QA／QC英文手册4版.doc

Chiwan SembawangEngineering Co Ltd Control No. : QS-CSE-M01QA/QC MANUALRev. 4Complied by: Li WeiWenChecked by:Ge Zhi HaiWei ZhaoHongReviewed by:Lv ZhongYiApproved by:Zhou XueZhongEnforcement Date : Sept. 24, 2004Chiwan Sembawang Engineering Co. Ltd. QA/QC MANUAL Contents Page: 1 of 59 Rev. No.: 4CONTENTS0.0 Introduction1.0 Quality & OHS Objective for QA/QC Department2.0Organization of Department3.0Responsibilities & Functions of Department4.0Responsibilities & Duties of Personnel5.0Control of Manual6.0QA System6.1Internal Audit6.2Document Control6.3Quality Record Control6.4Control of Measuring and Monitoring Devices6.5Welding Control6.6Training6.7Statistical Application and Techniques6.8Continual Improvement7.0QC System7.1Material Control7.2In-process Control7.3NDT Control7.4Inspection/Test Status7.5Non-conforming Product Control7.6Corrective Action7.7Preventive Action7.8Release Control47.9Inspection and Test Plan7.10OHS Management8.0List of QA/QC Produces9.0List of Quality Records10.0Issue RecordAttachment1: Typical Inspection Test PlanChiwan Sembawang Engineering Co. Ltd. QA/QC MANUAL Section: 0.0 Introduction Page: 2 of 59 Rev. No.: 40.0INTRODUCTION4A principal factor in the performance of an organization is the quality and safety of its products and services. There is a world-wide trend towards more stringent customers expectations with regard to quality & OHS. It is in view of this that this QA/QC Departmental Manual is prepared.This Manual is prepared by the QA Section Head as per the Companys Quality & OHS Manual, checked by QA/QC Manager and Safety Department Manager, reviewed by Management Representative and approved by GM. The Manual is a level 2 documents and is treated as a confidential and controlled document.Quality plan consistent with all requirements of the Companys Quality & OHS System is established by reviewing design, customer specification and job details, and the requirements of which are communicated to departments and personnel concerned.All materials are identified and traceable from their originality. The identification and traceability of materials are controlled by quality records. All material received are checked for their conformity. All non-conformance items are analyzed and reported to QA/QC Manager for review and comments.QC personnel carry out daily inspection and monitor the fabrication activities. Defects in weld are monitored on a weekly basis. Welders performance are controlled and assessed in a timely manner.QA personnel conduct day to day quality audit and review established quality system and monitors departmental function besides once-every-year internal quality audit organized by QA/QC Manager and conducted by QA audit team. All quality audit reports shall be submitted to GM/DGMs for information and comments.Measuring and test equipments are calibrated according to relevant requirements and procedure and control of calibrated equipment are maintained by the QA/QC Department.All non-destructive testing are carried out by qualified personnel in accordance with approved procedure. Inspection reports and procedures are maintained as quality records in QA/QC Department.4These Quality & OHS System are prepared in compliance with ISO 9001-2000 and OHSAS 18001-1999. Issue: Sept. 24, 2004 Chiwan Sembawang Engineering Co. Ltd. QA/QC MANUAL Section: 1.0 Quality Objective Page: 3 of 59 Rev. No.: 441.0QUALITY OBJECTIVE FOR QA/QC DEPARTMENTCompanys quality & OHS objectives have been broken down to the relevant function departments in the documented Annual Company & Department Quality Objectives and OHS Objectives.QA/QC Department shall establish and maintain its inspection and test system, control the product quality and safety according to customers requirements and relevant standards to achieve the related quality & OHS objectives.Chiwan Sembawang Engineering Co. Ltd. QA/QC MANUAL Section: 2.0 Organization Page: 4 of 59 Rev. No.: 42.0ORGANIZATION OF DEPARTMENTTo achieve the quality & OHS objectives, QA/QC Department has established a quality & OHS system structure for the effective control, evaluation and improvement of the quality & OHS of products and service throughout all stages of the fabrication of a product. Table 2-1 shows the organization structure.Chiwan Sembawang Engineering Co. Ltd. QA/QC MANUAL Section: 3.0 Department Functions Page: 6 of 59 Rev. No.: 43.0RESPONSIBILITIES & FUNCTIONS OF DEPARTMENT3.1ScopeThis section defines the organizational responsibilities for functions in relation to achievement of quality & OHS.3.2Responsibilities of QA/QC Department a) Responsible to ensure that Quality Management System are adequate and complete for implementation.b) Responsible to ensure that code requirements and customer specifications are complied.c) Identify quality problems and initiate corrective actions.d) Ensure that quality planning, material inspection, in process inspection, testing and documentation are carried out during fabrications.e) Coordinate with customer representatives and third party inspection agencies.f) Provide adequate training to QC/NDT personnel.g) Responsible for the QA/QC functions.4h) Responsible for the OHS activities related to QA/QC Department.3.3QA/QC FunctionsThe QA/QC Department mainly carries out various functions as given below.a) Establishment & maintenance of Quality System and Manuals.b) Quality planning.c) Material inspection.d) In-process inspection.e) Dimensional controlf) Surveillance for welding, thorough visual inspection prior to corrosion protection, blasting/coating, galvanizing.Chiwan Sembawang Engineering Co. Ltd. QA/QC MANUAL Section: 3.0 Department Functions Page: 7 of 59 Rev. No.: 4g) Non-destructive testing.h) Material traceability.i) Evaluation of welder performance.j) Disposal of non-conformance.k) QA/QC documentation.l) Liaison with customer inspectors and the Third Party inspectors.m) Training for QC personnel.n) Quality audit.3.4The Various Sections of QA/QC Department3.4.1Quality Assurance SectionThe Quality Assurance Section is headed by QA Section Head who is responsible to the QA/QC Manager for the following functions:a) Quality audit and surveillance.b) Preparation of project Quality Plan .c) Preparation and maintenance of the QA/QC Department Manual.d) Monitoring of various quality elements in related departments as per Companys Quality & OHS Manual and Departmental Manuals and Quality System Procedures. e) Carrying out audit on vendors / subcontractors. f) Calibration of measuring / test equipment.g) Evaluate the scope and requirement of tender document pertaining to quality control and NDT and assist in estimate the cost to perform such function.h) Control of welders/welding operators and their qualification .i) Control of welding consumables.j) Submission of final project documentation.Chiwan Sembawang Engineering Co. Ltd. QA/QC MANUAL Section: 3.0 Department Functions Page: 8 of 59 Rev. No.: 43.4.2QC SectionQC Section is controlled by QC Section Head who is responsible to the QA/QC Manager. Following are the QC Section functions to be performed.a) Material inspection.b) Fit-up inspectionc) In-process inspectiond) Welding surveillance / welding inspectione) Material traceabilityf) Dimension controlg) Blasting and painting controlh) Hydrostatic testingi) Final inspection and submission of documentation.j)k)3.4.3NDT SectionNDT Section is headed by NDT Section Head who is responsible to QA/QC Manager for coordinating with NDT operators in the performance of non-destructive testing of welds and materials as per code and customer specifications. Following are the NDT Section functions to be performed.a) Review of NDT procedure.b) Performing and evaluating test as per specification.c) Interpretation of radiographs.d) Weekly repair rate and welder performance.e) Liaison with customer inspector on quality problems concerned.f) Reporting non-conformity items to QC coordinator.4g) Training of NDT operators.h) OHS management of NDT operations.Chiwan Sembawang Engineering Co. Ltd. QA/QC MANUAL Section: 4.0 Personnel Duties Page: 9 of 59 Rev. No.: 44.0RESPONSIBILITIES & DUTIES OF PERSONNELThe responsibility, authority and interrelation of all personnel who manage, perform and verify work affecting quality & OHS shall be defined, particularly for personnel who need the organizational freedom and authority.QA/QC Department has explicitly defined the general and specific responsibility and duty for its personnel whose activities influence fabrication and/or service quality & OHS as follows:4.1QA/QC Department Manager The QA/QC Department Manager is responsible to the General Manager for the overall quality assurance of the Company Management System and the quality control of the production operation by initiating the following actions:a) Planning and maintaining an acceptable quality assurance program.4b) Preparing, maintenance and implementation of QA/QC procedures to ensure that all quality & OHS requirements are achieved in accordance with Clients Specifications, Standards, Codes and Companys Quality & OHS management system.c) Conforming to the specified contractual quality requirements for the project.d) Planning and organizing quality audits on a timely basis and reacting the findings in a positive manner.e) Ensuring the achievement of department quality & OHS objective.4f) Responsible for the OHS affairs of QA/QC Department, ensuring the safety of NDT activities and operations.4.2QA Section HeadThe QA Section Head is responsible for the QA function, including quality audits and monitoring of QA activities. He reports to the QA/QC Department Manager. The following will be his main tasks:a) Monitoring execution status of Quality & OHS System of the Company.b) Review of QA/QC procedures, such as quality plan, inspection and test plan, material control procedure, NDT procedures, NDT extent etc.Chiwan Sembawang Engineering Co. Ltd. QA/QC MANUAL Section: 4.0 Personnel Duties Page: 10 of 59 Rev. No.: 4c) Planning and performing of quality audits including major vendors and subcontractors.d) Liaison with customers representatives.e) Monitoring performance of non-conformity items.4.3QC Section HeadThe QC Section Head is responsibility for the implementation of QC activities, he reports to the QA/QC Department Manager, the following will be his main tasks:a) Controlling and evaluation of project QC coordinators, inspectors of all disciplines and surveyors.b) Liaison with the project manager and customer QA/QC representatives.c) Arrangement of quality meeting to avoid resulting in problems between disciplines and department regarding quality matters and inspection progress checks.44.4 NDT Section HeadThe NDT Section Head reports to the QA/QC Department Manager, and is responsible for the following tasks:a) Preparation, maintenance of NDT procedures and RT safety procedure.b) Performing and evaluating test as specified.c) Interpretation of radiographic films.d) Documentation of the test status.e) Liaison with customer inspector on quality problems concerned.f) Reporting of non-conformance items to project QC coordinator.g) Implementation of NDT procedures and ensuring the safety of NDT activities and operations.Chiwan Sembawang Engineering Co. Ltd. QA/QC MANUAL Section: 4.0 Personnel Duties Page: 11 of 59 Rev. No.: 44.5 QA EngineerThe QA Engineer is directly responsible for the QA activities and reports to the QA Section Head. The following will be his main tasks:a) Performance of quality audit including major vendors and subcontractors.b) Preparation of inspection and test procedures, Quality Plan and NDT extent etc.c) Liaison with project QC coordinator.d) Responsible for the calibration of measuring and testing equipment.e) Control of internal, external NCRs, and complaints from customer.f) Evaluation of work load for tenders.g) Review of NDT drawing.h) Document Filling systems and submission.4.6Welding EngineerThe Welding Engineer is directly responsible for the control of welder qualifications and welding consumables. He reports to QA Section Head. The following will be his main tasks:a) Receive inspection of welding consumables together with procurement personnel and preparing inspection report.b) Supervising and instructing the storage, baking and issuance of welding consumables.c) Organizing training and certifying of welder and welding operator.d) Evaluation the performance of welder and welding operator.4.7Assistant QA EngineerThe assistant QA engineer reports to the QA Section Head and shall be responsible for following tasks :a ) Preparation of summary sheet for material traceability and QC/NDT inspection reports.b ) Typing Quality System Manuals, procedures, inspection formats and project documents.c ) Preparation of as-built documentation for project and bidding.Chiwan Sembawang Engineering Co. Ltd. QA/QC MANUAL Section: 4.0 Personnel Duties Page: 12 of 59 Rev. No.: 44.8Project QC CoordinatorThe project QC coordinator is directly responsible for the quality control activities of the assigned project. He reports to the QC Section Head and has the responsibility of controlling and evaluating the QC inspectors engaged in his project. The following will be his main tasks:a) Implementation of QC procedures and assessment of QC inspectors.b) Liaison with personnel concerned including engineering , purchasing and PMT.c) Coordination with QA/QC Personnel including QA Engineer, NDT Personnel and inspectors of various disciplines.d) Preparation of non-conformance reports (NCR)e) Consult with Project Manager to discuss quality matters f) Control of inspection status.g) Release control4.9QC InspectorThe QC inspectors of various disciplines report to project QC coordinator and shall be responsible for the following tasks:a) Performing and evaluating/witnessing required inspe