Project QA&QC Documentation –

Effective Implementation at sites

Growing a diversified global business

Project Quality Plan (PQP)

Contents

QIPs - Effective Implementation

Quality Inspection Plans (QIPs)

Learning Objectives

PQP – Effective Implementation at sites

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

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 ?

A written plan

How you will manage quality?

Which describes:

Processes,

Activities, and

Resources

Key words?

Project Quality Plan (PQP)

Descon Standard PQP

Project Quality Plan (PQP)

Table Type

Types of PQP

Flow Chart Type

Types of PQP

Form Type

Types of PQP

Text Type

Types of PQP

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.

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

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

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

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

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

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

For Sample PQP

Sample PQP

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.

A document

Minimum requirement

Inspection workflow

Parties involved

Witness & hold points

Acceptance criteria

Records

Key words?

Quality Inspection Plan (QIP)

Descon Standard QIP

Quality Inspection Plan (QIP)

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)

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)

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)

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)

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)

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

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)

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)

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)

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)

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

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

QIP

Sample QIP

For Sample QIP

Question & Answers