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DOC ID© Chevron 2005

Quality Basic Conceptand Implementation 14 June 2006Tripatra Fluor ConsortiumQAQC DepartementTF Main Office-Duri, Sumatra



2DOC ID© Chevron 2005

Quality Basic ConceptAnd Implementation

WellcomeWellcome

toto

Flexible Program ManagementFlexible Program Management





Content:Content:

What is Quality?What is Quality?Quality in TF FPM PracticeQuality in TF FPM Practice





Quality:Quality:

What ?What ?


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How do we make things better?




Quality begins with the PDCA cycle and an

understanding of variation --not with ISO 9001

DALE K. GORDON is director of quality and business improvement for Rolls-

Royce Corp.'s Defense North American Business Unit in Indianapolis.

CONTINOUS IMPROVEMENT





Plan : Identify an opportunity and plan for change.

Do : Implement the change on a small scale.

Check : Use data to analyze the results of the change and

determine whether it made a difference.

Act : If the change was successful, implement it on a widerscale and continuously assess your results. If the change

did not work, begin the cycle again.




ISO 9000:2000 defines:

System is :

“ a set of interrelated or interacting elements" (clause

3.2.1)

Quality Management System is:

"a management system to direct and control an

organization with regard to quality" (3.2.3)







The system is a culmination of whatever the organization

says it is through the processes, activities and knowledge

it uses to meet product specifications and customer needs

Process

Activities

Knowledge

Product Spec&

CustomerNeeds





THE COST OF QUALITY

The “cost of quality” is NOT the price of creating a quality

product or service.

It’s the cost of NOT creating a quality product or service





THE COST OF QUALITY

Every time work is redone, the cost of quality increases. Obvious

examples include:

The reworking of a fabricated item.

The retesting of an assembly.

The correction of an invoice statement, report.

The reworking of a service, such as welding, building,

compacted ground, etc

In short, any cost that would not have been expended if

quality were perfect contributes to the cost of quality.





Quality:Quality:

Who ?Who ?





QUALITY CONTROL AND QUALITYASSURANCE

Assurance:

The act of giving confidence, the state of being certain or the act of makingcertain.

Quality assurance:

The planned and systematic activities implemented in a quality system so that quality requirements for a product or service will be fulfilled.

Control:

An evaluation to indicate needed corrective responses; the act of guiding a process in which variability is attributable to a constant system of chancecauses.

Quality control:

The observation techniques and activities used to fulfill requirements for quality.






Function in quality can vary from one organization to another. Nevertheless, a few primary jobclassifications are consistent, regardless of industry or organization:

Analysts initiate and/or coordinate quality-related data fromproduction and service activities and report these data usingstatistical techniques.

Associates are involved in quality improvement activities or

projects but not necessarily full-time. Auditors systematically inspect and examine a quality system to

ensure compliance to requirements.

Inspectors audit and report on materials, processes and productsusing variable or attribute-measuring instruments and techniques,to ensure conformance with the organization’s quality standards.






Quality engineers design, install and evaluate quality-assurance

process-sampling systems, procedures and statistical techniques; designor specify inspection and testing mechanisms and equipment; analyzeproduction and service limitations and standards; recommend revisionof specifications when indicated; and formulate quality assurancepolicies and procedures.

Quality managers oversee the administration of quality, processand/or business improvement efforts. They typically have authority over

a clearly defined area of the organization and a number of directreports.

Specialists perform specific functions within a quality initiative, such asstatistical analysis or testing. They have extensive experience ortraining.

Technicians perform basic quality tasks to track, analyze and report on

materials, processes and products, ensuring they meet organizationalstandards.





Content:Content:

Quality in TF FPM PracticeQuality in TF FPM Practice





KEY ISSUES

CPI & TF Management Expectations from Kick-off Meeting (20May05)

Mutual Expectation:

Safety, Cost and Quality are the three keyelements to our success





QUALITY BARS

COS/

CS/

RC

FPM Q u a

l i t y

Q





Is FPM CONTRACTOR delivering

High Quality,

Competitively priced work,

Safely and on time

KEY ISSUES

?





QTF FPM QUALITY SYSTEM GENERALTF FPM QUALITY SYSTEM GENERAL

Operating

SystemRequirements

ProvenProcesses &

Procedures

+

The TF Quality Program is based on

the FLUOR Operating System

Requirements (OSR) and Tripatra’s proven process & procedure





PROJECTEXECUTION





EXECUTIONPLAN

Content of

TF Project

Execution Plan

QUALITY





MANAGEMENTSYSTEM

Quality ManagementSystem is

the shared

responsibility of all

project team members

–

Engineer

Designer

Supplier/

Subcontractor,

Field personnel

QUALITY





MANAGEMENTSYSTEM

Content of

Quality

Managements

System

List of the forms





QUALITY PLAN

Quality Plan establishestop-level quality

assurance program

requirements –

References detailedimplementing

procedures, practice and

plans





TF DELIVERABLES LIST

Content of

Quality

Managements

System

Contract

Deliverables

HOW QUALITY IS ACHIEVED IN TF FPM





FPM CONTRACTOR

Q U A L I T Y A U D I T S

TF CONST

SUPERVISION/SUBCONTRACTOR

TF

SUPPLY CHAIN

MANAGEMENT

TF

ENGINEERING

DESIGN

QUALITY

CONTROL/ SURVEILLANCE

QUALITY

ASSURANCE/SURVEILLANCE

ACTIVITY

QUALITY

PLAN

HOW QUALITY IS ACHIEVED IN TF FPMORGANIZATION

ENGINEERING PROCUREMENT

E CP

QUALITY

CONTROL/

QUALITY

ASSURANCE

TF CONSTRUCTION

EQUIPMENT

CONSTRUCTION

MAINTENANCE,

REPAIR,

RECONDITION

C M

QA/QC ORGANIZATION





Construction

Equipment

Maintenance

Overall Quality System Control

Supply Chain Management

Site Construction QC Surveillance & Testing

Q QThis group is responsible for verifying the quality throughout allFPM Contractor activities

Project QA/QC Manager

Charles J. Brazel

Audits

M. Satir Hasibuan

Sastro Kuncung

HO

Quality Surveillance

Edward

SLN


Delta Ananda

SLS


Brammie D.K

CEM

Quality Inspector

(vacant)

Technical Assistant

Lydia Fanny

Quality Assurance- Contract

Zulkarnain H., Budi Purwanto

Quality Assurance- Procurement

Kiagus Ismail Hamzah

Vendor/Supplier Quality Surveillance

As required by WA

QC Inspectors QC Inspectors QC Inspectors

HO & SLN

NDE Coordination

Taufiq Rahman

SLS

NDE Coordination





How Quality is cascaded down to TFHow Quality is cascaded down to TF

SubcontractorSubcontractor

TF Subcontractor’s Quality Plan





FPM Contractor

TF Subcontractor s Quality Plan

CPI User + DOA

TF Contracts TF QA/QC TF Subcontractor

Tender Process

-Exhibit F

-Specification

(CPI, Codes, etc)

•Review Quotation•Pre Bid Meeting

•Site Surveillance•Audits

Develop

WAF

Comply with

Exhibit-F

(Subcontractor’s

quality

requirement)

&Specification

All Subcontractors performing work on the FPM Project shall

implement specific Quality Program adequate for the FPM project

quality management needs and requirements





Table of Contents

Quality Requirements for FPM Subcontractors

1.1 Quality Plan

1.2 Quality Objectives

1.3 Construction

1.3.1 Organization

1.3.2 Field Design Change Control

1.3.3 Purchasing

1.3.4 Document Control

1.3.5 Identification and Traceability of Equipment and Material

1.3.6 Inspection and Testing

1.3.7 Inspection, Measuring and Test Equipment

1.3.8 Quality Process Control

1.3.9 Inspection and Test Status Procedures & Reporting

Requirements

1.3.10 Control of Non-Conformance1.3.11 Material and Equipment Receiving, Handling, Storage and

Maintenance

1.3.12 Quality Records





DOCUMENT HIERARCHY





CTOP-400

Data Sheets

CPI Specification

TF FPM Specifications

Referenced Codes and Standards

Approved for Construction Drawings

Vendor/Supplier/Subcontractor Standards

DOCUMENT HIERARCHY

QUALITY :QUALITY : in TF FPM Practicein TF FPM Practice






1. Planning the

Work

2. Work out the

Plan

3. Document your work

Contract Awarded Work Execution

1. Develop Quality Plan

2. Develop Procedures

3. Develops the generic ITP

4. Establish Quality Organization

Develops the

specific ITP

Implementation of

the Quality Plan

Execute the workbased on the

specific ITP

Quality RecordsDocumentation

Record Inspectionand Test Report

TF Subcontractor’s Quality ImplementationTF Subcontractor’s Quality Implementation





Share Quality ResponsibilityShare Quality Responsibility

1. Planning the

Work

2. Work the Plan

3. Documentingthe work

TF Quality OrgTF Subcontractor

Quality Org

1. Review and approve Quality Plan

2. Review Procedures

3. Review the ITP

4. Review Quality Personnel

1. Develop Quality Plan

2. Develop Procedures

3. Develops the generic ITP

4. Establish Quality

Organization

1. Quality Assurance

2. Site Surveillance

3. Priodically Audits

Implementation of the

Quality Plan, Procedures,

ITPs

Assure and Audit QualityRecords Documentation

Records of Inspection andTesting Report, Projects

Document






Deliver the service in Quality

When you are as the TF FPM Subcontractor

and get the Work Order/Requisition, what

will you do ?







T F

Customer

TF FPM Subcontractor

Service Provider

Construction Services

No ActivitiesControlHold/ Witness/ Spot

Witness

ControlHold/ Witness/

Spot Witness

Acceptance

Criteria

Reference/

Document

QUALITY :Q in TF FPM Practice






T F

Customer

TF FPM Subcontractor

Service Provider

Construction Services

1. Planning the Work

2. Work out the Plan3. Document Your Work

ControlHold/ Witness/ Spot

Witness

Q






In order to deliver the QualityIn order to deliver the QualityService You have to:Service You have to:

1. Plan your work 1. Plan your work

2. Work your plan2. Work your plan

3. Documentation3. Documentation







1. Plan your work 1. Plan your work

- Read & Examine and socializes the Work Requsition

among the crew team

- Prepare Inspection and Test Plan (ITP) and socializes

among the crew team

- Prepare and/or develop work procedure

- Prepare other documents (JSA, GWP, etc)







2. Work your plan2. Work your plan

- Execute the work to follow the Work Requsition’s scope

- Execute the work to follow the Inspection and Test Plan

(ITP)

- Execute the work to follow the work procedure- Work beyond the JSA, GWP,







3. Documentation3. Documentation

- Progress Report on the Work Requsition’s scope

- Testing & Inspection Report based on the ITP

- Improve the work procedure based on the best practice

during the execution

QUALITY :QUALITY : What ? What ?





Satisfy

Happy to pay as the invoice

Happiness Long term relationship

Then...TF FPM will feel?

END





END

Thank You

TF FPM hand in hand to reach our goal

Deliver the service On time,Efficiently, Safe with high

Quality





ContentContent

Site Coordination withSite Coordination withConstruction GroupConstruction Group

SITE COORDINATION





SITE COORDINATION

FPM Subcontractor

QC Inspector CS Engineer

CS

SuperintendentSr. QC Inspector

CPI Construction

Representative

Coordination Line

SITE COORDINATION- Work Requisition Process Flow-





Work Requisition Process Flow

CPI User TF CS & PC TF QA/QC TF Subcontractor

Issue WR F002

Get WR F002 completion

approval from CPI

Received copy for

info and quality

control

implementation

Execute TF’s WR

Data

Complete

?

Receive TF’s WR, and

review

No

YesRe write a TF’s WR to

Subcont, supervise joband distribute copy to TF

PC, QC, HES

TF’s WR

Complete?

No

Sign for QC

acceptanceYes

Yes

Compile Report and get

completion approval

Check SOW and data

completeness

Data

Complete?

No

Close by signing

WR F002

Job

complete

d?

Back up data for

invoicing

No

Yes

Sign for TF’s WRtotal completion

and return to

Subcontractor

SITE COORDINATION- Inspection & Test Plan (ITP) Flow-





CPI User TF CS Engineer TF QC Inspector TF Subcontractor

Develop ITP

Supervise the

project to follow

the ITP &

procedures

Review

Copy and distribute to

CS & QC

Accept?ReviseNo

Yes

Project Execution

& ITP

Implementation

Quality Control

Surveillance

based on ITP

NCR

Respond to NCR

and implement

corrective action

YesYesSupervise the

corrective action

implementation

Surveillance Report

No

Get input from User and

CS on inspection points

and return to

Subcontractor

User to identify

hold and witness

points

Yes

CS to identify hold

and witness points

SITE COORDINATION- Request for Information (RFI) Process Flow-





TF Engineering TF CS Engineer TF QC Inspector TF Subcontractor

Initiate RFI

Get Info and

verify

implementation

Log

Accept and

Implement

Need

Design

Engineerin

g Support.?

Received &

Review

LogTransmit to

Subcontractor

Copy to QC and

log

NoYes

Respond to RFI Respond to RFI

SITE COORDINATION- Non Destructive Examination (NDE) Process Flow-





TF Subcontractor

Construction

TF CS Engineer TF NDE Testing

Coordinator

TF Subcontractor

NDE Service (SCI)

Finished Job

Execution

Requiring NDE

Instruct

Subcontractor to

repair the job

Review request and

Determine NDE &

order NDE Service

Interpretation and

Report

Test Accept?

Receive order

No

Yes

Testing

Verify Report

Check Job

Completion and

Request NDE to

TF QC Inspector

Job Pass QC?

No

Repair the job

Accept job

completion

Yes

Send copy to CPI

for information

Data Base ReportEvaluation

Data Base Report

Evaluation

Regular reporting

on data base,

weekly andmonthly

quality basic concept

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