Quality Induction [PDF]

Zitiervorschau

EXYTE - QUALITY INDUCTION Quality is defined as the degree to which a set of inherent characteristics of an object fulfills requirements (e.g. scope of work, policies, procedures, specifications, standards, client, contract etc.). Right First Time (RFT)  is about making sure that all our activities are carried out in the right manner the first time and every single time. Glossary: 1. "Degree” implies quality is a variable. 2. “a set of” implies quality is not a single characteristic. 3. “Inherent” as opposed to "Assigned", means existing in the object therefore neither price nor delivery is a quality characteristic of a product but can be a characteristic of a service. 4. “Object” means anything perceivable or conceivable therefore the term quality can be used relative to both tangible and intangible objects e.g. the quality of commitment. 5. “Requirement” means a need or expectation that is stated, generally implied or obligatory. Different aspects of Quality 1. Quality System The Quality System provides the framework for planning, implementing, documenting, and assessing work performed by Exyte Design Engineering, Construction Management, Commissioning / Qualification and subcontractors, Vendors and suppliers. 2. Quality Management Quality Management includes strategic planning, allocation of resources, and other systematic activities pertaining to quality activities. 3. Quality Assurance An integrated system of Management Activities involving planning, implementation, documentation, assessment reporting, and Quality Improvements. These Management Activities ensure that the project process, item, or engineering, construction and pre-commissioning / Commissioning is of the type and quality needed and expected by our client. 4. Quality Control The overall systems of technical activities that measures the attributes and performance of the project process, items of engineering or services against defined standards to verify that they meet the requirements established by our clients and our partners, operational techniques, and activities that are used to fulfill requirements for quality.

Basic principles of Quality Assurance 1. Quality must be designed and built in.  It cannot be inspected in or added at the end of the project. 2. Quality is everybody's business. It is important that every member of the organization understands that they have quality related responsibilities and understands what they are. 3. Quality is everybody's business. It is important that every member of the organization understands that they have quality related responsibilities and understands what they are. 4. Quality is everybody's business. It is important that every member of the organization understands that they have quality related responsibilities and understands what they are. 5. Effective, proactive quality management ensures that Stakeholder needs, and expectations are identified, communicated and addressed during the project design and execution activities. Done effectively it can positively impact the schedule, cost and ease of execution of the project 6. The concept of” Right First Time” helps achieve the project objectives at minimum cost.

EXYTE - QUALITY INDUCTION 7. Good planning will help identify and Anticipate Problems.

Why Quality is important and its benefits We commit to Excellence Quality Management System Benefits 1. Quality creates safety Having standards and procedures creates a better and safe place to work. 2. Quality is long term Growth can only be achieved through continuous improvement. 3. Quality reduces risk Quality Management Systems (QMS) reduce objective gaps and variations. 4. Quality shapes values It enhances a strong feeling of teamwork. 5. Quality is measurable Increases revenues and higher productivity. 6. Quality promotes satisfaction Satisfying our customers and employees leads to retaining their loyalty and repeat business. Management commitment to Quality Top Management of Exyte will demonstrate leadership in all matters relating to the  Quality Management System (QMS) as part of an Integrated Management System (IMS) and will promote continual improvement by: 1. leading by example, 2. establishing quality policy, objectives and targets that are SMART (Specific, Measurable, Attainable, Realistic and Time based) and at the same time are compatible with the strategic direction of Exyte, 3. promoting the use of the process approach and risk-based thinking, 4. ensuring the integration of QMS requirements into Exyte business processes 5. ensuring that the resources needed to establish, implement, maintain and improve the QMS are available, 6. communicating the importance of effective QMS management and conforming to the QMS requirements 7. ensuring the QMS achieves its intended outcomes, 8. directing and supporting persons to contribute to the effectiveness of the QMS, 9. ensuring and promoting continual improvement, 10. supporting other relevant management and senior leadership roles to demonstrate their leadership as applicable to their business units, regions, countries and functional areas of responsibility, 11. developing, leading and promoting a culture within Exyte Group that supports the intended outcome of the QMS, 12. developing, leading and promoting a culture within Exyte Group that supports the intended outcome of the QMS, 13. ensuring that Exyte Group establishes and implements a process of consultation and participation of workers, 14. supporting the establishment and functioning of the Quality Committee

Management Review

EXYTE - QUALITY INDUCTION The main purpose of the meeting is to ensure the continuing suitability of the Quality Management System for their entity and review where improvements should be made. Each review meeting also includes a focus on the current opportunities and risks and current actions against these are assessed for their effectiveness. Agenda includes: 1. 2. 3. 4. 5. 6.

The status of actions from previous management review Changes in external and internal issues that are relevant to the quality management system Information on the performance and effectiveness of quality management system The adequacy of resources The effectiveness of actions taken to address risk and opportunities Opportunities for improvement

What is a Quality Management System? 1. A Quality Management System (QMS) is a way of defining how an organization can meet the requirements of its customers and other stakeholders affected by its work. 2. It doesn’t specify what the objectives relating to “quality” or “meeting customer needs” should be, but requires organizations to define these objectives themselves and continually improve their processes in order to reach them. 3. It applies continual improvement processes – to continually achieves high quality services. 4. The QMS exists to ensure that quality is designed and built into our products.  5. It holds all the relevant documentation to ensure quality is followed throughout our projects from conception through to completion. 6. It means our approach to projects are approached in a consistent, replicable and standardized manner. 7. The QMS is a dynamic system as we continually improve our processes to meet customer specifications and helps us to continually achieve high quality services. Continuous Improvement (PDCA) Plan, Do, Check, Act (PDCA) PDCA is all about continuous improvement. Continuous Improvement is an important part of our quality processes. At Exyte, we strive for Excellence, it is one of our Core Values. Excellence is achieved through our high-quality standards. The process of ‘Plan, Do, Check and Act’ is written into the ISO 9001 standards and are the specific steps within the continuous improvement process.

Quality Documentation Pyramid

EXYTE - QUALITY INDUCTION Tier 0 (top): Quality Policy is a document developed by Management to express the directive of the top management with respect to Quality. Tier 1: Quality Management Manual describes methods for establishing, implementing and maintaining the QMS Tier 2: Processes / Standard Operating Procedures (SOP’s) describe the who, what and when things happen Tier 3: Work instructions describe how things happen and the individual steps required to complete the task.  Tier 4: Records: The completed forms and other records provide evidence of an effective QMS. This tier will include all project specific information such as drawings, meeting minutes, technical data etc.

EXYTE - QUALITY INDUCTION

Quality Management Throughout the project life-cycle Step 1 - Project Quality Plan (PQP) Project Quality Objectives and KPI's (Key Performance Indicators) include:       

Design Control Procurement Schedule Management Document Control Construction Construction Quality Commissioning / Handover

Step 2 - Quality Management in Design Design Reviews are a formal, documented and systematic critical study of a design by discipline leads, package owners and the client. These are performed during:

EXYTE - QUALITY INDUCTION  Concept Design   Preliminary Design / Basic Design  Detailed Design These reviews are performed to ensure our project design meets the highest internal quality and client standards and comply to several different standards such as code compliance and safety related regulations. Step 3 - Quality Management in Procurement Supplier Qualification is a process that Exyte needs to perform for the selection and retention of: reliable, competent, quality and safety conscious subcontractors, vendors, suppliers and consultants. This is done through prequalification, qualification and evaluation processes to control risks of defaulting / abandoning during project execution Documents that are critical at this phase are:       

Prequalification Technical Bid Evaluation (TBE) / Commercial Bid Evaluation (CBE) Non-disclosure Agreement (NDA) / Confidentiality Agreement Procurement Matrix Procurement Plan / Material and Equipment Control Plan Subcontractor / Vendor Audit Supplier Evaluation (after project close-out)

Step 4 - Quality Management in Schedule Management The Scheduling Plan defines the requirements for the planning and status reports on projects. The objective is to develop plans and schedules and then to monitor, analyse, report and forecast performance in such a manner that projects are delivered on or ahead of schedule. Reports / Plans issued are:       

Master Schedule Design Procurement Tender Matrix Construction and Commissioning Schedule Schedule changes (client approved) Bar Chart / 2-Weeks Look ahead Narrative Reports Progress showing actual manpower vs planned manpower

Step 5 - Quality Management in Project Mobilization Prior to a project physically commencing there is a detailed Project Mobilization plan. This includes information from all participating teams and includes various documents which must be completed prior to the construction commencing. Critical documentation includes: 1. Project Pre-start up and Mobilization Check: A checklist of items that a project needs to fulfill and pass. This will be checked via Audit. 2. Project Execution Plan (PEP): Depicts the project specific approach for all activities in Design, Construction, Procurement, Quality, EHS as well as the processes for reporting and project controls. 3. Risk Register: Documents all project related risks and estimated impacts on cost, schedule and quality. It also defines responses to risks which includes any potential outcome that compromises the Exyte core values and/or project objectives. The risk register is initially developed by

EXYTE - QUALITY INDUCTION Business Development and it will be fully updated by the Project team within 2 weeks of the client kick-off meeting. 4. Change Management / Change Control Plan: Lists the procedures related to design and scope changes. Step 6 - Quality Management in Commissioning The commissioning process is where we ensure that all systems and components are built as required to meet our client's expectations. The key quality management measures/documentation during commissioning are: 1. Commissioning Plan: is a document that describes the process of verifying that equipment and systems are installed according to specifications, placing the equipment and system into active service and verifying its operation before handing over to client. 2. Construction observations / walk-down: Are activities conducted to identify a list of defects that need to be fixed or completed before handover. 3.  Operation Manual: The operation and maintenance manual which includes information about all of the installed equipment is verified, and the client/user are trained. 4. Commissioning Method Statement: to be prepared and reviewed by Exyte. Step 7 - Quality Management in Handover Following the successful commissioning stage Exyte hand over the facility to the client. The documentation prepared and issued during handover is as follows:  1. Completion Certificate: The certificate provides formal handover of the Project from Exyte to the Client. The certificate contains a list of completed systems. Exyte requires the Client to sign and accept that all construction works are completed in accordance with the project approved design specifications, drawings and procedures. 2. Handover Document: A written notification offered by Exyte and accepted by the client when construction and commissioning for the entire facility is complete. 3. Structured handover package: A full documentation package is compiled. This includes as-built drawings, vendor manuals etc. as agreed by client. Quality Management in Document Control Up to date and accurate Document Control is essential to our quality processes and supports efficient project delivery. Without this efficient document control, time is lost by project teams as staff work out what information they can trust.  The Document Control Team will ensure: 1. That all documents and drawings produced go through the relevant review and approval processes and only approved documentation shall be issued and released to client and subcontractor. 2. All official documentation is registered in Exyte Systems and submitted via these systems to all the stakeholders. 3. That all superseded or obsolete documents and drawings shall be removed or marked as obsolete / superseded. 4. The correct distribution, access, storage, preservation, retrieval, disposition of controlled documentation. As part of the oneHORIZON project, our current Document Control System (DCS) and LINK are being updated into one new Document Management & Control System (DMCS). This will enable us to globally

EXYTE - QUALITY INDUCTION standardize our system, include valuable automated process and take advantage of a more “rest-of-theworld” modern experience to drive efficiencies. Please continue to review the News section for Corporate Project Control for the latest status update. Procurement: Vendor and Subcontrator Quality Plan and Mock-Up Subcontractor’s Project Quality Plan Is a document prepared by the subcontractor stating subcontractor’s Project Quality Management System that will be applied for their awarded Scope of Work (SOW). This is reviewed and approved by Exyte.  Vendor / Subcontractor Method Statement Is a document prepared by Subcontractor stating on how the work will be carried out safely. This is reviewed and approved by Exyte.  Sample Material and Mock-up Suppliers and contractors shall submit Material Samples and Mock-ups, together with applicable product catalogues and specification for Exyte / Client’s review and approval prior to the actual fabrication and construction. Inspection and Test Plan (ITP) The Inspection and Test Plan details the systematic approach to inspection and testing of all applicable activities and products. This might include materials, components, machines or whole work packages. These checks follow up on from what was agreed in the Scope of Works giving reference to Standards and applicable project procedures and specifications. These checks must be performed and all documentation resulting from these (reports, checklists etc.) must be issued and recorded in line with our document control procedures.  The specific test plan is prepared by the Subcontractor and includes the systematic approach to testing and inspection of a system or product (e.g. material, component, machine, work package, etc). The plan includes all activities such as a visual inspection, dimension inspection, etc. and defines the participation/responsibilities of each role. For example, who should be inspecting, testing, witnessing, monitoring… etc.  Audits and Inspection Audits Are an examination of results to verify their accuracy by someone or system other than the person responsible for producing them. Internal and external (subcontractors) audits are conducted during project execution. Inspections Are the examination of subcontractor work by Exyte QC (Quality Control) to determine whether it conforms to prescribed requirements. Typical inspections are welding, Non-destructive Testing (NDT), mock-ups etc. Non-conformance Is any unplanned event or deviation from procedure, work instruction and/or failure to meet specified limits? It is a non-fulfillment of a project requirement. A non-conformance must be recorded, investigated, reported, and included in the Project Monthly Report. A non-conformance could be identified through customer complaints, management reviews, internal audits, external audits, incoming material inspection or simply during routine inspection, monitoring and testing activities. Non-conformance Reporting Non-conformities identified are reported and closed on a timely basis. Client Feedback and Sponsors' Meetings

EXYTE - QUALITY INDUCTION Client Feedback Survey Enables the client to comment on Exyte’s performance during execution of project. Sponsors' Meeting Is a regular monthly meeting by Exyte Top Management (Project Sponsors) with the client on project performance. This will be conducted throughout the project until project close-out.