A01.f07 Project Quality Plan Rev E
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ABCD
Management System Location:
Template Owner:
Template Author:
Template Number:
Template Revision / Date:
Industrial Processes
Stephen Emmas (rewritten 2011)
A01.F07
E / 13-12-2011
Process Owner:
Template Original Release Date:
Template Type :
Page:
Darryl Dean
03-08-2003
Form
1 of 58
QA Cross Reference:
QA Doc Revision / Date :
QA Document Number:
Quality Manual
J / 14-11-2011
A01.M01
A01 Responsibility Authority Organisation
This document is authorised by the Process Owner and the Industrial Processes Department Control and maintenance of this document is as per A04.01.01 Control of System Procedures & Forms, check system for latest issue.
A01.F07 Project Quality Plan - PQP <ENTER CUSTOMER NAME & DETAILS HERE>
<ENTER PROJECT TITLE & CONTRACT NUMBER HERE>
Project Quality Plan for Project Name & Number Document Number: Project #-PQP-001 Revision: A Date of Issue: 28 Feb 2012 Number of Pages: 58 Position
Name
Prepared by:
TBA
Name
Approved by:
Project Quality Officer
Name
Approved by:
Site Manager
Name
Approved by:
Project Manager
Name
Authorised by:
Quality Manager
Name
Position
Name
Customer:
Signature
Date
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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CONTENTS 1.
2.
3.
4.
5.
6. 7. 8.
9.
Document revision, distribution and definitions ........................................................................................... 5 1.1 Document Revision Status ................................................................................................................ 5 1.2 Document Distribution ...................................................................................................................... 5 1.3 References ....................................................................................................................................... 6 1.4 Abbreviations.................................................................................................................................... 6 Scope (AS/NZS ISO 10005 5.1) ................................................................................................................... 7 2.1 Project Quality Plan Scope ................................................................................................................ 7 2.2 Safety and Environment Management Plan ....................................................................................... 7 2.3 Project Scope of Work ...................................................................................................................... 7 Quality Plan Inputs (AS/NZS ISO 10005 5.2) ............................................................................................... 8 3.1 Applicable Documents ....................................................................................................................... 8 3.2 Project Quality Planning.................................................................................................................... 8 3.3 Quality Safety and Environment Policy .............................................................................................. 9 Project Management Responsibility and Organisation (AS/NZS ISO 10005 5.5) .......................................... 10 4.1 Director Project Management ......................................................................................................... 10 4.2 Project Manager ............................................................................................................................. 10 4.3 Site Manager .................................................................................................................................. 10 4.4 Project Quality Officer ..................................................................................................................... 10 4.5 Supervisors .................................................................................................................................... 10 Document Control (AS/NZS ISO 10005 5.6) .............................................................................................. 11 5.1 Document and Data Control ............................................................................................................ 11 5.2 DOCUMENT NUMBERING SYSTEM ................................................................................................. 11 5.3 Control of Project Documents .......................................................................................................... 12 5.4 Drawing Control ............................................................................................................................. 14 5.5 Project Filing System ...................................................................................................................... 15 5.6 Related Procedures ......................................................................................................................... 15 Control of Records (AS/NZS ISO 10005 5.7) .............................................................................................. 16 6.1 Quality records ............................................................................................................................... 16 Manufacturer’s Data Record ..................................................................................................................... 17 7.1 Related Procedures ......................................................................................................................... 17 Resources (AS/NZS ISO 10005 5.8) .......................................................................................................... 18 8.1 Resource management.................................................................................................................... 18 8.2 Material Resources ......................................................................................................................... 18 8.3 Human Resources ........................................................................................................................... 18 8.4 Personnel Register .......................................................................................................................... 18 8.5 Site Induction ................................................................................................................................. 18 8.6 Consultation ................................................................................................................................... 19 8.7 Industrial Relations ......................................................................................................................... 19 8.8 Related Procedures ......................................................................................................................... 19 Requirements (AS/NZS ISO 10005)........................................................................................................... 20 9.1 Contract Review ............................................................................................................................. 20
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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10.
11.
12.
13.
14.
15.
16. 17.
18.
9.2 Related Procedures ......................................................................................................................... 20 Customer Communication ......................................................................................................................... 21 10.1 Correspondence .............................................................................................................................. 21 10.2 Progress Reports ............................................................................................................................ 21 10.3 Meetings ........................................................................................................................................ 21 10.4 Related Procedures ......................................................................................................................... 21 Design and Development (AS/NZS ISO 10005 5.11) .................................................................................. 22 11.1 Design Control ................................................................................................................................ 22 11.2 ALSTOM Internal Design and Drawing ............................................................................................. 22 11.3 Design Co-Ordination ...................................................................................................................... 22 11.4 Related Procedures ......................................................................................................................... 23 Purchasing (AS/NZS ISO 10005 5.12) ....................................................................................................... 24 12.1 Procurement/Subcontract Requirements ......................................................................................... 24 12.2 Related Procedures ......................................................................................................................... 27 Production and Service Provision (AS/NZS ISO 10005 5.13) ...................................................................... 28 13.1 Product realisation.......................................................................................................................... 28 13.2 Related Procedures ......................................................................................................................... 29 Process Control ........................................................................................................................................ 30 14.1 Identification of Special Processes (AS/NZS ISO 10005 5.14) ........................................................... 30 14.2 Manufacturing Methods .................................................................................................................. 31 14.3 Welding Operator Certification ........................................................................................................ 31 14.4 Inspection Certificates..................................................................................................................... 31 14.5 Installation ..................................................................................................................................... 31 14.6 Control of Commissioning and Testing ............................................................................................. 31 14.7 Project quality system review .......................................................................................................... 31 14.8 Related Procedures ......................................................................................................................... 32 Identification and Traceability (AS/NZS ISO 10005 5.14) ........................................................................... 33 15.1 Identification .................................................................................................................................. 33 15.2 Traceability ..................................................................................................................................... 33 15.3 Related Procedures ......................................................................................................................... 33 Customer Supplied Products or Services .................................................................................................... 34 16.1 Related Procedures ......................................................................................................................... 34 Handling, Storage, Packaging, Preservation and Delivery (AS/NZS ISO 10005 5.16) .................................. 35 17.1 Handling ........................................................................................................................................ 35 17.2 Storage .......................................................................................................................................... 35 17.3 Packaging, preservation, marking and delivery ................................................................................ 35 17.4 Waste ............................................................................................................................................ 35 17.5 Related Procedures ......................................................................................................................... 35 Control of Nonconforming Product (AS/NZS ISO 10005)............................................................................ 36 18.1 Nonconformance Reporting ............................................................................................................ 36 18.2 NCR Sources................................................................................................................................... 36 18.3 Disposition of Nonconforming Products ........................................................................................... 36 18.4 Identification of Items Subject to NCR ............................................................................................. 36
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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19.
20.
21. 22.
23. 24. 25.
18.5 Resolution of ALSTOM NCR’s .......................................................................................................... 37 18.6 Resolution of Other Parties NCR’s ................................................................................................... 37 18.7 Corrective & Preventive Action ........................................................................................................ 37 18.8 Related Procedures ......................................................................................................................... 38 Measurement Analysis and Improvement (AS/NZS ISO 10005) .................................................................. 39 19.1 Inspection, Measuring and Test Equipment ...................................................................................... 39 19.2 Inspection and Testing .................................................................................................................... 39 19.3 Inspection and Test Plans ................................................................................................................ 39 19.4 Incoming Goods Inspection ............................................................................................................. 40 19.5 In-Process Inspection ...................................................................................................................... 40 19.6 Final Inspection (and Handover) ..................................................................................................... 41 19.7 Installation/Commissioning Inspection & Testing ............................................................................. 41 19.8 Inspection Release Certificate .......................................................................................................... 41 19.9 Inspection and Test Records ............................................................................................................ 41 19.10 Inspection Status ............................................................................................................................ 41 19.11 Related Procedures ......................................................................................................................... 41 Audits (AS/NZS ISO 10005 5.19) .............................................................................................................. 42 20.1 Audit Schedule ................................................................................................................................ 42 20.2 Audits............................................................................................................................................. 42 20.3 Related Procedures ......................................................................................................................... 42 Procedure List .......................................................................................................................................... 43 Annex 1 – Position Descriptions ................................................................................................................ 44 22.1 Project Manager ............................................................................................................................. 44 22.2 Procurement Manager/Officer ........................................................................................................ 45 22.3 Programmer/Scheduler .................................................................................................................. 46 22.4 Financial Controller ......................................................................................................................... 47 22.5 Site Manager .................................................................................................................................. 49 22.6 Inspectors (Technical QA) ................................................................................................................ 50 22.7 Quality Officer/Representative ........................................................................................................ 51 22.8 Safety Adviser................................................................................................................................. 52 22.9 Supervisor ...................................................................................................................................... 54 22.10 Site Administration Officer .............................................................................................................. 55 Annex 2 – Safety and Environment Management System........................................................................... 56 Annex 3 – Applicable Legislation ............................................................................................................... 57 Annex 4 – Project Organisation Chart ........................................................................................................ 58
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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1. Document revision, distribution and definitions 1.1
Document Revision Status
Rev. A
Description
Date
Original Issue
1.2
Enter date
Document Distribution
This Project Quality Plan (PQP) is distributed using QDMS (Quality Document Management System) to manage distribution and control of updates. Where server or internet access is difficult or not available, a manual form (A04.F06 Document Distribution Record) can be used, this records details of the document holders who will be updated. QDMS is a software package that Alstom subscribe to; it is used for the purpose of formally recording document transmittals and receiver acknowledgements. The software package requires user licences setup via IT. The document controller at North Ryde is the main identified user of QDMS.
Table 1 – Document Distribution Table Copy No.
Recipient
Location
1
Alstom Limited, Thermal Services
16 Giffnock Ave North Ryde, NSW, 2113
2
Enter customer details
Enter details
3
Enter project manager details
Enter details
4
additional recipient details here
Enter details
5
additional recipient details here
Enter details Notice to ALSTOM Employees
Documents published on the company document management system are the latest available approved versions and are considered the ‘master’ copy. Printed copies need to be verified as the latest versions prior to use. Users should be aware that the electronic copy is subject to change and as such printed copies should not be retained.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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1.3
References Reference No
Title
AS/NZS ISO 9001:2008
Quality management systems – Requirements
AS/NZS ISO 10005:2006
Quality management systems – Guidelines for quality plans
A01.M01
ALSTOM Limited Quality Manual
Customer Contract No.
Contract Title
Alstom Contract No.
Contract Title
1.4
Abbreviations Abbreviation
Meaning
AS/NZS
Australian/New Zealand Standard
CAR
Corrective Action Request
CCI
Chamber of Commerce and Industry
CD
Compact Disc
ITP
Inspection and Test Plan
ISO
International Standards Organisation
MDR
Manufacturer’s Data Report
NCR
Non-conformance Report
NDT
Non Destructive Testing
PIP
Project Implementation Plan
PQP
Project Quality Plan
QA
Quality Assurance
QDMS
Quality Document Management System
QMS
Quality Management System
SEMP
Safety & Environment Management Plan
SOP
Standard Operating Procedure
WI
Work Instruction
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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2.
Scope (AS/NZS ISO 10005 5.1)
2.1
Project Quality Plan Scope
This PQP defines the Quality Management System (QMS) that shall be implemented on this project to deliver ALSTOM LIMITED Contract No. XXXXX. Contract No. XXXXX is hereafter referred to as “Contract”. ALSTOM LIMITED is hereafter referred to as “ALSTOM”. XXXXXX is hereafter referred to as “Customer”. This PQP is based on the procedures of the ALSTOM management system and reference should be made to these procedures for further details. To satisfy unique project/site requirements ALSTOM may implement project specific procedures in lieu of standard company procedures and these project specific procedures are identified in this PQP. Project specific procedures are assessed against ALSTOM standard procedures to ensure they do not conflict with or negate ALSTOM policies. Standard Operating Procedures (SOPs) or Work Instructions (WIs) referenced in this PQP are not for publication but may be viewed at ALSTOM office by ALSTOM approved Parties. Each Subcontractor shall develop, implement and maintain an ALSTOM approved PQP with relevant procedures/work Instructions applicable to their contract in keeping with AS/NZS ISO 9001:2008 and this PQP.
2.2
Safety and Environment Management Plan
A project Safety & Environmental Management Plan ‘XXXXX-SEMP-001’ has been developed for this project and shall be provided to the Customer.
2.3
Project Scope of Work
(AS/NZS ISO 10005 5.2)
2.3.1 Overview of the Scope of Works List scope of work as detailed in the contact here. The scope of work includes: if necessary insert bullet points here if necessary insert bullet points here
2.3.2 Exclusions List exclusions as stated in the contract here ALSTOM is not required to: a. if necessary insert bullet points here
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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3.
Quality Plan Inputs (AS/NZS ISO 10005 5.2)
3.1
Applicable Documents
Documentation applicable to this Contract is as follows: a. Customer Contract Document; b. Project Quality Plan (PQP); c. Project Implementation Plan (PIP); d. Project Safety & Environmental Management Plan (SEMP), and e. Project Organisation Chart. f.
Project Industrial Relations Plan;
g. ALSTOM Standard Operating Procedures (SOPs) and associated Forms, and h. Legislative and regulatory codes (refer Section 24).
3.2
Project Quality Planning
The project will be managed in accordance with this PQP, which is based on the ALSTOM Quality Management System conforming to AS/NZS ISO 9001:2008, as detailed and/or qualified below, as well as the Customer Contract Documents.
3.2.1 Document Precedence Where conflicting procedures are encountered the Customer Contract documents and this PQP shall take precedence (in that order).
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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3.3
Quality Safety and Environment Policy
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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4. Project Management Responsibility and Organisation (AS/NZS ISO 10005 5.5) The general functional responsibilities for key positions, as detailed on the project Organisation Chart, are as detailed in the following paragraphs, further definition is provided in the position descriptions detailed in Section 22 of this PQP.
4.1
Director Project Management
The Executive General Manager reports to the Managing Director and is responsible for providing direction and ALSTOM approval of policies and methods of execution for the contract by ALSTOM.
4.2
Project Manager
The Project Manager is responsible for overall planning, control and execution of the project in a cost-effective manner and shall ensure compliance with the Contract technical specification, program, ALSTOM financial and commercial policies and practices, safety and environmental requirements including the development, coordination and authorisation of the site specific management plans, incorporating the Customer’s site specific policies and procedures. The Project Manager shall manage the project to meet customer expectations and needs through management system audits, management reviews, customer feedback, performance monitoring and continuous improvement to achieve customer satisfaction. This position has overall authority in determination of all quality related matters affecting the project. The Project Manager also has direct access to the ALSTOM Quality Manager to resolve quality issues should this be necessary.
4.3
Site Manager
The Site Manager is responsible to the Project Manager for overall planning, control and execution of the project in a cost-effective manner and shall ensure compliance with legislation, the Contract technical specification, programme, ALSTOM financial commercial, quality, safety and environmental requirements. The Site Manager shall manage the site to meet customer expectations and needs through management system audits, management reviews, customer feedback, performance monitoring and continuous improvement to achieve customer satisfaction. This position has overall authority in determination of all quality, safety & environmental related matters affecting the Site. In addition the site Quality Officer has direct functional access to the ALSTOM Quality Manager to resolve quality issues should this be necessary.
4.4
Project Quality Officer
The project Quality Officer acts as the Management Representative for onsite quality management matters and checking that all activities are in accordance with this PQP and the procedures applicable to the project to meet Customer requirements.
4.5
Supervisors
Supervisors are responsible to the Site Manager to implement the requirements of the management system.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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5.
Document Control (AS/NZS ISO 10005 5.6)
5.1
Document and Data Control
Documentation applicable to this contract shall be controlled based on SOP ‘A04.01 Document Control’ and SOP ‘B10.01 Control of Records. The formal internal exchange of significant information between members of staff engaged on the Contract shall be by “Memo”, either in hard copy or electronic format. The format for a Memo may be any of the following:a. Contract Memo; b. Hand-written or computer generated file note (including Lotus Notes); c. Facsimiles; The minimum traceability requirements are; d. Correspondence number and date; e. Contract number; f.
Customer name/project name, and
g. Name of sender. For review/follow up purposes a duplicate of the Memo may be kept by the sender as appropriate to the document’s importance. Incoming correspondence shall be registered and may be exchanged internally by means of direct handover, or by copying and distributing (or circulating) same, per distribution list thereon. Review and approval of documentation shall be as per SOP ‘A04.01 Document Control’.
5.2
DOCUMENT NUMBERING SYSTEM
5.2.1 Correspondence Document Control All project correspondence shall be identified in a correspondence register number. The correspondence number shall be taken out of the appropriate correspondence register and included in the document. All project correspondence is to be numbered and controlled as defined in Extract from Form B10.F01 Project Filing System. Refer to the following Figure 1 for a summary of correspondence control system.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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Customer Name, Project Title, Contract No. XXXXX
For example: ALSTOM to CLIENT = Contract Number–AP–CL–XXX
XXXXX - XXXX - XXXXX -
0001 / XX
Alstom Project No./ Contract No. Originator Recipient Sequential Document No. Author Figure 1 – Correspondence Numbering Convention The originator codes are as defined in Table 2 – Correspondence Originator Codes.
Table 2 – Correspondence Originator Codes
5.3
Code
Originator
AP
ALSTOM
CL
Client
G
General
APE
ALSTOM Engineering
SC
Subcontractor
Control of Project Documents
Controlled documents shall be numbered in accordance with Figure 2. All numbers are to be allocated by the Document Controller. For example: This Project Quality Plan = Contract Number–GN–PQP–001. XXXXX - GN - PQP - 001 - Rev A Contract No. Area Code (WBS) Document Type Code Document Sequential No. Revision No.
Figure 2 – Controlled Documents Numbering Convention
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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The document type codes are as defined in Table 3 – Controlled Document Type Codes.
Table 3 – Controlled Document Type Codes Document
Code
Document
Code
Project Quality Plan
PQP
Welding Procedure Specifications
WPS
Safety Management Plan
SMP
Procedure Qualification Record (Welding)
PQR
Environmental Management Plan
EMP
Manufacturer’s Data Reports
MDR
Design Plan
DP
Operation and Maintenance Manual
OM
Inspection & Test Plan
ITP
Statutory Approvals
SA
Inspection & Test Plan Register
ITR
Preferred Suppliers/Subcontractors
PSS
Procedure
P
Contract Data Sheet
CDS
Instruction
I
Technical Specification
TS
Forms
F
General Specification
GS
Checklist
C
Purchase Order
PO
Sample
S
Concession Requests
CR
Project Plans
PP
Reports
RT
Program/Schedule
PRO
Scope of Work
SOW
Industrial Relations
IR
Sketch
SK
Forms Register
FR
Spares Schedule
SS
Contract
CON
Design Review Package
DRP
Functional Description
FD
Plant Test Procedures
PTP
Design Guide
DG
Turnover Package
TP
Design Report
DR
Data Sheet
DS
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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5.4
Drawing Control
Drawings shall be numbered as follows: Note: Drawing numbers shall be issued by the Engineering section to ensure consistency. XXXXX - BL - 028 - FD -
001
Rev 1
Contract No. Area Code (WBS) Plant/Sub No. Document/Drawing Code Sequential No. Revision No.
Figure 3 – Drawings Numbering Convention
5.4.1 Document Number Identifiers/Codes Area codes, Plant/Sub No codes and Document/Drawing codes are defined in SOP ‘B00.02.01Work Breakdown Structure’.
5.4.2 Drawing/Document Status Issue/revisions shall start with alpha characters (A, B, C) for drawings forwarded to Client ‘For Approval’. Approved/Certified for Construction status shall start with Rev 1 after approval. After Client approval, the status of resubmissions will be ‘For Information’ i.e. all drawings forwarded to Client for information will be Approved/Certified for Construction copies.
5.4.3 Document Cover Sheet Document cover sheet A04.F19 is used to identify and submit documents where documents (eg. external, supplier or other pdf’s etc) are unable to be numbered as per 5.3 Control of Project Documents.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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5.5
Project Filing System
As defined in SOP ‘B10.F01 Project Filing System’ the following standardised folder system shall be used to organise project documents
5.6
Section / Tab
DESCRIPTION
Area
1
CONTRACT CONDITIONS
Tender
2
TENDER SPECIFICATION
Tender
3
TENDER
Tender
4
CONTRACT ISSUE
Tender
5
CONTRACT DOCUMENTATION
Tender
6
CONTRACT START UP
Project Execution
7
EHS & LOSS
Project Execution
8
ENGINEERING
Project Execution
9
PLANNING & PROGRAMMING
Project Execution
10
QUALITY
Project Execution
11
SUBCONTRACT MANAGEMENT
Project Execution
12
MAJOR SUPPLIER MANAGEMENT
Project Execution
13
OTHER NON-LABOUR PROCUREMENT
Project Execution
14
CLIENT SUPPLIED ITEMS
Project Execution
15
CORRESPONDENCE
Project Execution
16
MEETINGS
Project Execution
17
COST MANAGEMENT
Project Execution
18
VARIATIONS
Project Execution
19
INVOICING & CLAIMS MANAGEMENT
Project Execution
20
REPORTING
Project Execution
21
STAFF
Project Execution
22
JOB FINALISATION
Project Execution
Related Procedures
A04.01, Document Control A04.01.01, Control of System Procedures and Forms A04.01.02, Control of Standards & Publications A04.01.08, Installing Databases from CD
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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6. 6.1
Control of Records (AS/NZS ISO 10005 5.7) Quality records
Identification, collection, indexing, filing, storage, maintenance and disposition of Contract specific records shall be carried out in accordance with SOP ‘B10.01 Control of Records’. Records shall indicate persons releasing the product. 6.1.1
System Conformance Records
These records shall be maintained as required by SOP ‘B10.01 Control of Records’. The following shall form the Contract requirement: a. Management reviews; b. Training records; c. Inspection and test plan records; d. Design Plan and verification, validation and design changes; e. Supplier evaluations; f.
Inspection equipment calibration records;
g. Special Process procedures and associated personnel qualifications; h. Non-conformances and resulting corrective actions, and i. 6.1.2
Quality Audit Records and surveillance reports.
Product and Service Conformance Records j.
Raw Material Certification (for critical components or pressure parts);
k. Inspection and Test Plan (ITP); l.
Non-Destructive Test Report (NDT);
m. Weld Procedures; n. Welder Qualifications; o. Heat Treatment Reports; p. Mechanical Test Reports; q. Hydrostatic Test Reports; r.
Stress Relief Certificates;
s. Pressure Part BR2 Manufacturer’s Forms; t.
Non-conformance Reports (NCRs);
u. Non-conformance Concession Record; v. ALSTOM Inspection Certificates; w. Customer or Third Party Release Certificate; x. Installation Reports and Checklists; y. Commissioning Report and Checklists, and z. Operating and Maintenance Manuals.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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7.
Manufacturer’s Data Record
Subcontractors shall, upon completion of work, provide the above product conformance records (as applicable) to ALSTOM in the form of a Manufacturer’s Data Report (MDR) bound in volume for each item of manufacture. This shall be specified in the Purchase Order and no purchase order shall be approved for payment without receipt and acceptance of the MDR and any other requested documentation. Records shall be preserved and stored as identified in B10.01 Control of Records. Records shall be legible and either recorded in English or appropriately translated into English. Each subcontractor, as part of their quality plan, shall detail the procedures for control of its quality records.
7.1 B10.01
Related Procedures Control of Records
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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8. 8.1
Resources (AS/NZS ISO 10005 5.8) Resource management
ALSTOM will supply adequate staffing, supervision, labour, construction equipment, onsite transportation, consumables, offices, crib rooms and safety equipment for the project, to complete the requirements of the above contracts within the project time constraints outlined in the Contract.
8.2
Material Resources
Material requirements are specified in the Contract, design specifications, inspection and test plans and in purchasing information.
8.2.1
Customer Supplied Material Resources
Materials supplied by the Customer are in the form of consumables or hardware/parts. These materials when supplied to ALSTOM shall be strictly controlled and where required traceability shall be maintained as defined in Section 15, Traceability.
8.3
Human Resources
The Project Manager shall ensure that project personnel undertaking work that may influence the quality of the work, have appropriate qualifications, training and experience. The Project Manager shall assess the training needs for the Project Team under their direct control and, if required, provide or arrange training to meet specific project requirements as defined in SOP ‘A06.01 Training’. Unless otherwise specified, personnel suitability shall be assessed on the basis of qualifications and/or experience as required by individual position descriptions and job specifications. Training courses shall be carried out in, but not limited to the following areas, as and when required: a. Site Induction; b. Quality Plan, SOPs and WIs (Office and Site), and c. Environment, Health and Safety. Records (including resumes, qualification reports, inductions, etc) substantiating qualifications of new employees or additional qualifications/experience of existing employees, shall be maintained.
8.4
Personnel Register
The Document Controller shall maintain ALSTOM and Contractor personnel records on the project filing system.
8.5
Site Induction
All ALSTOM employees and ALSTOM Subcontractors will be required to attend a general Site Induction session prior to commencement of work on site. As part of this process attendees will be issued with an Induction Handbook which provides an overview of site safety requirements.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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Each Subcontractor shall submit a written request for employee induction training to Project Manager at least five (5) days prior to commencement on site. Contractors may be required to attend a pre-commencement Meeting with the Project Manager to discuss and review all requirements associated with the contract. Site inductions shall comply with SOP ‘A06.01.01 Site Induction’. Site induction records shall be maintained as defined in SOP ‘B10.01 Control of Records’.
8.6
Consultation
ALSTOM is committed to health and safety consultation and addresses this through the provision and management of workgroups, provision of training, issue resolution measures, consultation and communication meetings such as toolbox meetings and resolution of safety disputes as defined in SOP ‘A06.05 Consultation’.
8.7
Industrial Relations
The Project Manager is responsible for personnel management and industrial relations in accordance with the project industrial relations and individual employment or performance agreements. The Project Manager shall: a. Participate in union/management negotiations for project agreements; b. Administer the provisions of the agreement including policy decisions, strategies and objectives; c. Participate in site industrial relations program including contacts with government authorities, unions and employer associations as necessary; d. Coordinate contractors in above matters; e. Interpret site agreement with assistance from Chamber of Commerce and Industry (CCI) as necessary; f.
Liaise with Union officials at all levels on industrial relations issues;
g. Provide advice to managers and supervisors on industrial relations practices; h. Maintain records, prepare reports on project industrial Relations performance;
8.8
i.
Be aware of the application of regulations and statutes including employment procedures, dismissal procedures, legal demands, standards, workers’ compensation.
j.
Advise and assist the Construction Project Manager in respect of publicity relating to industrial relations matters.
Related Procedures
A06.01 A06.01.01 A06.01.02 A06.05 B10.01
Training Site Induction Tool Box Meetings Consultation Control of Records
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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9. 9.1
Requirements (AS/NZS ISO 10005) Contract Review
The Contract requirements shall be reviewed as defined in SOP ‘B02.02 Contract Review’ and ‘B02.03 Contract Handover’ and includes (but is not limited to) the following : a. The review of the Customer’s Specification documents and ALSTOM Offer together with subsequent correspondence in order to consolidate and define the scope of work and the adequacy and the capabilities of necessary resources b. Documenting discrepancies if any, within the Contract documents and the consolidated tender documents, so that they can be resolved in a timely manner c. Where necessary, involvement of appropriate company interface groups in the contract review process d. Contract Variations (change orders), if any during execution of the contract, shall be similarly reviewed, but shall be processed in accordance with SOP ‘B03.01 Contract Administration’. Contracts with Subcontractors shall be similarly reviewed.
9.2
Related Procedures
B02.02 B02.03 B02.02.01 B03.01 B10.01
Contract Review Contract Handover Order Acceptance and Notification for Power Services Contract Administration Control of Records
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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10. Customer Communication 10.1
Correspondence
All formal/written communication with the Customer shall be directed through the Project Manager/Site Manager. All written communication to and from the site office shall be through the Project Manager or nominee.
10.2
Progress Reports
A monthly report submitted to the Customer by the Project Manager shall address, but is not limited to, the following: a. Executive Summary; b. Problem Areas; c. Engineering/Design; d. Procurement; e. Manufacture; f.
Construction;
g. Commissioning; h. Project Control; i.
Quality Management;
j.
Contract Administration;
k. Change Order Log, l.
10.3
Programme Update including S-Curves
Meetings
The following meetings will be conducted during the delivery project: Type
Frequency
Attendees
Planning Meeting
Weekly
Project Manager, Site Manager, Project Engineer
Coordination Meeting
Weekly
Project Manager, Site Manager, Project Engineer
Customer Site Progress Meetings
Fortnightly
Project Manager, Site Manager, Project Engineer
Tool Box Meetings
As determined on site
As determined on site (refer to SEMP).
Customer Meetings (additional)
On request
Project Manager, Site Manager, Project Engineer
An agenda shall be prepared and minutes reported.
10.4 B03.04
Related Procedures Project Implementation
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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11. Design and Development (AS/NZS ISO 10005 5.11) 11.1
Design Control
While ALSTOM is responsible for the design performance of the Contract, subcontractors and suppliers shall ensure adequate systems and procedures are established, implemented and maintained to satisfy/verify their own design performance requirements. ALSTOM shall address these requirements in procurement and subcontract documentation. The design performance shall also be reflected in the relevant Subcontractors’ Quality Plans or Inspection & Test Plans (ITPs) as appropriate. ALSTOM will conduct design and detailing functions at plant interfaces in keeping with the role of design planning, co-ordination and review with subcontractors as appropriate. Assessment of the adequacy of the design provisions shall be through: a. Documentation of design reviews to ensure completeness; b. Co-ordination and review meetings; c. Audit, and d. Inspection and Test activities.
11.2
ALSTOM Internal Design and Drawing
Design work is to be in accordance with SOP ‘B04.01 Design’ and the Project Design Plan, wherein the following shall be addressed; e. Organisational and Technical Interfaces; f.
Planning the method of design in terms of documenting design activities to be assigned to the design team members, including any external design services as nominated in the design plan;
g. Documenting and reviewing design inputs for adequacy; h. Carrying out preliminary design work as necessary; i.
Carrying out detailed design;
j.
Reviewing design output;
k. Carrying out design verification, and l.
11.3
Processing design changes.
Design Co-Ordination
Progress Meetings shall be held with Subcontractors performing Design work, as appropriate and as necessary, to discuss and resolve Design Inputs, Design Outputs, Design Verification, Design Changes, technical issues and progress of Design activities. Records of Design Co-ordination meetings shall be maintained in the form of Minutes of Meeting as minimum.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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11.3.1
Design Review / Verification
Design Review meetings shall be held internally for design output and with Subcontractors performing design work at appropriate stages of the design process to discuss and resolve Design Issues, Design Inputs and Outputs, Design Changes, Concession and Contract Changes and other technical issues affecting the project. Participants shall be chosen to represent all functions concerned with the stage of Design being reviewed. Records of Design Review meetings shall be in the form of Minutes as minimum.
11.4 A04.01 B04.01 B10.01 A04.F01
Related Procedures Document Control Design Control of Records Minutes of Meetings
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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12.
Purchasing (AS/NZS ISO 10005 5.12)
Goods and services required by ALSTOM shall generally be purchased from assessed suppliers as defined in SOP ‘B05.02.03 Thermal Service Procurement’. Standard supplementary terms and conditions required to be attached to Purchase Orders as defined in SOP ‘B05.02.03 Thermal Service Procurement’ are altered to include terms and conditions as applicable to specific equipment or services ordered and shall be ALSTOM approved at time of authorisation of the purchase by the signing authority of the Project Manager or his delegate (as per A01.2.1 Table of Authorities). Documentation to be included with Purchase Orders shall have a dedicated document number applicable to the document and must be listed on the Purchase Order and accompanied by a subcontract Transmittal Advice. Reference must be made to the Purchase Order. It is the responsibility of the Engineer who initially prepares or initiates changes to specification documents to ensure that the necessary issues and changes or revisions are issued to the Procurement Officer as applicable for arranging applicable order variations and on-forwarding. For quotation or enquiry purposes, technical specifications, drawings etc, may be issued as non-controlled documents, however the issue status must be recorded in the enquiry document. No final invoice from a subcontractor shall be approved for payment without receipt of full documentation requested as part of the Purchase Order.
12.1
Procurement/Subcontract Requirements
All Subcontractors/Suppliers, as part of their Quality Plans shall nominate the methods to identify and trace products where applicable based on the above requirements. Sub-contractors are assessed as defined in SOP ‘B05.01 Sub-contractor Assessment’, wherein the following will be addressed and documented: a. The evaluation and selection of subcontractors for components; b. The evaluation and selection of subcontractor’s Subcontractors. Subcontractor’s Subcontractors shall be evaluated by the head Subcontractor and evidence submitted to ALSTOM for approval prior to letting of orders; c. The requirements on the subcontractor for a particular purchase order; d. Reviews and approval of purchasing documents prior to issue; e. Surveillance of subcontractors, and f.
Amendments to purchase orders.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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12.1.1
Subcontractor’s Responsibility
While ALSTOM maintains the Contract responsibility for these activities until handover to the Customer, the main responsibility for carrying out the handling, storage, packaging, and preservation and delivery requirements of the project rests with the subcontractors and suppliers. They shall ensure adequate systems and procedures are established, implemented and maintained to satisfy Contract requirements. ALSTOM shall address these requirements in procurement and subcontract documentation. Such controls shall be reflected in the relevant subcontractor quality plan and/or ITPs as appropriate. Assessment of the adequacy of these provisions shall be through audit and inspection and test activities. The site storage facility allocation for subcontractors and suppliers will be designated at an appropriate time.
12.1.2
Subcontractor’s Role
Relevant to their scope of work, subcontractors shall identify, plan, implement and maintain the design, management, manufacture, construction, installation, commissioning, handover and warranty processes that are necessary to achieve project and Contract requirements, based on quality, cost and time requirements. These processes, including special processes, shall be carried out under controlled conditions including, but not limited to: Where process results cannot be verified by inspection and testing of the product, and where deficiencies may become apparent only after the product is in use, the process shall be performed by qualified operators and/or require continuous monitoring and control of the process to ensure compliance with the specification. Specific requirements for any qualifications, equipment and personnel shall be specified. Subcontractors shall have procedures to identify, control and dispose non-conformances and initiate and verify appropriate corrective actions, and subcontractors’ quality plans shall detail these procedures and their application to the project.
12.1.3
Management, Control and Surveillance of Subcontractors
ALSTOM shall manage subcontracted activities and shall conduct regular surveillance activities to ensure conformance to project and Contract requirements by conducting the following activities: a. Quality Audits; b. Progress Meetings; c. Design Co-ordination and Review Meetings; d. Review and mark-up and release of ITPs; e. Witnessing the relevant and nominated Inspections and Tests; f.
Records Review, and
g. Review of MDRs and Operation and Maintenance Manuals.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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12.1.4
Subcontractor’s Design Role
Design work for each Subcontract package shall be carried out by the appropriate Subcontractor as defined in their internal documented design procedure. The following shall be addressed: a. Organisation and Technical interfaces; b. Planning the method of design in terms of documenting design activities to be assigned to Design Team Members, including external design services and producing a Design Plan; c. Documenting and reviewing design inputs for adequacy; d. Carrying our preliminary design work as required; e. Reviewing design output; f.
Carrying out design verification, and
g. Processing design changes. These requirements shall be subject to audits by the subcontractor and ALSTOM during the execution of the work.
12.1.5
Sub-Contractors Design Responsibilities
Subcontractor’s design responsibilities shall be detailed in the subcontract documentation and where specified, the relevant subcontractor, in fulfilling the design requirements, shall be required to establish procedures, where appropriate, to: a. Develop detailed design plans or equivalent incorporating definition, assignment and planning of all design and development activities; b. Define organisational and technical interface which will input into the design process and establish appropriate systems for documenting, transmitting and reviewing the necessary information; c. Develop detailed design programmes incorporating all design and development activities to meet specified and agreed project targets and milestones; d. Provide sufficient qualified personnel with adequate resources to carry out the Design function to meet the design programme and satisfy Contract requirements. e. Identify, document, review and resolve design inputs f.
Document design outputs such that they: i.
Meet design Input requirements;
ii.
Contain or reference acceptance criteria;
iii.
Conform to appropriate statutory and regulatory requirements, and
iv.
Identify characteristics that are crucial to the safe and proper functioning of the relevant scope of work.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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g. Verify at appropriate stages of the design to establish that design output meets Input requirements by such means as: i.
Conducting and maintaining records of internal Design Reviews;
ii.
Attending and maintaining records of external Design Reviews, and
iii.
Conducting alternative calculations and/or comparisons with a proven design or tests.
h. Identify, document, control, review and approve design changes and modifications.
12.1.6
Design Input for Subcontract Packages
As part of design input, ALSTOM shall develop equipment/performance based Specifications detailing the requirements for design. These shall be controlled documents and shall be reviewed for adequacy prior to distribution to the “Supplier”. Processing of design output shall be per SOP ‘A04.01 Document Control’.
12.1.7
Design Output from Subcontractors
Design output in the form of Calculations, Drawings and Specifications shall be verified by the appropriate Subcontractor and submitted to ALSTOM for review and comments. Evidence of any reviews and approvals shall be the signatures in the document control stamp thereon.
12.1.8
Control and Management of Subcontractors’ Design
Control and management of Subcontractors’ Design shall be a combination of Design Co-ordination and Progress Review Meetings, Quality System Audits and Technical Surveillance of the Design process. The frequency of these controls will be varied according to criticality of the relevant Design phases and performance of the Subcontractor and will be reflected in the Quality Audit Schedule.
12.2
Related Procedures
A04.01 B05.01 B05.01.01 B05.01.02 B05.02.03 B10.01
Document Control Subcontractor Assessment Supplier Performance Reviews Subcontractor safety and Environmental Management Power Service Procurement Control of Records
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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13.
Production and Service Provision (AS/NZS ISO 10005 5.13)
13.1
Product realisation
13.1.1
Contract Programme
Activities covering engineering design, procurement, manufacture, delivery, installation, commissioning and testing shall be controlled in accordance with the contract programme. SOP ‘B03.02 Project Planning’ defines the procedure for the evaluating and quantifying resources, the provision of management information and time monitoring time, expenditure and resource management during the phases of the Contract. The software package to be applied is Primavera or an approved compatible/equivalent program. The program shall be submitted to the Customer in accordance with contract requirements. Programs for detailed planning, control and monitoring will be utilised internally by ALSTOM and Contractors as applicable. Activities covering design, purchasing, manufacture, delivery, installation and commissioning shall be planned, programmed, controlled and monitored. Contractors programs shall comply with these requirements and form part of the program. Site progress will be monitored, updated, assessed (including look ahead schedules & action plans as a result of negative float) and submitted fortnightly to the Project Manager for update of relevant programs. All official programs shall be issued as directed by the Project Manager. Program information may also be issued on site with the approval of the Project Manager. Subcontractors shall be required to comply with these requirements and their Programmes shall form an integral part of the overall Project Programme.
13.1.2
Cost Control
The Project Manager and Administration Manager shall establish and control a site cost control system and cost code structure in consultation with the Head Office Project Financial Controller. Site costs shall be monitored, controlled and reported by the Administration Manager. A monthly financial report shall be prepared and approved by the Project Manager. Site Personnel shall provide update information to the Administration Manager.
13.1.3
Progress Claims
Progress Claims shall be approved by the Project Manager and submitted to the Project Financial Controller for submission to the Customer.
13.1.4
Contractor Progress Claims
Contractor Progress Claims shall include a signed progress verification sheet and be reviewed and approved by the Project Manager.
13.1.5
Variations
Variations and any activities that may constitute a variation shall be recorded on the Site Variation Register, approved by the Project Manager and submitted to the Project Financial Controller for submission to the Customer.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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13.1.6
Petty Cash
Petty cash is only implemented on a project where it is deemed appropriate, it must be approved by the Financial Director. Where petty cash is implemented on a project, A08.04 Petty Cash Management is to be used.
13.2 B03.02 A08.04
Related Procedures Project Planning and Scheduling Petty Cash Management
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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14.
Process Control
ALSTOM’s role in meeting project and Contract requirements is that of a Subcontractor which includes design, procurement, inspection, installation, commissioning testing and warranty. While ALSTOM maintains overall contractual responsibility with the Customer, the specific responsibility for manufacture, supply, delivery, construction, installation, commissioning and warranty also rests with the relevant Subcontractors and is detailed in the relevant procurement documentation. Subcontractors shall detail in their respective Quality Plans the process control procedures for their scope of work. Processes which directly affect quality shall be identified and planned for all phases of the work. These processes shall be carried out under controlled conditions. ALSTOM processes include, but are not limited to: a. Quality Management; b. Safety Management; c. Environmental Management; d. Contract Review and Consolidation; e. Planning; f.
Communication;
g. Design, Design Co-ordination, Review, Verification and Validation; h. Design Concession and Change Control; i.
Procurement and Sub-contracting;
j.
Inspection and Testing;
k. Installation; l.
Commissioning and Performance Testing;
m. Finance; n. Audits and Audit Surveillance; o. Document Control; p. Records; q. Handover, and r.
14.1
Warranty.
Identification of Special Processes (AS/NZS ISO 10005 5.14)
Special manufacturing/ALSTOM inspection processes shall be identified as part of the design output where appropriate. Such processes shall be documented on the relevant engineering drawing or documented separately as Instructions, and shall be accomplished under appropriate controlled conditions by appropriately qualified personnel. Where necessary, personnel qualifications and corresponding personnel qualification records shall be maintained, together with any special equipment certification and calibration records and completed and signed ITPs.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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14.2
Manufacturing Methods
Manufacturing shall be carried out in accordance with codes nominated in the Contract specification and ALSTOM standards nominated in Purchase Order(s) and associated drawings and specifications.
14.3
Welding Operator Certification
All welders and weld procedures are to be qualified with respect to the Contract ITP and documentation provided for approval to ALSTOM prior to commencement of work.
14.4
Inspection Certificates
All fabricated items require an inspection certificate or, where inspected by the Customer or Third Party, a copy of their Inspection release certificate before dispatch, except where the dispatch of the products prior to final inspection has been approved by the ALSTOM Project Manager or Nominee. In this instance, final inspection and rectification of any deficiencies will be conducted at site by the appropriate Subcontractor to certify acceptance of the product. Evidence of non-acceptance shall be a completed Non-conformance Report (NCR).
14.5
Installation
Installation shall be carried out in accordance with certified Contract drawings, installation ITPs, installation instructions and approved SOPs. SOP ‘B07.01 Site Establishment and Installation’ refers to ALSTOM personnel activities at site.
14.6
Control of Commissioning and Testing
Where contracted to perform commissioning activities, Commissioning and Testing by ALSTOM shall be carried out as specified in the Commissioning ITPs, in line with SOP ‘B08.01 Commissioning’ and the specific requirements of the Contract. Subcontractors, in commissioning their plant and equipment, shall do so to established and approved ITPs and procedures.
14.7
Project quality system review
The Quality System is reviewed during regular site meetings which, as well as covering project matters, address: s. Any incidents including injuries reported since the last meeting; t.
Accident figures for area being reviewed;
u. Any customer complaints reported since the last meeting; v. Any audits and corrective actions raised, including their status; w. Significant nonconformances and estimated costs; x. Performance against objectives set for the area reviewed, and y. These meetings are minuted and actions identified and followed up by the delegated personnel. The implementation and review of the management systems are also addressed in project reports, prepared in accordance with the Contract requirements but usually monthly for significant projects. These reports cover system implementation, non-conformances, audits and corrective actions, and incidents. They are prepared for relevant circulation and for review by project and department management. © ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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14.8
Related Procedures
B03.02 B03.02.01 B03.02.02 B03.04 B03.04.01 B03.04.02 B03.04.03 B03.04.04 B03.04.05
Project Planning and Scheduling S-curves Planning & Scheduling Project Implementation Project Reviews Project Cost Control Accounting for Variations Recognition of Sales & Gross Margin Warranty Provision
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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15.
Identification and Traceability (AS/NZS ISO 10005 5.14)
15.1
Identification
The extent of Identification of Contract specific documentation and products/materials shall in accordance with SOP ‘B06.02 Identification and Traceability’, wherein all contract related documents, products (where practical) or service shall be identified with a unique Number.
15.2
Traceability
Traceability, other than that described herein is not required by this contract except to satisfy regulatory requirements and codes, where applicable. The extent of traceability required shall be defined in the product specification document attached to the Purchase Order.
15.3 B06.02
Related Procedures Identification and Traceability
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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16.
Customer Supplied Products or Services
Where products are supplied by the Customer the following shall be observed: a. Any products that may be supplied by the Customer will be examined upon receipt at the Site for completeness, proper type and any transportation damage, in accordance with SOP ‘B06.01 Inspection and Testing’, and b. Damaged products will be notified in writing to the Customer Control of these products after receipt will be in accordance with SOP ‘B06.01 Inspection and Testing’, wherein safe keeping, identification and traceability is assured.
16.1 B06.01 B06.02 B06.03
Related Procedures Inspection and Testing Identification & Traceability Inspection & Test Status
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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17.
Handling, Storage, Packaging, Preservation and Delivery (AS/NZS ISO 10005 5.16)
Where ALSTOM has a direct responsibility for handling and storage of equipment to and/or at the site, this shall be performed in accordance with SOP ‘B05.03 Handling, Storage, Packaging and Delivery’.
17.1
Handling
Items and products received at ALSTOM premises or site shall be handled in a manner that avoids damage or deterioration.
17.2
Storage
Receipt of goods at ALSTOM’s off site premises shall be limited to minor proprietary goods that can be easily manhandled and only when strictly necessary. At site, goods shall be stored in a designated storage area or lockable compound, where practical, to prevent loss or damage and where necessary suitably protected against climatic conditions and deterioration. In all cases goods shall be suitably tagged or marked for identification purposes. Goods stored shall be documented and shall be subject to regular monitoring in order to establish their continuing fitness for use. All plant and equipment installed shall be protected to ensure no deterioration occurs prior to handover to ALSTOM/Customer. Nonconforming goods shall be identified, segregated where practical and processed per requirements of SOP ‘A03.05 Non-conformance’.
17.3
Packaging, preservation, marking and delivery
Packaging of goods for delivery shall adequately protect the goods against damage and deterioration. Inspection ALSTOM prior to dispatch shall be carried out where nominated on the relevant ITP. Appropriate delivery documentation shall be provided according to specified requirements.
17.4
Waste
ALSTOM’s waste control measures comply with the relevant State regulatory requirements, as such site waste, for which ALSTOM is responsible, shall be controlled and or disposed as defined in SOP ‘A05.03.02 Waste’ or where required as defined in the Customers on-site procedures.
17.5
Related Procedures
A05.03 A05.03.01 A05.03.02
Handling Storage Packaging and Delivery Storage Requirements for Hazardous Material Control of Waste
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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18.
Control of Nonconforming Product (AS/NZS ISO 10005)
18.1
Nonconformance Reporting
Control of Non-conformances shall be as defined in SOP ‘A03.02 Control of Non-conformances’. The general steps of the procedure are as follows: a. Record the non-conformance discovered on the NCR section of the Actions Database, or if computer access not available then, Form A03.F05; b. Identifying and holding products subject to an NCR in a designated holding area. For bulky or large nonconforming products which cannot readily be segregated, the area(s) of nonconformity shall be marked such that it is readily visible to any other user. c. Recommendation and review of disposition/rectification by responsible parties; d. Corrective action to correct the non-conformance; e. Re-inspection of the reworked or repaired product; f.
18.2
If required obtain Customer approval for a Concession;
NCR Sources
The main sources of non-conformance may arise from but are not limited to: a. Receipt inspection; b. Manufacture, disassembly, assembly or construction processes, and c. Final inspections and test process.
18.3
Disposition of Nonconforming Products
Disposition of non-conformances may be achieved by: a. Rework to meet specified requirements; b. Acceptance with or without repair by concession; c. Regarding for alternative use, and d. Rejection/disposal.
18.4
Identification of Items Subject to NCR
Nonconforming items or products shall be appropriately identified, segregated and/or quarantined to prevent inadvertent use until appropriate disposition has been effected. Relevant parties such as the Project Manager/Engineer and Customer shall be informed that an item is subject to an NCR.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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18.5
Resolution of ALSTOM NCR’s
Where the non-conformance is related to ALSTOM the personnel responsible for that activity (in conjunction with the Project Safety/Quality Representative), are responsible for: a. Investigating the cause of non-conformances and approving and implementing the proposed corrective actions needed to prevent their recurrence b. Evaluating the sources of the non-conformances by analysing relevant information as applicable, procedures, work instructions, concessions, quality records and customer complaints, in order to detect and eliminate further and potential causes of non-conformances.
18.6
Resolution of Other Parties NCR’s
Where the non-conformance is related to other parties, the Project Safety/Quality Officer, in conjunction with the Project Manager or nominee is responsible for: a. Expediting the resolution of the non-conformance; b. Obtaining acceptance and approval of the corrective action from the relevant personnel and/or parties as required; c. Verifying implementation and effectiveness of corrective action through audit/surveillance/inspection as appropriate. d. Notification(s) of actual or potential non-conformances by the Customer shall be processed in accordance with SOP ‘A03.03 Corrective Action’.
18.7
Corrective & Preventive Action
Corrective and Preventive Action shall be carried out in accordance with SOP ‘A03.03 Corrective Action’, wherein: e. Non-conformances are reviewed to determine their causes and develop appropriate corrective and preventive action; f.
Potential causes of non-conformances are identified and corrective action developed to prevent the occurrence;
g. Corrective action is implemented and the effectiveness is followed up; h. Corrective action from results of audits is implemented effectively. The need for Corrective Action is normally identified through:
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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18.8 A03.02 A03.03 B10.01
iv.
Non-conformances
v.
Internal audits
vi.
External audits and Customer/Third Party audits.
vii.
Actions identified are logged on the Actions Database from the NCR or CAR form.
Related Procedures Control of Non-conformances Corrective and Preventive Action Control of Records
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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19.
Measurement Analysis and Improvement (AS/NZS ISO 10005)
19.1
Inspection, Measuring and Test Equipment
The calibration controls to be used for test equipment shall be as defined in SOP ‘A05.01 Control of Measuring and Test Equipment’. Subcontractor’s test equipment calibration work practices are to be approved at the time of Supplier Assessment or at the initial inspection visit by the Inspector. Subcontractors shall ensure adequate systems and procedures are established, implemented and maintained to satisfy contract requirements. For erection at site, evidence of current calibration status will be examined by ALSTOM prior to commencement of work. No work shall be carried out with un-calibrated testing and measuring equipment where such measurements are required to determine equipment status. The requirement will be subject to audit.
19.2
Inspection and Testing
Inspection and testing requirements are referenced in SOP ‘B06.01 Inspection and Testing’. Subcontractors shall detail their inspection and testing requirements in their respective Quality Plans (to be submitted for approval). Inspection and Testing for the project shall be carried out for: a. Incoming Goods Inspection; b. In Process Inspection; c. Final Test and Inspection; d. Installation Inspection and Tests, and e. Commissioning Inspection and Tests. ALSTOM’s role will be predominantly an audit surveillance role on Sub-contractor’s activities. Product conformance will be indicated on the Subcontractor’s ITPs. ALSTOM shall mark-up Subcontractors’ ITPs with Hold & Witness Points as required to verify conformance to project requirements. These ITPs will be stamped/approved prior to return to Subcontractors for use. ALSTOM may appoint qualified inspection personnel to carry out inspection or surveillance activities as required. Subcontractors, as part of their Quality Plan, shall detail the methods for inspection and tests both at their own premises and on site.
19.3
Inspection and Test Plans
Before commencement of work including site work, Subcontractors shall supply ITPs for their scope of work for approval and shall incorporate the elements of ITP Guidelines as a minimum and shall form a requirement of the purchase order. All ITPs shall be technically reviewed by the appropriate engineer and quality officer and approved by the Project Manager prior to issue for use. ITP’s shall contain at least the following information: © ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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a. Applicable steps/sequence of activities to effectively control and complete the process; b. Verifying procedure to be used and the acceptance criteria for each step/sequence; c. Responsibility for each inspection or test; d. Columns for inspection and test points for Subcontractor and/or their Subcontractors, ALSTOM and Regulatory/Statutory bodies as applicable; e. Resultant Records applicable to each step/sequence as applicable; f.
ITP steps/activities shall be progressively signed off as the relevant inspections and tests are completed and accepted. All pertinent records shall be available prior to signing off an ITP, unless agreed/provided for otherwise (e.g. positive recall provisions for urgent use items);
g. Registers of ITPs shall be developed for each phase, Subcontract or group of activities as appropriate and provided to ALSTOM for reference; h. ALSTOM shall maintain an ITP Register for monitoring purposes, and i.
19.4
Notification to ALSTOM of the timing of Witness and Hold Point shall be carried out in accordance with the requirements specified in the Purchase Order.
Incoming Goods Inspection
Incoming Goods Inspection shall be carried out by ALSTOM and its Subcontractors and Suppliers at their premises and/or on site as appropriate and as detailed on ITPs, to verify compliance with procurement and project requirements: a. Products shall not be used until incoming inspections are carried out; b. Nonconforming products shall be held from use pending disposition and corrective action and recorded on the Non-conformance Report, and c. The Goods Received Report or approved equivalent, shall be used by Subcontractors to record incoming inspections carried out on goods received at Site.
19.5
In-Process Inspection
Manufacturing and pre-dispatch inspection and testing shall be carried out by the prime Subcontractors and or their Subcontractors and Suppliers in accordance with ITPs submitted prior to manufacture commencing. Surveillance, witness and hold activities will be in accordance with the requirements marked up on the relevant ITP. Refer to SOP ‘B06.01 Inspection and Testing’ wherein: a. The level of inspection shall be as per ITP and signed off accordingly; b. Products shall be held until Hold Point inspections are carried out, and c. Nonconforming products shall be held pending disposition and corrective action as per Incoming Inspections.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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19.6
Final Inspection (and Handover)
As detailed by the relevant ITPs, any specified final inspection to be conducted by ALSTOM shall be at the point of handover of the equipment. Progressive completion of ITPs and verification of associated records shall be undertaken by the Subcontractor (unless otherwise noted on the ITP), such that at the point of handover to ALSTOM, records of completion and compliance for all Inspections and Tests are available for verification. For items of manufacture at a Subcontractor’s premises, final inspection by ALSTOM shall be carried out in accordance with SOP ‘B06.01 Inspection and Testing’, prior to release/acceptance. Inspection upon completion of installation for site work shall follow the same SOP, wherein the level of Inspection shall be as per ITP and signed off accordingly. Non-conformances as a result of unacceptable products shall be recorded on the Non-conformance Report and appropriate review and corrective action shall be taken before final acceptance.
19.7
Installation/Commissioning Inspection & Testing
Installation/Commissioning inspection and testing shall be carried out by the relevant Subcontractors and Suppliers in accordance with ITPs submitted. ITP approval shall be provided prior to installation/commissioning commencing. Surveillance, witness and hold activities by the relevant parties will be in accordance with the requirements marked up on the relevant ITP.
19.8
Inspection Release Certificate
Where indicated on the ITPs, an “Inspection Certificate” shall be issued by ALSTOM upon completion. Dispatch of those items/product nominated shall not proceed until this documentation has been issued.
19.9
Inspection and Test Records
Inspection & Test Records shall be produced as inspection & tests progress. These records shall be collected and assembled into MDRs for submittal to ALSTOM for review and ALSTOM approval. MDRs shall be prepared and presented as specified in Contract Manufacturer’s Data Report (MDR) Requirements.
19.10
Inspection Status
The means for providing assurance that the required inspections and tests on products have been carried out shall be by: d. Signed ITPs; e. Inspection Certificates; Relative to that product, and where necessary by physical stamping, labelling, tagging (as required) of that product or parts thereof, as per SOP ‘B06.01 Inspection and Testing’, in order to indicate final acceptance. Nonconforming product/items shall be separately identified / tagged and where practical, segregated from point of use. Subcontractors shall detail methods of establishing Inspection & Test Status in their Quality Plans.
19.11 A05.01 B06.01 B06.03
Related Procedures Management of Measuring and Test Equipment on site Inspection and Testing Inspection and Test Status
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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20.
Audits (AS/NZS ISO 10005 5.19)
Quality Audits shall be performed in accordance with SOP ‘A07.01 Audits’. These will be internal (and external for subcontracted work) and shall be carried out in accordance with the project audit schedule and as considered necessary. Subcontractors shall detail audit requirements in their Quality Plans and shall provide their own detailed audit schedule covering both internal and external audits on their subcontractors.
20.1
Audit Schedule
An Audit Schedule shall be established and progressively updated at appropriate intervals. Separate schedules shall be developed for internal and external audits. These schedules shall be established on the status and importance of each activity or subcontract and shall be varied according to the adequacy of the results. Follow-up audits may be performed where Corrective Action Requests (CARs) have been issued.
20.2
Audits
Audits may be carried out by the Project Safety/Quality Officer, or may be delegated to other appropriately qualified independent personnel as necessary. CARs raised during the audits shall be processed and followed up in accordance with SOP ‘A07.01 Audits’. CARs shall only be closed out after corrective actions have been verified and accepted. Audit records shall be maintained by the Project Safety/Quality Officer and distributed, as a minimum to: a. Director Project Management b. Project Manager c. Project Safety/Quality Officer d. Auditee(s) - Internal or external.
20.3 A07.01
Related Procedures Audits
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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21.
Procedure List
The following, but not limited to, list of ALSTOM procedures are used by ALSTOM to complete the contract works as detailed within this PQP: 1. A03.02 Control of Non-conformances 2. A03.03 Corrective and Preventive Action 3. A04.01 Document Control 4. A04.01.01 Control of System Procedures and Forms Control of Standards & Publications 5. A04.02 6. A04.08 Installing Databases from CD 7. A05.01 Management of Measuring and Test Equipment on site 8. A05.03 Handling Storage Packaging and Delivery 9. A05.03.01 Storage Requirements for Hazardous Material Control of Waste 10. A05.03.02 11. A06.01 Training 12. A06.01.01 Site Induction 13. A06.01.02 Tool Box Meetings 14. A06.05 Consultation Work Breakdown Structure 15. B00.02.01 16. B02.02 Contract Review 17. B02.03 Contract Handover 18. B02.02.01 Order Acceptance and Notification for Power Services 19. B03.01 Contract Administration 20. B03.02 Project Planning and Scheduling 21. B03.02.01 S-curves 22. B03.02.02 Planning & Scheduling 23. B03.04 Project Implementation 24. B03.04.01 Project Reviews 25. B03.04.02 Project Cost Control 26. B03.04.03 Accounting for Variations 27. B03.04.04 Recognition of Sales & Gross Margin 28. B03.04.05 Warranty Provision 29. B04.01 Design 30. B05.01 Subcontractor Assessment 31. B05.01.01 Supplier Performance Reviews 32. B05.01.02 Subcontractor safety and Environmental Management 33. B05.02.03 Power Service Procurement 34. B06.01 Inspection and Testing 35. B06.02 Identification & Traceability 36. B06.03 Inspection & Test Status 37. B10.01 Control of Records 38. B10.F01 Project Filing System © ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.
Annex 1 – Position Descriptions
The following generic positions descriptions apply to the positions detailed on the attached project organisation chart, refer Section 25.
22.1
Project Manager Scope: This project is directed and controlled by the Project Manager. Reports to: Director Project Management Responsibility: a. Overall direction, control and execution of the project in a cost effective manner and in compliance with the project’s commercial, technical, quality, safety and environmental requirements. b. Communication with customer and Independent Engineer. c. Selection of project team personnel. d. Financial progress reporting (monthly). e. Project reporting (internal/external). f. Project contractual compliance including changes to scope. g. Project quality and customer satisfaction. h. Project Environmental, Health & Safety (EH&S) performance. i. Personnel & Industrial Relations. j. Project environmental impact management. Authority: a. To select, appoint and change project team personnel. b. To approve the selection and appointment of subcontractors, consultants or partners. c. To approve financial commitment within the project budget. d. To obtain agreed resources necessary to achieve the project goals and objectives. e. To negotiate variations to the contract. Accountability: a. Achievement of the project goals and objectives including the Quality and EH&S policies. b. Project progress and reporting.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.2
Procurement Manager/Officer Scope: Procurement of items and equipment as required, to supplement the scope of supply by the major plant Subcontractors and as directed by the Project Manager. Reports to: Project Manager. Responsibilities: a. Ensuring the timely and cost effective procurement of plant, equipment and services to meet contract requirements. b. Preparation and issue of enquiries and subsequent assessment of tenders. c. Assessment of subcontractors and their quality systems (in conjunction with the Project Safety/Quality Officer). d. Negotiation, letting and monitoring of purchase orders. e. Administer purchase order variations. f. Disposition of supply non-conformances and develop, implement an monitor corrective and preventative actions ( in conjunction with the Project Safety/Quality Officer). g. Assisting with the preparation, review and monitoring of Inspection and test plans. h. Obtaining vendor data requirements and Manufacturer Data Reports (MDRs) as specified in purchases. i. Special procurement tasks as required by the Project Manager. j. Ensure timely processing of invoices. Authority: a. Initiate and control procurement activities delegated by the Project Manager to meet quality, programme and cost requirements. b. Authorize purchase orders up to the value as delegated by the Project Manager. c. Control further processing and delivery of non-conforming product until the deficiency or unsatisfactory condition has been corrected. d. Initiate action to prevent the occurrence of any supply nonconformities relating to items and equipment ordered. e. Verify the implementation of solutions to supply nonconformities. Accountability: a. On time and on budget procurement as defined by the Project Manager. b. Co-ordination of subcontractors and material logistics with respect to the project programme. c. On time processing of invoices and feedback to project manager on variations and price.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.3
Programmer/Scheduler Scope: Develops the programme and schedule of tasks for the project and updates on direction. Reports to: Project Manager Responsibilities: a. Develop, monitor and update the overall project programme to meet all contractual requirements and project milestones.. b. Develop lower level detail, summary and look-ahead programmes. c. Assist in gaining approval of the programme within the contract time constraints. d. Monitor the progress of the works by obtaining programme updates from sub-contractors and provide regular updates in appropriate detail to the Project Manager and other project team members. e. Monitoring of progress and the effect of changes to the contract. f.
Evaluate all data from engineering, procurement, manufacturing and construction in order to assess overall progress and identify and report deviations from the programme to the Project Manager.
g. Identify and predict potential problems as early as possible in order to allow effective corrective action to be taken. h. Evaluate the effect of and schedule variation work and advise the Project Manager. i.
Re-schedule activities in order to take into account delays and variations following agreement with the Project Manager.
j.
Prepare progress status reports for submission to the Project Manager.
k. Ensure that all personal work carried out is in accordance with the contract, quality assurance requirements and other relevant procedures applicable to the project. l.
Participate, where required, in the disposition of nonconformities relating to the progress of works.
Authority: Control further processing of nonconformities relating to the process of programming/scheduling activities. Accountability: Accurate and timely project programmes to meet contract and project milestones.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.4
Financial Controller Scope: Cost control of the project, ensuring conformity with the ALSTOM financial and commercial policies and practices. Reports to: Project Manager and Financial Controller Thermal Service. Responsibilities: a. Accounting. b. Month end close. c. Prepare cost control review on JDE and Excel. d. Predict revenue and cash flow. e. Correct posting errors and resolve queries. f.
Maintain invoice register for contract and variation income.
g. Liaise with the Financial Controller Thermal Service to ensure conformity with the ALSTOM policies and procedures in relation to the financial and commercial aspects of the project and their implementation on the project. Reporting: a. Prepare project report to management in conjunction with the Project Manager. b. Prepare for and participate in the Monthly Project Review Meetings, record and distribute the minutes. Contract Administration: a. Maintain purchase order register. b. Reconcile all project progress payments to sub-contractors and the customer. c. Ensure all invoices are in accordance with purchase order and that materials have been delivered and inspection reports issued and approve invoices for payment. d. Cash flow management together with cash flow projections and resultant financing gains/losses. e. Maintain records of bank guarantees and/or retention, insurances etc. f.
Maintain foreign exchange register and manage project foreign exchange.
g. Collect, check and countersign all office staff timesheets. Site Administration: a. Collect and check all site staff timesheets. b. Site petty cash (where implemented) c. Maintain site records. © ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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Progress Claims: a. Preparation and submissions of progress and variation claims (including all necessary support documentation). b. Liaise as necessary with Financial Institution and Customer in support of above activity. Authority: a. Initiate action to prevent the occurrence of nonconformities relating to cost control b. Control further processing of cost control nonconformities until the unsatisfactory condition has been corrected. Accountability: a. Accurate and complete reporting in accordance with the ALSTOM policies and procedures in relation to the financial and commercial aspects of the project and their implementation on the project. b. Additional reporting as defined herein. c. All reporting to be progressed and be finalised by the monthly dates set by the Financial Controller, Customer Service.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.5
Site Manager Scope: Management of site construction, commissioning, performance testing, quality & EH&S and industrial relations. Reports to: Project Manager. Responsibilities: a. Ensuring that the plant is constructed in accordance with ALSTOM requirements. b. Ensuring that the plant is constructed in accordance with the relevant Site Agreement. c. Site management and co-ordination of ALSTOM personnel and contractors d. Management and co-ordination of resources to ensure the programme of work is achieved. e. Adherence to the EHS policy and requirements per project SEMP. f. Adherence to the Industrial Relations/Employee Relations Plan. g. Quality requirements as specified in the Project Quality Plan (PQP) and procedures for site works. h. Identify and record any nonconformities relating to products or processes. i. Day to day interfaces with the customer, subcontractors, local authorities and other involved parties, on reporting, etc. j. Advising the Project Manager of potential shortfalls in the supply of plant or equipment to the site. k. Report progress and cost control regularly to the Project Manager. l. When assigned shall also assume the project Safety Adviser role/Inspector role (refer project organisation chart). Authority: a. Purchase from site of equipment/goods/services in accordance with provisions of the Contract and this Plan. b. Control further processing or installation of nonconforming products until the deficiency or unsatisfactory condition has been corrected. Accountability: a. Overall programme and quality of construction at site. b. Overall implementation of the project Safety and Environmental Management Plan (SEMP). c. Overall implementation of the Industrial Relations Management Plan. d. Provisions of adequate EH&S resources, services and facilities at site. e. Overall safety performance of the project at site.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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Inspectors (Technical QA) Scope: Quality verification of products and services through physical inspection. Reports to: Project Quality/Safety Officer or Quality Manager as applicable, refer project organisation chart. Responsibilities: a. Quality verification and the physical witnessing, inspection, testing, acceptance or rejection of items, equipment and components in accordance with the Inspection and Test Plans (ITPs) for the Contract. b. Ensure that all personal work carried out is in accordance with the contract, quality assurance requirements and other relevant procedures applicable to the project. c. Disposition of non-conformances and develop, implement and monitor corrective actions as appropriate. d. Assisting with the preparation, review and monitoring of ITPs. e. Ensuring that the procedures applied by the contractors are adequate for effective control of quality for their scope of manufactured work. f. Control and verification of corrective action when non-conformances are identified. g. Preparing and providing records of inspection and test. h. Verify on the relevant non-conformance report, the implementation of solutions to nonconforming product and re-inspection and acceptance of same. Authority: a. Accept or reject items, equipment and components during the manufacturing and installation stages of the Contract in accordance with the ITPs for the items or products. b. Control further processing and or delivery of non-conforming product until the deficiency or unsatisfactory condition has been corrected and accepted. Accountability: a. Quality verification of products and services through physical inspection of work activity and records of work.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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Quality Officer/Representative Scope: Project Management representative on project matters relating to quality assurance (QA). Reports to: a. Project Manager (direct reporting line). b. Functionally reports to the corporate Quality Manager. Responsibilities: a. Identification and preparation of contract specific Work Instructions and Inspection Test Plans (ITPs) as necessary. b. Regular review and updating when necessary of the projects quality system and related Project Quality Plan (PQP). c. Implementing the quality requirements of the PQP. d. Training project team members in the project quality system and the PQP. e. Auditing and monitoring the requirements of the PQP and project quality system. f. Ensure subcontractor/supplier quality requirements are met through ITPs, subcontractor/supplier assessments and quality audits. g. Carrying out internal and external quality audits. h. Liaise with Quality Manager to ensure conformity with corporate quality requirements, and provide assistance on corporate quality assurance matters. i. Monitor the effective operation of and corrective action systems through Non-conformance Reports (NCRs) and Corrective Action Requests (CARs). j. Participate, where required, in the disposition of non-conformances and in the development, implementation and monitoring of corrective actions. k. Review quality records and review and approval of Manufacturer Data Reports (MDRs) in conjunction with other designated personnel. l. Ensure inspection tasks are monitored and recorded and initiate appropriate corrective actions where necessary. m. Ensure all work is carried out in accordance with the Contract QA requirements and other relevant procedures applicable to the project, through surveillance. n. Special tasks as required by the Project Manager / Site Manager. o. Providing monthly reporting to Quality Manager on QA activities. Authority: a. Resolve all project QA matters. b. Verify and approve project corrective and preventive actions relating to nonconformities. Accountability: a. Implementation and maintenance of the project quality system.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.8
Safety Adviser Scope: Safety and Environmental Management Reports to: a. Project Manager (direct reporting line). b. Functionally reports to the corporate EH&S Manager. Responsibilities: a. Co-ordinate the implementation of the project Safety and Environmental Management Plan (SEMP). b. Carry out regular inspections of the work area with the respective project area members. c. Verify the effective implementation of the systems through planned audits. d. Assist at regular training talks, safety inductions and assist supervisors to develop area specific and generic tool box meeting topics. e. Provide advice on the development of Job Safety Environmental Analysis’ (JSEA’s) and operating standards. f. Advise supervisory staff and employees in the implementation of strategies to identify and control potential hazards. g. Develop and implement the project safety training programme. h. Provide assistance to supervisors with accident/incident investigation. i. Prepare significant accident/incident reports and co-ordinate investigation. j. Co-ordinate rehabilitation activities with the Site Manager. k. Attend pre-start meetings for each new subcontractor. l. Provide reports for project management advising of trends on site and provide recommended action plans. m. Conduct informal and formal safety inspections and audits of the project EH&S system. n. Review Subcontractor safety performance. o. Conduct the project specific safety inductions. p. Lead safety improvement meetings. q. Attend and participate in project safety tool box meetings. r. Be familiar with all relevant statutory requirements and industry practices. s. Work with the respective supervisors to overcome day to day problems in safety and environmental that may occur. t. Conduct audits against the requirements of the project SEMP. u. Managing activities within budget. Authority: a. Control further processing of nonconformities relating to unsafe and environmentally unacceptable practices.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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Accountability: a. Reporting performance against project goals and objectives including: b. Lost Time Injuries (LTI). c. Safety statics. d. Environmental NCR’s/incidents. e. Operations within budget.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.9
Supervisor Scope: Control and execution of the work in a cost effective manner. Reports to: Site Manager / Project Manager Responsibilities: a. Ensuring the functional and quality aspects required and specified are attained. b. When assigned shall also assume the Inspector role (refer project organisation chart). c. Assisting to define technical interfaces and reviewing technical documentation. d. Planning and implementation of assigned installation/ erection/ commissioning. e. Assisting with the preparation of technical and vendor data requirements of purchasing documentation as required. f. Ensure that all personal work carried out is in accordance with the Contract, quality assurance (QA) requirements and other relevant procedures applicable to the project. g. Liaison with the Project Manager and subcontractors as assigned. h. Participate, where required, in the disposition of non-conformances and develop, implement and monitor corrective actions. i. Assisting with the preparation, review and monitoring of Inspection and Test Plans. j. Special tasks as directed by the Boiler Superintendent, Site Manager and Project Manager. k. Co-ordinate with other faculties, consortium partners on site to ensure expedient execution of works. l. Maintaining Site ITP’s. m. Scheduling, controlling and ensuring inspection, testing and commissioning tasks are carried out in accordance with site ITP’s. n. Organising and participating in Site quality and safety audits according to schedule. o. Inspect the works for compliance with the contract, relevant specifications and codes. p. Verify/witness inspection and test activities in accordance with Contractor/supplier ITP requirements. q. Issue and disposition of Action Requests for non-conformances. r. Issue of Release Notes where applicable. Authority: a. Supervision of allocated personnel. b. Accept or reject items, equipment and components during the manufacturing and installation stages of the Contract in accordance with the Inspection and Test Plans for the items or products. c. Control further processing and or delivery of non-conforming product until the deficiency or unsatisfactory condition has been corrected and accepted. Accountability: a. Quality verification of products and services through physical inspection. b. Implementation of the project Occupational, Health and Safety Plan for the relevant area of responsibility.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.10
Site Administration Officer Scope: Document Control Reports to: Site Manager / Project Manager Responsibilities: a. Implement the necessary procedures to provide a satisfactory and efficient documentation control system for the control and management of all project documents. b. Establishing and maintaining a document filing system. c. Planning and supervising the document flow to/from all parties. d. Issue all documents and drawings, originate and verify transmittals, verify receipt of the documents issued, record the issuing data, monitor and maintain these records. e. Maintenance and control of specifications, codes and standards according to the Contract or as otherwise approved. f. Maintenance and upkeep of relevant procedures applicable to the project and revisions thereof. g. Provide project management with exceptions report indicating those documents which were not issued on schedule or those with changed issue date. h. Establish and maintain a database to record and track all project correspondence. i. Provide exception reports identifying correspondence which has passed the required response date. j. Ensure that obsolete/superseded quality documents are identified and removed from all areas of distribution and use. k. Notify the Project Manager of any deficiencies in the system and the corrective actions to improve the system. l. Participate, where required, in the disposition of non-conformances and develop, implement and monitor corrective actions. m. Co-ordinating the receipt of MDRs from Suppliers and their safe maintenance. n. Undertake special tasks as directed by the Project Manager. Authority: a. Control all documentation. b. Control further processing of non-conformities relating to document control practices. Accountability: a. Identification, distribution, filing and traceability of project documentation
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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23.
Annex 2 – Safety and Environment Management System
The project safety and environmental management system is fully defined in the project Safety & Environmental Management Plan (SEMP).
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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24.
Annex 3 – Applicable Legislation
The following state/territory and federal legislative and or regulatory codes shall apply to this Contract: Add regulatory codes / legislation list here
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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25.
Annex 4 – Project Organisation Chart
Project Manager Name
Engineering Support Name
Industrial Relations Manager Name
Site Manager Name
Contractors
Site Support
Name Role
Mechanical Names
Name Role
Electrical Names
Name Role
Fitters Names
Name Role
Riggers Names
Name Role
Welders Names
Planning Department
Workshop Support
Document Control
Project Quality Officer/Engineer
Project Safety Officer/Engineer
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Management System Location:
Template Owner:
Template Author:
Template Number:
Template Revision / Date:
Industrial Processes
Stephen Emmas (rewritten 2011)
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Template Original Release Date:
Template Type :
Page:
Darryl Dean
03-08-2003
Form
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Quality Manual
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A01.M01
A01 Responsibility Authority Organisation
This document is authorised by the Process Owner and the Industrial Processes Department Control and maintenance of this document is as per A04.01.01 Control of System Procedures & Forms, check system for latest issue.
A01.F07 Project Quality Plan - PQP <ENTER CUSTOMER NAME & DETAILS HERE>
<ENTER PROJECT TITLE & CONTRACT NUMBER HERE>
Project Quality Plan for Project Name & Number Document Number: Project #-PQP-001 Revision: A Date of Issue: 28 Feb 2012 Number of Pages: 58 Position
Name
Prepared by:
TBA
Name
Approved by:
Project Quality Officer
Name
Approved by:
Site Manager
Name
Approved by:
Project Manager
Name
Authorised by:
Quality Manager
Name
Position
Name
Customer:
Signature
Date
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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CONTENTS 1.
2.
3.
4.
5.
6. 7. 8.
9.
Document revision, distribution and definitions ........................................................................................... 5 1.1 Document Revision Status ................................................................................................................ 5 1.2 Document Distribution ...................................................................................................................... 5 1.3 References ....................................................................................................................................... 6 1.4 Abbreviations.................................................................................................................................... 6 Scope (AS/NZS ISO 10005 5.1) ................................................................................................................... 7 2.1 Project Quality Plan Scope ................................................................................................................ 7 2.2 Safety and Environment Management Plan ....................................................................................... 7 2.3 Project Scope of Work ...................................................................................................................... 7 Quality Plan Inputs (AS/NZS ISO 10005 5.2) ............................................................................................... 8 3.1 Applicable Documents ....................................................................................................................... 8 3.2 Project Quality Planning.................................................................................................................... 8 3.3 Quality Safety and Environment Policy .............................................................................................. 9 Project Management Responsibility and Organisation (AS/NZS ISO 10005 5.5) .......................................... 10 4.1 Director Project Management ......................................................................................................... 10 4.2 Project Manager ............................................................................................................................. 10 4.3 Site Manager .................................................................................................................................. 10 4.4 Project Quality Officer ..................................................................................................................... 10 4.5 Supervisors .................................................................................................................................... 10 Document Control (AS/NZS ISO 10005 5.6) .............................................................................................. 11 5.1 Document and Data Control ............................................................................................................ 11 5.2 DOCUMENT NUMBERING SYSTEM ................................................................................................. 11 5.3 Control of Project Documents .......................................................................................................... 12 5.4 Drawing Control ............................................................................................................................. 14 5.5 Project Filing System ...................................................................................................................... 15 5.6 Related Procedures ......................................................................................................................... 15 Control of Records (AS/NZS ISO 10005 5.7) .............................................................................................. 16 6.1 Quality records ............................................................................................................................... 16 Manufacturer’s Data Record ..................................................................................................................... 17 7.1 Related Procedures ......................................................................................................................... 17 Resources (AS/NZS ISO 10005 5.8) .......................................................................................................... 18 8.1 Resource management.................................................................................................................... 18 8.2 Material Resources ......................................................................................................................... 18 8.3 Human Resources ........................................................................................................................... 18 8.4 Personnel Register .......................................................................................................................... 18 8.5 Site Induction ................................................................................................................................. 18 8.6 Consultation ................................................................................................................................... 19 8.7 Industrial Relations ......................................................................................................................... 19 8.8 Related Procedures ......................................................................................................................... 19 Requirements (AS/NZS ISO 10005)........................................................................................................... 20 9.1 Contract Review ............................................................................................................................. 20
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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10.
11.
12.
13.
14.
15.
16. 17.
18.
9.2 Related Procedures ......................................................................................................................... 20 Customer Communication ......................................................................................................................... 21 10.1 Correspondence .............................................................................................................................. 21 10.2 Progress Reports ............................................................................................................................ 21 10.3 Meetings ........................................................................................................................................ 21 10.4 Related Procedures ......................................................................................................................... 21 Design and Development (AS/NZS ISO 10005 5.11) .................................................................................. 22 11.1 Design Control ................................................................................................................................ 22 11.2 ALSTOM Internal Design and Drawing ............................................................................................. 22 11.3 Design Co-Ordination ...................................................................................................................... 22 11.4 Related Procedures ......................................................................................................................... 23 Purchasing (AS/NZS ISO 10005 5.12) ....................................................................................................... 24 12.1 Procurement/Subcontract Requirements ......................................................................................... 24 12.2 Related Procedures ......................................................................................................................... 27 Production and Service Provision (AS/NZS ISO 10005 5.13) ...................................................................... 28 13.1 Product realisation.......................................................................................................................... 28 13.2 Related Procedures ......................................................................................................................... 29 Process Control ........................................................................................................................................ 30 14.1 Identification of Special Processes (AS/NZS ISO 10005 5.14) ........................................................... 30 14.2 Manufacturing Methods .................................................................................................................. 31 14.3 Welding Operator Certification ........................................................................................................ 31 14.4 Inspection Certificates..................................................................................................................... 31 14.5 Installation ..................................................................................................................................... 31 14.6 Control of Commissioning and Testing ............................................................................................. 31 14.7 Project quality system review .......................................................................................................... 31 14.8 Related Procedures ......................................................................................................................... 32 Identification and Traceability (AS/NZS ISO 10005 5.14) ........................................................................... 33 15.1 Identification .................................................................................................................................. 33 15.2 Traceability ..................................................................................................................................... 33 15.3 Related Procedures ......................................................................................................................... 33 Customer Supplied Products or Services .................................................................................................... 34 16.1 Related Procedures ......................................................................................................................... 34 Handling, Storage, Packaging, Preservation and Delivery (AS/NZS ISO 10005 5.16) .................................. 35 17.1 Handling ........................................................................................................................................ 35 17.2 Storage .......................................................................................................................................... 35 17.3 Packaging, preservation, marking and delivery ................................................................................ 35 17.4 Waste ............................................................................................................................................ 35 17.5 Related Procedures ......................................................................................................................... 35 Control of Nonconforming Product (AS/NZS ISO 10005)............................................................................ 36 18.1 Nonconformance Reporting ............................................................................................................ 36 18.2 NCR Sources................................................................................................................................... 36 18.3 Disposition of Nonconforming Products ........................................................................................... 36 18.4 Identification of Items Subject to NCR ............................................................................................. 36
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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19.
20.
21. 22.
23. 24. 25.
18.5 Resolution of ALSTOM NCR’s .......................................................................................................... 37 18.6 Resolution of Other Parties NCR’s ................................................................................................... 37 18.7 Corrective & Preventive Action ........................................................................................................ 37 18.8 Related Procedures ......................................................................................................................... 38 Measurement Analysis and Improvement (AS/NZS ISO 10005) .................................................................. 39 19.1 Inspection, Measuring and Test Equipment ...................................................................................... 39 19.2 Inspection and Testing .................................................................................................................... 39 19.3 Inspection and Test Plans ................................................................................................................ 39 19.4 Incoming Goods Inspection ............................................................................................................. 40 19.5 In-Process Inspection ...................................................................................................................... 40 19.6 Final Inspection (and Handover) ..................................................................................................... 41 19.7 Installation/Commissioning Inspection & Testing ............................................................................. 41 19.8 Inspection Release Certificate .......................................................................................................... 41 19.9 Inspection and Test Records ............................................................................................................ 41 19.10 Inspection Status ............................................................................................................................ 41 19.11 Related Procedures ......................................................................................................................... 41 Audits (AS/NZS ISO 10005 5.19) .............................................................................................................. 42 20.1 Audit Schedule ................................................................................................................................ 42 20.2 Audits............................................................................................................................................. 42 20.3 Related Procedures ......................................................................................................................... 42 Procedure List .......................................................................................................................................... 43 Annex 1 – Position Descriptions ................................................................................................................ 44 22.1 Project Manager ............................................................................................................................. 44 22.2 Procurement Manager/Officer ........................................................................................................ 45 22.3 Programmer/Scheduler .................................................................................................................. 46 22.4 Financial Controller ......................................................................................................................... 47 22.5 Site Manager .................................................................................................................................. 49 22.6 Inspectors (Technical QA) ................................................................................................................ 50 22.7 Quality Officer/Representative ........................................................................................................ 51 22.8 Safety Adviser................................................................................................................................. 52 22.9 Supervisor ...................................................................................................................................... 54 22.10 Site Administration Officer .............................................................................................................. 55 Annex 2 – Safety and Environment Management System........................................................................... 56 Annex 3 – Applicable Legislation ............................................................................................................... 57 Annex 4 – Project Organisation Chart ........................................................................................................ 58
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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Project Quality Plan
Customer Name, Project Title, Contract No. XXXXX
1. Document revision, distribution and definitions 1.1
Document Revision Status
Rev. A
Description
Date
Original Issue
1.2
Enter date
Document Distribution
This Project Quality Plan (PQP) is distributed using QDMS (Quality Document Management System) to manage distribution and control of updates. Where server or internet access is difficult or not available, a manual form (A04.F06 Document Distribution Record) can be used, this records details of the document holders who will be updated. QDMS is a software package that Alstom subscribe to; it is used for the purpose of formally recording document transmittals and receiver acknowledgements. The software package requires user licences setup via IT. The document controller at North Ryde is the main identified user of QDMS.
Table 1 – Document Distribution Table Copy No.
Recipient
Location
1
Alstom Limited, Thermal Services
16 Giffnock Ave North Ryde, NSW, 2113
2
Enter customer details
Enter details
3
Enter project manager details
Enter details
4
additional recipient details here
Enter details
5
additional recipient details here
Enter details Notice to ALSTOM Employees
Documents published on the company document management system are the latest available approved versions and are considered the ‘master’ copy. Printed copies need to be verified as the latest versions prior to use. Users should be aware that the electronic copy is subject to change and as such printed copies should not be retained.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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1.3
References Reference No
Title
AS/NZS ISO 9001:2008
Quality management systems – Requirements
AS/NZS ISO 10005:2006
Quality management systems – Guidelines for quality plans
A01.M01
ALSTOM Limited Quality Manual
Customer Contract No.
Contract Title
Alstom Contract No.
Contract Title
1.4
Abbreviations Abbreviation
Meaning
AS/NZS
Australian/New Zealand Standard
CAR
Corrective Action Request
CCI
Chamber of Commerce and Industry
CD
Compact Disc
ITP
Inspection and Test Plan
ISO
International Standards Organisation
MDR
Manufacturer’s Data Report
NCR
Non-conformance Report
NDT
Non Destructive Testing
PIP
Project Implementation Plan
PQP
Project Quality Plan
QA
Quality Assurance
QDMS
Quality Document Management System
QMS
Quality Management System
SEMP
Safety & Environment Management Plan
SOP
Standard Operating Procedure
WI
Work Instruction
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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2.
Scope (AS/NZS ISO 10005 5.1)
2.1
Project Quality Plan Scope
This PQP defines the Quality Management System (QMS) that shall be implemented on this project to deliver ALSTOM LIMITED Contract No. XXXXX. Contract No. XXXXX is hereafter referred to as “Contract”. ALSTOM LIMITED is hereafter referred to as “ALSTOM”. XXXXXX is hereafter referred to as “Customer”. This PQP is based on the procedures of the ALSTOM management system and reference should be made to these procedures for further details. To satisfy unique project/site requirements ALSTOM may implement project specific procedures in lieu of standard company procedures and these project specific procedures are identified in this PQP. Project specific procedures are assessed against ALSTOM standard procedures to ensure they do not conflict with or negate ALSTOM policies. Standard Operating Procedures (SOPs) or Work Instructions (WIs) referenced in this PQP are not for publication but may be viewed at ALSTOM office by ALSTOM approved Parties. Each Subcontractor shall develop, implement and maintain an ALSTOM approved PQP with relevant procedures/work Instructions applicable to their contract in keeping with AS/NZS ISO 9001:2008 and this PQP.
2.2
Safety and Environment Management Plan
A project Safety & Environmental Management Plan ‘XXXXX-SEMP-001’ has been developed for this project and shall be provided to the Customer.
2.3
Project Scope of Work
(AS/NZS ISO 10005 5.2)
2.3.1 Overview of the Scope of Works List scope of work as detailed in the contact here. The scope of work includes: if necessary insert bullet points here if necessary insert bullet points here
2.3.2 Exclusions List exclusions as stated in the contract here ALSTOM is not required to: a. if necessary insert bullet points here
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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3.
Quality Plan Inputs (AS/NZS ISO 10005 5.2)
3.1
Applicable Documents
Documentation applicable to this Contract is as follows: a. Customer Contract Document; b. Project Quality Plan (PQP); c. Project Implementation Plan (PIP); d. Project Safety & Environmental Management Plan (SEMP), and e. Project Organisation Chart. f.
Project Industrial Relations Plan;
g. ALSTOM Standard Operating Procedures (SOPs) and associated Forms, and h. Legislative and regulatory codes (refer Section 24).
3.2
Project Quality Planning
The project will be managed in accordance with this PQP, which is based on the ALSTOM Quality Management System conforming to AS/NZS ISO 9001:2008, as detailed and/or qualified below, as well as the Customer Contract Documents.
3.2.1 Document Precedence Where conflicting procedures are encountered the Customer Contract documents and this PQP shall take precedence (in that order).
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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3.3
Quality Safety and Environment Policy
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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4. Project Management Responsibility and Organisation (AS/NZS ISO 10005 5.5) The general functional responsibilities for key positions, as detailed on the project Organisation Chart, are as detailed in the following paragraphs, further definition is provided in the position descriptions detailed in Section 22 of this PQP.
4.1
Director Project Management
The Executive General Manager reports to the Managing Director and is responsible for providing direction and ALSTOM approval of policies and methods of execution for the contract by ALSTOM.
4.2
Project Manager
The Project Manager is responsible for overall planning, control and execution of the project in a cost-effective manner and shall ensure compliance with the Contract technical specification, program, ALSTOM financial and commercial policies and practices, safety and environmental requirements including the development, coordination and authorisation of the site specific management plans, incorporating the Customer’s site specific policies and procedures. The Project Manager shall manage the project to meet customer expectations and needs through management system audits, management reviews, customer feedback, performance monitoring and continuous improvement to achieve customer satisfaction. This position has overall authority in determination of all quality related matters affecting the project. The Project Manager also has direct access to the ALSTOM Quality Manager to resolve quality issues should this be necessary.
4.3
Site Manager
The Site Manager is responsible to the Project Manager for overall planning, control and execution of the project in a cost-effective manner and shall ensure compliance with legislation, the Contract technical specification, programme, ALSTOM financial commercial, quality, safety and environmental requirements. The Site Manager shall manage the site to meet customer expectations and needs through management system audits, management reviews, customer feedback, performance monitoring and continuous improvement to achieve customer satisfaction. This position has overall authority in determination of all quality, safety & environmental related matters affecting the Site. In addition the site Quality Officer has direct functional access to the ALSTOM Quality Manager to resolve quality issues should this be necessary.
4.4
Project Quality Officer
The project Quality Officer acts as the Management Representative for onsite quality management matters and checking that all activities are in accordance with this PQP and the procedures applicable to the project to meet Customer requirements.
4.5
Supervisors
Supervisors are responsible to the Site Manager to implement the requirements of the management system.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
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5.
Document Control (AS/NZS ISO 10005 5.6)
5.1
Document and Data Control
Documentation applicable to this contract shall be controlled based on SOP ‘A04.01 Document Control’ and SOP ‘B10.01 Control of Records. The formal internal exchange of significant information between members of staff engaged on the Contract shall be by “Memo”, either in hard copy or electronic format. The format for a Memo may be any of the following:a. Contract Memo; b. Hand-written or computer generated file note (including Lotus Notes); c. Facsimiles; The minimum traceability requirements are; d. Correspondence number and date; e. Contract number; f.
Customer name/project name, and
g. Name of sender. For review/follow up purposes a duplicate of the Memo may be kept by the sender as appropriate to the document’s importance. Incoming correspondence shall be registered and may be exchanged internally by means of direct handover, or by copying and distributing (or circulating) same, per distribution list thereon. Review and approval of documentation shall be as per SOP ‘A04.01 Document Control’.
5.2
DOCUMENT NUMBERING SYSTEM
5.2.1 Correspondence Document Control All project correspondence shall be identified in a correspondence register number. The correspondence number shall be taken out of the appropriate correspondence register and included in the document. All project correspondence is to be numbered and controlled as defined in Extract from Form B10.F01 Project Filing System. Refer to the following Figure 1 for a summary of correspondence control system.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
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For example: ALSTOM to CLIENT = Contract Number–AP–CL–XXX
XXXXX - XXXX - XXXXX -
0001 / XX
Alstom Project No./ Contract No. Originator Recipient Sequential Document No. Author Figure 1 – Correspondence Numbering Convention The originator codes are as defined in Table 2 – Correspondence Originator Codes.
Table 2 – Correspondence Originator Codes
5.3
Code
Originator
AP
ALSTOM
CL
Client
G
General
APE
ALSTOM Engineering
SC
Subcontractor
Control of Project Documents
Controlled documents shall be numbered in accordance with Figure 2. All numbers are to be allocated by the Document Controller. For example: This Project Quality Plan = Contract Number–GN–PQP–001. XXXXX - GN - PQP - 001 - Rev A Contract No. Area Code (WBS) Document Type Code Document Sequential No. Revision No.
Figure 2 – Controlled Documents Numbering Convention
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
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Revision:
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The document type codes are as defined in Table 3 – Controlled Document Type Codes.
Table 3 – Controlled Document Type Codes Document
Code
Document
Code
Project Quality Plan
PQP
Welding Procedure Specifications
WPS
Safety Management Plan
SMP
Procedure Qualification Record (Welding)
PQR
Environmental Management Plan
EMP
Manufacturer’s Data Reports
MDR
Design Plan
DP
Operation and Maintenance Manual
OM
Inspection & Test Plan
ITP
Statutory Approvals
SA
Inspection & Test Plan Register
ITR
Preferred Suppliers/Subcontractors
PSS
Procedure
P
Contract Data Sheet
CDS
Instruction
I
Technical Specification
TS
Forms
F
General Specification
GS
Checklist
C
Purchase Order
PO
Sample
S
Concession Requests
CR
Project Plans
PP
Reports
RT
Program/Schedule
PRO
Scope of Work
SOW
Industrial Relations
IR
Sketch
SK
Forms Register
FR
Spares Schedule
SS
Contract
CON
Design Review Package
DRP
Functional Description
FD
Plant Test Procedures
PTP
Design Guide
DG
Turnover Package
TP
Design Report
DR
Data Sheet
DS
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
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5.4
Drawing Control
Drawings shall be numbered as follows: Note: Drawing numbers shall be issued by the Engineering section to ensure consistency. XXXXX - BL - 028 - FD -
001
Rev 1
Contract No. Area Code (WBS) Plant/Sub No. Document/Drawing Code Sequential No. Revision No.
Figure 3 – Drawings Numbering Convention
5.4.1 Document Number Identifiers/Codes Area codes, Plant/Sub No codes and Document/Drawing codes are defined in SOP ‘B00.02.01Work Breakdown Structure’.
5.4.2 Drawing/Document Status Issue/revisions shall start with alpha characters (A, B, C) for drawings forwarded to Client ‘For Approval’. Approved/Certified for Construction status shall start with Rev 1 after approval. After Client approval, the status of resubmissions will be ‘For Information’ i.e. all drawings forwarded to Client for information will be Approved/Certified for Construction copies.
5.4.3 Document Cover Sheet Document cover sheet A04.F19 is used to identify and submit documents where documents (eg. external, supplier or other pdf’s etc) are unable to be numbered as per 5.3 Control of Project Documents.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
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Document Category:
Document Number:
Revision:
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5.5
Project Filing System
As defined in SOP ‘B10.F01 Project Filing System’ the following standardised folder system shall be used to organise project documents
5.6
Section / Tab
DESCRIPTION
Area
1
CONTRACT CONDITIONS
Tender
2
TENDER SPECIFICATION
Tender
3
TENDER
Tender
4
CONTRACT ISSUE
Tender
5
CONTRACT DOCUMENTATION
Tender
6
CONTRACT START UP
Project Execution
7
EHS & LOSS
Project Execution
8
ENGINEERING
Project Execution
9
PLANNING & PROGRAMMING
Project Execution
10
QUALITY
Project Execution
11
SUBCONTRACT MANAGEMENT
Project Execution
12
MAJOR SUPPLIER MANAGEMENT
Project Execution
13
OTHER NON-LABOUR PROCUREMENT
Project Execution
14
CLIENT SUPPLIED ITEMS
Project Execution
15
CORRESPONDENCE
Project Execution
16
MEETINGS
Project Execution
17
COST MANAGEMENT
Project Execution
18
VARIATIONS
Project Execution
19
INVOICING & CLAIMS MANAGEMENT
Project Execution
20
REPORTING
Project Execution
21
STAFF
Project Execution
22
JOB FINALISATION
Project Execution
Related Procedures
A04.01, Document Control A04.01.01, Control of System Procedures and Forms A04.01.02, Control of Standards & Publications A04.01.08, Installing Databases from CD
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
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Document Category:
Document Number:
Revision:
Revision Date:
Page:
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6. 6.1
Control of Records (AS/NZS ISO 10005 5.7) Quality records
Identification, collection, indexing, filing, storage, maintenance and disposition of Contract specific records shall be carried out in accordance with SOP ‘B10.01 Control of Records’. Records shall indicate persons releasing the product. 6.1.1
System Conformance Records
These records shall be maintained as required by SOP ‘B10.01 Control of Records’. The following shall form the Contract requirement: a. Management reviews; b. Training records; c. Inspection and test plan records; d. Design Plan and verification, validation and design changes; e. Supplier evaluations; f.
Inspection equipment calibration records;
g. Special Process procedures and associated personnel qualifications; h. Non-conformances and resulting corrective actions, and i. 6.1.2
Quality Audit Records and surveillance reports.
Product and Service Conformance Records j.
Raw Material Certification (for critical components or pressure parts);
k. Inspection and Test Plan (ITP); l.
Non-Destructive Test Report (NDT);
m. Weld Procedures; n. Welder Qualifications; o. Heat Treatment Reports; p. Mechanical Test Reports; q. Hydrostatic Test Reports; r.
Stress Relief Certificates;
s. Pressure Part BR2 Manufacturer’s Forms; t.
Non-conformance Reports (NCRs);
u. Non-conformance Concession Record; v. ALSTOM Inspection Certificates; w. Customer or Third Party Release Certificate; x. Installation Reports and Checklists; y. Commissioning Report and Checklists, and z. Operating and Maintenance Manuals.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
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Document Category:
Document Number:
Revision:
Revision Date:
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7.
Manufacturer’s Data Record
Subcontractors shall, upon completion of work, provide the above product conformance records (as applicable) to ALSTOM in the form of a Manufacturer’s Data Report (MDR) bound in volume for each item of manufacture. This shall be specified in the Purchase Order and no purchase order shall be approved for payment without receipt and acceptance of the MDR and any other requested documentation. Records shall be preserved and stored as identified in B10.01 Control of Records. Records shall be legible and either recorded in English or appropriately translated into English. Each subcontractor, as part of their quality plan, shall detail the procedures for control of its quality records.
7.1 B10.01
Related Procedures Control of Records
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
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Document Category:
Document Number:
Revision:
Revision Date:
Page:
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8. 8.1
Resources (AS/NZS ISO 10005 5.8) Resource management
ALSTOM will supply adequate staffing, supervision, labour, construction equipment, onsite transportation, consumables, offices, crib rooms and safety equipment for the project, to complete the requirements of the above contracts within the project time constraints outlined in the Contract.
8.2
Material Resources
Material requirements are specified in the Contract, design specifications, inspection and test plans and in purchasing information.
8.2.1
Customer Supplied Material Resources
Materials supplied by the Customer are in the form of consumables or hardware/parts. These materials when supplied to ALSTOM shall be strictly controlled and where required traceability shall be maintained as defined in Section 15, Traceability.
8.3
Human Resources
The Project Manager shall ensure that project personnel undertaking work that may influence the quality of the work, have appropriate qualifications, training and experience. The Project Manager shall assess the training needs for the Project Team under their direct control and, if required, provide or arrange training to meet specific project requirements as defined in SOP ‘A06.01 Training’. Unless otherwise specified, personnel suitability shall be assessed on the basis of qualifications and/or experience as required by individual position descriptions and job specifications. Training courses shall be carried out in, but not limited to the following areas, as and when required: a. Site Induction; b. Quality Plan, SOPs and WIs (Office and Site), and c. Environment, Health and Safety. Records (including resumes, qualification reports, inductions, etc) substantiating qualifications of new employees or additional qualifications/experience of existing employees, shall be maintained.
8.4
Personnel Register
The Document Controller shall maintain ALSTOM and Contractor personnel records on the project filing system.
8.5
Site Induction
All ALSTOM employees and ALSTOM Subcontractors will be required to attend a general Site Induction session prior to commencement of work on site. As part of this process attendees will be issued with an Induction Handbook which provides an overview of site safety requirements.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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Each Subcontractor shall submit a written request for employee induction training to Project Manager at least five (5) days prior to commencement on site. Contractors may be required to attend a pre-commencement Meeting with the Project Manager to discuss and review all requirements associated with the contract. Site inductions shall comply with SOP ‘A06.01.01 Site Induction’. Site induction records shall be maintained as defined in SOP ‘B10.01 Control of Records’.
8.6
Consultation
ALSTOM is committed to health and safety consultation and addresses this through the provision and management of workgroups, provision of training, issue resolution measures, consultation and communication meetings such as toolbox meetings and resolution of safety disputes as defined in SOP ‘A06.05 Consultation’.
8.7
Industrial Relations
The Project Manager is responsible for personnel management and industrial relations in accordance with the project industrial relations and individual employment or performance agreements. The Project Manager shall: a. Participate in union/management negotiations for project agreements; b. Administer the provisions of the agreement including policy decisions, strategies and objectives; c. Participate in site industrial relations program including contacts with government authorities, unions and employer associations as necessary; d. Coordinate contractors in above matters; e. Interpret site agreement with assistance from Chamber of Commerce and Industry (CCI) as necessary; f.
Liaise with Union officials at all levels on industrial relations issues;
g. Provide advice to managers and supervisors on industrial relations practices; h. Maintain records, prepare reports on project industrial Relations performance;
8.8
i.
Be aware of the application of regulations and statutes including employment procedures, dismissal procedures, legal demands, standards, workers’ compensation.
j.
Advise and assist the Construction Project Manager in respect of publicity relating to industrial relations matters.
Related Procedures
A06.01 A06.01.01 A06.01.02 A06.05 B10.01
Training Site Induction Tool Box Meetings Consultation Control of Records
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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9. 9.1
Requirements (AS/NZS ISO 10005) Contract Review
The Contract requirements shall be reviewed as defined in SOP ‘B02.02 Contract Review’ and ‘B02.03 Contract Handover’ and includes (but is not limited to) the following : a. The review of the Customer’s Specification documents and ALSTOM Offer together with subsequent correspondence in order to consolidate and define the scope of work and the adequacy and the capabilities of necessary resources b. Documenting discrepancies if any, within the Contract documents and the consolidated tender documents, so that they can be resolved in a timely manner c. Where necessary, involvement of appropriate company interface groups in the contract review process d. Contract Variations (change orders), if any during execution of the contract, shall be similarly reviewed, but shall be processed in accordance with SOP ‘B03.01 Contract Administration’. Contracts with Subcontractors shall be similarly reviewed.
9.2
Related Procedures
B02.02 B02.03 B02.02.01 B03.01 B10.01
Contract Review Contract Handover Order Acceptance and Notification for Power Services Contract Administration Control of Records
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
Document Category:
Document Number:
Revision:
Revision Date:
Page:
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10. Customer Communication 10.1
Correspondence
All formal/written communication with the Customer shall be directed through the Project Manager/Site Manager. All written communication to and from the site office shall be through the Project Manager or nominee.
10.2
Progress Reports
A monthly report submitted to the Customer by the Project Manager shall address, but is not limited to, the following: a. Executive Summary; b. Problem Areas; c. Engineering/Design; d. Procurement; e. Manufacture; f.
Construction;
g. Commissioning; h. Project Control; i.
Quality Management;
j.
Contract Administration;
k. Change Order Log, l.
10.3
Programme Update including S-Curves
Meetings
The following meetings will be conducted during the delivery project: Type
Frequency
Attendees
Planning Meeting
Weekly
Project Manager, Site Manager, Project Engineer
Coordination Meeting
Weekly
Project Manager, Site Manager, Project Engineer
Customer Site Progress Meetings
Fortnightly
Project Manager, Site Manager, Project Engineer
Tool Box Meetings
As determined on site
As determined on site (refer to SEMP).
Customer Meetings (additional)
On request
Project Manager, Site Manager, Project Engineer
An agenda shall be prepared and minutes reported.
10.4 B03.04
Related Procedures Project Implementation
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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11. Design and Development (AS/NZS ISO 10005 5.11) 11.1
Design Control
While ALSTOM is responsible for the design performance of the Contract, subcontractors and suppliers shall ensure adequate systems and procedures are established, implemented and maintained to satisfy/verify their own design performance requirements. ALSTOM shall address these requirements in procurement and subcontract documentation. The design performance shall also be reflected in the relevant Subcontractors’ Quality Plans or Inspection & Test Plans (ITPs) as appropriate. ALSTOM will conduct design and detailing functions at plant interfaces in keeping with the role of design planning, co-ordination and review with subcontractors as appropriate. Assessment of the adequacy of the design provisions shall be through: a. Documentation of design reviews to ensure completeness; b. Co-ordination and review meetings; c. Audit, and d. Inspection and Test activities.
11.2
ALSTOM Internal Design and Drawing
Design work is to be in accordance with SOP ‘B04.01 Design’ and the Project Design Plan, wherein the following shall be addressed; e. Organisational and Technical Interfaces; f.
Planning the method of design in terms of documenting design activities to be assigned to the design team members, including any external design services as nominated in the design plan;
g. Documenting and reviewing design inputs for adequacy; h. Carrying out preliminary design work as necessary; i.
Carrying out detailed design;
j.
Reviewing design output;
k. Carrying out design verification, and l.
11.3
Processing design changes.
Design Co-Ordination
Progress Meetings shall be held with Subcontractors performing Design work, as appropriate and as necessary, to discuss and resolve Design Inputs, Design Outputs, Design Verification, Design Changes, technical issues and progress of Design activities. Records of Design Co-ordination meetings shall be maintained in the form of Minutes of Meeting as minimum.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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11.3.1
Design Review / Verification
Design Review meetings shall be held internally for design output and with Subcontractors performing design work at appropriate stages of the design process to discuss and resolve Design Issues, Design Inputs and Outputs, Design Changes, Concession and Contract Changes and other technical issues affecting the project. Participants shall be chosen to represent all functions concerned with the stage of Design being reviewed. Records of Design Review meetings shall be in the form of Minutes as minimum.
11.4 A04.01 B04.01 B10.01 A04.F01
Related Procedures Document Control Design Control of Records Minutes of Meetings
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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12.
Purchasing (AS/NZS ISO 10005 5.12)
Goods and services required by ALSTOM shall generally be purchased from assessed suppliers as defined in SOP ‘B05.02.03 Thermal Service Procurement’. Standard supplementary terms and conditions required to be attached to Purchase Orders as defined in SOP ‘B05.02.03 Thermal Service Procurement’ are altered to include terms and conditions as applicable to specific equipment or services ordered and shall be ALSTOM approved at time of authorisation of the purchase by the signing authority of the Project Manager or his delegate (as per A01.2.1 Table of Authorities). Documentation to be included with Purchase Orders shall have a dedicated document number applicable to the document and must be listed on the Purchase Order and accompanied by a subcontract Transmittal Advice. Reference must be made to the Purchase Order. It is the responsibility of the Engineer who initially prepares or initiates changes to specification documents to ensure that the necessary issues and changes or revisions are issued to the Procurement Officer as applicable for arranging applicable order variations and on-forwarding. For quotation or enquiry purposes, technical specifications, drawings etc, may be issued as non-controlled documents, however the issue status must be recorded in the enquiry document. No final invoice from a subcontractor shall be approved for payment without receipt of full documentation requested as part of the Purchase Order.
12.1
Procurement/Subcontract Requirements
All Subcontractors/Suppliers, as part of their Quality Plans shall nominate the methods to identify and trace products where applicable based on the above requirements. Sub-contractors are assessed as defined in SOP ‘B05.01 Sub-contractor Assessment’, wherein the following will be addressed and documented: a. The evaluation and selection of subcontractors for components; b. The evaluation and selection of subcontractor’s Subcontractors. Subcontractor’s Subcontractors shall be evaluated by the head Subcontractor and evidence submitted to ALSTOM for approval prior to letting of orders; c. The requirements on the subcontractor for a particular purchase order; d. Reviews and approval of purchasing documents prior to issue; e. Surveillance of subcontractors, and f.
Amendments to purchase orders.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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12.1.1
Subcontractor’s Responsibility
While ALSTOM maintains the Contract responsibility for these activities until handover to the Customer, the main responsibility for carrying out the handling, storage, packaging, and preservation and delivery requirements of the project rests with the subcontractors and suppliers. They shall ensure adequate systems and procedures are established, implemented and maintained to satisfy Contract requirements. ALSTOM shall address these requirements in procurement and subcontract documentation. Such controls shall be reflected in the relevant subcontractor quality plan and/or ITPs as appropriate. Assessment of the adequacy of these provisions shall be through audit and inspection and test activities. The site storage facility allocation for subcontractors and suppliers will be designated at an appropriate time.
12.1.2
Subcontractor’s Role
Relevant to their scope of work, subcontractors shall identify, plan, implement and maintain the design, management, manufacture, construction, installation, commissioning, handover and warranty processes that are necessary to achieve project and Contract requirements, based on quality, cost and time requirements. These processes, including special processes, shall be carried out under controlled conditions including, but not limited to: Where process results cannot be verified by inspection and testing of the product, and where deficiencies may become apparent only after the product is in use, the process shall be performed by qualified operators and/or require continuous monitoring and control of the process to ensure compliance with the specification. Specific requirements for any qualifications, equipment and personnel shall be specified. Subcontractors shall have procedures to identify, control and dispose non-conformances and initiate and verify appropriate corrective actions, and subcontractors’ quality plans shall detail these procedures and their application to the project.
12.1.3
Management, Control and Surveillance of Subcontractors
ALSTOM shall manage subcontracted activities and shall conduct regular surveillance activities to ensure conformance to project and Contract requirements by conducting the following activities: a. Quality Audits; b. Progress Meetings; c. Design Co-ordination and Review Meetings; d. Review and mark-up and release of ITPs; e. Witnessing the relevant and nominated Inspections and Tests; f.
Records Review, and
g. Review of MDRs and Operation and Maintenance Manuals.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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12.1.4
Subcontractor’s Design Role
Design work for each Subcontract package shall be carried out by the appropriate Subcontractor as defined in their internal documented design procedure. The following shall be addressed: a. Organisation and Technical interfaces; b. Planning the method of design in terms of documenting design activities to be assigned to Design Team Members, including external design services and producing a Design Plan; c. Documenting and reviewing design inputs for adequacy; d. Carrying our preliminary design work as required; e. Reviewing design output; f.
Carrying out design verification, and
g. Processing design changes. These requirements shall be subject to audits by the subcontractor and ALSTOM during the execution of the work.
12.1.5
Sub-Contractors Design Responsibilities
Subcontractor’s design responsibilities shall be detailed in the subcontract documentation and where specified, the relevant subcontractor, in fulfilling the design requirements, shall be required to establish procedures, where appropriate, to: a. Develop detailed design plans or equivalent incorporating definition, assignment and planning of all design and development activities; b. Define organisational and technical interface which will input into the design process and establish appropriate systems for documenting, transmitting and reviewing the necessary information; c. Develop detailed design programmes incorporating all design and development activities to meet specified and agreed project targets and milestones; d. Provide sufficient qualified personnel with adequate resources to carry out the Design function to meet the design programme and satisfy Contract requirements. e. Identify, document, review and resolve design inputs f.
Document design outputs such that they: i.
Meet design Input requirements;
ii.
Contain or reference acceptance criteria;
iii.
Conform to appropriate statutory and regulatory requirements, and
iv.
Identify characteristics that are crucial to the safe and proper functioning of the relevant scope of work.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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g. Verify at appropriate stages of the design to establish that design output meets Input requirements by such means as: i.
Conducting and maintaining records of internal Design Reviews;
ii.
Attending and maintaining records of external Design Reviews, and
iii.
Conducting alternative calculations and/or comparisons with a proven design or tests.
h. Identify, document, control, review and approve design changes and modifications.
12.1.6
Design Input for Subcontract Packages
As part of design input, ALSTOM shall develop equipment/performance based Specifications detailing the requirements for design. These shall be controlled documents and shall be reviewed for adequacy prior to distribution to the “Supplier”. Processing of design output shall be per SOP ‘A04.01 Document Control’.
12.1.7
Design Output from Subcontractors
Design output in the form of Calculations, Drawings and Specifications shall be verified by the appropriate Subcontractor and submitted to ALSTOM for review and comments. Evidence of any reviews and approvals shall be the signatures in the document control stamp thereon.
12.1.8
Control and Management of Subcontractors’ Design
Control and management of Subcontractors’ Design shall be a combination of Design Co-ordination and Progress Review Meetings, Quality System Audits and Technical Surveillance of the Design process. The frequency of these controls will be varied according to criticality of the relevant Design phases and performance of the Subcontractor and will be reflected in the Quality Audit Schedule.
12.2
Related Procedures
A04.01 B05.01 B05.01.01 B05.01.02 B05.02.03 B10.01
Document Control Subcontractor Assessment Supplier Performance Reviews Subcontractor safety and Environmental Management Power Service Procurement Control of Records
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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13.
Production and Service Provision (AS/NZS ISO 10005 5.13)
13.1
Product realisation
13.1.1
Contract Programme
Activities covering engineering design, procurement, manufacture, delivery, installation, commissioning and testing shall be controlled in accordance with the contract programme. SOP ‘B03.02 Project Planning’ defines the procedure for the evaluating and quantifying resources, the provision of management information and time monitoring time, expenditure and resource management during the phases of the Contract. The software package to be applied is Primavera or an approved compatible/equivalent program. The program shall be submitted to the Customer in accordance with contract requirements. Programs for detailed planning, control and monitoring will be utilised internally by ALSTOM and Contractors as applicable. Activities covering design, purchasing, manufacture, delivery, installation and commissioning shall be planned, programmed, controlled and monitored. Contractors programs shall comply with these requirements and form part of the program. Site progress will be monitored, updated, assessed (including look ahead schedules & action plans as a result of negative float) and submitted fortnightly to the Project Manager for update of relevant programs. All official programs shall be issued as directed by the Project Manager. Program information may also be issued on site with the approval of the Project Manager. Subcontractors shall be required to comply with these requirements and their Programmes shall form an integral part of the overall Project Programme.
13.1.2
Cost Control
The Project Manager and Administration Manager shall establish and control a site cost control system and cost code structure in consultation with the Head Office Project Financial Controller. Site costs shall be monitored, controlled and reported by the Administration Manager. A monthly financial report shall be prepared and approved by the Project Manager. Site Personnel shall provide update information to the Administration Manager.
13.1.3
Progress Claims
Progress Claims shall be approved by the Project Manager and submitted to the Project Financial Controller for submission to the Customer.
13.1.4
Contractor Progress Claims
Contractor Progress Claims shall include a signed progress verification sheet and be reviewed and approved by the Project Manager.
13.1.5
Variations
Variations and any activities that may constitute a variation shall be recorded on the Site Variation Register, approved by the Project Manager and submitted to the Project Financial Controller for submission to the Customer.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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13.1.6
Petty Cash
Petty cash is only implemented on a project where it is deemed appropriate, it must be approved by the Financial Director. Where petty cash is implemented on a project, A08.04 Petty Cash Management is to be used.
13.2 B03.02 A08.04
Related Procedures Project Planning and Scheduling Petty Cash Management
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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14.
Process Control
ALSTOM’s role in meeting project and Contract requirements is that of a Subcontractor which includes design, procurement, inspection, installation, commissioning testing and warranty. While ALSTOM maintains overall contractual responsibility with the Customer, the specific responsibility for manufacture, supply, delivery, construction, installation, commissioning and warranty also rests with the relevant Subcontractors and is detailed in the relevant procurement documentation. Subcontractors shall detail in their respective Quality Plans the process control procedures for their scope of work. Processes which directly affect quality shall be identified and planned for all phases of the work. These processes shall be carried out under controlled conditions. ALSTOM processes include, but are not limited to: a. Quality Management; b. Safety Management; c. Environmental Management; d. Contract Review and Consolidation; e. Planning; f.
Communication;
g. Design, Design Co-ordination, Review, Verification and Validation; h. Design Concession and Change Control; i.
Procurement and Sub-contracting;
j.
Inspection and Testing;
k. Installation; l.
Commissioning and Performance Testing;
m. Finance; n. Audits and Audit Surveillance; o. Document Control; p. Records; q. Handover, and r.
14.1
Warranty.
Identification of Special Processes (AS/NZS ISO 10005 5.14)
Special manufacturing/ALSTOM inspection processes shall be identified as part of the design output where appropriate. Such processes shall be documented on the relevant engineering drawing or documented separately as Instructions, and shall be accomplished under appropriate controlled conditions by appropriately qualified personnel. Where necessary, personnel qualifications and corresponding personnel qualification records shall be maintained, together with any special equipment certification and calibration records and completed and signed ITPs.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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14.2
Manufacturing Methods
Manufacturing shall be carried out in accordance with codes nominated in the Contract specification and ALSTOM standards nominated in Purchase Order(s) and associated drawings and specifications.
14.3
Welding Operator Certification
All welders and weld procedures are to be qualified with respect to the Contract ITP and documentation provided for approval to ALSTOM prior to commencement of work.
14.4
Inspection Certificates
All fabricated items require an inspection certificate or, where inspected by the Customer or Third Party, a copy of their Inspection release certificate before dispatch, except where the dispatch of the products prior to final inspection has been approved by the ALSTOM Project Manager or Nominee. In this instance, final inspection and rectification of any deficiencies will be conducted at site by the appropriate Subcontractor to certify acceptance of the product. Evidence of non-acceptance shall be a completed Non-conformance Report (NCR).
14.5
Installation
Installation shall be carried out in accordance with certified Contract drawings, installation ITPs, installation instructions and approved SOPs. SOP ‘B07.01 Site Establishment and Installation’ refers to ALSTOM personnel activities at site.
14.6
Control of Commissioning and Testing
Where contracted to perform commissioning activities, Commissioning and Testing by ALSTOM shall be carried out as specified in the Commissioning ITPs, in line with SOP ‘B08.01 Commissioning’ and the specific requirements of the Contract. Subcontractors, in commissioning their plant and equipment, shall do so to established and approved ITPs and procedures.
14.7
Project quality system review
The Quality System is reviewed during regular site meetings which, as well as covering project matters, address: s. Any incidents including injuries reported since the last meeting; t.
Accident figures for area being reviewed;
u. Any customer complaints reported since the last meeting; v. Any audits and corrective actions raised, including their status; w. Significant nonconformances and estimated costs; x. Performance against objectives set for the area reviewed, and y. These meetings are minuted and actions identified and followed up by the delegated personnel. The implementation and review of the management systems are also addressed in project reports, prepared in accordance with the Contract requirements but usually monthly for significant projects. These reports cover system implementation, non-conformances, audits and corrective actions, and incidents. They are prepared for relevant circulation and for review by project and department management. © ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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14.8
Related Procedures
B03.02 B03.02.01 B03.02.02 B03.04 B03.04.01 B03.04.02 B03.04.03 B03.04.04 B03.04.05
Project Planning and Scheduling S-curves Planning & Scheduling Project Implementation Project Reviews Project Cost Control Accounting for Variations Recognition of Sales & Gross Margin Warranty Provision
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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15.
Identification and Traceability (AS/NZS ISO 10005 5.14)
15.1
Identification
The extent of Identification of Contract specific documentation and products/materials shall in accordance with SOP ‘B06.02 Identification and Traceability’, wherein all contract related documents, products (where practical) or service shall be identified with a unique Number.
15.2
Traceability
Traceability, other than that described herein is not required by this contract except to satisfy regulatory requirements and codes, where applicable. The extent of traceability required shall be defined in the product specification document attached to the Purchase Order.
15.3 B06.02
Related Procedures Identification and Traceability
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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16.
Customer Supplied Products or Services
Where products are supplied by the Customer the following shall be observed: a. Any products that may be supplied by the Customer will be examined upon receipt at the Site for completeness, proper type and any transportation damage, in accordance with SOP ‘B06.01 Inspection and Testing’, and b. Damaged products will be notified in writing to the Customer Control of these products after receipt will be in accordance with SOP ‘B06.01 Inspection and Testing’, wherein safe keeping, identification and traceability is assured.
16.1 B06.01 B06.02 B06.03
Related Procedures Inspection and Testing Identification & Traceability Inspection & Test Status
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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17.
Handling, Storage, Packaging, Preservation and Delivery (AS/NZS ISO 10005 5.16)
Where ALSTOM has a direct responsibility for handling and storage of equipment to and/or at the site, this shall be performed in accordance with SOP ‘B05.03 Handling, Storage, Packaging and Delivery’.
17.1
Handling
Items and products received at ALSTOM premises or site shall be handled in a manner that avoids damage or deterioration.
17.2
Storage
Receipt of goods at ALSTOM’s off site premises shall be limited to minor proprietary goods that can be easily manhandled and only when strictly necessary. At site, goods shall be stored in a designated storage area or lockable compound, where practical, to prevent loss or damage and where necessary suitably protected against climatic conditions and deterioration. In all cases goods shall be suitably tagged or marked for identification purposes. Goods stored shall be documented and shall be subject to regular monitoring in order to establish their continuing fitness for use. All plant and equipment installed shall be protected to ensure no deterioration occurs prior to handover to ALSTOM/Customer. Nonconforming goods shall be identified, segregated where practical and processed per requirements of SOP ‘A03.05 Non-conformance’.
17.3
Packaging, preservation, marking and delivery
Packaging of goods for delivery shall adequately protect the goods against damage and deterioration. Inspection ALSTOM prior to dispatch shall be carried out where nominated on the relevant ITP. Appropriate delivery documentation shall be provided according to specified requirements.
17.4
Waste
ALSTOM’s waste control measures comply with the relevant State regulatory requirements, as such site waste, for which ALSTOM is responsible, shall be controlled and or disposed as defined in SOP ‘A05.03.02 Waste’ or where required as defined in the Customers on-site procedures.
17.5
Related Procedures
A05.03 A05.03.01 A05.03.02
Handling Storage Packaging and Delivery Storage Requirements for Hazardous Material Control of Waste
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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18.
Control of Nonconforming Product (AS/NZS ISO 10005)
18.1
Nonconformance Reporting
Control of Non-conformances shall be as defined in SOP ‘A03.02 Control of Non-conformances’. The general steps of the procedure are as follows: a. Record the non-conformance discovered on the NCR section of the Actions Database, or if computer access not available then, Form A03.F05; b. Identifying and holding products subject to an NCR in a designated holding area. For bulky or large nonconforming products which cannot readily be segregated, the area(s) of nonconformity shall be marked such that it is readily visible to any other user. c. Recommendation and review of disposition/rectification by responsible parties; d. Corrective action to correct the non-conformance; e. Re-inspection of the reworked or repaired product; f.
18.2
If required obtain Customer approval for a Concession;
NCR Sources
The main sources of non-conformance may arise from but are not limited to: a. Receipt inspection; b. Manufacture, disassembly, assembly or construction processes, and c. Final inspections and test process.
18.3
Disposition of Nonconforming Products
Disposition of non-conformances may be achieved by: a. Rework to meet specified requirements; b. Acceptance with or without repair by concession; c. Regarding for alternative use, and d. Rejection/disposal.
18.4
Identification of Items Subject to NCR
Nonconforming items or products shall be appropriately identified, segregated and/or quarantined to prevent inadvertent use until appropriate disposition has been effected. Relevant parties such as the Project Manager/Engineer and Customer shall be informed that an item is subject to an NCR.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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18.5
Resolution of ALSTOM NCR’s
Where the non-conformance is related to ALSTOM the personnel responsible for that activity (in conjunction with the Project Safety/Quality Representative), are responsible for: a. Investigating the cause of non-conformances and approving and implementing the proposed corrective actions needed to prevent their recurrence b. Evaluating the sources of the non-conformances by analysing relevant information as applicable, procedures, work instructions, concessions, quality records and customer complaints, in order to detect and eliminate further and potential causes of non-conformances.
18.6
Resolution of Other Parties NCR’s
Where the non-conformance is related to other parties, the Project Safety/Quality Officer, in conjunction with the Project Manager or nominee is responsible for: a. Expediting the resolution of the non-conformance; b. Obtaining acceptance and approval of the corrective action from the relevant personnel and/or parties as required; c. Verifying implementation and effectiveness of corrective action through audit/surveillance/inspection as appropriate. d. Notification(s) of actual or potential non-conformances by the Customer shall be processed in accordance with SOP ‘A03.03 Corrective Action’.
18.7
Corrective & Preventive Action
Corrective and Preventive Action shall be carried out in accordance with SOP ‘A03.03 Corrective Action’, wherein: e. Non-conformances are reviewed to determine their causes and develop appropriate corrective and preventive action; f.
Potential causes of non-conformances are identified and corrective action developed to prevent the occurrence;
g. Corrective action is implemented and the effectiveness is followed up; h. Corrective action from results of audits is implemented effectively. The need for Corrective Action is normally identified through:
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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18.8 A03.02 A03.03 B10.01
iv.
Non-conformances
v.
Internal audits
vi.
External audits and Customer/Third Party audits.
vii.
Actions identified are logged on the Actions Database from the NCR or CAR form.
Related Procedures Control of Non-conformances Corrective and Preventive Action Control of Records
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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19.
Measurement Analysis and Improvement (AS/NZS ISO 10005)
19.1
Inspection, Measuring and Test Equipment
The calibration controls to be used for test equipment shall be as defined in SOP ‘A05.01 Control of Measuring and Test Equipment’. Subcontractor’s test equipment calibration work practices are to be approved at the time of Supplier Assessment or at the initial inspection visit by the Inspector. Subcontractors shall ensure adequate systems and procedures are established, implemented and maintained to satisfy contract requirements. For erection at site, evidence of current calibration status will be examined by ALSTOM prior to commencement of work. No work shall be carried out with un-calibrated testing and measuring equipment where such measurements are required to determine equipment status. The requirement will be subject to audit.
19.2
Inspection and Testing
Inspection and testing requirements are referenced in SOP ‘B06.01 Inspection and Testing’. Subcontractors shall detail their inspection and testing requirements in their respective Quality Plans (to be submitted for approval). Inspection and Testing for the project shall be carried out for: a. Incoming Goods Inspection; b. In Process Inspection; c. Final Test and Inspection; d. Installation Inspection and Tests, and e. Commissioning Inspection and Tests. ALSTOM’s role will be predominantly an audit surveillance role on Sub-contractor’s activities. Product conformance will be indicated on the Subcontractor’s ITPs. ALSTOM shall mark-up Subcontractors’ ITPs with Hold & Witness Points as required to verify conformance to project requirements. These ITPs will be stamped/approved prior to return to Subcontractors for use. ALSTOM may appoint qualified inspection personnel to carry out inspection or surveillance activities as required. Subcontractors, as part of their Quality Plan, shall detail the methods for inspection and tests both at their own premises and on site.
19.3
Inspection and Test Plans
Before commencement of work including site work, Subcontractors shall supply ITPs for their scope of work for approval and shall incorporate the elements of ITP Guidelines as a minimum and shall form a requirement of the purchase order. All ITPs shall be technically reviewed by the appropriate engineer and quality officer and approved by the Project Manager prior to issue for use. ITP’s shall contain at least the following information: © ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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a. Applicable steps/sequence of activities to effectively control and complete the process; b. Verifying procedure to be used and the acceptance criteria for each step/sequence; c. Responsibility for each inspection or test; d. Columns for inspection and test points for Subcontractor and/or their Subcontractors, ALSTOM and Regulatory/Statutory bodies as applicable; e. Resultant Records applicable to each step/sequence as applicable; f.
ITP steps/activities shall be progressively signed off as the relevant inspections and tests are completed and accepted. All pertinent records shall be available prior to signing off an ITP, unless agreed/provided for otherwise (e.g. positive recall provisions for urgent use items);
g. Registers of ITPs shall be developed for each phase, Subcontract or group of activities as appropriate and provided to ALSTOM for reference; h. ALSTOM shall maintain an ITP Register for monitoring purposes, and i.
19.4
Notification to ALSTOM of the timing of Witness and Hold Point shall be carried out in accordance with the requirements specified in the Purchase Order.
Incoming Goods Inspection
Incoming Goods Inspection shall be carried out by ALSTOM and its Subcontractors and Suppliers at their premises and/or on site as appropriate and as detailed on ITPs, to verify compliance with procurement and project requirements: a. Products shall not be used until incoming inspections are carried out; b. Nonconforming products shall be held from use pending disposition and corrective action and recorded on the Non-conformance Report, and c. The Goods Received Report or approved equivalent, shall be used by Subcontractors to record incoming inspections carried out on goods received at Site.
19.5
In-Process Inspection
Manufacturing and pre-dispatch inspection and testing shall be carried out by the prime Subcontractors and or their Subcontractors and Suppliers in accordance with ITPs submitted prior to manufacture commencing. Surveillance, witness and hold activities will be in accordance with the requirements marked up on the relevant ITP. Refer to SOP ‘B06.01 Inspection and Testing’ wherein: a. The level of inspection shall be as per ITP and signed off accordingly; b. Products shall be held until Hold Point inspections are carried out, and c. Nonconforming products shall be held pending disposition and corrective action as per Incoming Inspections.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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19.6
Final Inspection (and Handover)
As detailed by the relevant ITPs, any specified final inspection to be conducted by ALSTOM shall be at the point of handover of the equipment. Progressive completion of ITPs and verification of associated records shall be undertaken by the Subcontractor (unless otherwise noted on the ITP), such that at the point of handover to ALSTOM, records of completion and compliance for all Inspections and Tests are available for verification. For items of manufacture at a Subcontractor’s premises, final inspection by ALSTOM shall be carried out in accordance with SOP ‘B06.01 Inspection and Testing’, prior to release/acceptance. Inspection upon completion of installation for site work shall follow the same SOP, wherein the level of Inspection shall be as per ITP and signed off accordingly. Non-conformances as a result of unacceptable products shall be recorded on the Non-conformance Report and appropriate review and corrective action shall be taken before final acceptance.
19.7
Installation/Commissioning Inspection & Testing
Installation/Commissioning inspection and testing shall be carried out by the relevant Subcontractors and Suppliers in accordance with ITPs submitted. ITP approval shall be provided prior to installation/commissioning commencing. Surveillance, witness and hold activities by the relevant parties will be in accordance with the requirements marked up on the relevant ITP.
19.8
Inspection Release Certificate
Where indicated on the ITPs, an “Inspection Certificate” shall be issued by ALSTOM upon completion. Dispatch of those items/product nominated shall not proceed until this documentation has been issued.
19.9
Inspection and Test Records
Inspection & Test Records shall be produced as inspection & tests progress. These records shall be collected and assembled into MDRs for submittal to ALSTOM for review and ALSTOM approval. MDRs shall be prepared and presented as specified in Contract Manufacturer’s Data Report (MDR) Requirements.
19.10
Inspection Status
The means for providing assurance that the required inspections and tests on products have been carried out shall be by: d. Signed ITPs; e. Inspection Certificates; Relative to that product, and where necessary by physical stamping, labelling, tagging (as required) of that product or parts thereof, as per SOP ‘B06.01 Inspection and Testing’, in order to indicate final acceptance. Nonconforming product/items shall be separately identified / tagged and where practical, segregated from point of use. Subcontractors shall detail methods of establishing Inspection & Test Status in their Quality Plans.
19.11 A05.01 B06.01 B06.03
Related Procedures Management of Measuring and Test Equipment on site Inspection and Testing Inspection and Test Status
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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20.
Audits (AS/NZS ISO 10005 5.19)
Quality Audits shall be performed in accordance with SOP ‘A07.01 Audits’. These will be internal (and external for subcontracted work) and shall be carried out in accordance with the project audit schedule and as considered necessary. Subcontractors shall detail audit requirements in their Quality Plans and shall provide their own detailed audit schedule covering both internal and external audits on their subcontractors.
20.1
Audit Schedule
An Audit Schedule shall be established and progressively updated at appropriate intervals. Separate schedules shall be developed for internal and external audits. These schedules shall be established on the status and importance of each activity or subcontract and shall be varied according to the adequacy of the results. Follow-up audits may be performed where Corrective Action Requests (CARs) have been issued.
20.2
Audits
Audits may be carried out by the Project Safety/Quality Officer, or may be delegated to other appropriately qualified independent personnel as necessary. CARs raised during the audits shall be processed and followed up in accordance with SOP ‘A07.01 Audits’. CARs shall only be closed out after corrective actions have been verified and accepted. Audit records shall be maintained by the Project Safety/Quality Officer and distributed, as a minimum to: a. Director Project Management b. Project Manager c. Project Safety/Quality Officer d. Auditee(s) - Internal or external.
20.3 A07.01
Related Procedures Audits
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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21.
Procedure List
The following, but not limited to, list of ALSTOM procedures are used by ALSTOM to complete the contract works as detailed within this PQP: 1. A03.02 Control of Non-conformances 2. A03.03 Corrective and Preventive Action 3. A04.01 Document Control 4. A04.01.01 Control of System Procedures and Forms Control of Standards & Publications 5. A04.02 6. A04.08 Installing Databases from CD 7. A05.01 Management of Measuring and Test Equipment on site 8. A05.03 Handling Storage Packaging and Delivery 9. A05.03.01 Storage Requirements for Hazardous Material Control of Waste 10. A05.03.02 11. A06.01 Training 12. A06.01.01 Site Induction 13. A06.01.02 Tool Box Meetings 14. A06.05 Consultation Work Breakdown Structure 15. B00.02.01 16. B02.02 Contract Review 17. B02.03 Contract Handover 18. B02.02.01 Order Acceptance and Notification for Power Services 19. B03.01 Contract Administration 20. B03.02 Project Planning and Scheduling 21. B03.02.01 S-curves 22. B03.02.02 Planning & Scheduling 23. B03.04 Project Implementation 24. B03.04.01 Project Reviews 25. B03.04.02 Project Cost Control 26. B03.04.03 Accounting for Variations 27. B03.04.04 Recognition of Sales & Gross Margin 28. B03.04.05 Warranty Provision 29. B04.01 Design 30. B05.01 Subcontractor Assessment 31. B05.01.01 Supplier Performance Reviews 32. B05.01.02 Subcontractor safety and Environmental Management 33. B05.02.03 Power Service Procurement 34. B06.01 Inspection and Testing 35. B06.02 Identification & Traceability 36. B06.03 Inspection & Test Status 37. B10.01 Control of Records 38. B10.F01 Project Filing System © ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.
Annex 1 – Position Descriptions
The following generic positions descriptions apply to the positions detailed on the attached project organisation chart, refer Section 25.
22.1
Project Manager Scope: This project is directed and controlled by the Project Manager. Reports to: Director Project Management Responsibility: a. Overall direction, control and execution of the project in a cost effective manner and in compliance with the project’s commercial, technical, quality, safety and environmental requirements. b. Communication with customer and Independent Engineer. c. Selection of project team personnel. d. Financial progress reporting (monthly). e. Project reporting (internal/external). f. Project contractual compliance including changes to scope. g. Project quality and customer satisfaction. h. Project Environmental, Health & Safety (EH&S) performance. i. Personnel & Industrial Relations. j. Project environmental impact management. Authority: a. To select, appoint and change project team personnel. b. To approve the selection and appointment of subcontractors, consultants or partners. c. To approve financial commitment within the project budget. d. To obtain agreed resources necessary to achieve the project goals and objectives. e. To negotiate variations to the contract. Accountability: a. Achievement of the project goals and objectives including the Quality and EH&S policies. b. Project progress and reporting.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.2
Procurement Manager/Officer Scope: Procurement of items and equipment as required, to supplement the scope of supply by the major plant Subcontractors and as directed by the Project Manager. Reports to: Project Manager. Responsibilities: a. Ensuring the timely and cost effective procurement of plant, equipment and services to meet contract requirements. b. Preparation and issue of enquiries and subsequent assessment of tenders. c. Assessment of subcontractors and their quality systems (in conjunction with the Project Safety/Quality Officer). d. Negotiation, letting and monitoring of purchase orders. e. Administer purchase order variations. f. Disposition of supply non-conformances and develop, implement an monitor corrective and preventative actions ( in conjunction with the Project Safety/Quality Officer). g. Assisting with the preparation, review and monitoring of Inspection and test plans. h. Obtaining vendor data requirements and Manufacturer Data Reports (MDRs) as specified in purchases. i. Special procurement tasks as required by the Project Manager. j. Ensure timely processing of invoices. Authority: a. Initiate and control procurement activities delegated by the Project Manager to meet quality, programme and cost requirements. b. Authorize purchase orders up to the value as delegated by the Project Manager. c. Control further processing and delivery of non-conforming product until the deficiency or unsatisfactory condition has been corrected. d. Initiate action to prevent the occurrence of any supply nonconformities relating to items and equipment ordered. e. Verify the implementation of solutions to supply nonconformities. Accountability: a. On time and on budget procurement as defined by the Project Manager. b. Co-ordination of subcontractors and material logistics with respect to the project programme. c. On time processing of invoices and feedback to project manager on variations and price.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.3
Programmer/Scheduler Scope: Develops the programme and schedule of tasks for the project and updates on direction. Reports to: Project Manager Responsibilities: a. Develop, monitor and update the overall project programme to meet all contractual requirements and project milestones.. b. Develop lower level detail, summary and look-ahead programmes. c. Assist in gaining approval of the programme within the contract time constraints. d. Monitor the progress of the works by obtaining programme updates from sub-contractors and provide regular updates in appropriate detail to the Project Manager and other project team members. e. Monitoring of progress and the effect of changes to the contract. f.
Evaluate all data from engineering, procurement, manufacturing and construction in order to assess overall progress and identify and report deviations from the programme to the Project Manager.
g. Identify and predict potential problems as early as possible in order to allow effective corrective action to be taken. h. Evaluate the effect of and schedule variation work and advise the Project Manager. i.
Re-schedule activities in order to take into account delays and variations following agreement with the Project Manager.
j.
Prepare progress status reports for submission to the Project Manager.
k. Ensure that all personal work carried out is in accordance with the contract, quality assurance requirements and other relevant procedures applicable to the project. l.
Participate, where required, in the disposition of nonconformities relating to the progress of works.
Authority: Control further processing of nonconformities relating to the process of programming/scheduling activities. Accountability: Accurate and timely project programmes to meet contract and project milestones.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.4
Financial Controller Scope: Cost control of the project, ensuring conformity with the ALSTOM financial and commercial policies and practices. Reports to: Project Manager and Financial Controller Thermal Service. Responsibilities: a. Accounting. b. Month end close. c. Prepare cost control review on JDE and Excel. d. Predict revenue and cash flow. e. Correct posting errors and resolve queries. f.
Maintain invoice register for contract and variation income.
g. Liaise with the Financial Controller Thermal Service to ensure conformity with the ALSTOM policies and procedures in relation to the financial and commercial aspects of the project and their implementation on the project. Reporting: a. Prepare project report to management in conjunction with the Project Manager. b. Prepare for and participate in the Monthly Project Review Meetings, record and distribute the minutes. Contract Administration: a. Maintain purchase order register. b. Reconcile all project progress payments to sub-contractors and the customer. c. Ensure all invoices are in accordance with purchase order and that materials have been delivered and inspection reports issued and approve invoices for payment. d. Cash flow management together with cash flow projections and resultant financing gains/losses. e. Maintain records of bank guarantees and/or retention, insurances etc. f.
Maintain foreign exchange register and manage project foreign exchange.
g. Collect, check and countersign all office staff timesheets. Site Administration: a. Collect and check all site staff timesheets. b. Site petty cash (where implemented) c. Maintain site records. © ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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Progress Claims: a. Preparation and submissions of progress and variation claims (including all necessary support documentation). b. Liaise as necessary with Financial Institution and Customer in support of above activity. Authority: a. Initiate action to prevent the occurrence of nonconformities relating to cost control b. Control further processing of cost control nonconformities until the unsatisfactory condition has been corrected. Accountability: a. Accurate and complete reporting in accordance with the ALSTOM policies and procedures in relation to the financial and commercial aspects of the project and their implementation on the project. b. Additional reporting as defined herein. c. All reporting to be progressed and be finalised by the monthly dates set by the Financial Controller, Customer Service.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.5
Site Manager Scope: Management of site construction, commissioning, performance testing, quality & EH&S and industrial relations. Reports to: Project Manager. Responsibilities: a. Ensuring that the plant is constructed in accordance with ALSTOM requirements. b. Ensuring that the plant is constructed in accordance with the relevant Site Agreement. c. Site management and co-ordination of ALSTOM personnel and contractors d. Management and co-ordination of resources to ensure the programme of work is achieved. e. Adherence to the EHS policy and requirements per project SEMP. f. Adherence to the Industrial Relations/Employee Relations Plan. g. Quality requirements as specified in the Project Quality Plan (PQP) and procedures for site works. h. Identify and record any nonconformities relating to products or processes. i. Day to day interfaces with the customer, subcontractors, local authorities and other involved parties, on reporting, etc. j. Advising the Project Manager of potential shortfalls in the supply of plant or equipment to the site. k. Report progress and cost control regularly to the Project Manager. l. When assigned shall also assume the project Safety Adviser role/Inspector role (refer project organisation chart). Authority: a. Purchase from site of equipment/goods/services in accordance with provisions of the Contract and this Plan. b. Control further processing or installation of nonconforming products until the deficiency or unsatisfactory condition has been corrected. Accountability: a. Overall programme and quality of construction at site. b. Overall implementation of the project Safety and Environmental Management Plan (SEMP). c. Overall implementation of the Industrial Relations Management Plan. d. Provisions of adequate EH&S resources, services and facilities at site. e. Overall safety performance of the project at site.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.6
Inspectors (Technical QA) Scope: Quality verification of products and services through physical inspection. Reports to: Project Quality/Safety Officer or Quality Manager as applicable, refer project organisation chart. Responsibilities: a. Quality verification and the physical witnessing, inspection, testing, acceptance or rejection of items, equipment and components in accordance with the Inspection and Test Plans (ITPs) for the Contract. b. Ensure that all personal work carried out is in accordance with the contract, quality assurance requirements and other relevant procedures applicable to the project. c. Disposition of non-conformances and develop, implement and monitor corrective actions as appropriate. d. Assisting with the preparation, review and monitoring of ITPs. e. Ensuring that the procedures applied by the contractors are adequate for effective control of quality for their scope of manufactured work. f. Control and verification of corrective action when non-conformances are identified. g. Preparing and providing records of inspection and test. h. Verify on the relevant non-conformance report, the implementation of solutions to nonconforming product and re-inspection and acceptance of same. Authority: a. Accept or reject items, equipment and components during the manufacturing and installation stages of the Contract in accordance with the ITPs for the items or products. b. Control further processing and or delivery of non-conforming product until the deficiency or unsatisfactory condition has been corrected and accepted. Accountability: a. Quality verification of products and services through physical inspection of work activity and records of work.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.7
Quality Officer/Representative Scope: Project Management representative on project matters relating to quality assurance (QA). Reports to: a. Project Manager (direct reporting line). b. Functionally reports to the corporate Quality Manager. Responsibilities: a. Identification and preparation of contract specific Work Instructions and Inspection Test Plans (ITPs) as necessary. b. Regular review and updating when necessary of the projects quality system and related Project Quality Plan (PQP). c. Implementing the quality requirements of the PQP. d. Training project team members in the project quality system and the PQP. e. Auditing and monitoring the requirements of the PQP and project quality system. f. Ensure subcontractor/supplier quality requirements are met through ITPs, subcontractor/supplier assessments and quality audits. g. Carrying out internal and external quality audits. h. Liaise with Quality Manager to ensure conformity with corporate quality requirements, and provide assistance on corporate quality assurance matters. i. Monitor the effective operation of and corrective action systems through Non-conformance Reports (NCRs) and Corrective Action Requests (CARs). j. Participate, where required, in the disposition of non-conformances and in the development, implementation and monitoring of corrective actions. k. Review quality records and review and approval of Manufacturer Data Reports (MDRs) in conjunction with other designated personnel. l. Ensure inspection tasks are monitored and recorded and initiate appropriate corrective actions where necessary. m. Ensure all work is carried out in accordance with the Contract QA requirements and other relevant procedures applicable to the project, through surveillance. n. Special tasks as required by the Project Manager / Site Manager. o. Providing monthly reporting to Quality Manager on QA activities. Authority: a. Resolve all project QA matters. b. Verify and approve project corrective and preventive actions relating to nonconformities. Accountability: a. Implementation and maintenance of the project quality system.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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22.8
Safety Adviser Scope: Safety and Environmental Management Reports to: a. Project Manager (direct reporting line). b. Functionally reports to the corporate EH&S Manager. Responsibilities: a. Co-ordinate the implementation of the project Safety and Environmental Management Plan (SEMP). b. Carry out regular inspections of the work area with the respective project area members. c. Verify the effective implementation of the systems through planned audits. d. Assist at regular training talks, safety inductions and assist supervisors to develop area specific and generic tool box meeting topics. e. Provide advice on the development of Job Safety Environmental Analysis’ (JSEA’s) and operating standards. f. Advise supervisory staff and employees in the implementation of strategies to identify and control potential hazards. g. Develop and implement the project safety training programme. h. Provide assistance to supervisors with accident/incident investigation. i. Prepare significant accident/incident reports and co-ordinate investigation. j. Co-ordinate rehabilitation activities with the Site Manager. k. Attend pre-start meetings for each new subcontractor. l. Provide reports for project management advising of trends on site and provide recommended action plans. m. Conduct informal and formal safety inspections and audits of the project EH&S system. n. Review Subcontractor safety performance. o. Conduct the project specific safety inductions. p. Lead safety improvement meetings. q. Attend and participate in project safety tool box meetings. r. Be familiar with all relevant statutory requirements and industry practices. s. Work with the respective supervisors to overcome day to day problems in safety and environmental that may occur. t. Conduct audits against the requirements of the project SEMP. u. Managing activities within budget. Authority: a. Control further processing of nonconformities relating to unsafe and environmentally unacceptable practices.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
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Accountability: a. Reporting performance against project goals and objectives including: b. Lost Time Injuries (LTI). c. Safety statics. d. Environmental NCR’s/incidents. e. Operations within budget.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
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22.9
Supervisor Scope: Control and execution of the work in a cost effective manner. Reports to: Site Manager / Project Manager Responsibilities: a. Ensuring the functional and quality aspects required and specified are attained. b. When assigned shall also assume the Inspector role (refer project organisation chart). c. Assisting to define technical interfaces and reviewing technical documentation. d. Planning and implementation of assigned installation/ erection/ commissioning. e. Assisting with the preparation of technical and vendor data requirements of purchasing documentation as required. f. Ensure that all personal work carried out is in accordance with the Contract, quality assurance (QA) requirements and other relevant procedures applicable to the project. g. Liaison with the Project Manager and subcontractors as assigned. h. Participate, where required, in the disposition of non-conformances and develop, implement and monitor corrective actions. i. Assisting with the preparation, review and monitoring of Inspection and Test Plans. j. Special tasks as directed by the Boiler Superintendent, Site Manager and Project Manager. k. Co-ordinate with other faculties, consortium partners on site to ensure expedient execution of works. l. Maintaining Site ITP’s. m. Scheduling, controlling and ensuring inspection, testing and commissioning tasks are carried out in accordance with site ITP’s. n. Organising and participating in Site quality and safety audits according to schedule. o. Inspect the works for compliance with the contract, relevant specifications and codes. p. Verify/witness inspection and test activities in accordance with Contractor/supplier ITP requirements. q. Issue and disposition of Action Requests for non-conformances. r. Issue of Release Notes where applicable. Authority: a. Supervision of allocated personnel. b. Accept or reject items, equipment and components during the manufacturing and installation stages of the Contract in accordance with the Inspection and Test Plans for the items or products. c. Control further processing and or delivery of non-conforming product until the deficiency or unsatisfactory condition has been corrected and accepted. Accountability: a. Quality verification of products and services through physical inspection. b. Implementation of the project Occupational, Health and Safety Plan for the relevant area of responsibility.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
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22.10
Site Administration Officer Scope: Document Control Reports to: Site Manager / Project Manager Responsibilities: a. Implement the necessary procedures to provide a satisfactory and efficient documentation control system for the control and management of all project documents. b. Establishing and maintaining a document filing system. c. Planning and supervising the document flow to/from all parties. d. Issue all documents and drawings, originate and verify transmittals, verify receipt of the documents issued, record the issuing data, monitor and maintain these records. e. Maintenance and control of specifications, codes and standards according to the Contract or as otherwise approved. f. Maintenance and upkeep of relevant procedures applicable to the project and revisions thereof. g. Provide project management with exceptions report indicating those documents which were not issued on schedule or those with changed issue date. h. Establish and maintain a database to record and track all project correspondence. i. Provide exception reports identifying correspondence which has passed the required response date. j. Ensure that obsolete/superseded quality documents are identified and removed from all areas of distribution and use. k. Notify the Project Manager of any deficiencies in the system and the corrective actions to improve the system. l. Participate, where required, in the disposition of non-conformances and develop, implement and monitor corrective actions. m. Co-ordinating the receipt of MDRs from Suppliers and their safe maintenance. n. Undertake special tasks as directed by the Project Manager. Authority: a. Control all documentation. b. Control further processing of non-conformities relating to document control practices. Accountability: a. Identification, distribution, filing and traceability of project documentation
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
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23.
Annex 2 – Safety and Environment Management System
The project safety and environmental management system is fully defined in the project Safety & Environmental Management Plan (SEMP).
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
Document Name:
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Document Number:
Revision:
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24.
Annex 3 – Applicable Legislation
The following state/territory and federal legislative and or regulatory codes shall apply to this Contract: Add regulatory codes / legislation list here
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
ABCD
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Document Number:
Revision:
Revision Date:
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Customer Name, Project Title, Contract No. XXXXX
25.
Annex 4 – Project Organisation Chart
Project Manager Name
Engineering Support Name
Industrial Relations Manager Name
Site Manager Name
Contractors
Site Support
Name Role
Mechanical Names
Name Role
Electrical Names
Name Role
Fitters Names
Name Role
Riggers Names
Name Role
Welders Names
Planning Department
Workshop Support
Document Control
Project Quality Officer/Engineer
Project Safety Officer/Engineer
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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