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7/28/2019 Quality Intro
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INTRODUCTION OFPROJECT QUALITY MANAGEMENT
in Oil and Gas Industry
Public Lecture
Institut Sains Dan Teknologi Nasional
Jakarta
22 June 2013
Ina Khanifah Hakim ST.MT
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References
1. PMBOK Guide - 4th Edition
2. ISO 21500
3. ISO 9001 : 2008 Quality ManagementRequirements.
4. API Q1, 8th edition Specification for Quality Programfor the Petroleum, Petrochemical, and Natural GasIndustry.
5. ISO 10006 : 2003 Guideline for Quality Management
in Projects6. ISO 10005 : 2005 Quality Management System
Guideline For Quality Plans
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Quality is.
Fit For Purpose
Meeting Customer Requirements
Zero Defect Etc
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Why Quality important to ..
OWNER
a. Requirements are met
b. Defect free products
c. On-Time deliveriesd. Reliable service
CONTRACOR
a. Reduced cost
b. Improved productivity
c. Fewer problems
d. Avoids product liability
claims
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Consequences of Lack of Quality ..
OWNER
a. Requirements are not
met
b. Schedule delayc. Project cost increased
CONSTACTORa. Increased cost due to
inefficient performance
b. Reputation Suffer
c. Product liability claims
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Quality Life Cycle
Strategic Initiatives
Work Planning
for Prevention
Implement,
Plan &
Perform
Measure
Effect iveness
COQ (Project)
+
KP I
(Functional
Process)
+
Audits
+
Performance
AppraisalsEvaluate
Strengths
Weaknesses &
Risks
Determine
Action
Awareness Training - People
Change Process - ProcessLessons Learned - Project
New Materials/Equipment -
Resources
Revise
Prevention
Planning
IMS
Continuous
Improvement
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Commitment of Management
Quality is effective only when it is the intention
of Corporate Policy and Procedures
MEASURE OF
EFFECTIVENESS
POLICY IMS (INFRASTRUCTURE)
ACCOUNTABILITY QUALITY
AWARENESS
TRAINING
EXECUTIVE MANAGEMENT
COMMITMENT BY EXAMPLECOMMUNICATION
Effectiveness is a measure of the outcome of the cause
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Plan Quality
Input
1. Scope baseline
2. Stakeholder register
3. Cost performance baseline
4. Schedule baseline
5. Risk Register
6. Enterprise environmentalfactor
7. Organizational process assets
Tool and Techniques
1. Cost-benefit analysis2. Cost of quality
3. Control chart
4. Benchmarking
5. Design of experiments
6. Statistical sampling
7. Flow charting8. Proprietary qualitymanagement
9. Additional quality planningtools
Output1. Quality management plan
2. Quality metric
3. Quality checklists
4. Process improvements plan
5. Project document updates
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Project Quality Plan
1. Scope of the Plan2. Measurable Quality Objectives
3. Management Responsibilities
4. Documentation Management (including records)
5. Resources
6. Specific Requirements (project)
7. Communication8. Design development, validation and verification
9. Procurement
10. Fabrication / Construction (Production)
11. Identification and Traceability
12. Storage and Handling
13. Non Conforming Product14. Monitoring and Measurements
15. Inspection And Testing Equipment
16. Audit
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Project Quality Organization (typical)
Project QualityManager (PQM)
QA EngineerQC Supervisor /
Site QC
DisciplineInspectors
Certification
Secretary
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Quality Metric
How the Quality metric measurement drive the
improvement ?
1. Measure the efficiency and effectiveness of a
work process.2. Use to track improving or deteriorating TRENDS.
3. Use to identify where a problem lies.
4. Use to set improvement TARGETS and GOALS.
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Quality Metric measurement
KPI 4 (a) - Shop Drawing Zero Defect - Structural
(M 10)Data Source: Robin D' Cruz
0.04
0.19
0.060.14 0.12 0.07 0.05 0.04
0
1000
2000
3000
4000
5000
6000
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
Sum DeliverablesSum Errors
Avg. % ErrorsTarget
Formula: No. of Drawing Errors =Avg % Error No. of Draw ings Checked
CY 05 Target 0.25%
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Perform Quality Assurance
Input
1. Project Management Plan
2. Quality Metrics3. Work performanceinformation
4. Quality Control measurements
Tool and Techniques
1. Plan quality and performquality control tools andtechniques
2. Quality audit
3. Process analysis
Output1. Organization process assetsupdates
2. Change requests
3. Project management planupdates
4. Project documents updates
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Quality Audit
Audit within the Project may be used for severalpurposes, such as :
- To monitor the implementation and effectivenessof quality plans;
- To monitor and verify conformity with specifiedrequirements;
- For surveillance of suppliers to the organization;
- To provide independent objectives assessment,when required, to meet the needs of customersor other interested parties.
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Perform Quality Control
Input
1. Project management plan
2. Quality metrics
3. Work performancemeasurement
4. Approved change requests
5. Approved change request
6. Deliverables
7. Organizational process assets
Tool and Techniques
1. Cause and effect diagram
2. Control charts
3. Flowcharting
4. Histogram
5. Pareto chart
6. Run chart
7. Scatter diagram
8. Statistical sampling
9. Inspections
10. Approved change requestreview
Output
1. Quality control measurements
2. Validated changes
3. Validated deliverables
4. Organizational process assetsupdates
5. Change requests
6. Project Management Planupdates
7. Project document updates
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Inspection
An Inspection is the examination of a workproduct to determine whether it confirms to
documented standard. The result of an
inspection generally include measurements and
may be conducted at all level
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The figure represents the percentage error in the Welds
performed. The graph represents the data for Structural Linear
UT welds performed and the repairs done. The measurement
is categorized as 'Product Quality'. The data collected reflects
an increase in the weld repairs for the last three months but exhibits an
overall improvement in the process.
AREAS FOR IMPROVEMENT
1. Chevron cracking in December in Pipe Mill and avoidance
of Chevron Cracking
2. Implement preventive action
SHARE BEST PRACTICE ACTION PLAN
1. Welder training program and coaching
2. Welder audit on regular basis
3. Improve WPS
4. Modify PCM to ID welder individual repair rates
5. Train Supervisors to be coaches
6. Stage development of training & Qualification protocol of
Fillet, Plate and Pipe
7. PCM for welder performance
8. Source young talent to train
9. Recognition for good performance
10. Fitters to be measured
11. Empower welder to reject fit ups
12. Welding council to improve equipment quality
13. Stress on quality control topics during toolbox talks
14. First line inspection CWI for all leadermen15. Foreman to record manhours for repair
16. Maintain 40 hrs Training Course
17. Tool box Meeting to address Technical and Method
Statement prior to work commencement
18. Consider coaching of welder by Supervisors based on
criticality of work
KPI 1(b)-Weld Repairs by Discipline
Structural Linear - UT (M 2)
Process Owner: Roy Mathew
0 . 4 1
0.54
0 . 4 60 . 4 3
0 . 3 50 . 3 2 0 . 3 2
0.530.51
0 . 4 9
0.52
0 . 3 00 . 3 3
0 . 4 0
0 . 4 6
0
10000
20000
30000
40000
50000
Jan Feb M ar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb M ar
0.0
0.2
0.4
0.6
0.8
1.0
1.2
Length Tested
Repair Lengt h
Avg . %
Ind. Std
Target
Formula: Length Rejected =Avg. % Error
Length Tested
CY 2005CY 2004
CY 05 T arget 0.3%
CAUSE & EFFECT DIAGRAM
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DESIGN VERIFICATION& DESIGN REVIEW
DEFICIENCY
Management Commitment to Quality
Quality not considered a Value and compromised
Fab Supervision intimidation of QC Personnel
Product liability Claim
Loss of $ and Reputation
OUTCOME
PMT TEAMDEDICATED STAFF
PROJECTCONTROLS
DRIVESPROJECT
PLANNING IMS SYSTEMPROCUREMENTMATERIALS MGT.
FABRICATION
CLIENT
INFLUENCE
CLIENT
INFLUENCE
CLIENT
INFLUENCE
PROJECT TIME LINE
FUNCTIONAL INPUT CONTROLLED BY FUNCTIONAL STAFF
FUNCTIONAL INPUT CONTROLLED BY FUNCTIONAL STAFF
BIDSUBMISSION
SCHEDULE
HISTOGRAM
CRITICAL PATH
MILESTONE
LEVIL 1 GUIDELINES
LEVEL 2 PROCEDURES
LEVEL 3 PLANS
PROJECT AUDITS
FREE ISSUE
PROCUREMENT PLAN
RFQ & TBE
PRICE, DELIVERY
VENDOR CAPABILITY
SUB-CONTRACTOR CAPABILITY
CONTRACT
SOW & REQUIREMENT
CRITERIA SPEC
CHANGE ORDER/MGT.
DESIGN
TBE OF ENG. EQUIPMENT &ENG. BULK MATERIAL
EFFECTIVE & TIMELYDELIVERABLES (ROS)
MARINE
ENVIRONMENT
AGENT FACILITATION &SERVICES
SITE LOGISTICS
AWARD
FEED
PROGRESS MEASUREMENT
WBS
REPORTING EXPIDITING
QC/NDT PRODUCT CONFORMITY
PROJECT QA
CORPORATE AUDITS
QUALITY PLANNING
ISO 9000
MEASUREMENT
REVIEW LESSONS LEARNED
MILESTONES
PROJECT QA
DETAIL DESIGN
MATERIAL CONTROL
4 WEEK LOOK AHEAD
HSE
PRODUCTIVITY
QC/NDT PRODUCT CONFORMITY
HSE
CARGO BARGE
SUPPORT VESSEL
LAYRATE / CYCLE TIME
DOWNTIME
LOGISTIC SCHEDULE
QC/NDT PRODUCT CONFORMITY
LOCAL WORKFORCE
DESIGN PREMISE
MGT. COMMITMENT
BARGE SELECTION PREPARATION
RISK ASSESSMENT
DEPTH & TIDES & CURRENT
CONSTRUCTION AID
WELDING PROCEDURE
WELDING PROCEDURE
END
PRODUCT
CAUSE & EFFECT DIAGRAM
PROJECT EXECUTION CORE PROCESS
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