PROJECT QUALITY PLAN
PROJECT QUALITY PLAN
Prepared by : Mohammed
Reviewed by: kumaraguru
Approved by: Devadoss Suresh Kumar
PROJECT QUALITY PLAN
PURPOSE
The purpose of this Quality Plan is to define PETROLYNX Project Quality
Management System.
1.0 SCOPE
The scope of this Quality Plan includes Fabrication of steel Structure works for
KIRBY Project, done by PETROLYNX at the workshop.
This Quality Plan includes activities stipulated in the contract and specifications
incorporating the quality requirements in accordance with ISO 9001:2015.
2.0 DEFINITIONS
CLIENT: KIRBY BUILDING SYSYTEM
MAIN CONTRACTOR:
SUB CONTRACTOR:
VENDOR:
3.0 ORGANIZATION AND RESPONSIBILITIES
4.1 Organization
The interrelation between personnel who perform, manage and verify work
affecting the Quality Control System described in this Quality Plan.
4.2 Responsibilities
The general responsibilities of the Project personnel involved are as follows:
a. Implementing and maintaining the Project Quality Management System
b. Identifying and evaluating actual or potential problems which can adversely affect
quality.
c. Initiating, recommending and providing effective solution to such problems.
d. Ensuring awareness and understanding of the Project Quality Management System
by
Personnel involved in project for its implementation and improvement.
e. Ensuring customer satisfaction through daily operations.
f. Check opportunities for improvement of Quality Management System
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The responsibility for compliance with the appropriate Quality Management System
requirements shall be imposed on Vendors, Sub contractors thereof, consistent with
their scope of work, through the terms and conditions included in purchase orders and
subcontracts.
Managing Director
The Managing Director is responsible for forming and evaluating the company’s goal,
direction and strategies. He collaborates with the management team to carry out the
set goals.
Snr. Project Manager
The Snr.Project Manager directs the activities of Project Managers. He ensures that the
managers have resources necessary to complete projects including materials, trained
staff, and funding. He offers advice and assistance to his managers, which includes
keeping the team accountable for the goals of the project.
Project Manager
The Project Manager shall be ultimately responsible for the planning, executing and
finalizing projects according to strict deadlines and within budget. This includes
acquiring resources and coordinating the efforts of team members and contractors or
consultants in order to deliver projects according to plan. The Project Manager will also
define the project’s objectives and oversee quality control throughout its execution.
QHSE Manager
The QHSE Manager is the Management Representative with the necessary authority
and responsibility for ensuring that the requirements of this Quality Plan are established,
implemented and maintained. He is the final authority on quality matters and represents
PETROLYNX on all Quality Issues pertinent to the project. He ensures that safety
systems are implemented on site and ensure the provision of continued on-site support
by means of inspections, follow-up and internal audit
Project Engineer
The Project Engineer is responsible for the coordination of all technical activities on
assigned projects. He plans and coordinates assigned engineering work which includes
monitoring of works to applicable standards and codes. He ensures effective
communication and coordination between all disciplines and all project participants
QC Inspector
The QC Inspector is responsible for the quality control activities such as verification of
implementation of inspection plans within the assigned project. He monitors the
performance and overall progress of construction inspections to ensure adherence to
the quality plan. He maintains quality records in support of activities in area of
responsibility.
HSE Officer
The HSE Officer is responsible for the site inspection to ensure that safety procedures
and regulations are strictly followed. He assist in helping the workforce understand job
hazards and safety precautions.
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5.1 PROJECT QUALITY MANAGEMENT SYSTEM
5.1 General Requirement
A Project Quality Management System conforming to the requirements of ISO
9001:2015, is developed, effectively implemented, monitored and measured to
achieve continuous improvements. It is implemented by establishing a Quality
Plan, Quality Management Procedures, Inspection & Test Plans, and Method
Statements.
The Project Quality Management Systems is applied to all the project activities
including overall project control, design, management, planning, engineering,
procurement, construction, inspection and testing.
5.2 Documentation
The documents of PQMS will be controlled. The controls needed as below are defined
in documented procedures:
a) To approve documents for adequacy prior to its distribution
b) To ensure current revision status of applicable documents available at point of use
c) To control the documents of external origin and to control its distribution
d) To remain legible and readily identifiable, and to prevent unintended use of obsolete
documents, if they are retained for any specific purpose.
Records are generated and maintained in order to demonstrate achievements of the
required quality of service and effective operation of the documented Quality System.
Retention times of records are detailed in the Master list.
Records are stored and maintained in a way, which would prevent damage, deterioration
or loss and are legible and readily retrievable. Identification, collection, filing,
maintenance and retention of records are carried out by the QC Inspector with the
coordination and support from the Project Manager/ Project Engineer.
6.1 MANAGEMENT RESPONSIBILITIES
6.1 Management Commitment
Top management ensures that the respective personnel assigned on the project are
responsible and committed, for implementing and ensuring the effectiveness of the
project QMS in the company by providing evidence of:
a) Communicating within the company, the importance of meeting customer and other
statutory and regulatory requirements.
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b) Establishing the project QMS policy and objectives and reviewing the performance
against the objectives set during project reviews/management review.
c) Reviewing and provision of necessary resources.
d) Participate in management review and internal audit.
6.2 Customer Focus
Utilizing the documented QMS, the project management team ensures that customer
requirements are determined and that customer satisfaction is the underlying aim of all
processes. Additionally, PETROLYNX’s project management teams, from time to time,
directly interact with customers to assess their needs, requirements and overall
satisfaction with PETROLYNX and its projects. This information is fed back to the
project management team during management review meetings.
6.3 Planning
The management of PETROLYNX ensures that, planning of QMS is carried out to meet
the project’s requirements. The Project Manager prepares a Program of Works for the
project. The monitoring of detailed fabrication/ erection schedule and the progress is the
responsibility of the Project Engineer. List of documents are prepared and maintained
by the Project Engineer which serves as the planning for the submission and approval
status for all the document deliverables.
6.4 Responsibility, Authority and Communication
The management of PETROLYNX ensures that the responsibilities and authorities are
defined and communicated within the project organization. The responsibilities and
authorities are defined in Section 2 of this Quality Plan.
6.5 Management Review
PQMS review meetings are conducted once in six months covering the agenda as per
ISO 9001:2015. The review forum is chaired by the Managing Director. The focus of this
meeting is to evaluate the effectiveness of PQMS to recommend areas for improvement.
The agenda are described below:
a) Results of internal audits
b) Customer feedbacks / complaints
c) Customer satisfaction survey results
d) Interested party feedback & complaints
e) Project performance
f) Preventive / corrective actions
g) Legal / other requirements compliance and gaps
h) Results of participation and consultation (suggestions review)
i) Status of PQMS policy and objectives
j) Management programmes and status
k) Results of incident investigation and actions taken
l) Follow-up actions from previous reviews
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Attendance and minutes of meeting shall be maintained.
7.0 RESOURCE MANAGEMENT
7.1 Provision of Resources
The top management of PETROLYNX ensures that adequate resources required for
nurturing the project QMS are provided. The resources include man, material, machine,
method, PPE, environment and infrastructure for:
a) Implementing and maintaining the project QMS
b) Continually improving the effectiveness of the project QMS
c) Enhancing the customer satisfaction by meeting the requirement
Personnel with adequate training & skills are deployed to perform specific assigned tasks.
Resources provided are:
a) Competent personnel
b) Trained and certified workers for the project execution
c) Trained internal auditors
d) PPE
e) Preventive maintenance
f) Measuring & monitoring equipment
g) Adequate handling and storage facilities
7.2 Competence, Training and Awareness
HR / Admin Department in the Head Office is overall responsible to determine and
provide with adequate number of personnel with the required competencies (educational
qualifications, training, skills and experience) as and when required by the Project
Manager after the approval of Snr. Project Manager. Project specific training like safety
induction, welder qualification is maintained by the Project Engineer.
7.3 Infrastructure
The top management of PETROLYNX determines and provides infrastructure needed
to execute the projects. Appropriate maintenance and other applicable functions; ensure
that these infrastructures are suitably maintained. The organization shall provide the
necessary infrastructure like equipped buildings, associated utilities, process
equipment, communication and logistics.
7.4 Work Environment
The top management of PETROLYNX determines and manages the work environment
by continuously emphasizing and up keeping of office premises, site offices / work area.
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Safety walkthrough will be carried out by site safety officers to determine the safety
lapses, unsafe act / unsafe condition at work sites.
8.0 PRODUCT REALIZATION
8.1 Planning of Product Realization
The product realization processes is consistent with the process of the quality
management system of the company. While project execution, PETROLYNX shall
consider the following as appropriate:
a) Project scope and objectives
b) Processes, resources – manpower, utilities and BOQ required
c) Drawings from consultants/main contractors
d) Verification, validation, inspection, measuring and test activities specific to the project
e) Quality / HSE plan for the project.
f) Day to day reporting and other records to be maintained by the project team/plant
departments.
The project master schedule shall be made by the Project Manager covering all the
important milestones, activities and services that are essential for project execution.
8.2 Customer Related Process
The Contracts Engineer will be responsible to review the complete scope of work/tender
documents as received. The review shall be conducted prior to the estimation and BOQ,
before the submittals of tender documents. PETROLYNX shall ensure that:
a) Scope of work matches with the tender documents reviewed
b) BOQ matches with the drawings received from contractors/client
c) PETROLYNX and its capability to execute and complete the projects/product
d) Previously agreed pricelist (if any), addition of equipments supply (firefighting /
security
devices) or clear statement of technical / commercial scope of work specific to the
tender.
PETROLYNX shall not execute any verbal content provided, even if the content specific
to supply / addition of equipment’s/devices, unless otherwise a formal work order /email
received from the client. While any formal changes/additions of equipments, changes in
drawings received, the project execution team shall be informed and relevant
documents will be supplied. In case if the project execution team receives any such
information, the Project Director shall be consulted before execution/supply of
equipments.
PETROLYNX shall implement effective arrangements for communicating with
customers in relation to: project information; enquiries; contracts or order handling,
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including changes; customer feedback, including customer complaints. This is
accomplished through direct interactions with the customer by PETROLYNX’s project
execution team personnel whether in person or via phone, fax or email.
8.4 Purchasing
General
PETROLYNX shall ensure that materials/services purchased for the project/plant needs
meet the requirements of specified project/purchase requirements. The type and extent
of control applied to supplier and the purchased materials or equipments, shall depend
upon the effect of the materials purchased while project is delivered, where required
within warranty and during the maintenance period
PETROLYNX shall evaluate and select the suppliers / partners based on the ability to
supply the materials / equipments in accordance with the project requirements. Criteria
for selection, evaluation and re-evaluation are performed by Purchasing Department.
Records of evaluation and results of evaluation shall be maintained.
Purchase Requisition
Based on project specifications, data sheets and approved drawings, the Engineering
department specifies the material, items and services to be purchased and relevant
requirements by issuing the Material Consumable Requisition.
Verification of Purchased Products
The Storekeeper shall verify against Purchase Order (PO) and Purchase Requisition all
deliveries to the site/ workshop. The verification shall be carried out by comparing with
approved sample if appropriate. Certificate shall be verified by QC Inspector.
If the item is acceptable the delivery documents shall be signed by both
Storekeeper and QC Inspector. Only accepted product shall be stored in the site/
workshop. The Storekeeper shall update stock register.
If the product does not comply with PO requirements or fails to match with approved
sample, the item shall be rejected and a Non-Conformance Report (NCR) shall be
issued to the supplier. Copy of NCR shall be given to Procurement Department for
further action.
In case any rejected product needs to be stored on site for a while till a decision is made
on disposition, the item must be identified appropriately and segregated in order to avoid
any inadvertent use.
8.5 Production and Service Provision
Control of Production and Service Provision
Projects department shall be responsible for project execution. The project execution
shall be done in controlled conditions. Controlled conditions include:
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a) Quality plan for the project
b) HSE plan / HSE requirements
c) Availability of safety procedures/work procedures
d) Use of suitable equipments at the project sites
e) Availability and use of suitable monitoring and measurement devices at project sites
f) Compliance with reference standards, codes with acceptance criteria
g) Qualification / approval of processes and equipment as appropriate
Validation of Production and Service Provisio
PETROLYNX shall validate process for production and service provision, where
resulting output cannot be verified during project execution/product realization,
handover or completion, where deficiencies become apparent only after the completion.
Validation shall demonstrate the ability of these processes to achieve planned results.
Identification and Traceability
Materials and equipment are identified by their self-identity, trade names or general
name/terminology used in the construction industry. Individual part like beam, column,
plate is identified by suitable number or description as detailed in approved drawings.
All documents, drawings, inspection records etc. are identified by appropriate title,
unique number etc.
Traceability of purchased materials and products shall be maintained to the extent
required by individual contract. All inspection and test reports should have adequate
information for traceability purpose.
Customer Property
All customer supplied products shall be inspected and checked on receipt for identity
markings, damages, and specification and quality standards against relevant
Customer’s delivery documents.
Inventory of customer materials shall be maintained by site/shop storekeeper and
adequately identified with customer details. The customer property shall be
protected during all stages of construction by the concerned personnel. Any
customer property which is lost, damaged, or otherwise found not suitable shall be
brought to the notice of Project manager who shall report to the customer, resolve the
issue and maintain records.
Customer supplied products include drawings, specifications etc. provided for
construction purposes shall be checked on receipt for completeness, drawing
numbers, specifications and stated quality standards.
Preservation of Product and Services
Project materials, products and equipment, regardless of source or size, shall be
handled properly to maintain conformity to requirements. Procurement Manager shall
ensure that any specific requirements for handling, storage, packaging, preservation
and delivery are clearly indicated to the suppliers.
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Project Engineer shall ensure that suitable handling equipment for all tasks is provided
to personnel, and that the personnel are instructed in the correct use of handling
equipment for the work tasks they perform. The responsibility for this instruction may be
delegated, by the Project Manager to the Foremen responsible in each area or activity.
Project Manager shall ensure that suitable storage areas and in appropriate
environment are provided for all materials. Storage areas shall be maintained in a clean
and tidy condition. Where appropriate, storage areas shall be clearly marked.
Control of Monitoring and Measuring Equipment’s
PETROLYNX shall ensure that monitoring and measurements equipment used for
projects execution / production activities are suitable and calibrated at regular
intervals as per the defined time period.
The related documents shall be maintained with QHSE department which includes
Calibration Certificates and Calibration List.
9.0 MEASUREMENT, ANALYSIS AND IMPROVEMENT
9.1 General
PETROLYNX has planned and implemented the monitoring, measurement, analysis
and improvement processes needed:
a) To demonstrate conformity to the projects and services
b) To ensure conformity to PQMS
c) To continually improve the effectiveness of the PQMS
9.2 Monitoring and Measurement
Customer Satisfaction
PETROLYNX shall monitor its customer’s perception by conducting customer
satisfaction survey once during the project duration. If the project duration is more than
12 months, the survey shall be taken at least twice during the project duration.
Customer complaints will be received, analysed and incorporated for continuous
improvement of process / product / system.
Internal Audit
PETROLYNX shall plan and conduct the internal audits to determine whether the PQMS
conforms to the policies and procedures drafted and if implemented and maintained
effectively.
Documented procedure is established including audit planning for complete PQMS and
projects, taking actions on non-conformities observed during the audit, Non-
conformance closure, audit planning and scheduling, criteria and methods shall be
defined. The audit plan shall be made taking in to the consideration of status and
importance of projects, department/process being audited.
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Monitoring and Measurement of Processes
All processes are inspected / tested in accordance with the ITP/procedure. Incoming
inspection, in-process inspection and final inspection shall be conducted during the
project execution and shall show conformity to the acceptance criteria.
9.3 Control of Non-Conforming Product
PETROLYNX shall ensure that the item which does not conform to the requirements is
identified, documented, evaluated, and segregated for disposition to the concerned
departments/ sections.
It is the responsibility of all employees to report discovered or potential nonconformities
at any stage of the processes to prevent unplanned use, application or installation of
nonconforming product / service. Non-conformity register is maintained and all the
above types of non-conformities observed, action taken will be recorded.
9.4 Analysis of Data
PETROLYNX determines, collects and analyzes appropriate data to demonstrate the
suitability and effectiveness of the PQMS, and to evaluate its continual improvement.
Trends are analyzed and compared to overall business goals and objectives as a means
for identifying opportunities for preventive action and continual improvement. Project
Manager performs these analyses in preparation for and during the Management
Reviews.
10.0 IMPROVEMENT
10.1 Continual Improvement
Continual Improvement in each area is part of the PQMS policy and objectives of the
company. These are achieved through analysis of the results of internal audits,
service/product non-conformances, customer complaints and feedback, employees’
suggestion and by identifying corrective and preventive action.
10.2 Corrective Action
The corrective action shall be taken to eliminate the causes of non-conformities in order
to prevent its recurrence. Documented procedure is established to review, determine
root cause analysis, detailed incident investigation, recording the results of review /
incident investigation and reviewing its effectiveness.
10.3 Preventive Action
The preventive action shall be taken in order to prevent the occurrence of non-
conformities and other desirable potential situations. Preventive action possibilities are
as follows:
a) Reporting unsafe acts and unsafe conditions.
b) Horizontal deployment of corrective actions in other relevant areas in order to prevent
potential problems
c) Project status review and performance reviews
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Documented procedure is established to review, determine potential causes, actions to
be taken, recording the results and reviewing effectiveness of preventive action taken.
11.0 ATTACHMENTS
Project Quality Objective
Project Quality Policy
Company vision and Mission statement
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Project Quality Objective
Continual improvements and customer satisfaction shall be the permanent objective with
all other objectives formulated, reviewed in order to achieve these objectives.
• Project progress shall be monitored and from the data gathered issues that have effect
shall be discussed and corrected where possible with the objective of completing work
on schedule.
• In order to continually improve relation with customer, feedback being gathered and
this shall be analyzed and any downward trends investigated and corrective action
proposed initiated and verified.
• Accident and incident figures shall be gathered and analyzed in order to minimize lost
time. Injury to personnel and any damages, material or environment.
• Quality awareness and communication will be increased by the initiation of project
quality meeting or on a bi-monthly basis topics to be discussed will include lessons
learned from previous month, non-conformity, proposal of preventive action and
resources
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Project Quality policy
The Quality system established and maintained by PETROLYNX specifies the principles
procedures and sequences to used in order to ensure that the products and services offered
by the company conform to the specified requirements.
In order to establish the objective evidence of Quality in its functioning, the Managers of
PETROLYNX have made a policy decision that all activities provided by the company shall be
governed by a Quality system meeting the requirements of ISO 9001: 20.
The PETROLYNX Project Manager Team shall identify the installation processes, which
directly affects quality and shall ensure that these processes are carried out according to the
documented work instructions and procedures defining the manner according to which
installation shall proceed.
These quality requirements shall be extended to all sub-contractors. In order to achieve this
objective, the Project Manager shall appoint a subcontracts controller who shall be responsible
for the surveillance of the sub-contractors activities accordance with relevant procedures and
specifications. The sub-contractors controller shall control the interfaces between the various
departments and the sub contractors.
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Company Vision and Mission Statement
VISION
Our vision is to transform the company into a customer and results oriented, and team focused
organization. This transformation will happen through a process of educating, guiding,
mentoring and motivating employees at every level to encourage initiatives and creativity;
which in turn will improve overall performance of the company in its mission to better serve its
customers.
MISSION
Our mission is to become the best company in its field of work, while maintaining the
profitability of the company to ensure its long-term survival.
