Audit Analz

Nonconformity Cause for failure Clouse Number

Corrective/Preventive action

Master list of documents are not available

No clear idea about Master list

4.2.4 Master list of docs will be prepared by using correct ISO format

Drawing register is not complete

Drawing issued personals were not clearly indicated in drawing register

4.2.4 Drawing register will be updated with indication of the issued personal

Inventory register is incomplete Correct format of Inventory has not used

4.2.4 Correct ISO format of Inventory registry now is being used and updated

Project specific documents shall be approved by H/O

From starting stage some formats were used without prior approval of H/O because of the urgency

4.2.3 All Project specific docs have been approved by H/O QA dept prior to issue

Customer complaint was not properly managed and adhered Customer complaint register was not properly updated

Due to lack of manpower 8,2,1 Appointed a system coordinator to handle all system related failuresCustomer complaint register and Customer Complaints were updated

Procedure for Control of Records has not adhered properly

Updating of few records were missing

4.2.4 All records are controlled and updated in proper manner

Vehicle maintenance records have not updated

Updating of few records were missing


No proper Master list of records Updating of few records were missing


No corrective action records for quality failures (B/P)

Corrective action was taken but not documented

8.5.2 Now all quality failures addressed properly with corrective action. In future system coordinator will responsible for maintaining documents

No records of Calibration audit of plant & equipment (Calibration schedule)

Accepted the failure 7.6 Separate format has been designed for this purpose and in future calibration audit will be done by Plant Engineer



Approved Organization structure is not displayed at the main Office

Organization chart prepared previously but not displayed

5.5.3 Organization chart already displayed @ Project Manager’s Office

Catch up programme (Accelerated) could be updated for management information

- 5.5.3 Accelerated programme is now in place

Road reinstatement Process back log achievement method not identified

- 7.5.1 New Programme has prepared to achieve backlog of road reinstatement

Document Control system could be improved – section wise no records

- 4.2.3 Document control system now has been improved

Customer complaint Management system is very poor Eg: No Customer Complaint RegisterNo Customer complaint format is used

The person who handle has resigned and not handed over to counterpart

8.2.1 Customer complaint register was prepared and correct format is being used now

Bin Cards are not maintaining properlyEg : No approval, Bin Card register not updated

New Store keeper is in duty now 4.2.4 Educate the Store keeper on Stores management and Bin card is being update now

Quality ObjectiveNo progress monitored on last 3 months

Relevant data was processing during audit period

- Informed QS section the data required dates for updating quality Objective

Laboratory scales are not calibrated

Because of heavy work load at site it was unable to release from site for Calibration

- Update the Calibration schedule and strictly adhere the calibration before due date



Customer complaints register not in proper order. It should incorporate in to Master list of records

Even though educated in this regard they are not kept properly

4.2.4 Customer complaint register now are in proper order It has incorporated into master list of register

Some QMS formats are not in correct version

Due to heavy work load we could not update

4.2.3 All relevant QMS formats are now in correct version

Project specific format should be approved by H/O

Due to heavy work load we could not update

4.2.3 Project specific formats now have been approved by QA dept at H/O

Maga “Quality Policy” has not displayed at main stores

- 5.3 -

No Quality Objective has been established

- 5.4.1 -

Inventory List/Register is not available

- 4.2.3 -

Master List of Records are not updated

- 4.2.3 -

Bin Cards are not authorized/updated

- 4.2.3 -

Main stores following areas needs to be improved

Housekeeping General knowledge of QMS

Procedures including Stores management

File labeling Rack Identification

- 6.4/6.2.2/7.5.3

-



Fire Prevention plan also helpful to minimize damages

Expenses for annual safety could also give indication on safety improvement

- - -

Approval of Project specific format could be get from H/OEg Asphalt Production Order, Asphalt production report etc

Daily check list for Plant & M/c could be filled in daily to identify failures

- - -

No list of Plant & Machinery - - -

No preventive maintenance plan identified (C/P)

- - -

It is advisable to get H/O approval for the Project Specific FormatsEg: Laboratory formats- Compressive strength of concrete cubes (M/O)

- - -

Some QMS formats correct version has not been used (M/O)

- - -

Master list of Document contains RecordsEg: Weather report, RFI Etc (M/O)

- - -

It is advisable to have separate Organizational Structure (M/O)

- - -



Master Programme for each Project and it should be available at coordinating office and it should be monitored (M/O)

- - -

Road accident will be reduce by using Safety Helmets

- - -

Safety of Diesel storage tank can be improved by installing Fire point

- - -

Test reports shall be approved by authorized person

- - -

Non conformance management not followed

- - -

Design drawingsNo evidence of approval & control statusNo revision statusIdentification is not effectiveEg: two drawing found in same numberDES/CS/UTR/241-0 – Udawalawa Thanamalwila road

- - -

Established Quality ObjectivePossible areas to reduce ABC wastage not identified and documentedEg : Possible areas could be

Road edge wastage Material issue & receive

data Sub base level tolerance

- - -



Defined Quality Objective, Could be displayed to

identify No progress to monitor

Quality Objective has discussed among ourselves but not displayed

5.5.3 1) Displayed main office and sites

2) Progress is being monitored now

Some used QMS formats are outdated. Relevant version is not been usedEg: Attendance sheet, Weather report etc

The person who responsible is not aware

4.2.4 All outdated formats were destroyed and new version was introduced

NO safety manual is in place QAE is responsible for Safety but no documented procedure is in place

4.2.1 QAE is responsible for Safety but no documented procedure is in place

Compressive strength of concrete cubs should be approved by consultant representative

- 7.5.2 This was a pending test report. Later consultant’s Technical Officer has approved

Defined Quality Objective, Could be displayed to

identify No progress to monitor

- - -

It is advisable to get approval for Project specific format from Head OfficeSome used QMS formats are outdated. Relevant version is not been usedEg: Personal feedback form, Personal data etc

- - -

NO safety manual is in place - - -



Stock verification done on 31st December 2010 reveal that 19 items having stock difference But remarks column says “used”. No evidence found

- - -

Rehabilitation plan could be prepared for Barrow pit operation as a continual improvement

- - -

Progress photograph could be attached in to the monthly progress report

- - -

No safety Manual identified in the project

- - -

Fire point not established near the fuel storage area

- - -

No master list of documents & records

- - -

New QMS formats could be used in place of old formats

- - -

Office environment could be improved to get the maximum outputEg : Unsafe power supply Heat generation and proper ventilation

- - -

Available costing method is not acceptableEg: Poor budget cost systemNo item wise cost calculation with related to BOQ

- - -



Quality Objective Progress details are very

poor Not displayed and not

communicated Measured vehicle are

not been used

- - -

In Blasting detail report (AD/MANC/01), blasting pressing details could be shown for future reference. This will be very important in an emergency situation.Eg: No pressing details after 4th June 2010

- - -

Calibration audit has not been carried out by the plant

- - -

Non Conformance Product Notification (NCPN) raised by the Resident Engineer, have not been closed by the Contract Representative.Eg: 2 NCPN’s attached

- - -

Defined Quality Objective has not been properly understood by responsible OfficersEg : Document ControllerIt could be displayed various location to identify others

- - -

Most of the formats are not updated as per the QMS requirementEg : IOU, Daily advance format, Vehicle Accident format etc

- - -



Admin Officer’s duty is vital in Maga construction projects.No proper records maintain by the admin officerEg: Personnel records and HR records

- - -

Control of documents not properly identifiedEg: ICTAD specs

- - -

General Register (Accident) has not updatedEg : Only one was recorded on 2010/08/06After that five cases claimed. But not incorporated in to Accident register

Planning engineer has assigned for ISO work.

4.2.4 Accident register now has been updated

Bin cards of fast moving items have not been updated since last monthEg: River sand – Bin card # 314Diesel – Bin card # 315Bricks – Bin card # 311

Negligence of Store Keeper 4.2.4 All Bin Cards now have been updated. This will monitor by Project Manager in weekly basis

As per the Safety Manual safety harness/ safety belt has to be wear when working at height. But two riggers found without using safety equipment at 11th & 12th floor at the time of audit

Totally negligence of riggers and supervisors

4.1 Strictly warned these two riggers Full responsibility has given to relevant supervisors and Safety Officer will be monitored in daily

Ground contamination could be minimized by preventing Oil & Fuel leakages atGenerator area MGE /37 , MGE/97 & MGE/159 Generators

- 6.4 Separate trays have fabricated and placed under the Generators



It is advisable to get H/O approval for the Project Specific FormatsEg: Public complain report

Lack of knowledge on the Project specific approval system

4.2.4 QAM provided the required information and identified project specific format to be get H/O approval and ready to send to H/O

There are more than 20 Public complaints in the file without closing- no final decision

Provincial council feedback are getting late

4.2.4 Project Manager will address to Provincial council to expedite this process

Documents

Audit Analz