Quality assurance documentation

Concept of Project quality plan and Quality inspection plans and their effective implementation at project sites

1. Project QA&QC Documentation –
Effective Implementation at sites




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global business

2. Project Quality Plan (PQP)
Contents
QIPs - Effective Implementation
Quality Inspection Plans (QIPs)
Learning Objectives
PQP – Effective Implementation at sites

3. Learning Objectives
 What is Project Quality Plan – PQP?
Structure of PQP
Why do we need PQP – DIMS & ISO 9001?
Improving implementation of PQP at sites

What is Quality Inspection Plan (QIP)?
Structure of QIP
Requirement of QIPs – DIMS & ISO 9001
Improving implementation of QIPs at projects

4. Project Quality Plan (PQP)
A written plan that details how you will manage quality on a specific project

A document which describes the processes, activities and resources that will be
put into place to ensure that quality deliverables are produced


Definition of PQP in ISO 9000 :2005

A document that describe how the quality management system is applied to a
specific product, project or contract; such documents are referred to as quality
plans – ISO9000:2005 ,Clause 2.7.2 (Types of documents used in QMS )

What is a PQP ?

5. A written plan
How you will manage quality?
Which describes:
 Processes,
Activities, and
Resources
Key words?
Project Quality Plan (PQP)

6. Descon Standard PQP
Project Quality Plan (PQP)

7. Table Type
Types of PQP

8. Flow Chart Type
Types of PQP

9. Form Type
Types of PQP

10. Text Type
Types of PQP

11. Structure of PQP
1.Scope:

Examples
•Statement of purpose
•Aspects of project etc. etc.

Scope should be clearly stated

2. Quality Objectives:
PQP should state project quality objectives
Should be established in relation to quality characteristics of project
Should be SMART

3. Management Responsibilities:
Identify individuals on project who are responsible for ensuring that the
activities required for project are planned, implemented & being monitored.

12. Structure of PQP
4.Control of Documents:
Should state how the documents required for the project will be identified
Document distribution

5. Resource Management:
Identification of resources needed for the successful execution of project
This includes material, machinery and manpower
Infrastructure & work environment

6. Communication:
Communication with customer
Means to be used for customer communication
Records to be kept of customer communication

7. Design and development:
To be included if design is in project scope

13. Structure of PQP
Other activities may include:

8.Purchasing
9.Control of design change
10.Identification & traceability
11.Control of non conforming products
12.Monitoring and measurement
13.Audits

14. Why do we need PQP?
To show how the organization’s QMS applies to the project
To meet customer requirements
To demonstrate internally / externally, how quality requirement will be met


Requirement of Descon Quality Management System
Planning of Product Realization starts with the preparation of project Quality
and HSE plans for each new project

In planning product realization the Organization determines:

•Preparation of PQP (Project Quality Plan) and HSE Plan
– DIMS Manual ,Clause 7.1, Planning of product realization

15. Effective implementation of PQP

1.Identification of required inputs and development of PQP as per project
requirements
2.Distribution of quality plan
3.Internal / External monitoring for the conformity with the quality plan
Reviews
Audits
4.Training
5.Revision of Project Quality Plan
6.Feedback and Improvement

16. Benefits of implementation of PQP

1.High level of compliance
2.Increased confidence that requirements will be met
3.Greater assurance that processes are in control
4.Insight into opportunity of improvement

17. PQP – Some facts

1.PQP can be prepared whether or not organization has conformity with
ISO 9001 standard
2.PQP primarily focused on “product realization” and not to
“organizational quality management system”
3.PQP can referred to appropriate documented procedures or other
documents
4.A client may specify requirements for the quality plan

18. For Sample PQP
Sample PQP

19. Quality Inspection Plan (QIP)
What is a QIP ?
Quality Inspection Plans (QIP) is the minimum requirement of the activities for
quality control and inspection of the field construction work. This inspection and
testing plan outline the extent of witness inspection and its reporting.


OR

A document detailing a systematic approach for testing. This document
typically contains a detailed understanding of what the inspection workflow
will be.

OR

An Inspection and Test Plan identifies the work to be inspected or tested, at
what stage it will be tested, as well as Hold and Witness Points, references to
relevant standards, acceptance criteria and the records to be maintained.

20. A document
Minimum requirement
Inspection workflow
Parties involved
Witness & hold points
Acceptance criteria
Records
Key words?
Quality Inspection Plan (QIP)

21. Descon Standard QIP
Quality Inspection Plan (QIP)

22. Quality Inspection Plans (QIP) lists down the following in a single document
and identifies:
Inspection and Test Activity.
Inspection and Test Frequency.
Acceptance Criteria.
Verifying Documents.
Inspection Codes.
Inspection Parties Involved.
Scope of QIP:
Quality Inspection Plan (QIP)

23. In DESCON, usually QIPs are classified as follows :
For Civil works.
For Mechanical works.
For E & I works.
Classification of QIPs :
•These QIPs are further prepared discipline wise as subclasses ( e.g. QIPs for
civil can be subdivided separately for Piling works, Earth works etc).
Quality Inspection Plan (QIP)

24. QIPs require following inspection codes :
H= ‘hold point’;
defines a point beyond which work may not proceed without the
authorization of a designated QC personnel or authority.
•Layout after excavation
•Formwork
•Pressure testing in piping works

W=‘witness point’
is a point in a construction activity where inspection must take place.
On a case by case basis, the inspection witnessing may be waived.
In this case, inspection may proceed without attendance. However,
inspection data must be recorded and submitted for review and approval.

Inspection Codes
Quality Inspection Plan (QIP)

25. R=‘review point’ is a point in a construction activity where any document is
submitted for review or comment

S= ‘surveillance point’; Intermittent monitoring of any stage of the work in
progress (whether internal or customer).


Inspection Codes
Quality Inspection Plan (QIP)

26. Inspections as per QIPS are carried out as follows :
QC personnel shall perform quality control checks, tests and
inspections in accordance with the inspection intervention
requirements documented in Contractor’s company approved ITP
to verify the product meets stated ( and implied) needs.

Such checks, tests and inspections shall be undertaken & the
product verified as a acceptable prior to requesting attendance of
Contractor via issuance of an Request For Inspection (RFI).
Inspection as per QIP
Quality Inspection Plan (QIP)

27. Why do we need QIP?
ISO 9001 requirement
In planning product realization, the organization shall determine the following:

•Required verification, validation, monitoring, measurement, inspection
and test activities specific to the product and the criteria for product
acceptance;
•Records needed to provide evidence that the realization processes and
resulting product meet requirements
– ISO 9001:2008,Clause 7.1 (c & d), Planning of product realization


Descon Quality Management System requirement
In planning product realization, the Organization determines:

•The required verification, validation, monitoring, inspection and test
activities specific to product/project and the criteria for acceptance.

– DIMS Manual ,Clause 7.1, Planning of product realization

28. As 100% inception and testing in most cases is neither practical nor possible
, it is necessary to adopt a testing frequency. Inspections are often done
after a number of activities mostly on critical ones.
Therefore QIPs are used in determining the type and extent of
inspections and documenting the test results for these critical activities
accordingly.
These approved QIPs are also easier to determine as they are usually
specified and identify particular stages requiring inspections and
testing.
Need of QIP
Quality Inspection Plan (QIP)

29. Major causes for ineffective implementation of QIPs at site :
Latest Revision of Approved Documents : Usually at project
sites, the major issue is the non availability of latest approved
drawings/ drawings. For effective implementation of QIPs, latest
approved drawings should be available with all latest revisions.

IMTEs : Use of only calibrated IMTEs must be ensured
Effective Implementation of QIP
Quality Inspection Plan (QIP)

30. Major causes for ineffective implementation of QIPs at site :
Materials Approvals: Lab reports for materials inspections with
proper TPI (if required or mentioned in QIP) should be available.
 Internal Inspection Points Clearance : QC personnel usually
make sure the all the activities incorporating “H” are cleared as
per set standard procedure, whereas for effective implementation
of QIP, standard procedure must be followed for inspection codes
like “W” or “S”.

Effective Implementation of QIP
Quality Inspection Plan (QIP)

31. Major causes for ineffective implementation of QIPs at site :
NCR : For effective implementation of quality /QIP, if any non
conformance is observed at any stage during the inspection, NCR
must be raised and reported immediately.

Effective Implementation of QIP
Quality Inspection Plan (QIP)

32. QIPs
Major causes for ineffective implementation of QIPs at site :
Proper Plan/ Checklist for Inspection and Testing: Note down
the key aspects of checklist as follows for effective use of QIP for
inspection:

Check whether the QIP is covering all the relevant
activities of the discipline
Are the verification documents are properly referred
Are all related the formats/ records legible, readily
identifiable


Effective Implementation of QIP

33. QIPs
Major causes for ineffective implementation of QIPs at site :
Proper Plan/ Checklist for Inspection and Testing: (Cont….)
Is the Inspection code identified for each activity?
Are these QIPs updated to reflect the changes, if any, to the
clients’ needs?
Do this QIP defines the complete acceptance criterion for
inspection and testing.


Effective Implementation of QIP

34. QIP
Sample QIP
For Sample QIP

35. Question & Answers