quality basic concept
TRANSCRIPT
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Quality Basic Conceptand Implementation 14 June 2006Tripatra Fluor ConsortiumQAQC DepartementTF Main Office-Duri, Sumatra
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WellcomeWellcome
toto
Flexible Program ManagementFlexible Program Management
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Content:Content:
What is Quality?What is Quality?Quality in TF FPM PracticeQuality in TF FPM Practice
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Quality:Quality:
What ?What ?
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How do we make things better?
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Quality begins with the PDCA cycle and an
understanding of variation --not with ISO 9001
DALE K. GORDON is director of quality and business improvement for Rolls-
Royce Corp.'s Defense North American Business Unit in Indianapolis.
CONTINOUS IMPROVEMENT
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CONTINOUS IMPROVEMENT
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CONTINOUS IMPROVEMENT
Plan : Identify an opportunity and plan for change.
Do : Implement the change on a small scale.
Check : Use data to analyze the results of the change and
determine whether it made a difference.
Act : If the change was successful, implement it on a widerscale and continuously assess your results. If the change
did not work, begin the cycle again.
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ISO 9000:2000 defines:
System is :
“ a set of interrelated or interacting elements" (clause
3.2.1)
Quality Management System is:
"a management system to direct and control an
organization with regard to quality" (3.2.3)
CONTINOUS IMPROVEMENT
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CONTINOUS IMPROVEMENT
The system is a culmination of whatever the organization
says it is through the processes, activities and knowledge
it uses to meet product specifications and customer needs
Process
Activities
Knowledge
Product Spec&
CustomerNeeds
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THE COST OF QUALITY
The “cost of quality” is NOT the price of creating a quality
product or service.
It’s the cost of NOT creating a quality product or service
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THE COST OF QUALITY
Every time work is redone, the cost of quality increases. Obvious
examples include:
The reworking of a fabricated item.
The retesting of an assembly.
The correction of an invoice statement, report.
The reworking of a service, such as welding, building,
compacted ground, etc
In short, any cost that would not have been expended if
quality were perfect contributes to the cost of quality.
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Quality:Quality:
Who ?Who ?
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QUALITY CONTROL AND QUALITYASSURANCE
Assurance:
The act of giving confidence, the state of being certain or the act of makingcertain.
Quality assurance:
The planned and systematic activities implemented in a quality system so that quality requirements for a product or service will be fulfilled.
Control:
An evaluation to indicate needed corrective responses; the act of guiding a process in which variability is attributable to a constant system of chancecauses.
Quality control:
The observation techniques and activities used to fulfill requirements for quality.
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QUALITY CONTROL AND QUALITYASSURANCE
Function in quality can vary from one organization to another. Nevertheless, a few primary jobclassifications are consistent, regardless of industry or organization:
Analysts initiate and/or coordinate quality-related data fromproduction and service activities and report these data usingstatistical techniques.
Associates are involved in quality improvement activities or
projects but not necessarily full-time. Auditors systematically inspect and examine a quality system to
ensure compliance to requirements.
Inspectors audit and report on materials, processes and productsusing variable or attribute-measuring instruments and techniques,to ensure conformance with the organization’s quality standards.
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QUALITY CONTROL AND QUALITYASSURANCE
Quality engineers design, install and evaluate quality-assurance
process-sampling systems, procedures and statistical techniques; designor specify inspection and testing mechanisms and equipment; analyzeproduction and service limitations and standards; recommend revisionof specifications when indicated; and formulate quality assurancepolicies and procedures.
Quality managers oversee the administration of quality, processand/or business improvement efforts. They typically have authority over
a clearly defined area of the organization and a number of directreports.
Specialists perform specific functions within a quality initiative, such asstatistical analysis or testing. They have extensive experience ortraining.
Technicians perform basic quality tasks to track, analyze and report on
materials, processes and products, ensuring they meet organizationalstandards.
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Content:Content:
Quality in TF FPM PracticeQuality in TF FPM Practice
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KEY ISSUES
CPI & TF Management Expectations from Kick-off Meeting (20May05)
Mutual Expectation:
Safety, Cost and Quality are the three keyelements to our success
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QUALITY BARS
COS/
CS/
RC
FPM Q u a
l i t y
Q
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Is FPM CONTRACTOR delivering
High Quality,
Competitively priced work,
Safely and on time
KEY ISSUES
?
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QTF FPM QUALITY SYSTEM GENERALTF FPM QUALITY SYSTEM GENERAL
Operating
SystemRequirements
ProvenProcesses &
Procedures
+
The TF Quality Program is based on
the FLUOR Operating System
Requirements (OSR) and Tripatra’s proven process & procedure
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PROJECTEXECUTION
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EXECUTIONPLAN
Content of
TF Project
Execution Plan
QUALITY
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MANAGEMENTSYSTEM
Quality ManagementSystem is
the shared
responsibility of all
project team members
–
Engineer
Designer
Supplier/
Subcontractor,
Field personnel
QUALITY
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MANAGEMENTSYSTEM
Content of
Quality
Managements
System
List of the forms
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QUALITY PLAN
Quality Plan establishestop-level quality
assurance program
requirements –
References detailedimplementing
procedures, practice and
plans
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TF DELIVERABLES LIST
Content of
Quality
Managements
System
Contract
Deliverables
HOW QUALITY IS ACHIEVED IN TF FPM
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FPM CONTRACTOR
Q U A L I T Y A U D I T S
TF CONST
SUPERVISION/SUBCONTRACTOR
TF
SUPPLY CHAIN
MANAGEMENT
TF
ENGINEERING
DESIGN
QUALITY
CONTROL/ SURVEILLANCE
QUALITY
ASSURANCE/SURVEILLANCE
ACTIVITY
QUALITY
PLAN
HOW QUALITY IS ACHIEVED IN TF FPMORGANIZATION
ENGINEERING PROCUREMENT
E CP
QUALITY
CONTROL/
QUALITY
ASSURANCE
TF CONSTRUCTION
EQUIPMENT
CONSTRUCTION
MAINTENANCE,
REPAIR,
RECONDITION
C M
QA/QC ORGANIZATION
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Construction
Equipment
Maintenance
Overall Quality System Control
Supply Chain Management
Site Construction QC Surveillance & Testing
Q QThis group is responsible for verifying the quality throughout allFPM Contractor activities
Project QA/QC Manager
Charles J. Brazel
Audits
M. Satir Hasibuan
Sastro Kuncung
HO
Quality Surveillance
Edward
SLN
Quality Surveillance
Delta Ananda
SLS
Quality Surveillance
Brammie D.K
CEM
Quality Inspector
(vacant)
Technical Assistant
Lydia Fanny
Quality Assurance- Contract
Zulkarnain H., Budi Purwanto
Quality Assurance- Procurement
Kiagus Ismail Hamzah
Vendor/Supplier Quality Surveillance
As required by WA
QC Inspectors QC Inspectors QC Inspectors
HO & SLN
NDE Coordination
Taufiq Rahman
SLS
NDE Coordination
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How Quality is cascaded down to TFHow Quality is cascaded down to TF
SubcontractorSubcontractor
TF Subcontractor’s Quality Plan
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FPM Contractor
TF Subcontractor s Quality Plan
CPI User + DOA
TF Contracts TF QA/QC TF Subcontractor
Tender Process
-Exhibit F
-Specification
(CPI, Codes, etc)
•Review Quotation•Pre Bid Meeting
•Site Surveillance•Audits
Develop
WAF
Comply with
Exhibit-F
(Subcontractor’s
quality
requirement)
&Specification
All Subcontractors performing work on the FPM Project shall
implement specific Quality Program adequate for the FPM project
quality management needs and requirements
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Table of Contents
Quality Requirements for FPM Subcontractors
1.1 Quality Plan
1.2 Quality Objectives
1.3 Construction
1.3.1 Organization
1.3.2 Field Design Change Control
1.3.3 Purchasing
1.3.4 Document Control
1.3.5 Identification and Traceability of Equipment and Material
1.3.6 Inspection and Testing
1.3.7 Inspection, Measuring and Test Equipment
1.3.8 Quality Process Control
1.3.9 Inspection and Test Status Procedures & Reporting
Requirements
1.3.10 Control of Non-Conformance1.3.11 Material and Equipment Receiving, Handling, Storage and
Maintenance
1.3.12 Quality Records
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DOCUMENT HIERARCHY
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CTOP-400
Data Sheets
CPI Specification
TF FPM Specifications
Referenced Codes and Standards
Approved for Construction Drawings
Vendor/Supplier/Subcontractor Standards
DOCUMENT HIERARCHY
QUALITY :QUALITY : in TF FPM Practicein TF FPM Practice
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QUALITY :QUALITY : in TF FPM Practicein TF FPM Practice
1. Planning the
Work
2. Work out the
Plan
3. Document your work
Contract Awarded Work Execution
1. Develop Quality Plan
2. Develop Procedures
3. Develops the generic ITP
4. Establish Quality Organization
Develops the
specific ITP
Implementation of
the Quality Plan
Execute the workbased on the
specific ITP
Quality RecordsDocumentation
Record Inspectionand Test Report
TF Subcontractor’s Quality ImplementationTF Subcontractor’s Quality Implementation
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Share Quality ResponsibilityShare Quality Responsibility
1. Planning the
Work
2. Work the Plan
3. Documentingthe work
TF Quality OrgTF Subcontractor
Quality Org
1. Review and approve Quality Plan
2. Review Procedures
3. Review the ITP
4. Review Quality Personnel
1. Develop Quality Plan
2. Develop Procedures
3. Develops the generic ITP
4. Establish Quality
Organization
1. Quality Assurance
2. Site Surveillance
3. Priodically Audits
Implementation of the
Quality Plan, Procedures,
ITPs
Assure and Audit QualityRecords Documentation
Records of Inspection andTesting Report, Projects
Document
QUALITY :QUALITY : in TF FPM Practicein TF FPM Practice
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Deliver the service in Quality
When you are as the TF FPM Subcontractor
and get the Work Order/Requisition, what
will you do ?
QUALITY :QUALITY : in TF FPM Practicein TF FPM Practice
QUALITY :QUALITY : in TF FPM Practicein TF FPM Practice
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T F
Customer
TF FPM Subcontractor
Service Provider
Construction Services
No ActivitiesControlHold/ Witness/ Spot
Witness
ControlHold/ Witness/
Spot Witness
Acceptance
Criteria
Reference/
Document
QUALITY :Q in TF FPM Practice
QUALITY :QUALITY : in TF FPM Practicein TF FPM Practice
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T F
Customer
TF FPM Subcontractor
Service Provider
Construction Services
1. Planning the Work
2. Work out the Plan3. Document Your Work
ControlHold/ Witness/ Spot
Witness
Q
QUALITY :QUALITY : in TF FPM Practicein TF FPM Practice
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In order to deliver the QualityIn order to deliver the QualityService You have to:Service You have to:
1. Plan your work 1. Plan your work
2. Work your plan2. Work your plan
3. Documentation3. Documentation
QUALITY :QUALITY : in TF FPM Practicein TF FPM Practice
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In order to deliver the QualityIn order to deliver the QualityService You have to:Service You have to:
1. Plan your work 1. Plan your work
- Read & Examine and socializes the Work Requsition
among the crew team
- Prepare Inspection and Test Plan (ITP) and socializes
among the crew team
- Prepare and/or develop work procedure
- Prepare other documents (JSA, GWP, etc)
QUALITY :QUALITY : in TF FPM Practicein TF FPM Practice
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In order to deliver the QualityIn order to deliver the QualityService You have to:Service You have to:
2. Work your plan2. Work your plan
- Execute the work to follow the Work Requsition’s scope
- Execute the work to follow the Inspection and Test Plan
(ITP)
- Execute the work to follow the work procedure- Work beyond the JSA, GWP,
QUALITY :QUALITY : in TF FPM Practicein TF FPM Practice
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In order to deliver the QualityIn order to deliver the QualityService You have to:Service You have to:
3. Documentation3. Documentation
- Progress Report on the Work Requsition’s scope
- Testing & Inspection Report based on the ITP
- Improve the work procedure based on the best practice
during the execution
QUALITY :QUALITY : What ? What ?
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Satisfy
Happy to pay as the invoice
Happiness Long term relationship
Then...TF FPM will feel?
END
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END
Thank You
TF FPM hand in hand to reach our goal
Deliver the service On time,Efficiently, Safe with high
Quality
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ContentContent
Site Coordination withSite Coordination withConstruction GroupConstruction Group
SITE COORDINATION
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SITE COORDINATION
FPM Subcontractor
QC Inspector CS Engineer
CS
SuperintendentSr. QC Inspector
CPI Construction
Representative
Coordination Line
SITE COORDINATION- Work Requisition Process Flow-
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Work Requisition Process Flow
CPI User TF CS & PC TF QA/QC TF Subcontractor
Issue WR F002
Get WR F002 completion
approval from CPI
Received copy for
info and quality
control
implementation
Execute TF’s WR
Data
Complete
?
Receive TF’s WR, and
review
No
YesRe write a TF’s WR to
Subcont, supervise joband distribute copy to TF
PC, QC, HES
TF’s WR
Complete?
No
Sign for QC
acceptanceYes
Yes
Compile Report and get
completion approval
Check SOW and data
completeness
Data
Complete?
No
Close by signing
WR F002
Job
complete
d?
Back up data for
invoicing
No
Yes
Sign for TF’s WRtotal completion
and return to
Subcontractor
SITE COORDINATION- Inspection & Test Plan (ITP) Flow-
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CPI User TF CS Engineer TF QC Inspector TF Subcontractor
Develop ITP
Supervise the
project to follow
the ITP &
procedures
Review
Copy and distribute to
CS & QC
Accept?ReviseNo
Yes
Project Execution
& ITP
Implementation
Quality Control
Surveillance
based on ITP
NCR
Respond to NCR
and implement
corrective action
YesYesSupervise the
corrective action
implementation
Surveillance Report
No
Get input from User and
CS on inspection points
and return to
Subcontractor
User to identify
hold and witness
points
Yes
CS to identify hold
and witness points
SITE COORDINATION- Request for Information (RFI) Process Flow-
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TF Engineering TF CS Engineer TF QC Inspector TF Subcontractor
Initiate RFI
Get Info and
verify
implementation
Log
Accept and
Implement
Need
Design
Engineerin
g Support.?
Received &
Review
LogTransmit to
Subcontractor
Copy to QC and
log
NoYes
Respond to RFI Respond to RFI
SITE COORDINATION- Non Destructive Examination (NDE) Process Flow-
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TF Subcontractor
Construction
TF CS Engineer TF NDE Testing
Coordinator
TF Subcontractor
NDE Service (SCI)
Finished Job
Execution
Requiring NDE
Instruct
Subcontractor to
repair the job
Review request and
Determine NDE &
order NDE Service
Interpretation and
Report
Test Accept?
Receive order
No
Yes
Testing
Verify Report
Check Job
Completion and
Request NDE to
TF QC Inspector
Job Pass QC?
No
Repair the job
Accept job
completion
Yes
Send copy to CPI
for information
Data Base ReportEvaluation
Data Base Report
Evaluation
Regular reporting
on data base,
weekly andmonthly