Qaulity assurance

A Project Quality Initiative (PQI) has been prepared and formulated by EICC to set out the management practices and describe the company’s Quality Management System. This initiative is applicable to all Designs, Engineering, Procurement, Construction, Inspection, Testing and Commissioning works carried out by EICC.

To understand the (PQI), a list of terms have been defined below for ease of reference and to ensure a consistent and accurate rendering of texts and a level of translation quality that is even through out the entire course.

TERMINOLOGY

ON THE SITE: HEIRARCHY AND RESPONSIBILITIES

PROJECT MANAGER

• Responsible to the EICC Committee.
• Administrates the Contract until completion
• Represents EICC to clients, attends co-ordination meeting with client, implements meetings out come in
• connection with Works Manager of EICC. Co-ordinates with local administration.
• Mobilization of resources and execution of works within the parameters of time and cost, quality and
• Productivity.
• Monitors progress with respect to EICC Planning, reports to client on progress, invoice EICC bill to
• Engineer, conducts weekly review meetings with site staff.

CONSTRUCTION MANAGER

• Reports to Project Manager
• Responsible for execution of works as per contract specications, schedules and milestones.
• Responsible for providing timely resources including trained personal for specialized activities in consultation with Project Manager.
• To ensure compliance to quality and safety standards.
• Conducts daily/weekly site meetings with sta and to maintain regular contact with client/engineer representatives for getting timely decisions on matters related to work.

PLANNER

• Reports to the Project Manager.
• Prepare Methodology, Project schedules in consultation with Head Office and Project Manager.
• Prepare Accepted Cost Estimates, obtain approvals for the estimates from parent entities.
• Continuous monitoring of work plans, productivity, resource utilization and other variances from the schedule.
• Controls Receipt/Issue of all drawings, letters, and any other communications to and from Project Manager
  office/ Parent entities.
• Prepare monthly Progress Report to Project Manager oce (for submission to client & respective entities,
  regional / head office).
• Process enquiries, recommends sub-contractor or supplier agencies with in advance for approvals by
  authorized personnel (Management).

QUALITY CONTROL ENGINEER

• Reports to Project Manager & QC Manager for setting up of site laboratory for testing various construction materials.
• Testing of the products as per test plans and inspecting the construction materials received at site.
• Indents all laboratory equipment, Commissions and conduct calibration exercises as per plan.
• Documents all tests in standard formats.
• Liaison with external lab, third party agency labs.
• Conduct Laboratory Activities independently and reports any potential problems to the Project Manager.
• Interaction with Client / Consultant regarding material selection / testing / mix design and approval.

QUALITY ASSURANCE COORDINATOR

Acts as a Quality Assurance Administrator & additional duties are as follow:

• Checks and approves work procedures of Section Engineers based on mock-up results.
• Monitors implementation of procedures, record keeping by section through weekly audits.
• Reports non- compliance and proposes remedial action to Site Staff and Senior Management.
• Follows up through remedial measures.
• Conducts himself articulately and impartially with all sections.
• Send monthly reports through Project Manager to respective regional/head office coordinators of each entities

SURVEYOR

• Reports to Construction Manager.
• Understands client’s requirements, prepares Project
• survey Plan and Survey Scheme(Sketches)
• Locates Grid Control Stations, Benchmarks, etc.. in consultation with the Section Engineer responsible.
• Constructs such survey features through the Section Engineers.
• Provides survey assistance for sections.
• Maintains daily survey records.
• Ensures calibration of all measuring equipment as per calibration plan.
• Safe keeps all equipment under his scope.
• Conducts post construction checks – Reports deciencies to Planning Engineer and QA.

BILLING ENGINEER

• Reports to Project Manager.
• Receives, checks fortnightly measurements from Site Engineers.
• Prepares Sub – Contractor bills in time.
• Prepares client bills.
• Conducts monthly physical stock verication with Stores and prepares bulk material reconciliation on 25th of each month.
• Reconciles quantities paid by client and those paid to sub – contractors.

SECTION ENGINEER

• Reports to the Construction Manager.
• Prepares daily plans of work from agreed weekly/monthly plans.
• Organizes manpower, materials, equipment to achieve plans.
• Complies to all procedures, drawings while execution (Project Quality Plan)
• Checks all works done by subordinates and maintains
  check records applicable to each activity.
• Co-ordinates with other agencies when required.
• Ensures safety in the workplace as per Project Safety Plan.
• Inculcates good housekeeping practices.
• Prepares Sub-contractors bills in time and submits to the Billing Engineer.
• Affords all facilities to quality audits.
• Reports any errors to Works Manager, endeavors to improve.

PLANT AND MACHINERY ENGINEER

• Reports to the Project Manager & Equipment and Logistic Manager functionally.
• Co- ordinates with Works Manager for daily deployment of plant to
  various sections (Planning Engineer allots to sections as per priority).
• Conducts all preventive maintenance as per equipment manuals.
• Ensures adequate stock of fast moving spares.
• Allots duty rota to Operators.
• Administrates fuel oil supply, reconciles usage in consultation with Stores Department, submits reconciliation statements as on 25th of each month to Planning Department.
• Conducts repairs, breakdown maintenance, arranges alternative equipment when required economically.

SAFETY ENGINEER

• Reports to the Project Manager & Safety Manager.
• Prepares Project Safety Plan, gets approval from clients.
• Implement safety practices in workforce. Conducts lessons on good practices.
• Supervises work of Safety Stewards.

ACCOUNTS AND ADMINISTRATION OFFICER

• Reports to Financial Manager & Project Manager administratively.
• Processes local purchases, sub-Contractor payments and other payments to suppliers.
• Follows up with client for running bills.
• Liaises with all local bodies and ensure administrative support to Construction Manager (e.g Communication, Transport, etc.)
• Staff welfare activities.

TIME OFFICER

• Responsible to Accounts and Administration ocer.
• Labor attendance

STORES IN-CHARGE

• Reports to Project Manager.
• Processes all local purchase requirements and bulk purchase through Concerned Oce.
• Receipt, Storage of Bulk Material, equipment.
• Material reconciliation and all accounting matters associated with Stores.

PROJECT CONTROL

The control and administration of the project plays an important part in EICC’s operation to ensure a system that is both sound, eective and ecient. The methods include Contract Review, Contract Variation, Planning & Scheduling, Administration, and Reporting.

CONTRACT REVIEW

Prior to commencing work on the project, the contract documents are reviewed by the appropriate personnel (identied for each project) to ensure that all references, codes and standards were clearly identified so that a complete assessment of the engineering design/construction are made, leading to the eventual realization of the project. Omissions or errors are notied to the owner / consultant.

CONTRACT VARIATIONS

Any variations to the contract raised by either the client or the contractor are reviewed to assess its impact on the project schedule and cost implications. All variations to the contract are dealt with in accordance to agreed procedures.

PLANNING AND SCHEDULING

The planning and scheduling of the project are achieved by Management Planning and Control System and are maintained by the Project Manager of each sector to show the status of the project at any given time. Periodic reports are sent to HCC Committee through Project Manager.

REPORTING

The Project progress is reported to the Client by means of a monthly report, which reflects the Contractor’s performance during the reporting period. This report contains all the necessary information to enable the Client to assess progress and to establish whether the project is on schedule. In general the report summarizes the project status by reference to agreed milestones and forecast completion dates and supplemented by ‘’S’ curves, bar charts and photographs. Such a report is furnished in a format acceptable to Client.

DESIGN

EICC ensures that designs are coordinated through various methods and procedures necessary for the control and administration of design.

DESIGN CONTROL

The purpose of design control is to ensure that the Owner’s requirements are reflected in the final design, that all of the appropriate codes and standards have been observed. To this end, the Design Control is implemented by EICC to address these criteria and to ensure compliance with the contract specifcations.

DESIGN PLANNING

Design Planning forms an overall part of the EICC’s project schedule. Individual discipline design planning will be the responsibility of the various divisions who are to carry out the design and supply of major equipment and services. The Project Coordinator monitors such planning to ensure that the necessary technical interfaces are efected and that such planning is integrated into project schedule

DESIGN INPUT

Design input is based on the client supplied technical specifications and is issued to the division by the Project Coordinator for application within its design. Conflicting and ambiguous designs are resolved between the divisions and their vendors as required.

DESIGN OUTPUT

All design output by the EICC and its Vendors are documented by means of specifications, drawings, calculations and analysis. EICC ensures that all design output meets the requirements of the design input and contain or refer the necessary acceptance criteria, conform to the necessary regulatory requirements, and identify the characteristics, which are crucial to the safe operation of the designed product.

DESIGN VERIFICATION

Design verification are carried out by EICC to ensure the design meets the input/output requirements by holding regular design reviews, implementing the necessary qualication tests, reviewing and checking calculations and by comparison with similar proven design.

DESIGN CHANGE CONTROL

Design changes and modifications are identified and documented by the EICC for review and approval on the appropriate form.

DOCUMENTS CONTROL

EICC’s procedures are modified as necessary to take into account the contract requirements for the methods of control of numbering, review, distribution and revisions. All documents prepared for the project are identified and controlled in a manner, which enables the easy identification and retrieval of the documents when required. Similarly, any revisions or changes to documents are controlled to ensure that only the latest issue is in use.

PROCUREMENT

The responsibility for all procurement activities rests with the Materials Department. All procurement and associated expediting are carried out in accordance with the Materials Management Manual.

VENDOR QUALIFICATION SELECTION

EICC has existing procedures for vendor selection, as per Materials Management Manual.

MATERIALS IDENTIFICATION AND TRACTIBILITY

All materials procured for the project are subjected to the verification controls as required by the specifications. In addition, records are maintained to ensure that materials are traced back to their origin and to confirm that they have been supplied in accordance with the project specifications. EICC have procedures for the control of material identification and marking.

HANDLING, PACKING, STORAGE AND DELIVERY

Procedures for the handling, packing, marking, preservation, storage and delivery of material are developed to take into account the prevailing weather conditions on the construction site and the likely conditions encountered during transit.

CONSTRUCTION

EICC utilizes methods in controlling the control of inspection and test activities to ensure the smooth progress of the construction work.

INSPECTION AND TEST PLAN

All construction activities are subjected to inspections and tests to conrm that a particular process is satisfactorily completed and that the construction work goes on smoothly. The scope of such inspections and tests extends from receiving inspections on material arriving at site and material identication, production, through to final completion of the project. Detailed Construction Inspection and Test Plans for the project are developed to reflect the scope of quality control and inspection activities.

CONSTRUCTION PLAN AND METHOD STATEMENTS

EICC developed a construction plan and method statements which detail the sequence and scope of each work package and the procedures required to perform the work. The plan describes the interfaces between the diferent construction groups and how the coordination of these activities are achieved.

COMMISSIONING

All commissioning activities are performed in accordance with the Contract requirements and specic procedures

QUALITY CONTROL

THIRD PARTY INSPECTION

The Inspection and Test Plans details the extent of the quality control activities on the project and indicate the scope of any Third Party Inspectorate involvement.

QUALITY CONTROL PROCEDURES

At EICC, whenever a quality control action is required by the inspection and Test Plans, reference is made to the applicable quality control procedures which are used in conjunction with the applicable codes and standards to assess the acceptability or otherwise of the material, tests or procedures.

MEASURING AND TEST EQUIPMENT

EICC is aware of its responsibility to ensure that all measuring and test out in accordance with the its procedures and contract requirements.

NON-CONFORMANCE AND CORRECTIVE ACTION

EICC considers non-conformance to be separated into those dealing with construction quality system and those dealing with material non-conformance. In either case, non-conformance are clearly documented, its cause identified and appropriate corrective actions are taken to remove the non-conformance. Wherever practicable, preventive action is taken to ensure that the risk of recurring non-conformance is avoided.

QUALITY AUDITS

During the course of the project, regular quality audits are performed to determine the effectiveness of the quality system and a plan in particular. To this end an audit schedule is prepared to cover all quality related activities on the project and is implemented at a frequency determined by project activity

QUALITY RECORDS

EICC establishes for maintaining the following functions :

• Contract review.
• Design verification.
• Inspection and test records.
• Internal quality audits.
• Training.
• Master list of design calculation and drawings.
• Identification of the the current revision of drawings.
• Special processes, specialized skilled manpower.
• Calibration records for inspection, measuring and test equipment.
• Non-conformity review and corrective action.

TRAINING

Personnel assigned to the project are selected on the basis of qualifications and experience. Where this is not practicable, training is provided. Similarly, personnel who require to be regularly examined to re-qualify, their duties are regularly assessed and where appropriate retrained to maintain their skill level. In addition, all staff receive basic training in safety as a part of the project program.

SAFETY

Safety is an essential requirement if a timely and effective completion of the project is to be achieved. In recognition of this fact, the EICC allocates adequate resources to establish and implement a Project Safety Program. This Program is intended to compliment rather than replace the client’s safety policy.