PLANT DESIGN - ENGINEERING - EPC …cdn.ibauhamburg.com/pdf/ibau-hamburg-quality-management-system.pdfPLANT DESIGN - ENGINEERING - EPC-CONTRACTING ... Central Cone Silos EPC-Contracting

Your efficient partner for modern and effective bulk material handling

PLANT DESIGN - ENGINEERING - EPC-CONTRACTING

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I BAU HAMBURG

CEMENT - THERMAL POWER - MINERALS

Single silos. Ring silos.

Multicompart-ment silos. From 2 to

22 chambers,diameters:

14 to 27 m.

Advanced technology for

self-discharging Cement Carriers

including the Midship tunnel.

Marine Cement Terminals

Central Cone Silos EPC-Contracting

Silo Conversions

Components

Spare Parts

Cement Carriers

Ship Unloaders

Floating terminals.

Mini terminals.Silo systems.

Dome systems.Flat storage

terminals.

Stationary ormobile types:

From the5,000 class

up to the60,000 class.

Piling. Civil works. Steel structure, supply/erection. Electrical/mechanical supply and erection.

Economic modifications with advanced cutting-edge technology.

The key for a well functioning plant: Components, all made to measure.

High stock availability:Just-in-time supply of spare parts.After-sales Service.

QUALITYMANAGEMENT

SYSTEM

A HAVER & BOECKER Company

IBAUHAMBURG

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How does the I BAU HAMBURGengineeringcompany work?

In 1975, I BAU HAMBURGstarted working according toits own high quality standardsand a quality management

system (QMS), of which manyaspects correspond to thesubsequently introducedISO 9001.

Each part to be delivered is designed and manufacturedaccording to the importantnational and internationalstandards and regulations forsafety and quality.

We are able to react quicklyand flexibly to problemswithout high costs.

All I BAU HAMBURGemployees work according toan internal QM manual.

Competenceand Innovation

I BAU HAMBURG has morethan 35 years of experiencein the storage, transportationand metering of bulk goodsand is one of the world's lead-ing companies in this sector.These years of experience helpus in supporting our customersin implementing their projectsby developing and applyingcustomised solutions andcomplete system concepts ofthe highest quality.

As an innovative company,I BAU HAMBURG can con-tinually develop its productsand undergo continual qualityimprovements, with the goalof putting efficiency and thedesires of its customers at theheart of all operations. Ourentrepreneurial operations arecarried out by a goal-orientedbusiness management on alllevels, as well as the strongmotivation and methodologi-cal competence of ourqualified employees. Ourproject teams work under theirown responsibility, indepen-dently and performance-oriented, combining profes-sional competence and experi-ence in doing so.

The I BAU HAMBURGmechanics are technicallyqualified, experienced,flexible, reliableand efficiency-oriented.

Products and globalactivities in thestorage, transportand metering of bulkgoods sectors

This quality managementbrochure, which is based onextensive experience andon our DIN ISO 9001 certifi-cation, is designed to showour clients what is being doneto serve them with the highestquality - to their fullsatisfaction.

We offer:

- engineering for turnkeyprojects

- airslide systems

- individual components suchas flow-control and cut-offgates, rotary bottom androtary side dischargers

- bulk loading technology

- mechanical material trans-port using screws

- pneumatic tube conveyortechnology with screwpumps, two-way valves, jetconveyors, airlifts

- mechanical mixers andmixing plants

- global projects incooperation withHAVER & BOECKER:Complete plant concepts forsilo technology, includingpacking systems and loadingtechnologies

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InformationThe QUALITY MANAGEMENT SYSTEM of I BAU HAMBURG

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The company

The I BAU HAMBURG engi-neering company was foundedin 1975 and is active in theRock Products Industry andthere primarily in the cementindustry.

Our product portfolio includessilo technology, as well as theoutfit of self-unloading shipsand the "Marine Business",i.e. mechanical shipunloadersand cement terminals. Otherfocal points are the coal-firedpower plant technology, flyash handling and the aluminaindustry.

Since 1997, I BAUHAMBURG is a 100 % partof the Haver & BoeckerGroup, which is located inOelde/Westphalia and is alsocertified in accordance withISO 9001.

I BAU HAMBURG currentlyhas 150 employees. Besides itsown office building atRödingsmarkt/Hamburg citycentre, I BAU HAMBURG alsohas approximately 6000 m2

of warehouse space inHamburg-Allermöhe. Here,products such as shipunload-ers, conveying pumps andcomponents for pneumatic andmechanical transport systemsare assembled.

HAVER IBAU SHENZENLTD., our subsidiary inChina, was founded in 2005.The IBAU building in the city centre of Hamburg

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30 employees are currentlyworking there, offeringengineering, sales and servicesfor HAVER & BOECKER,I BAU HAMBURGand FEIGE FILLING.

Quality policyandquality principles

Our long-term success is basedon adherence to our qualitypromise. Whether consulting,planning or turnkey supply – allof our services are performedwith the consistent observanceof strict regulations.

Our company policy serves as aset of guidelines for all employ-ees in their daily work and isfocused on the following areas:

The customers

There is a constant communi-cation to completely identifyour customer's requirements.We listen carefully to ourcustomers, understand theirexpectations and consistentlyfulfil the agreed requirementsfor service as well as continu-ally meet the high demandsfor quality. We react flexiblyto requests for modificationsduring the cooperation.

The customer's satisfactionplays the most important role,every delivery and servicemust be a recommendation forfurther projects.

Documentation preparation

Order processing team – engineer and draughtsman

Employee training

Project planning meeting

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The suppliers

By selecting experienced andqualified suppliers and serviceproviders, we boost the qualityof our products and thereforeour competitiveness. An earlyinvolvement, comprehensivetwo-way communicationand a continual common willto improve are the basis forlong-term partnerships withour suppliers.

The employees

Each employee is responsiblefor the quality of her/his ownwork. We ensure that ouremployees follow and pass oninstructions properly and thatthey work according to ourcertified quality managementsystem and safety standards,support them and help todevelop them continuously.

The attitude and conduct ofthe I BAU HAMBURGemployees are marked by:

- objectivity

- consistency and prudence

- open-mindednessand transparency

- know-how transfer

- open, constructiveand interdisciplinarycommunication

- team spirit

- internationality

- commitment andresponsibility

- quality awareness andinnovative capability

Environmental protectionand safety

The most important goal isto prevent danger to humansand the environment, reducethe environmental impactsand preserve resources.

This is achieved by continuousprocess and product improve-ment in close cooperation withour customers.

The company'squality goals

By continuous improvementsand further development,I BAU HAMBURG is ableto constantly improve theirproducts and to adapt themto the latest standardsand market requirements.

That means:

- the development of cost-effective solutions

- an optimised price/perfor-mance ratio

- the supply of impeccableproducts and services whilekeeping to the warranteddeadlines and qualities.

- striving for 100 % freedomfrom faults

- working methods andprocedures according to theregulations being the basis

- the development and mainte-nance of proceduresdesigned to increase productquality, productivity andsafety. The promotion of thecapabilities of our employ-ees and establishment of amotivating working environ-ment while imparting vividquality awareness.

Furthermore, all employeesare responsible for familiaris-ing themselves with the infor-mation and procedures fromthe certified QM system thatconcern their own work areain our company and for fol-lowing and meeting all thedemands of these procedures.

The certifiedQUALITYMANAGEMENTSYSTEM of I BAU HAMBURGaccordingto DIN ISO 9001

I BAU HAMBURG's certifiedquality management system(QMS) defines the proceduresand responsibilities for allcompany processes that havean influence on the quality ofthe services and products.

This guarantees a systematicprocess for planning, control-ling, securing and improvingquality.

Order processing – discussing details

Preparing drawings and checking details

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Managementsystem structure

The certified I BAUHAMBURG quality manage-ment system consists of thefollowing three levels:

The first level is the highestand consists of the QM manu-al, which presents the qualitypolicies of our companyand links them to instructionsfor certain procedures.

The manual is the most impor-tant reference document fordescribing the managementsystem. It contains theprinciples, responsibilities andthe comprehensive methodsand procedures for company

processes. It is the referencedocument for the drawingup and maintenance of theQM system and the basis forbusiness processes.

The second level consists ofthe process instructions, whichdescribe by which processesand responsibilities therequired quality is to beachieved.

In order to ensure that ourproducts meet the require-ments and expectations of ourcustomers, the legal regula-tions and national and interna-tional standards, our companyhas documented the relevantprocesses and their reciprocaleffects in process and workinstructions.

The third level consists ofproduct-specific documents ondevelopment and production.

Managementprocesses Managementresponsibilities

The management controls thequality policies, determinesthe quality goals and regularlyinspects the quality manage-ment system for effectiveness.It initiates the implementationof quality policies and sees itas a responsibility to maintainand continue to improve theI BAU HAMBURG qualitymanagement system describedin the manual.

Model of a process-orientedQUALITY MANAGEMENT SYSTEM

The required product realisation processes derivefrom the company structure, which is described in detailin the corresponding organisational chart.

Structure and organisation

The I BAU HAMBURG quality management systemis certified in accordance with DIN ISO 9001.

Constant improvementof the quality management system

Customers

Customers

Satisfaction

Requirements

Managementresponsibilities

Managementof resources

Evaluation, analysisand improvement

Productrealisation

Productor

service Real net output Information

Legend

QMmanual

QM process instructions

product-specific

• notes• standards/company standards

• work and testing instructions• forms

The firstlevel

The secondlevel

The thirdlevel

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Customer orientation

Our quality policy is cus-tomer-oriented. It complieswith the customers' require-ments, which are evaluatedby constant direct communi-cation. As one of our qualitygoals, satisfying customerrequirements is therefore inthe central focus of interestand has top priority for allemployees.

Furthermore, meeting alllegal requirements concerningproduct safety and conformitywith the relevant standardsis ensured and the effectson the environment are alsoinvestigated.

Communication,responsibilityand authority

Responsibilities and compe-tence are delegated by meansof employment contracts, jobdescriptions and signatureregulations.

Communication within ourcompany is characterisedby a continuous flow ofinformation from the companymanagement to the employeesand back, to generatea uniform information statusthroughout the company andto incorporate the employeesinto the decision-makingprocesses. Furthermore, wepromote the further education ofour employees by continuousadvanced training.

Managementofresources

The processes relevant toquality and the requiredimprovements are plannedin the company, based on thestipulated quality goals.

The department heads areresponsible for choosing therequired means for ensuringthe quality goals and control-ling processes. The requiredresources are determinedcontinuously under considera-tion of current and futurerequirements and are madeavailable by the management.

Human resources

The personnel are selectedin cooperation with the depart-ment heads according to therequirements of the projectsand processes, under consider-ation of the education, trainingand aptitude of the individualemployees.

All works in the companyare carried out by qualifiedpersonnel.

Adequate qualification isensured through a review ofaptitude in the hiring process.

When hiring new employeesqualifications are verifiedaccording to the requirementsof the job description. In addi-

tion, new staff are instructedand trained by experiencedand skilled personnel.

During this training, theemployees are also taughtthe quality managementregulations, processes andmeasures to be used in theirown specific areas.

Infrastructureandworking environment

Each employee is providedwith the equipment relevantfor their working area andwith a connection to the entireinternal computer network.

The computer infrastructureand the corresponding licencesare supervised and maintainedby the administrator.

A daily backup protects theavailability of the electronicdata.

Protection against virusesis guaranteed by continuallyupdated virus scanners.

Our workplaces are organisedin accordance with the aspectsof health, safety and environ-mental protection.

A specific training and instruc-tions regarding work safetyfor new employees and whenassigning new working areasis in the responsibility of thesuperiors. Drawing control

Sample control

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Sectional view of a central cone silo

Business processes

Product realisation

The business processes de-scribe the product realisationat I BAU HAMBURG. Theintroduction of official proce-dures, including all quality-relevant business processes,ensures that these activitiesare controlled and carried outwith suitable documentationand monitoring to maintaincontinuous control.

This is presented in the respec-tive procedural descriptions inthe QM manual, in which thecompany processes relevant tothe realisation of a product aredescribed and defined asmandatory specifications.Here, suitable measures aredefined indicating how theprocesses are to be performedin controlled circumstances,how the customer require-ments will be put into effectwith suitable means, how therespective quality testing willbe carried out and the respon-sibilities of the respectiveemployees and organisationalinterfaces. The determinedinterfaces between contiguousprocesses result in an inte-grated quality planning for theentire company.

Customer-related processes

The business processes of ourorganisation are adapted to therequirements of our customers,

i.e. not only at the beginningof a business relationship dowe attempt to achieve a clearunderstanding of the require-ments of our customers, butthat these will be continuouslyexamined throughout theentire duration of a projectand the services rendered.

Proposalandproject management

Proposal processing

The process of "Proposal andproject management" is han-dled within our organisation inthe project department. Here,the proposals are created,processed and followed up.After a customer inquiry, thefeasibility of an order isexamined. The actual prepara-tion of an offer is started witha PROPOSAL EVALUATION.

In this phase:

• terms of payment

• special quality requirements

• special documentationrequirements

• contract law

• technical delivery conditions

• after-sales services are clari-fied and incorporated intothe proposal.

After the project engineer hasinvestigated and clarified allthe relevant key points, a pre-

liminary project plan is createdfor customer-specific modifi-cations and complete systemconcepts. During this phase,the initially required technicaldocuments and flowsheets arecreated.

The CALCULATION is basedon these first preliminary doc-uments. The results of thesethree phases, proposal evalua-tion, preliminary projectplanning and calculation areintegrated into a written pro-posal in the form of a supplierspecification by the projectengineer and are then transmit-ted to the customer.

These procedures guaranteethat any discrepancies arerecognised and clarified in theearly phases of the process.Those activities that refer tothe design of the necessarydocuments for theproposal/contract evaluationarespecified in the internalQM manual.

Order processingThe order processing includescomplete coordination of allother processes serving to car-ry out the product realisationand the rendering of services.The delivery specificationsand the preliminary documen-tation and drawings createdin the previous process"Proposal and projectmanagement" in the project

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department are the basis. Order analysis

After receipt of an order, theengineer carefully checksthe congruency of the proposaland the incoming orderunder consideration of thelegal regulations.

Open points are clarified withthe customer and the projectengineer and documentedaccordingly. Upon a positiveresult, the customer receivesan order confirmation.

Based on the technical propos-al and the meetings with thecustomer after order place-ment the delivery specificationis created.

This delivery specificationis the basis for the engineer,being in charge of therealisation of the plannedinstallation, as well as for theplanning of details.

The process entails the follow-ing procedures:

• supervising and controllingthe engineering concept for:logic, function, compliancewith all specifications andguidelines

• planning of concept details,which includes:

• creating overview and detaildrawings of the installationconcept

• calculation and dimen-sioning of the installationcomponents

• creating functionaldescriptions

• verification of the needfor special constructions/concept modifications

• verifying production orassembly drawings

• scheduled planning forprocurement, provision,fabrication and assemblyof the correct components

• coordinating, tracking andmonitoring of production,assembly and acceptancedeadlines

• coordinating and monitoringof all subsequent processes,such as procurement,construction, fabricationand assembly, shipping,documentation and after-sales service

• invoice release by thepurchasing department

• recorded project meetingswith the customer at regularintervals:

- ongoing communicationwith the customer

- continuous investigation,coordination and adaptationof the plant concept duringthe process under considera-tion of customer wishes

- initial analysis of customersatisfaction during thecourse of the project

- flexible reaction to changesrequested by the customer

• coordination of the commis-sioning with subsequentfunction test of the plantunder consideration of thecontract-related guaranteespecifications.

Development/construction

The development of I BAUproducts as well as the modifi-cation of existing products incase of special requirements orspecial frameworks is carriedout in the constructionprocess.

Our products are developedand documented from theinitial draft right up to thefinal documentation by usingmodern CAD workstations.

Detailed manufacturing draw-ings with welding and testinginstructions are the basis forthe order placement.

The construction processincludes the followingprocesses:

• creation of manufacturingdrawings, parts lists, weldingand test plans

• release of test documentation• verification of development

results• verification of manu-

facturing documentation• transfer of verified docu-

ments to the manufacturingdepartment in the context ofthe procurement process

• continuous communicationbetween construction andmanufacturing departmentrespectively with the finalassembly in order to preventfaults or for improvement Cross-section of a mixing plant

Dedusting

Feeding pipesfrom the mills

Fluidslides tolarge-size silos

Large-size silos

Dischargelarge-size silos

Weighing andmetering bin

Product andloading silos

Bag andbig-bag feeding

Weighing andmetering bin

Simplexloaders

Mixer

Bulk loading

Control room

Screw pump

Weighing bridge

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Procurement

The quality of supplier partsand products as well as ser-vices and production serviceshas a major influence onthe quality that we offer ourcustomers.

The procurement process istherefore the guarantee for acompletion on time of theproducts and services by ap-proved suppliers while main-taining the required specifica-tions and commercial condi-tions that are agreed upon.

Most of our suppliers of rawmaterials, casted parts andpurchased parts have beenworking for us for decades.Companies that do not achieveour quality standards will notbe admitted to our supplierpool. The majority of oursuppliers are alsocertified accord-ing to DIN ISO9001, e.g. Aerzen-er Maschinenfab-rik (blowers andscrew compres-sors), Atlas Copco(compressors),Reitz Ventilatoren(fans), Siemens(electrical compo-nents), ABB(electrical com-ponents), Flender(couplings andgearboxes), etc.Those long-termco-operations

with qualified supplierscontribute to the reliability ofthe procurement process,therefore increasing the quali-ty of service to our customers.

This includes using thefollowing quality assuranceprocedures:- proposal evaluation- verification of product

specifications- material tests- tests by independent experts

(e.g. Germanischer Lloyd,Bureau Veritas, etc.)

- inspection of documen-tation/test reports

- regular quality and function-al tests on-site in case ofexternal production activities

- regular quality and function-al tests at supplier premises,e.g. test stand runs

- supplier audits

Production

The assembly of supplier partsand I BAU products takesplace in our workshops inHamburg-Allermöhe. Here,the incoming parts are testedupon receipt with regard toour internal drawings andstandards.

Rejected parts are immediatelyreturned to the suppliers andaccepted parts are sent on tothe production process.

The straightforward organisa-tional structure is characteristi-cally for our workshops.The short distances, a highdegree of transparency and acontinuous information flowenable quick reactions of theemployees to queries andmodification requests by ourengineers or customers. Due

to the distinctiveknow-how of ourmechanics anda smooth coopera-tion with theconstruction andprocessing depart-ments, produc-tion-relevantmeasures arerecognised, im-proved and put in-to use at an earlystage. Thus, ouremployees alwayshave an awarenessfor quality andmaintain that qual-ity at all times.

Quality control monitors thefollowing processes:

• incoming goods check/ac-ceptance ofpurchased parts

• production, production mon-itoring by checklists accom-panying the production

• assembly, coating and instal-lation of the components

• monitoring the assembly• acceptance and function test-

ing/final checks according toour standards

• acceptance accordingto external standards/certifications

• Preparation of test reports• Packing by a certified

packing company• shipping of components:- labelling of components- inspection of the packing- examination of shipping

documents

During production, ourcustomers are able to checkthe progress and quality of theordered parts at any time. Theready-to-ship note is handedout a few days/weeks beforethe delivery so that thecustomer is able to perform afinal check of their equipmentwith regard to quality, func-tionality and packing on site,prior to shipment.

The customer is then presentedwith the test reports for theequipment. Every part thatleaves our facility is checkedaccording to our test reports.Loading chute in the test stand

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After-salesservice/spare parts

If there are unusual or unex-pected problems, which mighthave been caused by faultyfunctioning or quality, I BAUHAMBURG guarantees agenerous customer serviceand provides the entire rangeof spare parts and the replace-ment thereof when necessary.

The responsible engineersanswer all questions from thecustomer and help him to findthe right solutions.

Based on the contractuallydefined guarantee conditions,I BAU HAMBURG also pro-vides the required personnelresources on-site, e.g. super-visors or technicians.

The following procedures areused:

• analysis of customerproblems

• preparation of solutionsand presenting them to thecustomer

• repair of equipment andinstallations

• obtaining field experiencesby the operators

• analysis of customersatisfaction High capacity shipunloader with pneumatic conveying system

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Single-shaft batch type mixerIBAU Pressure vessels in the Litvinov power plant

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Preparations for shipping components to the customer

Compilation of individual components for an order

Quality control of spare parts

Final assembly at the IBAU manufacturing

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Drilling of nozzles according to order specifications

Assembly of a two-way valveManufacturing control of an airslide

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Assembly of IBAU Flow-control gates at the Hamburg-Allermöhe workshops

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Functional test of a flow-through mixer

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feedback from our customersfrom the first meeting on-wards. This system is usedin all other processes, fromthe procurement to productionto customer service.

Testing of products

The monitoring of qualityrequirements for the productis guaranteed by inspectionand comparing with thespecifications.

The type of test to be per-formed is documented and isdone e.g. in the form of:

• incoming goods inspection

• intermediate inspectionduring manufacturing

• final tests in the form offunctional tests

The results of these tests aredocumented based on require-ments and are used for furtheranalysis when required.

Use and monitoring of testequipment

Test equipment for incominggoods inspection, final accep-tance or control measurementsare chosen within the contextof realising the product accor-ding to the respective productrequirements.

All quality-relevant test equip-ment is maintained and cali-brated or adjusted at defined

intervals, by external serviceproviders when necessary. Inthis context, maintaining thedefined limit values for maxi-mum error in the test equip-ment is guaranteed by specifi-cations and maintenance forthe entire service life.

This rules out the possibilityof using unsuitable, faulty testequipment.

Corrective and preventivemeasures

The results of customer-speci-fic problem analyses serve asthe basis for corrective andpreventive measures.

These measures are performedto prevent repeated errors andrectifying possible sources oferrors.

The process is triggered bycomplaints, internal errormessages and suggestions forimprovement from employees.

The implementation of themeasures in the affectedprocesses is monitored and theeffectiveness of the measuresinvestigated.

Document and data control

Those involved in the indivi-dual departments are responsi-ble for the maintenance andrelease of contract-relateddocuments and data requiredwhile processing an order.

Control offaulty products

Products that do not meet therequirements are identifiedand marked, to preventaccidental use or delivery tocustomers.

Depending on the type andlocation of the fault, therespective measures aretaken to discard or rework therespective item.

These measures include:

• identification and marking

• authorisation, release

• fault rectification

• documentation

Documentation

For every order, the documen-tation department prepares acomprehensive technical do-cumentation and subsequentlysubmits it to the customer.This also includes documentscreated upon customer requestfor the quality assurance, suchas acceptance test certificates,material test certificates, de-clarations of conformity, etc.

After acceptance by our custo-mers, our own copies of thisdocumentation are carefullystored for years so that theycan be used as security andproof of the correct quality forthe company and the customer.

Supportingprocesses

Evaluation, analysis and improvement

Evaluation ofcustomer satisfaction

The satisfaction of ourcustomers is the mostsignificant factor in evaluatingour management system.

This is done through theevaluation of customer-relatedinformation:

• direct communication withthe customers

• collecting comments fromcustomers upon request

• recorded project meetingswith the customers

• communication with thecustomers in the contextof after-sales service.

While an order is beingprocessed with I BAUHAMBURG, the customeris continually supported withcontinuous communication.

Our engineers in the order pro-cessing department supportour customers through regular,recorded meetings on-site.

This way, not only is itpossible to react quickly andflexibly to customer wishes,but we maintain a permanent

Preparing components for shipping

Documents

PLANT DESIGN - ENGINEERING - EPC …cdn.ibauhamburg.com/pdf/ibau-hamburg-quality-management-system.pdfPLANT DESIGN - ENGINEERING - EPC-CONTRACTING ... Central Cone Silos EPC-Contracting