INSPECTION AND TEST STATUS

7.4.3 Verification of Purchased Product

Store personnel receives the materials and is accepted based on fulfilling requirement of incoming materials inspection. Quality Control engineer inspects the same materials and conduct sampling and testing as per approved ITP or QAP.

Receipt Inspection Items received from H.O. like Cement, Reinforcement steel, Admixture etc.

should be accompanied by Manufacturer‟s Test Certificate. Items received from vendors at site should be inspected / tested by the QC Engineer and records shall be maintained. Rejected materials are to be returned to the vendor and details are entered in the register. The Inspection and Test Plan and method of testing for incoming materials is defined in the Quality Assurance Plan.

a) In process Inspection and testing

In process Inspection and testing shall be carried out as per test/Inspection Plan and test results shall be recorded. QC Engineer will be responsible for this activity. QA test plan for in process testing and receiving inspection is detailed in Quality Assurance Plan. List of processes for Inspection/testing is enclosed.

b) Final Inspection and test

Before asking the Engineer In-charge for joint inspection, thorough check shall be carried out by QC Engineer. Project In-charge will make request for inspection to Engineer In-charge.

B) INSPECTION AND TEST STATUS

Inspection and Test Status of materials and processes shall be identified by tags, marking or by documenting the test results indicating the conformance of the material/ processes based on the inspection/test performed. Non-conforming materials/processes shall be clearly identified to avoid their unintended use till the non-conformity is removed.

All records shall be maintained by the QA Engineer on completion and acceptance of an activity by Client. All the measuring test and inspection Equipment‟s shall bear a sticker signed by the site QA In-charge containing all details related to its identification & calibration. Periodic cross verification of Equipment shall be done by the site QA In-charge for its accuracy.

Nicmar Hyderabad. ^{Page 108}

7.5 PRODUCTION AND SERVICE PROVISION

7.5.1 Control of Production and Service Provision

To establish, implement and maintain a procedure for control of production and service provision for all permanent and temporary works in the site. The same is carried out by approved methodology of the respective activity like excavation, concreting for raft foundation, etc.

7.5.2 Validation of Processes for Production and Service Provision

Validation of process for product shall be done based on the QCP approved by client.

7.5.3 Identification and traceability

Product identification and traceability shall be carried out for critical items. Paperboard shall be kept near the critical material, which posses expiry date and these shall be depleted in the

“First in First Out” system.

Identification boards shall be displayed near the reinforcement steel/ structural steel indicating the diameter/size/specification.

All critical materials (other than coarse and fine aggregates) purchased shall be accompanied by Manufacturer‟s test certificates.

Details of Product Batch no., Lot no., Location, Date of use etc. shall be maintained in product for all critical materials. Records shall be maintained by QA Engineer.

For example for cement Batch number shall be traced out with manufacturer material test certificates and Week number shall be traced out from cement bag and related documents.

For steel Lot number shall be traced from manufacturer test certificate and at site from tags which is tied to the Reinforcement and as well as it will be transferred into issue register and steel register book, so that the traceability of steel shall be ensured. Product like Precast items shall have the product identification and traceability.

7.5.4 Customer Property

There is no supply of materials by customer. It is applicable for some embedment parts and the same shall be controlled in the following manner: -

The indent shall be reviewed and approved by site in charge and submitted to the customer.

The store In-charge shall verify the quantity of the customer-supplied materials.

Project In-charge shall ensure that the Manufacturer‟s test certificates are supplied by the customer with each lot of material. In addition, random sampling and independent testing of customer supplied-product shall be carried out. Non-conforming materials shall be returned to the customers and record maintained.

Nicmar Hyderabad. ^{Page 109} 7.5.5 Preservation of Product

All the material received at stores is preserved at store. Material is accounted and entered in stores ledgers. The care is taken to store the material at appropriate place. They are traced appropriately with their identification of the material.

The main product required for this job is as follows:

a) Cement

h) Structural Steel for ladders, lightening, Earthing etc.

i) M.S.Pipes a) Cement

Cement shall be stored in closed godown as per Indian standard practices (IS 4082) and the same cement shall be issued to site as per the requirement. The cement older than six months will be rejected from its use.

b) Admixture

Admixture shall be stored in Closed Godown and same shall be issued to site as per requirement.

c) Reinforcement

Reinforcement should be stored diameter wise and stacked over the wooden sleepers or pedestals. Tags will be used to identify each diameter of reinforcement.

d) PVC Water Stopper

PVC Water Stopper should be stored in open or closed godown as per size and should be covered. Material code shall be written over it and tags will be used to identify each.

e) Bituminous paint

Bitumen paint shall be stored in closed go down and shall be issued to site as per requirement.

Nicmar Hyderabad. ^{Page 110} 7.6 CONTROL OF MONITORING AND MEASURING DEVICES

A list of all inspection, measuring and test Equipment‟s shall be maintained with the details of the Equipment Identification number, Calibration frequency, Date of Calibration, next due date of calibration, calibration agency (in-house or external lab). In-house calibration shall be carried out as per equipment manual. QA In-charge shall be responsible for the calibration of the equipment and maintenance of documents and records. List of Inspection, Measuring and Test Equipment‟s has been prepared and given in Annexure-4.

All the inspection, measuring and test equipment shall bear sticker signed by the site QA In-charge containing the details related to its identification and calibration status. Periodic cross verification of Equipment‟s shall be done by site QA In-charge for its accuracy.

8.0 MEASUREMENT, ANALYSIS AND IMPROVEMENT

Nicmar Hyderabad. ^{Page 111} 8.2 Monitoring and Measurement

8.2.1 Customer Satisfaction

Customer‟s feedback shall be taken proactively once in every Three Months for various attributes of project execution. A customer satisfaction index shall be assessed and corrective action shall be taken to improve QMS‟s performance

8.2.2 Internal Audit

Management Representative will send quarterly audit plan and SMR will prepare audit schedule for internal audit before scheduled date of internal audit which includes name of trained internal auditors, auditor, date & time, duration of audit & location. The same shall be distributed to all concerned. Internal Quality auditing shall be carried out at the interval of three months.

As soon as audit is over, SMR shall ensure that NCR‟s are duly endorsed with proper corrective action and data by the auditor and are sent to MR at HO. These non-conformities are brought to the knowledge of Site In-charge who will conduct and chair the management review meetings after preparing necessary agenda for the same. During this meeting site In-charge shall discuss the reasons/causes of non-conformity with all Section In-charges and suggest corrective action.

Corrective action plan shall be finalized with the staff for closure of non-conformity report. SMR shall maintain a register of non-conformities stating details of non-conformities and corrective action taken for closing non-conformity.

The following audit records shall be maintained: - a) Auditor‟s note to MR.

b) NCR Form c) Audit Plan d) Audit Schedule e) NCR Register

f) Report of Site Management Review Meeting.

g) Audit Report.

SSTPP NDCT shall be provided to access all the Quality documents maintained at site for any audit conducted by them.

8.2.3 Monitoring and Measurement of process

Monitoring and Measurement criteria are decided for various processes at site, which are termed as "Process Parameters". These are listed for each major process and are as shown in various activity process plans. The results of the process measurements are assessed with those

Nicmar Hyderabad. ^{Page 112} planned. If these are found to be not in line with the planed ones suitable corrective actions are taken.

8.2.4 Monitoring and Measurement of Product

Monitoring and Measurement of product are done at project sites. Inspection and testing requirements are documented in Inspection and Test plan (ITP). The ITP gives characteristics to be tested, applicable codes, testing methods, acceptance criteria, variance allowed etc.

The record of test result as evidence of conformity to the acceptance criteria is maintained.

If any deviations in the results are noted then such products are segregated and they are not used.

Also deviations if any from acceptance criteria are validated from clients and then on its acceptance only material are used.

8.3 CONTROL OF NON-CONFORMING PRODUCT

a) The site ensures that the nonconforming products are not used in the works and are identified and are segregated.

b) The non-conformity in the product shall be noted at the time of inspection and testing by Quality Control Engineer. In case of non-conformity product he shall take appropriate action &

reporting the same to Project Manager.

c) The products, which received from clients, have identified as non-conformity by Quality Control Engineer shall be segregated and reported to clients through Project Manager.

d) Product found nonconforming after receiving inspection and in-process inspections are identified and segregated till disposition is decided.

8.4 Analysis of Data

Data generated from the above processes is analyzed for initiating corrective and preventive action.

Nicmar Hyderabad. ^{Page 113} 8.5 IMPROVEMENT

8.5.1 Continual Improvement

The site has targeted quality objectives based on company‟s Mission-Vision Quality Policy.

Results obtained while analyzing the data shall be used in further improving the Quality Management System. Results of Internal audits Data shall be analyzed and actions shall be taken for continual improvement of the Quality Management System. Data from various sources shall be analyzed and corrective and preventive actions shall be planned.

8.5.2 Corrective Action

Corrective actions are initiated once the nonconformity is detected in view to eliminate its root cause and to prevent its reoccurrence. The Site In-charge shall initiate the corrective actions as and when nonconformity is encountered.

Corrective actions include following actions:

Nonconformity are reviewed Root cause are investigated

Actions are evaluated and decided in view to avoid its re-occurrence Actions determined are implemented

Records of such actions are recorded and are copied to CMS and MR Corrective actions so taken are reviewed for its appropriate Implementation.

8.5.3 Preventive Action

The company has a system to initiate preventive actions for the events, which shall result in nonconformity at later stage. These events can be detected during the safety and quality audits.

The Project Manager shall initiate the preventive actions as and when felt necessary.

The actions taken during the preventive actions are as follows: - Events of potential nonconformity are reviewed

Actions needed are evaluated and decided in view to prevent its occurrence Actions determined are implemented

Records of such actions are recorded and are copied to CMS & MR

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