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Department:- Mechanical Dt. 22-May-2013 Timing:- 11 hrs. to 1300 hrs. & 1430 hrs. to 1530 hrs.

17TH INTERNAL AUDIT

AUDIT FINDINGS
Auditee:- Kapil Dev Singh Auditor:- D.Satpathy

Overall
Good housekeeping at Work shop.
No open maintenance orders prior to 1st May,

2013.

Non-conformity:Observations:-

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Opportunity for improvement:- 3

Clausal reference and nonconformity summary


S.N. 1 2 Clausal Ref. ISO 9001:2008 (4.2.4) ISO 9001:2008 (8.2.3) Description Control of Records Monitoring & measurement of Processes No. of observations 3 3

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ISO 9001:2008 (4.2.3) ISO 9001:2008 (7.5.5)


ISO 14001:2004 (4.4.6) ISO 14001:2004 (4.3.1)

Control of Documents Preservation of Product


Operational Control Environmental Aspects

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Observations
S.N. 1 Observation In SOP/02 (SOP for Air Heater Fans), there is reference for greasing of fan & motor bearing (3 monthly) & record/form reference FRM/03. Following observations are made:a) FRM/03 was not maintained in QHSE file with Mechanical. Form is however available in soft format b) Records not being maintained as per FRM/03 Note:- Records not being maintained for FRM/04 as well. With reference to SOP/15 (SOP for Air Compressor Screw Type), - SOP for 4000 hrs. maintenance. Checked for U703A done on 16-October-2012 A type maintenance where it is mentioned Oil Filter Change; however, as per checklist maintained by Mechanical, this element is missing in A type maintenance kit. With reference to FRM/10 Equipment Maintenance Schedule, records available for year 2010 only - not updated for 2011, 12 Type Observation Clausal Ref ISO 9001:2008 4.2.3 and 4.2.4

Observation

ISO 9001:2008 4.2.3

Observation

ISO 9001:2008 4.2.4

Old Revision of Process Chart PLL/Mech/cht/01 revision 10 is available as controlled copy along with updated revision 11
With reference to SOP/03 (SOP for Boil off Gas Compressor) and SOP/04 (SOP for Diesel Engine & EDG), both 24 months maintenance overhauling & 12 months PM is mentioned. However, in records, only 12 months PM is available

Opportunity for Improvement


Observation

ISO 9001:2008 4.2.3


ISO 9001:2008 8.2.3

Observations
contd.
S.N. 6 Observation With reference to FRM/05 (format for MPR/Machine Availability), following observations are made:1. Feb-2013, PM Schedule (sr.No.2)- MD-1 CT winch completed / not completed could not be ascertained from records (field kept blank). In SAP, history sheet is maintained, but the date is not matching (it is of year 2009) 2. December-2012, PM Schedule Booster Pump P-60601 B completed / not completed could not be ascertained from records (field kept blank). It is not being used/is idle; however, note /reference to the same is not available. 3. March 2013, PM Schedule Sludge Transfer Pump FUP-60302 completed / not completed could not be ascertained from records (field kept blank). In SAP, history sheet is maintained. With reference to Process Chart PLL/MECH/CHT/01, parameter defined is PM Schedule Completion (95%) Monitored monthly. This can be calculated from FRM/05 maintained monthly; however the performance indicator is not mentioned in percentage. Availability of critical equipments in the same form is mentioned in %age. With reference to last internal audit, FRM/11- Incident Report to be deleted. The reference of deletion is available in Sr.No.11 of process Chart, but the Form is still available in the QHSE manual of mechanical. Type Observation Clausal Ref ISO 9001:2008 4.2.4

Opportunity for improvement

Observation

ISO 9001:2008 4.2.3

Last test date / colour coding is not available on Chain Pulley Block no. 8620 available in the Tool Room

Observation

ISO 9001:2008 8.2.3

Observations
contd.
S.N. 10 Observation Observations at Tool Room:1. Bin marked as Cotton Bin is used for storage of Hoses 2. Broken tools like spanners etc. are kept in the bin marked as Gasket Last test date / colour coding is not available on Hoist of Screw Air Compressor Observations at Fabrication Yard:1. General housekeeping is not good 2. Empty cylinders (Oxygen/acetylene no. MAZ 0477 & RAP 230 ) were not stored properly 3. Bin marked as Cotton Waste Bin is filled with cotton waste, plastic waste, paper waste etc. 4. Specific bin for Oil soaked cloths is not available Type Opportunity for improvement Observation Observation Clausal Ref ISO 9001:2008 7.5.5

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ISO 9001:2008 8.2.3 ISO 14001:2004 4.4.6 & ISO 14001:2004 4.3.1

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