensure that the calibration
is carried out on prescribed intervals.

5.4.3 Disposition of Products Measured by the Faulty Equipment

The QC Engineer shall ensure that the following are carried out :

(a) The works measured by the faulty equipment shall be identified.


QA Programme – Construction of Transportation Engineering Project

(b) Their parameters shall be re-validated starting from the latest by another piece
of equipment certified to be of good condition. The re-validation will stop at the
works that show satisfactory results.

(c) If necessary, a meeting shall be held amongst the QC Engineer, to discuss the
disposition of the non-conforming works.

The affected works shall be verified with the client to determine if :

(i) Works still within design requirement;


(ii) Works comply with requirements with recommended improvements;
(iii) Works must be reconstructed.