controlled quality manual

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IRON OX METAL WORKS LIMITED

1.0.1.1

1.0.1.2

Table of Contents................................................................................................................................................................................1

DOCUMENT NUMBER ...........................................................................................................................................1IOX/QMS/M-001 .....................................................................................................................................................1DOCUMENT TITLE ........................................................................................................................................... .....1QUALITY MANUAL .................................................................................................................................................1

REVISION AND APPROVAL HISTORY...........................................................................................5

DOCUMENTNUMBER

IOX/QMS/M-001

DOCUMENT TITLE QUALITY MANUAL

0 13-03-11 1st Draft M Bature M Bature K Taleb

Rev Date Purpose Author Reviewed Approved

DOCUMENT REVISION AND APPROVAL RECORD

The electronicversion of thisdocument iscontrolled. Hardcopies signed byIron Ox personnel’sare controlled.

UNCONTROLLED



IRON OX METAL WORKS LIMITED Doc. No: IOX/QMS/M-0001

QUALITY MANUALRev. No: Rev 0

Issued Date: 10-03-2011

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1.1 GENERAL ..................................................................................................................................................................8

1.2 INTRODUCTION ........................................................................................................................................................8

1.3 REFERENCED ATTACHMENT ................................................................................................................................9

1.4 SCOPE ....................................................................................................................................................................11

1.5 QUALITY POLICY STATEMENT .............................................................................................................................13

2.0 COMPANY HISTORY ................................................................................................................. 14

3.0 COMPANY CONTACT INFORMATION .....................................................................................15

4.0 QUALITY MANAGEMENT SYSTEM ......................................................................................... 16

4.1 GENERAL REQUIREMENTS ..................................................................................................................................16

4.0 DOCUMENTATION REQUIREMENTS ....................................................................................................................204.0.1 GENERAL .........................................................................................................................................................204.0.2 QUALITY MANUAL ...........................................................................................................................................214.0.3 CONTROL OF DOCUMENTS ...........................................................................................................................21

5.0 MANAGEMENT RESPONSIBILITY ........................................................................................... 23

5.2 CUSTOMER FOCUS ..............................................................................................................................................23

5.3 QUALITY POLICY ....................................................................................................................................................23

5.0 PLANNING ...............................................................................................................................................................255.0.1 Quality Objectives .............................................................................................................................................25

5.0.1.1 Classification of Quality Objectives ............................................................................................................255.0.2 Quality Management System Planning ....................................................................................................... ......26

5.1 RESPONSIBILITY, AUTHORITY, AND COMMUNICATION .................................................................................. ..275.1.1 Responsibility and Authority .............................................................................................................................27

5.5.1.2 Management Responsibilities ................................................................................................................. ...31






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5.5.2 Management Representative ......................................................................................................................... ...325.1.2 Internal Communication ................................................................................................................................ ....32

5.2 MANAGEMENT REVIEW ............................................................................................................................... .........335.2.1 General.................................................................................................................................................... .........335.2.2 Review Input.................................................................................................................................................... .335.2.3 Review Output...................................................................................................................................................33

6.0 RESOURCE MANAGEMENT .....................................................................................................34

6.1 PROVISION OF RESOURCES ................................................................................................................................346.0.1 General.................................................................................................................................................... .........346.0.2 Responsibilities for Determination of Required Resources ..............................................................................346.0.3 Provision of Resources .....................................................................................................................................34

6.1 HUMAN RESOURCES ................................................................................................................................ ............356.1.1 General.................................................................................................................................................... .........356.1.2 Competence, Awareness, and Training .......................................................................................................... .35

6.2 INFRASTRUCTURE ......................................................................................................................................... .......36

6.3 WORK ENVIRONMENT .......................................................................................................................................... .36

7.0 PRODUCT REALIZATION ......................................................................................................... 36

7.1 PLANNING OF PRODUCT REALIZATION ..............................................................................................................37

7.0 CUSTOMER-RELATED PROCESSES ....................................................................................................................377.0.1 Determination of Requirements Related to the Product................................................................................... .377.2.2 Review of Requirements Related to the Product..............................................................................................37

6.1.3 Customer Communication .................................................................................................................................38

7.1 DESIGN AND DEVELOPMENT ........................................................................................................................... ....397.1.1 Design and Development Planning ...................................................................................................................397.1.2 Design and Development Inputs .......................................................................................................................407.1.3 Design and Development Outputs .............................................................................................................. ......407.1.4 Design and Development Review .....................................................................................................................40

7.1.5 Design and Development Verification .............................................................................................................. .417.1.6 Design and Development Validation ................................................................................................................ .417.1.7 Control of Design and Development Changes ..................................................................................................41

7.2 PURCHASING ................................................................................................................................................ .........427.2.1 Purchasing Process ......................................................................................................................................... .427.2.2 Purchasing Information ................................................................................................................................. ....427.2.3 Verification of Purchased Product.................................................................................................................... .42

7.3 PRODUCTION AND SERVICE PROVISION ................................................................................................. ..... .....43






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7.3.1 Control of Production and Service Provision .....................................................................................................437.3.2 Validation of Processes for Production and Service Provision ..........................................................................437.3.3 Identification and Traceability ............................................................................................................................447.3.4 Customer Property ............................................................................................................................................447.3.5 Preservation of Product.....................................................................................................................................44

7.4 CONTROL OF MONITORING AND MEASURING EQUIPMENT ........................................................................... .45

8.0 MEASUREMENT, ANALYSIS, AND IMPROVEMENT ..............................................................46

8.1 GENERAL ................................................................................................................................................................468.1.1 Planning ...........................................................................................................................................................46

8.2 MONITORING AND MEASUREMENT .....................................................................................................................468.2.1 Customer Satisfaction .......................................................................................................................................468.2.2 Internal Audit.....................................................................................................................................................468.2.3 Monitoring and Measurement of Processes ......................................................................................................478.2.4 Monitoring and Measurement of Product and/or Service ................................................................................. .47

.............................................................................................................................................................................47

8.3 CONTROL OF NONCONFORMING PRODUCT .....................................................................................................48

8.4 ANALYSIS OF DATA ...............................................................................................................................................48................................................................................................................................................................................ .48

8.5 IMPROVEMENT .......................................................................................................................................................498.5.1 Continual Improvement ....................................................................................................................................498.5.2 Corrective Action ...............................................................................................................................................498.5.3 Preventive Action ..............................................................................................................................................49






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REVISION AND APPROVAL HISTORY






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Revision Description Approved By Date

1 Original Release Khalil Taleb 10-03-2011






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1.1 GENERAL

1.2 INTRODUCTION

IOX Metal Works recognizes its responsibility as a manufacturer of quality products/provider of quality services. To this end, IOX Metal Works has developed and documented a qualitymanagement system. The quality system complies with the international standard ISO9001:2008, Quality management systems – Requirements. The quality system also

complies with Standards mandated by our customers.

The purpose of this manual is to provide comprehensive evidence to all customers,suppliers and employees of what specific controls are implemented to ensureproduct/service quality. This manual also governs the creation of quality related documents.It will be revised, as necessary, to reflect the quality system currently in use. It is issued ona controlled copy basis to all internal functions affected by the quality system and on anuncontrolled copy basis to customers and suppliers. It may be issued to customers on acontrolled copy basis upon customer request. This manual is divided into eight main sections. Sections 4-8 are modeled on the sectional

organization of the ISO 9001:2008 standard. Sections are further subdivided into severalsubsections representing main quality system elements or activities.

__________________________________ (Khalil Taleb), Managing Director CEO






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1.3 REFERENCED ATTACHMENT






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S/NO DOCUMENT TITLE DOCUMENT NUMBER REVATTACHMENT

NUMBER

1 CONTROL OF DOCUMENT IOX/DCP/001 0 AA

2 CONTROL OF RECORDS IOX/CRP/002 0 AB

3 INTERNAL COMMUNICATION IOX/ICP/003 0 AC

4 MANAGEMENT REVIEW PROCEDURE IOX/MRP/004 0 AD

5 TRAINING PROCEDURE IOX/STP/005 0 AE

6 FACILITY MANAGEMENT IOX/FMP/006 0 AF

7 PRODUCT REALIZATION PROCEDURE IOX/PRP/007 0 AG

8 CONTRACT REVIEW PROCEDURE IOX/CRP/008 0 AH

9 DESIGN AND DEVELOPMENT IOX/DDP/009 0 AI10 MATERIAL PURCHASING PROCEDURE IOX/MPP/010 0 AJ

11 PROCESS CONTROL PROCEDURE IOX/PCP/011 0 AK

12 PRODUCT SERVICING PROCEDURE IOX/PSP/012 0 AL

13 PROCESS VALIDATION PROCEDURE IOX/PVP/013 0 AM

14 IDENTIFICATION AND TRACEBILITY IOX/IDT/014 0 AN

15 CONTROL OF CUSTOMER SUPPLIEDPRODUCT

IOX/CSP/015 0 AO

16 HANDLING, STORAGE & PACKAGING IOX/HSDP/016 0 AP

17 CONTR. OF MEASR. & MONTR. EQUIP. IOX/MEP/017 0 AQ

18 CONTR. OF MEASR. & MONTR.CUSTOMER SATISFACTION

IOX/MCS/018 0 AR

19 INTERNAL AUDIT PROCEDURE IOX/IAP/019 0 AS

20 INSPECTION AND TEST PROCEDURE IOX/ITP/020 0 AT

21 INSP. & TEST STATUS PROCEDURE IOX/ITS/021 0 AU

22 CONTROL OF NON CONFORMANCE IOX/NCP/022 0 AV

23 STATISTICAL TECHNIQUE PROCEDURE IOX/STP/023 0 AW

24 CONTINUAL IMPROVEMENT PROCEDURE IOX/CIP/024 0 AX






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25 CORRECTIVE AND PREVENTIVEPROCEDURE

IOX/CPA/025 0 AY

1.4 SCOPE

Iron Ox Metal Works quality system processes are developed to manage product realizationof our Products or Services as included in the scope of registration, thus:

1 Minor Construction Services – surface storage tanks (SST), Overhead Tanks andCulverts

2 Protocol and Logistics Services – Car / Vehicle hire and leasing3 Consultancy Services – Nigerian man power supply (Nigerian Professionals Only)4 Minor Construction Services – Minor Civil Engineering and minor metal fabrication

EXCLUSIONS

Iron Ox Metal Works Quality System exclude design and development all the requirements

of ISO 9001:2008; therefore, no exclusions are claimed.

Our capability includes:

Mobile Housing Steel Structures*Construction of camps*Towers, platforms, staircases, cat walks*Rotating furnace cradles, spools, oil services

Factories and Buildings*Warehouses, hangers

*Process factories, bulk storage houses*Large canopies 85x13 m plus*Aluminium or Steel roofing and Cladding*Translucent fiber glass

Tanks*Petrol products tanks 5,000,000L plus*Above ground storage tanks






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*Elevated water tanks*Ground level and underground tanks

Piping / Pipeline*Associated Piping, fitting and pumping*Process Piping*Pipeline fabrication for gas or liquid transportation

Pressure Vessels*Pressure and heat industrial sterilizer

*Compressed air Receiver

Water Works*Boreholes, Water intakes*Water Storage, treatment plant and distribution

Marine Works*Barges, Pantoons and Floating Jetties

Concrete Works*Foundations, concrete slabs, suspended slabs

*Warehouse partitioning*Retaining Walls

Fabrication*Industrial Pallet Racking*Steel moulds and formworks*Screw Conveyors insulated / double wall*Offshore / Onshore Structural Platforms*Jackets and other miscellaneous structures

Leasing

*Leasing and Fabrication of Waste Mud Skips*Compressors*Blasting and Painting Equipment*Airless and Conventional Spraying Machines*Welding / Gas Cutting Machines






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1.5 QUALITY POLICY STATEMENT

The management of Iron Ox Metal Works and all of its employees arecommitted to achieving excellence in the quality of our products and

services by meeting or exceeding our stated quality objectivesWE ACCOMPLISH OUR COMMITMENT THROUGH THE:

Continuous strive to achieve and maintain an industry’s leading position in the quality of our

products and services.Maintaintainance of our quality management system to meets or exceed the ISO 9001:2008

standard as well as statutory and regulatory requirements.

Continuous improvement of customer satisfaction with our products and services.

Development and enhancement of a culture for continuing improvement of our products,services and quality management system.

The management team will periodically review the performance of the

quality management system and our quality objectives to ensure their

effectiveness, continuing relevance and suitability.

KHALIL TALEBMD/CEO

IRON OX METAL WORKS






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2.0 COMPANY HISTORY

IOX Metal Works designs/develops, distributes and services Marine, Oil and Gas products.Iron Ox Metal Works Ltd was founded in year 2000 as a general engineering company, Iron OxMetal Works Ltd, has developed over the succeeding years into a quality Assured SteelFabrication company with a diversified design, manufacturing and installation capacity.The design and production capability includes products demanding site specific design skills andutilises a workforce with the traditional standards of a permanent and established works productionteam .

Our mission is to provide quality exploration, production and projectSupervisory services to the oil and gas industry, especially in Nigeria and West Africa.

Our plan is to understand our customers goals and objectives andAssist them in surpassing those goals and objectives.

FacilityEach contract is assigned a dedicated Project Manager, who along with his team is responsible for all aspects of the construction. This phase is carried out by experienced personnel who will ensurethat the costs and Programme are met.

The company employs a fully qualified safety officer and a team of outside safety advisors whomanage safety in all aspects of the company, both in-house and on site.Risk assessments, method statements and company safety statements are provided for eachcontract and any further activities required.






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3.0 COMPANY CONTACT INFORMATION

Iron Ox Metal Works is located at:27 Elf Road Trans-Amadi Industrial Layout PortHarcourt Rivers State Nigeria.

Phone: 08059444444, 08062261636, 08023406300

E-mail : info @ ironoxmetalworks.com; khaliltaleb @ ironoxmetalworks.com

Web Site: www.ironoxmetalworks.com

mailto:[email protected]









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4.0 QUALITY MANAGEMENT SYSTEM

4.1 GENERAL REQUIREMENTS

IOX Metal Works has developed, documented, implemented and maintained its quality

system in accordance with the requirements of ISO 9001:2008, Quality managementsystems – Requirements. IOX Metal Works‘s quality system is based upon a “processapproach” to quality management and:

a) determines the processes needed for the quality system and their applicationthroughout the organization;b) determines the sequence and interaction of these processes (see Table 1.);c) determines criteria and methods required to ensure the effective operation andcontrol of these processes;d) ensures the availability of resources and information necessary to support theoperation and monitoring of these processes;

e) monitors, measures, and analyzes these processes; andf) implements actions necessary to achieve planned results and continualimprovement of the processes.

IOX Metal Works continually maintaines and improves these processes in accordance withrequirements of ISO 9001:2008, Quality management systems – Requirements.

Where IOX Metal Works chooses to outsource processes that affect the conformance of theproduct to requirements, IOX Metal Works ensures control over these processes. The typeand extent of control to be applied to these processes is defined within our qualitymanagement system. Ensuring control over the outsourced processes does not absolve

IOX Metal Works of the responsibility of conformance to customer, and applicable statutoryand regulatory requirements.






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Table 1.Sequence and Interaction of IOX Metal Works Quality Management System






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# Process Related Procedures ISO9001

Clause

1.Customer Need isIdentified

- Measuring and Monitoring Customer Satisfaction 8.2

2.Product/Service isDesigned/Developed

- Control of Monitoring and Measuring Devices Procedure- Control of Nonconforming Product Procedure- Design and Development Control Procedure

7.68.37.3

3. Quotations areSent andOrders areReceived

- Contract Review Procedure 7.2.2

4.ServicePlanning

- Facility Management Procedure- Product Realization Planning Procedure

6.37.1

5.Materials arePurchased

- Control of Nonconforming Product Procedure- Identification and Traceability Procedure- Purchasing Procedure

8.37.5.37.4

6.Service,Verification,

Shipment

- Control of Customer-Supplied Product Procedure- Control of Monitoring and Measuring Devices Procedure

- Control of Nonconforming Product Procedure- Facility Management Procedure- Process Control Procedure- Process Validation Procedure- Statistical Techniques Procedure- Handling, Storage, Packaging, Preservation, And Delivery- Inspection and Test Procedure- Inspection and Test Status Procedure

7.5.37.6

8.36.37.5.17.5.28.47.5.58.2.48.2.4

7.

Customer Service

- Measuring and Monitoring Customer Satisfaction 8.2






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8.

Servicing - Measuring and Monitoring Customer Satisfaction- Process Control Procedure- Process Validation Procedure- Servicing Procedure- Statistical Techniques Procedure

8.27.5.17.5.27.5.18.4

Continual Improvement of IOX Metal Works Quality Management SystemPDCA Related Procedures ISO

9001

ClausePlan - Control of Documents Procedure

- Statistical Techniques Procedure- Product Realization Planning Procedure- Training Procedure

4.2.38.47.16.2.2

Do - Control of Quality Records Procedure- Statistical Techniques Procedure- Training Procedure

4.2.48.46.2.2

Check - Control of Quality Records Procedure- Measuring and Monitoring Customer Satisfaction- Inspection and Test Procedure- Internal Audits Procedure- Management Review Procedure- Process Validation Procedure- Statistical Techniques Procedure- Training Procedure

4.2.48.28.2.48.2.25.67.5.28.46.2.2

Act - Continual Improvement Procedure- Corrective and Preventive Action Procedure- Statistical Techniques Procedure- Internal Communication Procedure

8.5.18.5.28.45.5.3






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4.0 DOCUMENTATION REQUIREMENTS

4.0.1 GENERAL

IOX Metal Works' quality system documentation is comprised of:

a) documented statements of quality policy and quality objectives;b) this Quality Manual, which includes all the procedures required by theISO 9001 standard;c) documented procedures required by applicable standards andregulations;d) documents, including records, needed to ensure the effective operationand management of the processes (i.e., where applicable, process maps,quality plans, work instructions, samples, drawings, and bills of materials).e) records required by IOX Metal Works, by the ISO 9001 standard andany other applicable standards and regulations

The extent of IOX Metal Works's documentation depends on the:

a) organizational needs;b) complexity and interaction of the processes;c) competence of personnel performing the tasks.

Documents are maintained on various media such as paper, electronic, video, etc.






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4.0.2 QUALITY MANUAL

The Quality Manual is the principal document that defines the quality system at IOXMetal Works. It includes:

a) the scope of the quality system, including details of, and justification for,any exclusions;b) documented procedures;c) references to documented procedures and external documents not

included in the quality manual;d) a description of the sequence and interaction of the processes includedin the quality system.

4.0.3 CONTROL OF DOCUMENTS

IOX Metal Works identifies and controls documents required by the quality systemaccording to the Control of Documents Procedure IOX/DCP/P-001 . It ensures thatdocuments:

a) are reviewed and approved for adequacy prior to issue;

b) are updated, reviewed, re-approved, and re-issued as necessary;c) are identified with their current revision status;d) are available at point of use;e) remain legible, readily identifiable, and retrievable;f) of external origin are identified and their distribution is managed;g) that are obsolete are prevented from unintended use and are suitablyidentified if they are retained for any purpose.

Documents defined as quality records are managed per the Control of QualityRecords Procedure IOX/CRP/P-002 .

4.2.4 CONTROL OF QUALITY RECORDS

IOX Metal Works has established and maintained quality records to provide evidenceof conformance to requirements and of effective operation of the quality system. TheControl of Quality Records Procedure IOX/CRP/P-002 ensures proper identification,storage, retrieval, protection, retention time, and disposition of quality records.






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All records are adequately maintained to ensure they remain legible, identifiable, andretrievable.






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5.0 MANAGEMENT RESPONSIBILITY

5.1 MANAGEMENT COMMITMENT

IOX Metal Works’s management provides evidence of its commitment to the development,implementation, and continual improvement of the effectiveness of the quality system by:

a) communicating to the organization the importance of meeting customer,regulatory, and legal requirements;b) establishing and documenting the quality policy and quality objectives asdescribed in the Management Review Procedure-IOX/MRP/P-004 ;c) conducting management reviews as described in the Management ReviewProcedure- IOX/MRP/P-004; d) ensuring the availability of necessary resources.

5.2 CUSTOMER FOCUS

The management of IOX Metal Works will ensure that customer needs and expectations areidentified, transformed into requirements, and fulfilled with the intent of achieving andexceeding customer satisfaction. Customer needs and expectations are identified via theMeasuring and Monitoring Customer Satisfaction Procedure,-IOX/MCS/P-018 and ContractReview Procedure-IOX/CRP/P-008 , and translated via the Design and DevelopmentControl Procedure-IOX/DDP/P-009 . IOX Metal Works complies with all relevant regulatoryand legal requirements.

5.3 QUALITY POLICY

The quality policy is established by top management and is approved by the ManagingDirector. The management of IOX Metal Works ensures that the documented quality policy:

a) is appropriate to the purpose of IOX Metal Works;b) includes a commitment to meeting requirements and to continuingimprovement of the quality system per the Continual Improvement Procedure-IOX/CIP/P-024 ;






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c) provides a framework for establishing and reviewing quality objectives;d) is communicated and understood at appropriate levels of the organization per the Training Procedure-IOX/STP/P-005 , and in addition it is posted throughout visibleareas of the company;e) is reviewed for continuing suitability per the Management Review Procedure-IOX/MRP/P-004






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5.0 PLANNING

5.0.1 Quality Objectives

The management of IOX Metal Works establishes annual key initiatives that includequality objectives. The objectives are established via the Management ReviewProcedure-IOX/MRP/P-004 and communicated to all levels of the organization for use in establishing each function’s and employee’s annual key objectives. Qualityobjectives are measurable, include business performance indicators reflectingrequirements for products/services, and are consistent with the quality policyincluding the commitment to continuous improvement. The use of quality objectivesfor facilitating continual improvement is explained in the Continual ImprovementProcedure-IOX/CIP/P-024

5.0.1.1 Classification of Quality Objectives

Quality objectives are classified into the following four categories:

• Policy objectives: Are principal, strategic objectives that apply to the entireorganization. They are normally included in the quality policy itself; if not, theyare communicated via memorandum. Policy objectives are developed by topmanagement and approved by the Managing Director.

• Quality performance objectives: Are objectives that set specific targets for measuring and improving performance to ensure product quality and customersatisfaction. They apply to all functions that have direct responsibility for product/service quality.

• Product quality objectives: Are objectives that pertain to the improvement of product and service associated with the product. The Managing Director andtop executive managers responsible for marketing and product developmentestablish these objectives. They can be documented in product briefs,memoranda, or minutes of meetings and apply to functions responsible for research, design, and development of products and services.






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• Quality system objectives: Are objectives that pertain to the improvement of quality system processes and performance.

5.0.2 Quality Management System Planning

The management of IOX Metal Works ensures that quality management systemplanning is executed to meet the requirements provided in Section 5.4.1, as well asthe quality objectives. Quality planning includes:

a) the processes of the quality system, including permissible exclusions;b) the resources needed;c) continual improvement of the quality system.

Table 1 in Section 4.1 depicts the quality management system planning processoutput at IOX Metal Works and describes the sequence and interaction of theprocesses of the quality management system. IOX Metal Works‘s quality system isbased upon a “process approach” to quality management. For each instance of quality management system planning, the output is documented accordingly, andchanges are conducted in a controlled manner.






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5.1 RESPONSIBILITY, AUTHORITY, AND COMMUNICATION

5.1.1 Responsibility and Authority

IOX Metal Works has defined all functions and their responsibilities within theorganization. Responsibilities and authorities are defined and communicated in orderto facilitate effective quality management.






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5.5.1.1 IOX Metal Works Organization Chart

IMPAC

Operations Manager Haytan Taleb/Muhammed Hachem

Base /OnshoreManager Zaher Aichan

Offshore InstallationManager Mahmoud Taleb

Fitters/Welders Supervisor Ikechukwu Everest.O

Cost andSchedule Manager Sallah Taleb

Admin/PersonnelManager Ernest Boms

Facility Manager Abdallah Taleb

QA/QC Manager Muhammed Bature

HSE Manager Victor Ogbani

EngineeringManager

AccountantGift Sambo

Time Keeper Abarugo C.Precious

Facility coordinator Gbenga Samuel

QA/QC DocumentController Lionel Akere ola

HSE Officer ThompsonNwaonu

Board of Directors

Logistics/Procurement-Dele Adebayo-Stella Mbah

StoreTunde Amori-supervisor Joy Akpan-Store Officer Alex B. Alex-Store Officer Preciou Iyie- Store Officer

SecuritySupervisor Progress Ogonor

Security GuardsSegun Adebayo-DayFriday John-DayIbrahim Abubakar-NightTemple Ogolo-ShiftFerdinand Oghar-ShiftCashmier Anyuogu-ShiftEdward Udoh-Shift

AccountOfficer Amaka Njoku

Cashier Roberta Ekine

QA/QC WeldingInspector Onyedika Ikwumelezeh

QA/QC Blasting andPainting Inspector Onyedika Ikwumelezeh

HSE Fire WatchGodwin Nwagha

IndustrialNurseElizabeth Obasi

Drafing Engin

Systems ITAnalystIyke Ogbuso

Managing Director Khalil Taleb

Secretary to MDBlessing Napoleon

PA to MDVish Chibar

Workshop ForemanMike Nnah

Blasting and PaintingSupervisor Jackson Boms

JanitorsJoy Effiong

Victoria Archibong



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5.5.1.2 Management Responsibilities

• The Managing Director approves the quality policy and all other policiesdeemed necessary for the organization, initiates the quality system, providesthe necessary resources to maintain the quality system, and must be presentand contributes to the success of annual management reviews of the qualitysystem.

• Marketing/Sales conducts market research and analysis to define marketdemand as to the grade, price range, and potential quantities; establishes thedesired quality characteristics of products/services including unstatedexpectations, establishes specifications for products and associated services,communicates all customer requirements and expectations clearly andaccurately within the company, advertises and promotes company’s products,monitors the quality of competitors’ products and services, carries out contractand order reviews, processes contracts and orders, provides customer liaisonand service, and handles customer complaints.

• Engineering prepares product functional specifications from Marketing

specifications or customer-specified requirements, designs and developsproducts/services, initiates design and development reviews and assures thatdesign and development output meets the design and development input,verifies and tests the designs, collects field performance and reliability data,and participates in the disposition of nonconforming products.

• Production alongside with quality department determines productionpersonnel and equipment requirements, controls and monitors processes,defines workmanship standards, maintains production equipment, administersstorage areas, performs production engineering, prepares production plans,prepares quality plans, and participates in the disposition of nonconforming

products.

• Purchasing selects qualified suppliers and subcontractors, prepares andapproves purchasing documents, monitors and assesses supplier performance, and participates in the disposition of nonconforming products.






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• Personnel department defines personnel qualification requirements,implements employee incentive programs, implements training programs, andmaintained training records.

• Quality department establishes and maintaines the quality managementsystem, audits implementation of the quality system, initiates requests for, andfollow up on corrective actions, maintaines and calibrates measuring and testequipment, carries out supplier quality surveys and audits, determinesstatistical techniques, performs inspections and testing in accordance with thequality plans, handles and participates in the disposition of nonconforming

products, coordinates document control activities, and maintaines inspectionrecords.

5.5.2 Management Representative

IOX Metal Works designates the Quality Manager as the ManagementRepresentative-MR. The MR, is a member of IOX Metal Works management, andirrespective of other responsibilities, has the authority and responsibility for:

a) ensuring that the processes of the quality system are established,

implemented and maintained;b) reporting to top management on the performance of the quality system,including any needs for improvement;

c) ensuring promotion of awareness of customer requirements throughout theorganization;d) acting as liaison with external parties on matters relating to the qualitysystem.

5.1.2 Internal Communication

IOX Metal Works management ensures that communication regarding the

effectiveness of the quality management system is facilitated throughout theorganization via the Internal Communication Procedure-IOX/ICP/P-003






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5.2 MANAGEMENT REVIEW

5.2.1 General

The management of IOX Metal Works conducts reviews of the quality system eachOctober, as described in the Management Review Procedure IOX/MRP/P-004 . Thereviews evaluate the system’s continuing suitability, adequacy, effectiveness and theneed for any potential changes, including the quality policy and quality objectives.

5.2.2 Review Input

Inputs to management reviews may include, but not be limited to, current

performance data and potential improvement opportunities related to:

a) audit results;b) customer feedback;c) process performance and product conformance;d) status of corrective and preventive actions;e) follow-up actions from previous management reviews;f) changes that may affect the quality system, andg) recommendations for improvement

5.2.3 Review Output

Outputs from management review include conclusions reached and action itemsrelated to:

a) improvement of the quality system and its processes;b) improvement of product related to customer requirements; and






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c) necessary resources.

Results of management reviews are recorded as described in the ManagementReview Procedure IOX/MRP/P-004 and maintained per the Control of QualityRecords Procedure IOX/CRP/P-002 .

6.0 RESOURCE MANAGEMENT

6.1 PROVISION OF RESOURCES

IOX Metal Works management is committed to provide adequate resources to:

a) implement and improve the processes of the quality system and continually improveits effectiveness, and

b) promote customer satisfaction by meeting customer requirements.

6.0.1 General

The required resources for implementation and improvement of the quality system,and for addressing customer satisfaction, may include any of the following:suppliers, information, infrastructure, work environment, and financial funds. Theprincipal means for determining and communicating resource requirements aremanagement reviews of the quality system. For details, refer to the ManagementReview Procedure IOX/MRP/P-004 .

6.0.2 Responsibilities for Determination of Required Resources

The Quality Manager and all management personnel affected by the quality systemare responsible for determining resource requirements for the implementation andimprovement of the system.

6.0.3 Provision of Resources






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• Top management has the responsibility and authority for provision of resources.

• Resources for designated activities are integrated with the process of definingand initiating the activity. They may take the form of personnel assignments,allocation of space or equipment, training, procurement decisions, budgets, etc.

• Allocation of resources may be documented in the quality manual, operationalprocedures, and minutes of meetings, memoranda, or any other form. Approvalsof resource allocations may also be communicated verbally.

6.1 HUMAN RESOURCES

6.1.1 General

IOX Metal Works selects and assigns qualified personnel to ensure that those whohave responsibilities defined in the quality system are competent on the basis of applicable education, training, skills, and experience.

Any personnel working within the quality management system may directly or indirectly affect the conformance of the product to quality requirements.

6.1.2 Competence, Awareness, and Training

IOX Metal Works has established and maintained a Training Procedure IOX/STP/P-005 to:

a) identify competency needs for personnel who perform tasks affecting quality /conformance to product requirements;b) provide training to address these needs or take other actions to achieve thenecessary competence;c) assess the effectiveness of the training provided and ensure the achievement of necessary competence;d) ensure that personnel are aware of the relevance and importance of their activitiesand how they contribute to the achievement of the quality objectives; and






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e) maintain appropriate records of education, training, skills, experience, andqualifications per the Control of Quality Records Procedure IOX/CRP/P-002 .

6.2 INFRASTRUCTURE

To ensure that our infrastructure is suitable for achieving conformance to productrequirements, IOX Metal Works has established and maintained a Facility ManagementProcedure IOX/FMP/P-006 . Assessment and maintenance of infrastructure includes:

a) workspace, associated facilities and utilities;b) process equipment, hardware, and software; anda) supporting services (i.e. transport, communication, information systems, etc.)

6.3 WORK ENVIRONMENT

IOX Metal Works has implemented and maintained a Facility Management ProcedureIOX/FMP/P-00 to manage the human and physical factors of the work environment that arenecessary for achieving conforming product. Such factors include, but are not limited to:

a) safety and ergonomics;b) light;c) noise;d) cleanlinesse) heat and humidity;f) space, and

g) language

7.0 PRODUCT REALIZATION






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7.1 PLANNING OF PRODUCT REALIZATION

IOX Metal Works has established and maintained a documented Product RealizationPlanning Procedure IOX/PRP/P-007 to ensure that processes and sub-processes areconducted under controlled conditions. Planning of the realization processes is consistentwith the other requirements of the organization’s quality system. Product realization plansdetermine the following:

a) quality objectives for the product, project or contract;

b) the need to establish processes and documentation, and provide resources,infrastructure, and work environment necessary to produce conforming product;c) required verification, validation activities, monitoring, measuring, inspection, test and

the criteria for the determination of acceptable product;d) the records that are needed to provide evidence that the realization processes and

resulting product conform to specified requirements.

7.0 CUSTOMER-RELATED PROCESSES

7.0.1 Determination of Requirements Related to the Product

IOX Metal Works has established a Design and Development Control ProcedureIOX/DDP/P-009 and a Contract Review Procedure IOX/CRP/P-008 for identifyingcustomer requirements. These processes determine:

a) product requirements specified by the customer, including therequirements for availability, delivery, and post-delivery support;b) product requirements not specified by the customer but necessary for intended or specified use, where known;c) obligations related to product, including regulatory and legalrequirements;d) any additional requirements determined by IOX Metal Works.

7.2.2 Review of Requirements Related to the Product






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IOX Metal Works reviews the identified customer requirements together withadditional requirements that are not specified but are necessary for fitness for useand governed by laws and regulations, and requirements for availability, delivery,and support. This review is conducted prior to commitment to supply a product to thecustomer per the Contract Review Procedure IOX/CRP/P-008 . The review process

ensures that:

a) product requirements are defined;b) contract or order requirements differing from those previouslyexpressed in a tender or quotation are resolved;

c) IOX Metal Works has the ability to meet the customer requirements;d) in situations where the customer provides no documented statement of requirements, or where customer requirements are changed, customer requirements are confirmed before acceptance;e) the results of the reviews, pertinent related correspondence, andnecessary follow-up actions are documented by IOX Metal Works order number and customer name.

6.1.3 Customer Communication

IOX Metal Works has implemented and maintained processes for communication

with the customers. Customer communications includes:

a) product/process information as described in the Customer SatisfactionProcedure IOX/MCS/P-018 , Continual Improvement Procedure IOX/CIP/P-024, and Servicing Procedure IOX/PSP/P-012 ;

b) addressing inquiries, contracts or order handling, including amendments asdescribed in the Contract Review Procedure IOX/CRP/P-008 ;

c) customer feedback, including customer complaints as described in theCorrective and Preventive Action Procedure IOX/CPA/P-025 ;






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7.1 DESIGN AND DEVELOPMENT

7.1.1 Design and Development Planning

IOX Metal Works plans and manages the design and development of itsproduct/service in accordance with the Design and Development Control Procedure

IOX/DDP/P-009 . Design and development is viewed as a creative activity involvingconceptual elements. It is not viewed as encompassing minor modifications tostandard products, or the specification of details from standard data tables or equivalent.

The design and development process determines:

a) stages of the design and development process;b) review, verification and validation activities appropriate to each design and

development stage;c) responsibilities and authorities for design and development activities.

Organizational interfaces between the different groups involved in design anddevelopment are managed as described in the Design and Development ControlProcedure IOX/DDP/P-009 to ensure effective communication and clarity of responsibilities. Planning output is updated at appropriate stages as design anddevelopment progresses.

Design and development reviews, verification and validation are conducted in series,or in parallel, as determined by the design and development team.






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7.1.2 Design and Development Inputs

Inputs relating to product/service requirements are defined per the Design andDevelopment Control Procedure IOX/DDP/P-009 . These include:

a) functional and performance requirements;b) applicable regulatory and legal requirements;c) applicable information derived from previous similar designs;d) any other requirements essential for design and development.

These inputs are reviewed for adequacy. Incomplete, ambiguous, or conflictingrequirements are resolved.

7.1.3 Design and Development Outputs

The outputs of the design and development process are recorded and expressed interms of requirements, calculations, analysis, or other means that can be verifiedagainst input requirements as described in the Design and Development ControlProcedure IOX/DDP/P-009 . This process ensures that design and developmentoutputs:

a) meet the design and development input requirements;b) provide adequate information, which may include instructions for product preservation, to purchasing, production and service operations;c) contain or reference product acceptance criteria;d) define the characteristics of the product that are essential for its safeand proper use.

All design and development output documents are reviewed and approved beforerelease per the Control of Documents Procedure IOX/DCP/P-001 .

7.1.4 Design and Development Review

Systematic reviews are planned, conducted, and documented at suitable stages of design and development per the Design and Development Control ProcedureIOX/DDP/P-009 to:

a) evaluate the ability to fulfill requirements;b) identify problems and propose necessary follow-up actions.






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Participants in the design and development review include representatives of functions concerned with the design and development stage under review.Records of reviews and necessary follow-up actions are maintained in accordancewith the Control of Quality Records Procedure IOX/CRP/P-002.

7.1.5 Design and Development Verification

Design and Development verification are defined, planned, executed, and recordedby competent personnel to ensure that the design and development output meets theinputs. The results of the verification and subsequent necessary follow-up actions are

recorded per the Control of Quality Records Procedure IOX/CRP/P-002 .

7.1.6 Design and Development Validation

Design and development validation is performed per the Design and DevelopmentControl Procedure IOX/DDP/P-009 to ensure that resultant products are capable of meeting the requirements for the specified application or intended use, where known,prior to release for delivery or implementation. Where it is impossible to perform fullvalidation prior to delivery or implementation, partial validation is performed to theextent applicable.

The results of the validation and subsequent necessary follow-up actions arerecorded per the Control of Quality Records Procedure IOX/CRP/P-002 .

7.1.7 Control of Design and Development Changes

Design and development changes are documented and controlled in accordancewith the Design and Development Control Procedure IOX/DDP/P-009 and Control of Documents Procedure IOX/DCP/P-001. This process includes evaluation of theimpact of the changes on constituent parts and delivered products. The changes areverified, reviewed, validated, and approved before implementation, as appropriate.






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7.2 PURCHASING

7.2.1 Purchasing Process

IOX Metal Works ensures that the purchasing process is controlled such thatpurchased products and subcontracted services, which affect product quality,conform to specified requirements. The type and extent of methods to manage thepurchasing process depends on the effect on subsequent realization processes and

their output or the final product. For details, refer to the Purchasing ProcedureIOX/MPP/P-010 .

IOX Metal Works evaluates and selects suppliers as described in the PurchasingProcedure IOX/MPP/P-010 . Selection is based on suppliers’ ability to deliver

products that satisfy all IOX Metal Works requirements. Criteria for selection,periodic evaluation, and re-evaluation are defined. The results of evaluations andnecessary follow-up actions are recorded.

7.2.2 Purchasing Information

Purchasing documents contain data clearly describing the product to be purchased,including, the following, where appropriate:

a) requirements for approval or qualification of product, procedures,processes, and equipment;b) requirements for qualification of personnel; andc) quality management system requirements.

IOX Metal Works ensures the adequacy of specified requirements contained in thepurchasing documents prior to their release to suppliers.

7.2.3 Verification of Purchased Product






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IOX Metal Works has identified and implemented verification activities for ensuringthat purchased product conforms to specified purchase requirements. Verificationactivities are defined in the Inspection and Test Procedure IOX/ITP/P-020 . WhereIOX Metal Works or its customer requests verification activities at the supplier'sfacility, IOX Metal Works specifies the required verification arrangements andmethod of product release in the purchasing documents per the PurchasingProcedure IOX/MPP/P-010 .

7.3 PRODUCTION AND SERVICE PROVISION

7.3.1 Control of Production and Service Provision

Processes that directly affect quality of intermediate and end products are carried outunder controlled conditions. To this end, IOX Metal Works has established andmaintained a Process Control Procedure, a Process Validation ProcedureIOX/PVP/P-013 and a Servicing Procedure IOX/PSP/P-012. Controlled conditionsinclude the following:

a) the availability of information that specifies the characteristics of the product;b) where necessary, the availability of work instructions;c) the use and maintenance of suitable equipment for production and service

operations;d) the availability and use of measuring and monitoring equipment per the

Control of Monitoring and Measuring Equipment Procedure IOX/MEP/P-017 ;e) the implementation of monitoring and measurement activities;f) the implementation of defined processes for release, delivery and applicable

post-delivery activities.

7.3.2 Validation of Processes for Production and Service Provision

Any IOX Metal Works production and service processes where the resulting outputcannot be verified by subsequent measurement or monitoring, are validated inaccordance with the Process Validation Procedure IOX/PVP/P-013 . This includesany processes where deficiencies may become apparent only after the product is inuse or the service has been delivered.






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Process validation demonstrates the ability of the processes to achieve plannedresults. IOX Metal Works has defined arrangements for validation that include thefollowing, as applicable:

a) qualification of process per the Process Validation ProcedureIOX/PVP/P-013 ;b) qualification of equipment and personnel per the Process ValidationProcedure IOX/PVP/P-013 and the Training Procedure IOX/STP/P-005 ;c) use of defined methodologies and procedures per the correspondingprocedures;

d) requirements for records per the Control of Quality Records ProcedureIOX/CRP/P-002 ;

e revalidation per the Process Validation Procedure IOX/PVP/P-013 .

7.3.3 Identification and Traceability

IOX Metal Works maintaines a documented procedure for identifying the product by suitablemeans throughout all stages of production, delivery, installation, and service operations.This process identifies the status of the product with respect to measurement andmonitoring requirements. Where traceability is a requirement, unique identification of theproduct is recorded and controlled. Product identification and traceability are maintained

and controlled through IOX Metal Works's Identification and Traceability ProcedureIOX/IDT/P-014.

.

7.3.4 Customer Property

IOX Metal Works exercises care with customer property while it is under IOX MetalWorks's control or being used by IOX Metal Works as defined in the Control of Customer Supplied Product Procedure IOX/csp/P-015 . IOX Metal Works ensuresidentification, verification against specified requirements, and protection andsafeguarding of customer property provided for use or incorporation into the product.

Any customer property that is lost, damaged or otherwise found to be unsuitable for use is recorded and reported to the customer.

Customer property may include intellectual property, such as information provided inconfidence.

7.3.5 Preservation of Product






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To preserve conformance of product with customer requirements during internalprocessing and delivery to the intended destination, IOX Metal Works has developedand maintained a documented Handling, Storage, Preservation and DeliveryProcedure. Details for identification of product are described in the Identification andTraceability Procedure IOX/IDT/P-014 . These procedures ensure adequate

identification, handling, packaging, storage and protection and also apply to theconstituent parts of the product.

7.4 CONTROL OF MONITORING AND MEASURING EQUIPMENT

IOX Metal Works ensures that the monitoring and measurement activities are identified, andthat the necessary monitoring and measuring equipment is available to assure conformanceof the product to specified requirements. IOX Metal Works’s Control of Monitoring andMeasuring Equipment Procedure IOX/MEP/P-017 is used to control measuring andmonitoring equipment so that measurement capability is consistent with the measurementrequirements. Measuring and monitoring equipment:

• is calibrated and adjusted periodically or prior to use against standards traceable tothe international or national standards;

• is safeguarded from adjustments that would invalidate the calibration;

• is protected from damage and deterioration during handling, maintenance andstorage;

• has the results of its calibration recorded;

• has the validity of previous results re-assessed if it is are subsequently found to beout of calibration and corrective action is taken per the Control of NonconformingProduct Procedure IOX/NCP/P-022 .

Software used for monitoring of specified requirements is validated according to definedguidelines prior to release for use in production, installation, and servicing.






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8.0 MEASUREMENT, ANALYSIS, AND IMPROVEMENT

8.1 GENERAL

Measurement and analysis activities that are required to assure product quality andcontribute to continual improvement are planned, and defined; statistical techniques areused for analyzing measurement of data.

8.1.1 Planning

Measurement and analysis activities, to verify and assure product quality, are definedin engineering specifications and drawings, production work orders, inspection andtesting procedures, and process control procedures.

8.2 MONITORING AND MEASUREMENT

8.2.1 Customer Satisfaction

A key measure of IOX Metal Works’s quality system performance is the informationobtained on customer satisfaction. The methodologies for obtaining and usingcustomer satisfaction data are documented in the Monitoring and MeasuringCustomer Satisfaction Procedure IOX/MCS/P-018 .

8.2.2 Internal Audit

IOX Metal Works conducts periodic internal audits, in accordance with the InternalAudits Procedure IOX/IAP/P-019 to ensure that the quality system:

a) conforms to the requirements of the applicable standards andregulations;b) has been effectively implemented and maintained.






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IOX Metal Works plans, conducts, and reports on internal audits in accordance withthe Internal Audits Procedure IOX/IAP/P-0019 . The audit scope, frequency andmethodologies are defined. Audit plans take into consideration the status andimportance of the activities and areas to be audited as well as the results of previousaudits. The audits are conducted by personnel independent of the activities beingaudited. Timely corrective action is taken on deficiencies found during the audits.Follow-up actions include the verification of the implementation of the correctiveactions and the reporting of verification results per the Corrective and PreventiveAction Procedure IOX/CPA/P-025 .

8.2.3 Monitoring and Measurement of Processes

IOX Metal Works applies suitable methods for measurement and monitoring of thoserealization processes that are required to meet customer requirements. Thesemethods are applied in accordance with the Statistical Techniques Procedure andassure the continuing ability of each process to satisfy the intended purpose.When planned results are not achieved, action is taken to correct the immediateproblem as specified in the Corrective and Preventive Action Procedure.

In the determination of suitable methods, IOX Metal Works takes into considerationthe type and extent of measurement or monitoring that are appropriate to each of its

processes in relation to their impact on the conformity to product requirements andon the effectiveness of the quality management system.

8.2.4 Monitoring and Measurement of Product and/or Service

IOX Metal Works measures and monitors the characteristics of the product to verifythat requirements for the product are met. This is carried out at appropriate stages ofthe product realization process in accordance with the Inspection and TestProcedure. Products are not released/service delivery does not proceed until allplanned monitoring and measuring activities have been satisfactorily completed.Evidence of conformance to the acceptance criteria is documented as described in

the Inspection and Test Procedure and Inspection and Test Status Procedure.Records include the authority responsible for release of the product.






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8.3 CONTROL OF NONCONFORMING PRODUCT

To ensure that product that does not conform to specified requirements is properly identifiedand managed, to prevent unintended use or delivery; IOX Metal Works has established andmaintained a documented Control of Nonconforming Product Procedure IOX/NCP/P-022 .Nonconforming product is corrected, where applicable, and subject to verification after correction to demonstrate conformance. In the event nonconforming product is detectedafter delivery or after it started being used, it is appropriately identified and managed.

Where product is accepted under concession, it is authorized for use by a relevant authoritysuch as the customer, the end user, regulatory body, or other applicable authority.

Records of the nature of nonconformances and any subsequent actions taken, includingauthorized concessions are maintained.

8.4 ANALYSIS OF DATA

IOX Metal Works has established and maintained a documented Statistical TechniquesProcedure IOX/STP/P-023 to collect and analyze appropriate data to determine the

suitability and effectiveness of the quality system and to identify improvement that can bemade. This includes data generated by measuring and monitoring activities and other relevant sources.

IOX Metal Works analyzes this data to provide information on:

a) customer satisfaction per the Customer Satisfaction Procedure IOX/MCS/P-018 ;b) conformance to customer requirements per the Design and Development Control

Procedure IOX/DDP/P-009 and the Corrective and Preventive Action ProcedureIOX/CPA/P-025 ;

c) process characteristics;

d) supplier performance per the Purchasing Procedure IOX/MPP/P-010 .






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8.5 IMPROVEMENT

8.5.1 Continual Improvement

It is the overall responsibility of top management of IOX Metal Works to continuallyimprove the effectiveness of the quality management system in accordance with theContinual Improvement Procedure IOX/CIP/P-024 . This process describesfacilitation of the continual improvement of the quality system through the use of the

quality policy, objectives, audit results, analysis of data, corrective and preventiveaction and management review. Each manager/supervisor is responsible for thecontinual improvement of the quality management system in his or her respectiveareas. Effectiveness of continual improvement activity is assessed during theManagement Review Process as described in the Management Review ProcedureIOX/MRP/P-004 .

8.5.2 Corrective Action

IOX Metal Works has established and maintained a documented Corrective andPreventive Action (CAPA) Procedure for eliminating the causes of nonconformity in

order to prevent recurrence. Corrective actions taken are appropriate to the impactof the problems encountered. The Corrective and Preventive Action Proceduredefines requirements for:

a) identification of nonconformities, including customer complaints;b) determination of the causes of nonconformities;c) evaluation of the need for actions to ensure that nonconformities do not recur;d) determination and implementation of corrective actions needed;e) recording the results of actions taken;f) reviewing the effectiveness of the corrective action taken.

8.5.3 Preventive Action

IOX Metal Works has established and maintained a documented quality plan, aDesign and Development Control Procedure, and a CAPA Procedure for eliminatingthe causes of potential nonconformities to prevent occurrence. Preventive actionstaken are appropriate to the impact of the potential problems. Quality plans and theprocedures define requirements for:






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a) identification of potential nonconformities and their causes;b) determination and implementation of preventive action needed;c) recording results of action taken;d) reviewing the effectiveness of the preventive action taken.






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END