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ITD CEMENTATION INDIA LTD

INTEGRATED MANAGEMENT SYSTEM


PROCEDURES









































INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 1


Version 1.0 Page 1 of 6
ITD Cementation India Ltd














PROCEDURE P-1 : CONTROL OF DOCUMENTS


















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 1


Version 1.0 Page 2 of 6
ITD Cementation India Ltd

1.0 PURPOSE

The purpose of this procedure is to ensure that all documentation of Integrated
Management System including externally originated documents are controlled.

2.0 SCOPE

This procedure covers all documentation prepared for defining Integrated
Management System.

3.0 RESPONSIBILITY

Direct responsibility for implementation & maintenance of this procedure shall be as
follows:

a) IMS Apex Manual and
Procedures
Document controller at BU
b) Project specific IMS documents
including Quality / Environment
/ Safety Plan
Respective Project In Charge
c) Externally originated
documents

At Project Site

At offices other than Project
Sites



Project In Charge

Document Controller / Respective HOD

4.0 DEFINITION

1
st
level document IMS Apex Manual

2
nd
level document IMS Procedures (including Data Sheets, Formats for
Records / Tags / Labels / Placards)

3
rd
level document Operational Control Procedures

Externally originated
Documents
All Standards / Codes / Legal Acts referred in IMS or in
contract for use as reference documents.

Annexure This document to be used as reference guidelines for
preparation & maintenance of project specific Quality /
Environment / Safety Plan. These shall also be
treated as externally originated document for
document control purpose. This contains following
types :

a) Various Data Sheets defining process &
inspection parameters.





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 1


Version 1.0 Page 3 of 6
ITD Cementation India Ltd

b) Various Work Instructions & operational control
procedures.

c) Improvement Programmes.

d) Specimen formats for records.

5.0 PROCEDURE

The numbering system followed for IMS documentation is given in DS-1/1.

All IMS documentation or their amendments shall be reviewed & approved by the
following authorities, prior to issue.

a) IMS Apex Manual Managing Director
b) IMS Procedures except Purchase,
Commercial and Stores
Director & General Manager
c) IMS Purchase and Commercial
Procedures
Director Commercial
d) IMS Stores Procedure
d) Project specific Quality Plan. Contract Manager
e) Project specific IMS documents except
for Quality Plan.
Project In Charge


M R shall preserve Master Copy of IMS Apex Manual and Procedures. Only two
hardcopies of Apex Manual and Procedures shall be prepared and stamped
Controlled Copy. A copy each will be with MR and Document Controller, at BU.
Softcopy of Apex Manual and Procedures shall be write protected and M R will
have password for modifying the same.

IMS Apex Manual and Procedures shall be made available on computer server of
the organization in the public folder ISO as pdf files. Wherever access to server is
not available, softcopy shall be made available on CD.

All printed copies of Apex Manual and Procedures will be automatically marked as
uncontrolled Copy

Quality, Environment and Safety plan as also all External Originated Documents
shall be with the Project In Charge. These copies shall be marked Controlled
Copy. Copies of these documents shall be issued after marking as uncontrolled
Copy

For any amendment in IMS document, the concerned person who requires the
amendment shall communicate the same to MR/AMR. Requirement of such
amendment in IMS documentation shall be discussed with respective approving
authority. After approval amendment shall be incorporated in the relevant document
(Soft copy).





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 1


Version 1.0 Page 4 of 6
ITD Cementation India Ltd

For any amendment in the IMS Apex Manual and Procedures, the version shall be
incremented by 1.0 to denote the amendment status. This exercise will be carried
out in the month of December every year. Status of amendments shall be recorded
in R - 1/1 and shall be maintained at office of MR.

For any amendment in Quality / Environment / Safety Plan, the version shall be
incremented by 1.0 to denote the amendment status. Status of amendments shall
be recorded in R-1/1 and shall be maintained at office of Project In Charge.

One softcopy copy of the obsolete IMS Apex Manual and Procedures shall be
maintained in the server in user area of MR and also a back up in CD shall be
maintained.

Obsolete version of Quality / Environment / Safety Plan shall be stamped
Obsolete and shall be retained in the office of Project In Charge till project
completion.

Latest standards shall be procured and the obsolete ones shall be replaced. A copy
of the obsolete standards/ documents of external origin shall however be
maintained.

IMS records shall be maintained as per formats given in the document. However if
the format(s) other than that given in this system documents is followed, the same
shall be included in the Quality / Environment / Safety Plan of that site.

6.0 CROSS REFERENCES
IMS Manual: Section 4.4

7.0 RECORDS
R 1/1: Amendment status record

8.0 RECORDS AVAILABILITY
R 1/1: Document controller for IMS Apex Manual and Procedures
: Project In Charge for Quality, Environment, Safety & Health Plan

9.0 RECORD RETENTION
As per procedure P-2























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 1


Version 1.0 Page 5 of 6
ITD Cementation India Ltd

DATA SHEET - DS 1/1 : DOCUMENT NUMBERING SYSTEM

1.0 ABBREVIATIONS

IMS - Integrated Management System Manual
P - Procedure
OCP - Operation Control Procedure
DS - Data Sheet
R - Specimen Record format
TL / CB / WS - Tag - Label / Caution Board / Warning Sign*

* These are used to identify status at a particular given time. These should not be
considered as Quality / Environment / Safety records and need not be preserved
as these are destroyed after the purpose is served.

2.0 BASIS FOR NUMERICAL CODES

Each Procedure has unique identification number. Procedure number should start
with the procedure abbreviation P followed by a serial number.

Work Instruction, Data Sheet, Record, Tag - Label shall be numbered in the
following sequence

a) Abbreviation of the document followed by ' - '
b) Serial No of the document followed by ' / '
c) Serial No of the Procedure or abbreviation of Apex manual where this is
referred.

For specimen format specific to a Project / Site, which are not identical to the
standard formats, the Record numbering shall be as follows: R / Code No. /
Relevant Procedure No. The code No. may be alphabetical, numeric or
alphanumeric. The same numbering system shall be followed for DS, OCP, TL
etc.

3.0 EXAMPLES OF THE NOMENCLATURE

For example, procedure number for Marketing & Proposal is P-6, where P stands
for procedure & '6' is the serial number of the procedure.

Data sheet number 1 for Marketing & Proposal Procedure shall be as DS-1/6,
where, in sequence, 'DS' stands for Data Sheet, 1 is the serial number of the Data
Sheet given in the Procedure, '6' is procedure serial No. Same method shall be
followed for the numbering of OCPs and Record.























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 1


Version 1.0 Page 6 of 6
ITD Cementation India Ltd

RECORD R 1/1 : AMENDMENT STATUS RECORD


Sr.
No.
Section
Amended
Version
No.
Version
Date
Details of Amendment





























































INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 2


Version 1.0 Page 1 of 7
ITD Cementation India Ltd














PROCEDURE - P-2 : CONTROL OF RECORDS


















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 2


Version 1.0 Page 2 of 7
ITD Cementation India Ltd
1.0 PURPOSE

The purpose of maintaining records is to give evidence that the IMS is operating
effectively.

2.0 SCOPE

This procedure shall be applicable for all records including those referred in IMS
Documentation as Record.

3.0 RESPONSIBILITY

The responsibility for implementation & maintenance of this Procedure shall be with
all responsible authorities defined in IMS Manual for their own areas.

4.0 DEFINITION

None required

5.0 PROCEDURE

All records covered as detailed in DS-1/2 or otherwise maintained shall bear distinct
identification, date (s) and carry authorized signatures, as may be applicable and
shall be legible.

Any record pulled out from the filing system shall be noted in the file as to issue
particulars and to be returned by the using person immediately after use and this
has also to be noted. For necessary and unavoidable permanent issue, a
photocopy of the original shall be maintained in the files with an endorsement by the
controlling authority on such photocopy.

Record shall be kept either as hard copy or soft copy. Hard copies shall be kept in
the files and these files shall be stored in suitable locations. Soft copies shall be
stored in suitable locations. For soft copy, access control for write authority and
back-ups shall be maintained.

All filing systems shall be guarded against moisture, chemicals, smoke, fumes, heat,
dust, insects, fire etc. to ensure prevention from damage or loss of legibility for the
period for which they are to be retained.

The custodian shall preserve records for the time period as mentioned in DS-1/2.
However, due to contractual or statutory requirements, these may be preserved for
longer periods. In case a project is not closed within the above time frame, all-
relevant records shall be preserved until closure of the project.

Authority for disposal of any records shall be with the custodian as specified in DS-
1/2.

Any Record format specified in Contract or as required by the Customer shall
prevail over the format specified in the IMS Documentation.





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 2


Version 1.0 Page 3 of 7
ITD Cementation India Ltd

A list of records referred in specific Quality / Environment/Safety Plan for individual
site along with its custodian shall be maintained by Project In charge.

6.0 CROSS REFERENCES
IMS Manual : Section 4.5
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 2


Version 1.0 Page 4 of 7
ITD Cementation India Ltd

DATA SHEET - DS 1/2 : PARTICULARS OF RECORDS

Sr.
No.
Record
No
Title Of Record Form/
Register
Originator Location Frequency of
Record
Generation
Custodian Retention
Period
1 1/IMS Pi Record Form Managing
Director
Corporate Once a Year HOD
Engineering
Permanent
2 1/1 Amendment Status
Record
Form M R Corporate Once a Year Document
Controller
Permanent
3 1/3 Environmental Risk
Assessment Register
(For Routine And Non-
Routine Activities)
Form ERA
Coordinator
Project/
Depot/
office
Once in Six
Months
Project In
Charge/
Depot
Head/BU
Admn Head
Project
Completion/
1 Year
4 2/3 Environmental Risk
Assessment Register
(For Potential
Emergency Conditions )
Register ERA
Coordinator
Project/
Depot/
office
Once in Six
Months
Project In
Charge/
Depot
Head/ BU
Admn Head
Project
Completion /
1 Year
5 3/3 Analysis Of Significant
Environmental Aspects
For Improvement
Programmes
Form ERA
Coordinator
Project/
Depot/
office
Once in Six
Months
Project In
Charge/
Depot
Head/ BU
Admn Head
Project
Completion /
1 Year
6 1/4 IMS Legislation Matrix Form Corporate
Head
Environment
and
Corporate
Head Safety
Corporate Once a Year Project In
Charge /
Depot Head
Project
Completion /
3 Year
7 1/5 Improvement
Programme Details
Form Safety &
Env. Officer
Project/
Depot/
office
Once a Year Project In
Charge/
Dept Head /
BU Admn
Head
Project
Completion /
3 years
8 1A/6-
BU I
Preliminary Tender
Summary
Form Manager
Estimation
BU office As and when
required
Manager
Estimation
1 Year
9 1B/6-
BU II
Preliminary Tender
Summary
Form Manager
Estimation
BU office As and when
required
Manager
Estimation
1 Year
9 1C/6
BU III
Preliminary Tender
Summary
Form Manager
Estimation
BU office As and when
required
Manager
Estimation
1 Year
10 2/6 Enquiry / Tender
Register
Register Manager
Estimation
BU Office As and when
required
Manager
Estimation
Permanent
11 3/6 New Award Record Form Manager
Estimation
BU Office As and when
required
Manager
Estimation
1 Year
12 1/7 Review & Verification
Plan For Design
Form HOD
Engineering
BU office Once in
beginning of
project
HOD
Engineering
Project
Completion
13 2/7 Input & Output Analysis Form HOD
Engineering
BU Office Once in
beginning of
project
HOD
Engineering
Project
Completion
14 3/7 Design Consultant
Performance Record
Form HOD
Engineering
BU Office Once in
beginning of
project
HOD
Engineering
Project
Completion
15 1 / 8 Purchase Order Form HOD
Purchase /
Purchase In
Charge
BU Office/
Project
Site
As and when
required
HOD
Purchase /
Purchase In
Charge
3 Years
16 2 / 8 Questionnaire For
Vendor / Supplier
Form HOD
Purchase /
Purchase In
Charge
BU Office/
Project
Site
Once in Six
Months
HOD
Purchase /
Purchase In
Charge
Project
completion
17 3 / 8 List Of Approved
Vendors
Form HOD
Purchase /
Purchase In
Charge
BU Office/
Project
Site
Once in Six
Months
HOD
Purchase /
Purchase In
Charge
Project
completion






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 2


Version 1.0 Page 5 of 7
ITD Cementation India Ltd
Sr.
No.
Record
No
Title Of Record Form/
Register
Originator Location Frequency of
Record
Generation
Custodian Retention
Period
18 4/8 Emergency Purchase
Document
Register HOD
Purchase /
Purchase In
Charge
Project
Site
As and when
required
HOD
Purchase /
Purchase In
Charge
3 Years
19 5/8 Record Of Vendor
Evaluation
Form HOD
Purchase /
Purchase In
Charge
BU office Once in Six
Months
HOD
Purchase /
Purchase In
Charge
Project
completion
20 6/8 Purchase Register Register Purchase In
Charge
Project
Site
As and when
required
Purchase In
Charge
Project
completion
21 1/10 Weekly/Monthly
Progress Report
Form Engineer
Planning
Project
Site
Once a Week HOD
Planning
Project
completion
22 -- Quality Plan -- Project In
Charge
Project
Site
Once in the
beginning
Project In
Charge
Project
completion
23 .. Environment Plan -- Project In
Charge
Project
Site
Once in the
beginning
Project In
Charge
Project
completion
24 .. Safety Plan -- Project In
Charge
Project
Site
Once in the
beginning
Project In
Charge
Project
completion
25 1/11 Plan For Construction
Activities
Form Project In
Charge
Project
Site
Once in the
beginning
Project In
Charge
Project
completion
26 2/11 Quality/Environment/
Safety Plan Amendment
Status Record
Register Project In
Charge
Project
Site
As and when
required
Project In
Charge
Project
completion
27 -- Minutes For Kick Off
Meeting
Form BU Head Project
Site
Once in the
beginning
Contract
Manager
Project
completion
28 1/12 Inspection & Test Plan Form Project In
Charge
Project
Site
Once in the
beginning
Project In
Charge
Project
completion
29 1/13 Measurement And
Monitoring Plan
Form Project In
Charge
Project
Site
Once in the
beginning
Project In
Charge
Project
completion
30 2/13 Measurement And
Monitoring Non-
Conformity Report
Form Project In
Charge
Project
Site
As and when
required
Project In
Charge
Project
completion
31 1/14 Inspection, Measuring &
Test Equipment
Calibration Plan
Form QA Engineer
/ Laboratory
Officer
Project
Site/
Depots
Once in six
months
QA
Engineer /
Laboratory
Officer
3 Year /
Project
completion
32 2/14 List Of Calibrated Master
Equipments
Form QA Engineer
/ Laboratory
Officer
Project
Site/
Depots
Once in six
months
QA
Engineer /
Laboratory
Officer
3 Year /
Project
completion
33 1/15 Monthly Consolidated
Plant Statement
Form Engineer
Plant
Maintenance
Project
Sites
Once in month HOD Plant Project
completion
34 2/15 Weekly Plant Report Form Engineer
Plant
Maintenance
Project
Sites
Once in month HOD Plant Project
completion
35 3/15 Monthly Plant Report Form Engineer
Plant
Maintenance
Project
Sites
Once in month HOD Plant Project
completion
36 1/16 Record Of
Nonconforming Product
Register Project In
Charge
Project
Sites
As and when
required
Project In
Charge
3 Year /
Project
completion
37 1/17 Corrective And
Preventive Action Record
Register Project In
Charge
Project
Sites
As and when
required
Project In
Charge
Project
completion
38 2/17 Customer Complaint
Record
Register Project In
Charge
Project
Sites
As and when
required
Project In
Charge
Project
completion
39 1/18 Checker's Slip Form Admin.
Officer
Project
Sites
As and when
required
Admin.
Officer
Project
completion
40 2/18 Stock Register / Kardex Form Admin.
Officer
Project
Sites
As and when
required
Admin.
Officer
Project
completion
41 1/19 Training Record Register BU- HRD
Head
BU office As and when
required
Project In
Charge
Project
Completion
42 1/20 Annual Internal Audit
Plan
Form Chief IA BU office Once a Year Chief -IA 3 years/
Project





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 2


Version 1.0 Page 6 of 7
ITD Cementation India Ltd
Sr.
No.
Record
No
Title Of Record Form/
Register
Originator Location Frequency of
Record
Generation
Custodian Retention
Period
Completion
43 2/20 Internal Audit
Programme
Form Chief IA BU office Once in Six
Months
Chief -IA 3 years/
Project
Completion
44 3/20 Non Conformity Report Form Auditor Project
Site
Once in Six
Months
Chief -IA 3 years
45 4/20 Summary Of Internal
Audit Report
Form Chief -IA Corporate Once in six
months
Chief -IA 3 years
46 1/22 Risk Assessment Form Form Project In
Charge/Dep
ot Head/ BU
Admn Head
Project
Site /
Depot /
office
Once in Six
Months
Project In
Charge/Dep
ot Head/ BU
Admn Head
Project
Completion /
1 Year
47 2/22 Critical Task Analysis
Worksheet
Form Project In
Charge/Dep
ot Head/ BU
Admn Head
Project
Site /
Depot /
office
Once in Six
Months
Project In
Charge/Dep
ot Head/ BU
Admn Head
Project
Completion /
1 Year
48 2/23 Legislative Compliance
Register
Form Project In
Charge/Dep
ot Head/ BU
Admn Head
Project/
Depot/
office
Once in Six
Months
Project In
Charge/Dep
ot Head/ BU
Admn Head
Project
Completion /
3 Years

Safety Records

Sr.
No.
Format
For
Report /
Exercise
Details Of The Activity
/ Output
From/
Register
Responsibi
lity
Location Frequency
of
Reporting /
Completion
Custodian Retention
Period
1 RA-01 Occupational safety
and health risk analysis
(OSHRA)
Register Project In
Charge
Project Site Before the
commence
ment of
work / after
any change
Project In
Charge
Project
Completion
2 SR 1

Immediate reporting of
injuries and dangerous
occurrence and near
misses
Form Safety
Officer
Project Site Immediately
after the
incident
Corporate
Head Safety
3 Years
3 SR 2 Site safety and health
inspection report form


Form Safety
Officer
Project Site Monthly Project In
charge
Project
Completion
4 SR 3 Average daily
manpower form


Form Safety
Officer
Project Site Monthly Project In
Charge
Project
Completion
5 SR 4 Details of injuries /
dangerous occurrence
form (Inquiry Register)

Form Safety
Officer
Project Site Monthly Project In
Charge
Project
Completion
6 SR 5 Toolbox talk form Form Safety
Officer
Project Site Monthly Project In
Charge
Project
Completion
7 SR 6 Induction training form Form Safety
Officer
Project Site Monthly Project In
Charge
Project
Completion
8 SR 7 Expenditure on
treatment of injuries
form

Form Safety
Officer
Project Site Monthly Project In
Charge
Project
Completion
9 SR 8 Senior management
inspection form

Form Safety
Officer
Project Site After the
visit
Project In
Charge
Project
Completion






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 2


Version 1.0 Page 7 of 7
ITD Cementation India Ltd
Sr.
No.
Format
For
Report /
Exercise
Details Of The Activity
/ Output
From/
Register
Responsibi
lity
Location Frequency
of
Reporting /
Completion
Custodian Retention
Period
9 SR 9 Monthly safety
summary data sheet
Form Safety
Officer
Project Site Monthly Corporate
Head Safety
3 Years
10 SCL 1 Standards and
inspection forms for
working at heights

Form Frontline
Engineer
Project Site Fortnightly Project In
Charge
Project
Completion/
Six Months
11 SCL 2 Standards and
inspection forms for
scaffolds

Form Frontline
Engineer
Project Site Weekly Project In
Charge
Project
Completion/
Six Months
12 SCL 3 Standards and
inspection forms for
plant and machines


Form Frontline
Engineer
Project Site Fortnightly Project In
Charge
Project
Completion/
Six Months
13 SCL 4 Standards and
inspection forms for
cranes and lifting
devices

Form Frontline
Engineer
Project Site Fortnightly Project In
Charge
Project
Completion/
Six Months
14 SCL 5 Standards and
inspection forms for
excavation

Form Frontline
Engineer
Project Site Fortnightly Project In
Charge
Project
Completion/
Six Months
15 SCL - 6 Standards and
inspection forms for
temporary electrification

Form Frontline
Engineer
Project Site Fortnightly Project In
Charge
Project
Completion/
Six Months
16 SCL 7 Standards and
inspection forms for
piling
Form Frontline
Engineer
Project Site Fortnightly Project In
Charge
Project
Completion/
Six Months
17 SCL 8 Fortnightly checklist Form Safety
Officer
Project Site Fortnightly Project In
Charge
Project
Completion/
Six Months
18 SCL 9 Investigation of injuries
and dangerous
occurrence
Form Project In
Charge
Project Site Next day of
the incident
Project In
Charge
Project
Completion/
Six Months
19 SCL - 10 J ob Safety Analysis
Form
Form Frontline
Engineer
Project Site On
commence
ment of new
task
Project In
Charge
Project
Completion/
Six Months
20 SCL - 11 Authorisation certificate
for crane operators and
vehicle drivers
Form Project In
Charge /
Plant
Engineer
Project Site Monthly Project In
Charge
Project
Completion/
Six Months
21 SR 10 Walkabout report Form Project In
Charge
Project Site Weekly

Project In
Charge
Project
Completion/
Six Months
22 SR 11
SR 12
Subcontractors
assessment form DS
Form Project In
Charge
Project Site Monthly Project In
Charge
Project
Completion/
Six Months





























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 3


Version 1.0 Page 1 of 8
ITD Cementation India Ltd















PROCEDURE P-3 : ENVIRONMENTAL RISK ASSESSMENT (ERA)


















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 3


Version 1.0 Page 2 of 8
ITD Cementation India Ltd

1.0 PURPOSE

This procedure shall be followed for Environmental Risk Assessment (ERA)
involving:
Identification of the environmental aspects of ITDCems activities that it can
control and those it can influence; and
Determination of those aspects, which have or can have significant impact
on the environment.

2.0 SCOPE

The procedure shall be applicable to all activities of ITDCem under
normal/abnormal/emergency conditions at:
Project Sites;
Depots; and
Corporate Offices.

3.0 RESPONSIBILITY

Project In charge at sites, Head Depots, and Environmental officer in Corporate
offices shall be responsible for coordinating identification of environmental aspects
related to activities under ITDCem control and activities of suppliers/contractors over
which ITDCem has influence.

Corporate Head Environment shall provide technical support for identifying
significant environmental aspects.

4.0 DEFINITIONS

Environmental Aspects - Element of ITDCems activities that can interact with the
environment. They include:
Consumption of resources including but not limited to cement, steel,
aggregates, bitumen, diesel, water and paper;
Emissions of gases / vapours / dust / heat to air;
Generation of noise;
Generation of vibrations in ground;
Discharge of wastewater;
Leakage/spillage of fuels / lubricants / chemicals / adhesives / wastewater;
Disposal of solid wastes such as construction debris, waste products,
packing material, containers, waste/used/unused material, food etc.;
Disposal of hazardous wastes;
Excavation of borrow pits;
Removal of rocks / sand /soil;
Compaction / stabilization of soil;
Cutting of trees; and
Change in catchment area characteristics.



























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 3


Version 1.0 Page 3 of 8
ITD Cementation India Ltd
Environmental Impact - Any change to environment, whether adverse or beneficial
wholly or partly resulting from ITDCem activities and includes:
Depletion of resources;
Change in air quality in the terms of odours, ambient temperature,
suspended particulate matter, Sulphur dioxide, Nitrogen dioxide, vapours of
volatile compounds etc;
Change in noise levels;
Change in surface/ground water quality in the terms of pH, temperature,
Biochemical Oxygen Demand, Chemical Oxygen Demand, metals, toxic
compounds etc;
Damage to structures due to vibrations;
Loss of natural habitat of birds / animals;
Loss of fish/fish yield;
Loss of soil fertility;
Loss of green cover; and
Change in rate of soil erosion and siltation.

5.0 PROCEDURE

In the case of project sites with contract period less than 4 months, HOD
Engineering of respective BU in consultation with Corporate Head Environment,
within two weeks of mobilization, shall identify significant environmental aspects
based on review of contract documents and / or site visit.

HOD Engineering shall communicate to the Project In Charge:
Significant aspects; and
Operational Control Procedures for controlling those aspects.

Detailed Environmental Risk Assessment (ERA) shall be carried out at all project
sites with contract period more than 4 months, depots, and Corporate offices as per
procedure delineated below.

Project In charge at sites / Head Depots / Environmental officer in Corporate/BU
offices shall:
Identify a group of persons working in different sections/areas and form
ERA-Team; and
Identify coordinator for ERA-Team

Project In charge at sites / Head Depots / Environmental officer in Corporate/BU
offices shall:
Assess training requirements of the ERA-Team for carrying out ERA; and
Arrange for training if necessary in consultation with AMR BU level and
Corporate Head Environment.

ERA Team through group working shall list activities carried out in routine and non-
routine conditions in the recent past, ongoing, and to be taken up in future that have
interaction with environment and identify the interaction as environmental aspects
for each activity.
























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PROCEDURE P- 3


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ERA Team shall also identify potential emergency conditions that can affect
environment such as fire, spillage, over toppling of vehicles, surface runoff during
storms etc.

In identification of activities and environmental aspects ERA Team shall consider:
Direct activities which include all activities carried out by ITDCem and sub-
contractor at the project site/depot/office, and activities carried out by
ITDCem off-site; and
Indirect activities that include activities carried out by sub-
contractors/suppliers for ITDCem but not at location of project/office/depot.

ERA Team shall identify environmental impact(s) associated with each of the
aspects and also affected receptor (workers/employees/general public,
plants/animals, building/land, resource base).

ERA-Team shall identify existing control measures practiced to minimize
environmental impact.

ERA-Team shall enter routine/non-routine activities, type of activity, environmental
aspects, environmental impact, receptor and existing controls in Environmental
Risk Assessment Matrix using format R-1/3.

ERA Team shall enter potential emergency conditions, environmental aspects,
environmental impact, and receptor in Environmental Risk Assessment Matrix using
format R-2-/3.

ERA-Team shall prioritize environmental aspects using Environmental Risk Priority
Number (ERPN) to identify significant aspects. The criteria for estimation of ERPN
shall be :

For Routine/Non-Routine Activities

Sr. No. Criteria Score
A. Quantity (Magnitude) of Impact
Excessive 5
Very high 4
High 3
Moderate 2
Low 1
B. Probability Of Occurrence of Impact when activity is in progress
Continuous 5
Several times a day 4
Less than once a day 3
Once a week 2
Once a month or less frequent 1
C. Severity of Impact
Fatal to human life. 5
Human health effect such as illness 4
Loss of fish, plants, animals, or global issue 3
Causes discomfort or nuisance 2
Slight impact or negligible visual impact 1
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 3


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D. Legal Requirement Related to Aspect
Covered by Legislation 10
Covered by legislation however controls in place and effective 5
Not covered by Legislation 1

E. Controls on Activity for Impact Minimization
Control absent or ineffective 5
Control mechanism in place but not reliable 3
Effective control available 1

F. Time Required for Impact Detection
More than 24 hours 5
12 to 24 hours 4
6 to 12 hours 3
1 to 6 hours 2
Less than 1 hour 1


The Environment Risk Priority Number ( ERPN ) = A * B * C * D * E * F
For potential emergency conditions

Sr. No. Criteria Score
A. Probability of Occurrence of Emergency Condition
Negligible 0.1
Very low 1
Low 2
Moderate 3
High 4
B. Time Required for Detection of Emergency Condition Detection
Real time continuous 0.1
Within 01 hours 1
Within 08 hours 2
Within 24 hours 3
More than 24 hours 4
C. Nature Of Consequence such as damage to human/animal/plant life or
Insignificant 0.1
Very low 1
Low 3
Moderate 5
High 10

Environment Risk Priority Number ( ERPN) = ( A + B ) x C

ERA-Team shall decide the cut-off score of ERPN for identifying significant aspects
and state the same in R-1/3 and R-2/3.

ERA-Team shall evaluate the significant environmental aspects in order to identify:
The aspects where significance can be reduced through planning and
implementation of Improvement Programme (IP) so that the score under
criteria A: Quantity of Impacts, B: Probability of Occurrence, C: Severity of
Impact, or F: Time for Detection of Impact is reduced.

The aspects where significance can be reduced through development and
implementation of Operational Control Procedure (OCP) so that the score
under criteria E: Controls on Activity for Impact Minimization is reduced.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 3


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ITD Cementation India Ltd
ERA-Team shall assess the feasibility of taking up Improvement Programme in
terms of :
Legal Requirements (LR) in the terms of need to reduce significance so as to
comply with the legal obligation;
Views of Interested Parties (VIP) about the environmental aspect under
review;
Technological feasibility (TF) in the terms of operation & maintenance
requirements;
Financial Feasibility (FF) in the terms availability of finances;
Operational Feasibility (OF) in the terms of continuous working hours and
supervision requirements; and
Business Requirements (BR) such as gaining competitive edge.

Improvement programme is taken up in the cases where:
IP is required for legal compliance; or
IP is required in view of strong concerns of interested parties; or
IP is technologically, financially, and operationally feasible; and it gives
significant business edge.

ERA-Team shall record analysis of significant aspects using format R-3/3.

ERA shall be carried out within two months from the kick-off meeting.

Project In Charge / Head Depot / Environment officer at Corporate/BU office shall
review Aspect Register.

Aspect Register shall be revised as and when a new activity is taken up or there is
any change in methodology or at least once in a year

Corporate Environment Head shall review this procedure in the case of changes in
environmental legislations and inform ERA-Teams necessary changes in ERA
Procedure.

6.0 CROSS REFERENCES

ISO 14001, Clause no. 4.3.1 :Environmental Aspects
IMS-Manual : Section 3.1

7.0 RECORDS

R-1/3 : Environmental Risk Assessment Matrix Routine/Non-Routine Activities
R-2/3 : Environmental Risk Assessment Matrix Potential Emergency Conditions
R-3/3 : Environmental Aspect Analysis for Improvement Programmes

8.0 RECORDS AVAILABILITY

R-1/3 and R-2/3 for Site/Depot/Office- Project In Charge
Relevant section of R-1/3 and R-2/3 Respective HOD
R-3/3 Project In Charge/Head Depot/Environmental officer in Offices






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 3


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ITD Cementation India Ltd
9.0 RECORD RETENTION
As per Procedure P-2.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 3


Version 1.0 Page 8 of 8
ITD Cementation India Ltd

RECORD - R 1/3: ENVIRONMENTAL RISK ASSESSMENT REGISTER
( ROUTINE/NON-ROUTINE CONDITIONS)

Project No : Revision No : Date :

S.
No.
Activity Routine/
Non-
Routine
Direct/
Indirect
Aspect
No.
Aspect Impact Recepto
r
Existing
Controls
Score ERPN * S /
NS

A B C D E F






* S Significant, NS Non Significant, Cut Off ERPN =


RECORD R-2/3 : ENVIRONMENTAL RISK ASSESSMENT REGISTER
( POTENTIAL EMERGENCY CONDITIONS)

Project No : Revision No : Date :

S.
No.
Activity Routine/
Non-
Routine
Direct/
Indirect
Aspect No. Aspect Impact Receptor Existing
Controls
Score ERPN

A B C






All Emergency Aspects to be considered as Significant & addressed in Emergency
Preparedness & Response Plan


RECORD R 3/3 : ANALYSIS OF SIGNIFICANT ENVIRONMENTAL ASPECTS FOR IMPROVEMENT
PROGRAMMES

Project No : Revision No : Date :

S.
No.
Activity Aspect Aspect
No.
Impact Receptor Existing
Controls
Yes/No
IP
I
P
OCP

LR VIP TF FV OR BR






























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 4


Version 1.0 Page 1 of 5
ITD Cementation India Ltd













PROCEDURE P- 4 : IDENTIFICATION OF LEGAL AND
NON-REGULATORY REQUIREMENTS


















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 4


Version 1.0 Page 2 of 5
ITD Cementation India Ltd

1.0 PURPOSE

This procedure shall be followed for identification of legal and other non-
regulatory requirements related to environmental aspects, and occupational
safety & health risks.

2.0 SCOPE

The procedure shall be applicable to all activities of ITDCem at :
Project Sites;
Depots; and
Offices.

3.0 RESPONSIBILITY

Identifying legal and non-regulatory requirements as also actions required related
to :
Environmental Aspects : Corporate Head Environment
Occupational Safety and Health Risks : Corporate Head Safety

M R shall be responsible for communicating actions required for meeting legal
and non-regulatory requirements to Project In Charges at sites and Heads at
Depots.

Project In Charges at Sites and Heads at Depots shall be responsible for
communicating actions required for meeting legal and non-regulatory
requirements to concerned employees and relevant interested parties.

4.0 DEFINITIONS

Legal Requirements : are obligations to be fulfilled for compliance of:
Acts passed by Central/State Governments;
Rules framed under the Acts;
Notifications Issued by the Central / State Government,;
Directives Issued by Regulatory Authorities; and
Case Law.

Non-Regulatory Requirements are obligations to be fulfilled as organizational
commitment to comply with:
Contractual Requirements;
National Standards;
Codes of Practice;
Charters of Professional Bodies; and
Societal Commitments.

5.0 PROCEDURE

Procedure For Identification Of Legal Requirements

Corporate Head Environment and Corporate Head Safety shall be in touch with





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 4


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ITD Cementation India Ltd
concerned authorities for obtaining up to date information on:
Existing legislations;
Amendments in the legislations; and
New/potential legislations

related to environmental aspects of ITDCem activities as also those related to
occupational safety and health.

These authorities shall include:
Ministry of Environment and Forests;
Ministry of Labour;
Central Pollution Control Board;
D G FASLI;
Confederation of Indian Industry;
National Safety Council;
State Departments of Environment;
State Pollution Control Boards; and
State Departments of Labour Welfare
Central Labour Institute.

Corporate Head Environment and Corporate Head Safety shall identify the
obligation(s) to be fulfilled for compliance of legal requirements using format
R-1/4.

MR shall communicate the actions required for meeting legal requirements at
project sites / depots to Project In Charge /Heads.

Project In Charge / Head Depots shall communicate actions required for meeting
legal requirements to concerned employees and relevant interested parties.

Procedure For Identification of Non-Regulatory Requirements

Corporate Head Environment and Corporate Head Safety shall identify non-
regulatory requirements related to environmental aspects of ITDCem activities as
also those related to occupational safety and health. These requirements shall
include:
National Standards;
Commitments of ITD Group to Public;
Commitments of ITD Group to ILO and Other International Bodies;
Commitments of ITDCem Management to Public;
Commitments of ITDCem to Industry Associations in India; and
Reports that need to be submitted to ITDCem/ITD Group Management as
a part of ESH monitoring system.

Corporate Environment Head and Corporate Safety Head shall identify the
obligation(s) to be fulfilled under non-regulatory requirements using format R-2/4.

MR shall communicate the actions required in fulfillment of non-regulatory
requirements at project sites / depots / Offices to Project In Charge / Head Depots
/ Head Administration.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 4


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ITD Cementation India Ltd
Project In Charge / Head Depots /Head Administration shall communicate actions
required for meeting non-regulatory requirements to concerned employees and
relevant interested parties.

Corporate Head Environment and Corporate Head Safety shall review and
update R-1/4 and R-2/4 at least once a year and keep Management informed
through MR.

6.0 CROSS REFERENCES

ISO 14001, Clause no. 4.3.2: Legal and Other Requirements
OHSAS 18001, Clause no. 4.3.2: Legal and Other Requirements
IMS- Manual: Section 3.2

7.0 RECORDS

R-1/4: Environment, Occupational Safety & Health Legal Requirements Matrix
R-2/4: Environment, Occupational Safety & Health Non-Regulatory Requirements
Matrix

8.0 RECORDS AVAILABILITY

R-1/4 and R-2/4 - for Site / Depot / Office Project In Charge / Head Depot /
Head Administration
Master R-1/4 Corporate Head Environment, Corporate Head Safety, and MR

9.0 RECORD RETENTION

As per Procedure P-2.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 4


Version 1.0 Page 5 of 5
ITD Cementation India Ltd

RECORD - R-1/4 : ENVIRONMENT, OCCUPATIONAL SAFETY & HEALTH LEGAL REQUIREMENT
MATRIX

Project No /Depot : Revision No : Date :


Sr.
No.
Act/Rule Obligation Regulatory
Agency
Applicability to
Site / Depot
(Yes/No)
(If yes, State
related
Environmental
Aspect /
Occupational
Hazard)
Reasons For
Non
Applicability
and Action
Required in
Case of
Applicability
Responsibility Target Date






MR

RECORD - R-2/4 : ENVIRONMENT, OCCUPATIONAL SAFETY & HEALTH
NON-REGULATORY REQUIREMENTS MATRIX

Project No / Depot /Office : Revision No : Date :


Sr.
No.
Description of Non-
Regulatory Requirement
Applicability to Site/
Depot / Office
(Yes/No)
(If yes, State
related
Environmental
Aspect /
Occupational
Hazard)
Reasons For Non
Applicability and Action
Required in Case of
Applicability
Responsibility Target Date








MR






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 5


Version 1.0 Page 1 of 5
ITD Cementation India Ltd














PROCEDURE P- 5: DEVELOPING AND REVIEWING
IMPROVEMENT PROGRAMMES

















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 5


Version 1.0 Page 2 of 5
ITD Cementation India Ltd
1.0 PURPOSE

This procedure shall be used to develop and review Improvement Programme(s)
for achieving objectives and targets set by ITDCem for improving environmental
and occupational safety & health performance.

2.0 SCOPE

The procedure shall be applicable to Management Programmes to be taken up
at:
Project Sites;
Depots; and
BU/Corporate Offices.

Improvement Programmes shall be developed for:
Reducing significance of environmental aspects for which Environmental
Risk Assessment (ERA)-Team found that it is feasible to take up such
programme and recorded so in R-3/3; and
Improving safety & health performance.

Improvement Programme(s) shall also be developed to meet objectives targets
for:
Achieving legal compliance; and
Responding to views of interested parties.

3.0 RESPONSIBILITY

Programme Leader(s) shall be responsible for coordinating all activities related
to development and implementation of Improvement Programme(s).

Project In charge at sites and Head Depots shall be responsible for allocating
resources for Improvement Programme (s) at site level.

BU Head and Corporate Plant Head shall be responsible for approving
resources for Improvement Programme (s) at BU Level.

Project In charge at sites, Head Depots, and Environmental officer in Corporate /
BU offices shall be responsible for review of implementation of Improvement
Programme (s).

Corporate Head Environment and Corporate Safety Head shall provide technical
support for developing and implementing Improvement Programme(s).

4.0 DEFINITIONS

Improvement Programme ; Programmes approved by the Management for
meeting the objectives and targets set for continual improvement of
environmental, occupational safety, and health performance and shall include:
Change in plant/equipment for better resource (e.g. raw material, diesel,
water, etc) utilization;
Change in plant/equipment for reducing air pollutant emission/noise





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 5


Version 1.0 Page 3 of 5
ITD Cementation India Ltd
generation;
Change in raw material (e.g. Flyash in place of cement, stone dust in
place of cement, water based paint in place of solvent based paint etc);
Retrofitting pollution control system to existing plant/equipment;
Installing automatic controls;
Installing automatic detection/monitoring system;
Proactive measurement and monitoring;
Development of new methodology for execution; and
Awareness campaigns.

5.0 PROCEDURE

Project In charge at sites, Head Depots, BU Heads at BU offices and MR at
Corporate Office shall nominate Programme Leader(s) for developing
Improvement Programme(s) at site / depot / BU / Corporate Level.

Programme leader shall prepare Improvement Programme using format R-1/5
specifying:
Action Plan;
Responsibilities for implementing the actions;
Resource Requirements; and
Time frame.

Project In charge at sites, Head Depots, BU Heads at BU offices and MR at
Corporate Office shall review, approve the Improvement Programme at relevant
level, and allocate resources..

Implementation of Improvement Programme(s) shall be reviewed every month
at relevant level and amended, if necessary.

6.0 CROSS REFERENCES

ISO 14001, Clause no. 4.3.3 :Objectives, Targets, Programme(s)
OHSAS 18001, Clause no. 4.3.4 : OH & S Management Programmes
IMS-Manual : Section 3.3

7.0 RECORDS

R-1/5 : Improvement Programme Details

8.0 RECORDS AVAILABILITY

R-1/5- for Site/Depot/Office Project In Charge / Head Depot / Head
Administration
R-1/5 for BU - AMR BU
R-1/5 for Corporate Corporate Head Environment and Corporate Head Safety
List of Improvement Programmes for all sites in BU AMR BU
List of Improvement Programmes at BU and Corporate Level Corporate Head
Environment, Corporate Head Safety, and MR






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 5


Version 1.0 Page 4 of 5
ITD Cementation India Ltd
9.0 RECORD RETENTION
As per Procedure P-2.























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 5


Version 1.0 Page 5 of 5
ITD Cementation India Ltd

RECORD - R-1/5 : IMPROVEMENT PROGRAMME DETAILS

Project No : Revision No : Date :

IP No.
Objective
Programme Leader

Targets

Sr
No
Target (s) Reason for Taking Target Date by Which Target
to be Achieved










Resources: (Persons and/or Finance)



Key Characteristic(s) To Monitor :

Sr
No
Target Characteristic Frequency










Action Plan :

Sr.
No.

Actions Responsibility Start
Date

Completi
on Date

Revised
Completi
on Date
Reasons for
Delay




























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


Version 1.0 Page 1 of 19
ITD Cementation India Ltd














PROCEDURE P- 6 : MARKETING AND PROPOSAL


















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR COMMERCIAL






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


Version 1.0 Page 2 of 19
ITD Cementation India Ltd

1.0 PURPOSE

The purpose of this procedure is to ensure that proper system is maintained in
preparation and submission of proposals which after conversion into contracts
will be beneficial for the company

2.0 SCOPE

The scope of this procedure is limited to the tenders / contracts for all works.

3.0 RESPONSIBILITY

Responsibility for implementation and maintenance of this procedure lie with
HOD Proposal.

4.0 DEFINITION

None required

5.0 PROCEDURE

MARKETING
The Corporate Marketing Head manages and controls data available, that may
be required by potential customers for the purpose of pre qualification,
expressing interest, obtaining further information, maintenance of approved
listings or applications for new listings. Potential opportunities are identified from
the government Gazette, market and industry sources and where information
permits the requirements are determined, resources planned and assigned for
prequalification activities. Potential projects of particular interest are highlighted
for more intensive investigation, strategy formulation, consultation and review of
product and customer requirements prior to tender stage.

TENDER RECEIPT
Tender documents are collected from the customer subsequent to customer's
inquiry or advertisements in the media. Alternately based on customers
requirement the proposals are prepared. Salient information about the tender
are noted down and approval for submission from BU Head / Director(s) is
obtained.

If it is decided for submission, then the tender document is forwarded to
Manager Estimation, who shall then proceed with estimation. HOD Proposal
may appoint project specific Manager (s) Estimation from time to time for any
tender (s) and in such cases all tender documents and related records shall be
with the custody of that particular Manager(s) Estimation. HOD-Proposal shall
keep the record of the team members responsible for the tender decided for
submission. For BU-2 & 3 one Bid Manager may be identified and appointed by
the BU Heads for tender value more than 20 Cr, however for BU-1, this shall be
done for every project. He is the representative of project team and jointly works
with the Estimation team during preparation of the tender and provides technical





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


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ITD Cementation India Ltd
inputs. In other cases, Manager Estimation shall work as Bid Manager. A
consultant may be appointed for design and working out quantities.

HOD-Proposal shall do the follow-up and maintain Tender & Enquiry Register
for every tender / enquiry submitted as R-2/6.

TENDER PROCESSING

Inputs for tendering shall be collected from various departments as per DS-1/6.
Salient details of the tender shall be recorded in the R-1/6. Proposal Department
shall keep risk analysis report prepared by Commercial Department for tender
values more than Rupees 20 Cr. For tender values less than 20 Cr Estimation
Manager shall study the commercial conditions of the tender and in case of any
salient clauses, same shall be discussed with Commercial Department. Actions
to be taken against such clauses shall be kept.

Based on requirement of the work specified in the tender a detailed time
program with month wise break up of activities shall be prepared.

Manager Estimation shall work out the requirements of necessary resources as
below :-

Machinery requirement,
Material requirement and
Manpower requirement for incorporating in the estimation.

MACHINERY REQUIREMENT

For tenders of value more than Rs. 20 crores, based on specific requirements in
the programme of work, methodology of carrying out the same shall be worked
out. Equipment required for various activities during project period are planned
depending on quantity of such activities to be executed in each month as laid
down in programme and complete the whole job within the stipulated completion
schedule.( DS-2/6)

Total requirement of equipment and their source of deployment is found out
such as, whether it is to be deployed from existing company holding.
Alternatively, they are to be deployed after hiring from external sources during
project period. Lastly, it is opted for new purchase. These shall be decided and
recorded in estimation sheet

MATERIAL REQUIREMENT

Material required under different items is worked out from Bill of quantities of the
tender document. Quantity of material required for concrete of different grade is
calculated based on the past records and mix design, if required. A general
guideline of common materials for arriving at material requirement is shown in
DS-3/6. Resource requirements are recorded in the estimation sheet by
Manager Estimation, in consultation with HOD Proposal and Bid manager.























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


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ITD Cementation India Ltd
MANPOWER REQUIREMENT

Guideline to find out manpower requirement shall be as per Data Sheet DS-4/6.
Manpower as required is listed in estimation sheet/ proposal sheet.

Apart from Machinery, Material and Manpower, other costs (DS-5/6) required for
execution of the project shall then be calculated by Manager Estimation and
recorded in the Estimation sheet.

OTHER REQUIREMENTS

Abstract Cost, Plant Build Up sheet and Cash flow for tender estimate is
prepared to review the financial position as required.

SCRUTINY

Based on the inputs and comments/qualifications from the different
departments, and the calculation prepared by Manager - Estimation, HOD
Proposal along with Bid Manager shall first scrutinize the estimation. It is then
appraised and discussed with BU Head / Director(s) for approval of submission.

For tenders of value above Rs.20 crores, summary of tenders shall be prepared
by Manager Estimation / HOD Proposal in consultation with Bid Manager and
sent to ITD, Bangkok for advice after incorporating comments suggestions of
BU Head / Director(s).

Any Contract awarded as an extension of any previous Contract on negotiation,
above analysis need not be carried out for the relevant portion of Contract
Document.

TENDER SUBMISSION & NEGOTIATION

Approved tender / offer of the Company shall be submitted to the customer.

BU Head or his representative / Bid Manager shall negotiate with the customer
on tender submission to sort out any differences between companys tender and
customers requirements and prices.

Periodic review of unsuccessful tenders will be made by the HOD Proposal.
Comparison statement and reasons for the price difference will be prepared.

AWARDING OF CONTRACT

Customers work order to the company shall be treated as the awarding of
contract. However, in some cases the same may also be notified through a
letter of Intent prior to the work order. Initiation of the contract on receipt of a
Letter of Intent will be started. Mobilisation, initial setting up of site
establishment and starting of actual work may be done on the basis of this letter
of intent. However, once the work order is received, the same shall be
reviewed.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


Version 1.0 Page 5 of 19
ITD Cementation India Ltd
BU Head will decide a Contract Manager / Project In charge for a specific
project and all relevant document and related papers shall be handed over to
him by the HOD Proposal for follow up work.

Work orders received from customers shall be reviewed and compared with the
offer/ tender documents by the concerned Contract Manager in association with
the Bid Manager and HOD-Commercial (P-9). Any differences noticed shall be
resolved through correspondence/ interaction with customer, which shall also be
maintained together with the tender and contract documents.

For all confirmed orders, the connected tender document shall be treated as
part of customers specifications/ requirements. After award of work, all contract
specification, drawings, etc. shall be handed over to the Contract Manager by
HOD Proposal under a handing over note. Proper document control system
shall be maintained thereafter by maintaining a list of such document.

CONTRACT EXECUTION

BU Head shall intimate through R-2/6 with other Departmental heads and
sectional heads about the contract (s) awarded to the company in order to
initiate respective functions.

6.0 CROSS REFERENCES

ISO 9001:2000, Clause no. 7.1 : Planning for Product Realization and
7.2 : Customer Related Processes
IMS Manual Section 4.7

7.0 RECORDS

R -1/6 : Preliminary Tender Summary
R -2/6 : Enquiry/Tender Register
R-3/6 : New Award Record

8.0 RECORDS AVAILABILITY

R -1/6 : Preliminary Tender Summary : BU Head Proposals
R -2/6 : Enquiry/Tender Register: BU Head Proposals
R-3/6 : BU Head Commercial

9.0 RECORD RETENTION

As per P-2

























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


Version 1.0 Page 6 of 19
ITD Cementation India Ltd

DATA SHEET - DS 1/6 : MARKETING & PROPOSAL

Sr. No Source Inputs
1 Organizations
Representative(s)

1. Site visit report.

2 Planning
Department
1. Identification of activities, constraints & their schedule.
2. Methodology along with Bid Manager.
3. Resource requirement.

3 Commercial
Department
1. Risk analysis report.
2. Suggested qualifications commercial/ financial implication.
3. Pre bid queries commercial

4 Plant Department 1. Availability of Plant.


5 Purchase
Department

1. Obtain and negotiate quotation received from Vendors.

6 Engineering
Department
1. Design & Drawing.
2. Material Specification related to design.
3. Technical qualifications
4. Pre bid queries technical

7 Accounts
Department
1. Details of taxation as per latest legislation in the state of
project location
8 Corporate Insurance 1. Details of Insurance Premium to be considered as per
guidelines.
9 Corporate Safety 1. Specific requirements such as site medical facilities etc, if
any
10 Corporate
Environment
1. Environmental sensitivity of site
2. Requirement of Environmental Clearance, if any

Note : Some of the functions of various departments will be carried out by Estimation Manager in
consultation with respective Functional departments depending upon value and nature of work.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


Version 1.0 Page 7 of 19
ITD Cementation India Ltd


DATA SHEET - DS - 2/6 : FLOW CHART FOR EQUIPMENT SELECTION & REQUIREMENT


RECEIPT OF TENDER
DOCUMENTS
PREPARATION OF
METHOD STATEMENT
PREPARATION OF
DETAILED
PROGRAMME
DEFINE THE TYPE OF
EQUIPMENT
REQUIRED FOR
VARIOUS ITEMS
FIND OUT THE
PRODUCTIVITY OF
EQUIPMENT
FIND OUT THE DAILY /
HOURLY DEMAND
FOR THE ITEMS (FOR
WHICH EQUIPMENT
ARE TO BE USED)
GET THE NO. OF
EQUIPMENT






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


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ITD Cementation India Ltd


DATA SHEET - DS - 3/6 : COMPANY GUIDELINES FOR COMMON MATERIAL REQUIREMENT

Name of Material

Basis of Estimating Material Requirements
1. Concrete Materials
(a) Cement Based on tender specification, records of actual consumption,
industry manual.
(b) Stone chips of different
gradations
Do
(c) Sand Do
(d) Admixtures Do
2.Steel
(a) Reinforcement Steel Based on records and tender conditions - Laps, chairs and
wastage are considered.
(b) Structural Steel Based on records and tender conditions- Cutting loss, fusion
loss, wastage is considered.
3.Shutterings and Scaffoldings

Based on programme of carrying out concrete, requirement for
shuttering for different members is distributed on monthly
basis. Depending on no. of repetition, no. of sets is assessed.
Shutterings and scaffoldings material costs are thus calculated
after deciding on the quantities available within the company /
to be hired / to be procured for the job.
4. Brickwork and Plastering
(a) Bricks Based on size of bricks available in the area and strength of
mortar, consumption for usage of the same in volume / area
are given at industry manuals. They are checked from records
also.
(b) Cement Do
(c) Sand Do
5.Finishing Items
Doors, Windows, Flooring, Roofing and Cladding, Fixtures and
Fittings, Painting, Protective coatings etc is calculated as per
requirements.
6. Tunneling / Rock Excavation
(a) Explosive Based on Past Record and Soil Report

7. Roads / Highways / Flyovers
(a) Bitumen Based on Client Specification

8. Piling
(a) Pile Shoe Based on Client Specification
(b) Bentonite Do

Note : The above indicative requirement may be modified in case of special requirement or any
Construction Handbook may be referred for additional considerations.
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


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ITD Cementation India Ltd
DATA SHEET - DS 4/6 : GUIDELINES TO FIND OUT MANPOWER REQUIREMENT

Manager(s) required are estimated depending on scope of work and employed in phased
manner for overall supervision. A person is designated as Project In-charge, who is responsible
for full work and all other member shall report to him through level of responsibilities.

1.0 DIRECT EXECUTION

Activities are identified under the scope of work. Magnitude of work of each activity is
assessed.

Based on the working fronts of such activities, number of zones of operation is decided.

Manpower in each zone is decided.

Head of each Zone is assisted by shift personnel (Engineering Assistants/ Supervisors)
depending upon the size of each zone and type of work in the zone. If more than one shift
working is to be resorted to, then number of shift personnel shall be increased to achieve
reasonable progress.

2.0 OTHERS ENGINEERS & SUPPORTING STAFF

2.1 Engineer : Quality assurance
Engineer / Engg. Asst: Quantity survey
Engineer : Plant running and maintenance
F Superintendent : Field survey
Engineer / Engg. Asst.: Planning
Engineer / Officer : Safety & Environment
Accounts Officer : with support staff accountant(s) , and Office Asst(s)
Administrative Officer : with support staff like assistant officer(s) and Office Asst(s)
Stores and purchase officer : One number with support staff like assistant officer(s) and
Office Asst(s)


Engineering assistant/ Supervisors are attached to Engineers as per requirement.

3.0 SKILLED WORKMEN

Skilled workmen for Plant operation, maintenance, electrification, plumbing etc are
engaged along with plant deployment, workshop, and site facilities.

4.0 UNSKILLED / SEMISKILLED WORKMEN

Unskilled / Semi skilled workmen assist plant operators, mechanic, and electrician.
General site labourers are estimated depending on miscellaneous work.























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PROCEDURE P- 6


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ITD Cementation India Ltd

DATA SHEET - DS- 5/6 : GUIDELINES SHEET FOR ESTIMATION

Information To Be Considered
General
Location
Scope of Work
Time of Completion
Validity of Tender
Details of EMD from Client ( If any ) - Bank Guarantee / DD / Pay Order
Value of Work (If any)
Variation (+/-) of Contract Value
Escalation
Payment Terms
Other Requirements

Consideration Of Estimate
Basic Assumptions
Basic Material Prices
Basic Labour Rates
Progress assumed Activity-wise time schedule ( Program of work )

Cost Estimate

Labour
Plant
Direct Material
Labour Contract / Subcontract
Indirect Material
GCE cost / General cost estimate ( Mobilisation & Demobilisation cost )
On-cost


























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PROCEDURE P- 6


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ITD Cementation India Ltd

DATA SHEET - DS- 6/6 : CHECK-LIST FOR SITE VISIT REPORT

1. Name of the person visited site
2. Client name
3. Consulting Engineers
4. Location of Site
5. Brief description of railway facilities
6. Electric power supply
7. Details of soil strata
8. Details of site topography
9. Material price
10. Hire plant rate
11. Details of utility authority
12. Contractors-item rate for labour only
13. Availability of local labour
14. Area available for waste disposal
15. Area available for labour camp
16. Medical facilities in nearby areas including ambulance
17. Nearby habitations likely to be affected due to project activities
18. Nearest source of diesel supply
19. Source of water supply
20. Availability of sand and gravel




























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PROCEDURE P- 6


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ITD Cementation India Ltd


RECORD - R- 1A/6 : PRELIMINARY TENDER SUMMARY ( BU I)


TENDER NO : DUE DATE :

1. PROJ ECT TITLE:
2. PROJ ECT DESCRIPTION AND LOCATION :
3. COUNTRY : CLEARANCE Yes / No
4. CLIENT FINANCIAL STANDING :
5. MAIN CONTRACT / SUBCONTRACT / FEE CONTRACT
NAME OF MAIN CONTRACTOR ( IF APPLICABLE)
6. OWN BID/ J OINT VENTURE / CONSORTIUM OUR %
PARTNER(S) AND % : FINANACIAL
7. PARTNERS CROSS GUARANTEES : YES / NO/ NA
8. ENGINEER / ARCHITECT :
9. FORM OF CONTRACT CONDITIONS : GCC
SCC
10. ADVERSE PHYSICAL CONDITIONS CLAUSE : Yes / No
11. TIME EXTENSION FOR INCLEMENT WEATHER : Yes / No
12. UNUSUAL CONDITIONS OF CONTRACT :
13. LAW OF CONTRACT : J URISDICTION
CLEARANCE : Yes / No LANGUAGE
ARBITRATION : VENUE
14. COMMENCEMENT DATE :
CONTRACT PERIOD
MAINTENANCE PERIOD
15. APPROXIMATE TENDER VALUE :
16 PRICE FLUCTUATION :
TENDER VALIDITY :
17. GROSS MARGIN : %
18. SPONSOR FEE (IF ANY) :
19. LIQUIDATED DAMAGES : LIMIT (IF ANY)
20. EXPORT CREDIT INSURANCE : DATE APPLIED FOR/RECEIVED
TYPE COMMENTS
21. BONDS :
CALL
BASI
S
PERIOD EXPIRY
DATE
% VALUE

A. TENDER
B PERFORMANCE
C. ADVANCE PAYMENT
D. RETENTION
E. OTHER
F. COMMENTS REG. WORDING, UNFAIR CALLING COVER ETC.
22. OTHER CONTINGENT LIABILITIES (EXCLUDING BONDS):
PARENT COMPANY GUARANTEE : YES / NO LEVEL :
WARRANTIES : YES / NO TO WHOM GRANTED
23. NEW PLANT REQUIREMENTS :





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


Version 1.0 Page 13 of 19
ITD Cementation India Ltd
AS PERCENTAGE OF TENDER VALUE :
VALUE TO BE ABSORBED BY CONTRACT
INITIAL DETAILS :
24. CASH / FINANCE CONTRACT :
25. FINANCING ARRANGEMENTS (IF ANY ) :
26. FOREIGN CURRENCY EXPOSURE
PAYMENT CURRENCY (IES)
CURRENCY (IES) OF SPEND :
% SPEND IN CURRENCY OTHER THAN PAYMENT
CURRENCY :

HOW IS RISK COVERED :
27. PAYMENT TERMS :
VALUATION METHODS :
MINIMUM PAYMENT:
TIME FOR PAYEMNT :
RETENTION LIMIT OF RETENTION ( IF ANY ) :
RELEASE OF RETENTION:
28. TAXATION CONSIDERATION
29. COST OF BID (THIRD PARTY COSTS):
30. DESIGN WORK REQUIRED
31 OTHER COMMENTS/ REMARKS
CONTRACT CONDITIONS TO BE CHECKED BY
BONDS TO BE CHECKED BY
INSURANCES TO BE CHECKED BY :
PREPARED
SENIOR ESTIMATOR
Date:























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


Version 1.0 Page 14 of 19
ITD Cementation India Ltd


RECORD - R- 1B/6 : PRELIMINARY TENDER SUMMARY ( FOR BU 2 )

Tender No :

Date :

Due Date:

1 Project:

2 Project Description And Location :

3 Country : Clearance :

4 Client :

5 Client Financial Standing :

6 Main Contract: Subcontract: Management Contract :

Main Contractor If Not Company Submitting Bid :

7 Partner (S) % And Financial Standing :

8 Engineer / Architect :

9 Form Of Contract Conditions :

10 Adverse Physical Conditions Clause :

11 Time Extension For Inclement Weather :

12 Unusual Conditions Of Contract :

13 Law Of Contract :

Arbitration :

14 Contract Commencement Date :

Contract Period :

Maintenance Period :

15 Currency Of Bid :

16 Tender Value : (Approx) In Rupees

17 Price Fluctuation :

Fixed Price :
Fixed Fees :
Tender Validity :
18 Gross Margin : %
Nett Margin : %























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


Version 1.0 Page 15 of 19
ITD Cementation India Ltd
19 Sponsor Fee (If Any)


20 Other Fees (If Any)

21 Liquidated Damages :

Maximum :
Bonus :
Maximum :
Ld On Milestone :
Maximum :

22 E C D G Cover :

Date Applied For / Received :
Type :
Comments :

23 Bonds : Call
basis
Period Expiry Date % Value
23.1 Tender /EMD
23.2 Performance Security
23.3 Advance Payment (Mob Adv)
23.4 Advance Payment (Eqpt Adv )

23.5 Advance Payment (Secured Adv)

23.6 Comments Upon Wording, Unfair Calling, Cover, etc.

24 Other Contingent Liabilities (Excluding Bonds)

24.1 Parent Company Guarantee :

Percentage :

25 New Plant Requirements :

25.1 As Percentage Of Tender Value :

25.2 Percentage Value To Be Absorbed By Contract :

25.3 Initial Details :

26 Foreign Currency Content Amount Equivalent

26.1 Currency Type :

27 Type Of Contract :

27.1 Cash Contract :

27.2 Finance Contract :

27.3 Financial Arrangements :
28 Payment :

28.1 Minimum : Frequency :

28.2 Payment Terms :






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


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ITD Cementation India Ltd
28.3 Retention :

28.4 Retention Release :

29 Cash Profile (Including New Plant)

29.1 Currency :

29.2 Peak :

30 Taxation Consideration :

31 Cost Of Bid :

32 Design Work Required :

33 J oint Venture Partners (S) Cross Guarantees :

34 Known / Anticipated Competitors :

35 Other Comments/ Remarks :


Conditions Checked By :

Bonds Checked By :

Insurance Checked By :


Prepared

Estimating Engineer























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


Version 1.0 Page 17 of 19
ITD Cementation India Ltd

RECORD - R 1 C/6 : PRELIMINARY TENDER SUMMARY ( FOR BU 3 )

TENDER NO :


DUE DATE :

1 Project Description And Location :
2 Owner :
3 Main Bidder ( If Not ITDCem) :
4 Engineer / Consultant :
5 Tender Validity :
6 Contract Period :
7 Defect Liability Period :
8 Tender Value : ( Approx. ) In Rs :
9 Price Fluctuation :
10 Variation :
11 Extra Items :
12 Liquidated Damages :
Minimum :
Maximum :
LD On Milestone (If Any)
13 Bonds : Call
Basis
Period Expiry Date %
Value
13.1 Tender / EMD
13.2 Performance Security
13.3 Advance Payment ( Mob Adv )
13.4 Advance Payment ( Eqpt Adv )
13.5 Advance Payment ( Secured Adv )
14 New Plant Requirements :
15 Payment :
15.1 Minimum : FREQUENCY
15.2 Payment Terms :
15.3 Retention :
15.4 Retention Release :
16 Taxation Consideration :
17 Arbitration :
18 Cost Of Bid :
19 Design Work Required :
20 Known / Anticipated Competitors :

21 Other Comments/ Remarks, If Any




Prepared Checked Checked Approved Approved


Estimate Comm.
Engg Mgr.

HOD Proposal VP/Gm Managing Director/
Director

Note : Approval Of Director Required For Value More Than 10 Crores.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


Version 1.0 Page 18 of 19
ITD Cementation India Ltd


RECORD - R- 2/6 : ENQUIRY / TENDER REGISTER

Enquiry No. /
Tender No.
Client Project Description EMD Tender
Submission
Date
Validity Remarks












































INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 6


Version 1.0 Page 19 of 19
ITD Cementation India Ltd

RECORD - R - 3/6 : NEW AWARD RECORD

Contract No : Location : Contract Value :

Date Of Award :


LOI/LOA Ref. No.

Contract Period : (Months)

Project Name :




Work Description:




Client Details

Name :

Postal Address :




Designation :



Phone: Fax : Email:

Note :





Date : BU - Head




CC : Departmental Heads & Sectional Heads

































INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 7


Version 1.0 Page 1 of 8
ITD Cementation India Ltd














PROCEDURE - P-7 : ENGINEERING PROCEDURE


















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 7


Version 1.0 Page 2 of 8
ITD Cementation India Ltd

1.0 PURPOSE

Purpose of this procedure is to ensure that the design and development activities,
to be performed by the organization, are identified in time and are planned and
controlled, so that :
the product meets the functional and performance requirements with due
consideration to:
- applicable statutory, regulatory and contractual requirements,
- safety of the product,
- safety of persons and environment under influence of the product,
- economy.

temporary and supporting structures for product realization meet the
functional and performance requirements with due consideration to,
- applicable statutory, regulatory and contractual requirements,
- safety of these elements,
- safety of persons and environment under influence of these
elements,
- economy.


2.0 SCOPE

This procedure shall be applicable for controlling the design and development of
permanent as well as temporary/ supporting structures as per requirements.

3.0 RESPONSIBILITY

Direct responsibility for implementation of this procedure shall be with BU-HOD
Engineering.

4.0 DEFINITION

a) Permanent structure - The structure, which is required to be constructed as
per contract and will be handed over to customer after construction.

b) Temporary or supporting structure: The structure, which will not be handed
over but will be required for constructing permanent structure or its part.


c) Design and development validation. : The process to ensure that the
resulting product is capable of meeting the requirements for specified
application or intended use.

5.0 PROCEDURE

The requirement of broad design of permanent structure shall be identified by the
BU HOD Proposal during tender stage. Contract Manager or Project in-charge
shall identify the detailed design requirement of permanent as well as temporary





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 7


Version 1.0 Page 3 of 8
ITD Cementation India Ltd
structures during execution stage and this shall be highlighted in Quality Plan as
per DS-2/11. This shall be intimated to BU HOD-Engineering.

Design related activities and their implementation at site shall be coordinated
through a temporary works coordinator nominated by Project In-charge.

BU HOD Engineering or any person authorized by him shall prepare a design and
development plan for all stages of design and specify the concerned responsible
and authorized persons for carrying out the design and development including
review & verification. The same shall be recorded in R -1/7.

Design and development plan shall be updated, as appropriate, based on review
of design and development proceedings and/or customers requirement.

Design of permanent / temporary / supporting structure may be carried out
engaging outside agency (service provider) or may be carried out In-House.

Review and verification will be done either through outside agency or in-house.
The responsibility and authority of each person of all the above activities will be
identified in R-1/7.

Inputs for design and development, related to product, shall be determined.

Inputs shall include,
a. functional and performance requirements of product/structure,
b. applicable statutory, regulatory and contractual requirements, (Technical
data given in tender/contract document and relevant Indian/International
standards shall be referred for the same.)
c. information derived from previous similar designs,
d. other essential requirements for design and development. (These may be
obtained from local information, good practices of other organizations,
suggestion from client, suggestion from internal safety authorities).
e. Environmental and Safety requirements and obligations.
Record of inputs, as determined above, shall be maintained by enumerating or
referring in the corresponding design notes.

The outputs of design and development shall be provided in a form that enables
verification against design and development input.

Outputs shall
a. meet the requirements for design and development specified in input,
b. provide appropriate information for purchasing, production and for service
provision. (This will be accomplished through generating any appropriate
combination of following:
- drawings,
- bill of quantities,
- specifications for materials, construction and erection,
- erection/operation methodology.)
c. contain or refer product acceptance criteria. (This will be accomplished
through any appropriate combination of following:
- By mentioning acceptance criteria, of structure or





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 7


Version 1.0 Page 4 of 8
ITD Cementation India Ltd
components of structure, in the drawings.
- By developing/referring specifications of structure or
components of structure.

Review of design and development shall be carried out at following stages, as
found appropriate:
a. Planning of design and development,
b. To check adequacy of inputs for design,
c. Analysis and design of components of structure or whole structure,
as per requirement,
d. Drawings,
e. Bill of quantities,
f. Specifications for materials, construction and erection,
g. Erection/operation methodology.

Review of design and development is aimed to evaluate the ability of outputs of
design and development to meet the requirements of product identified through
inputs. Problems identified during review serve as guide for corrective actions, so
that, outputs necessarily meet the input requirement.


Verification of design and development shall be done to ensure that outputs meet
the input requirements of design and development. This will be covered in the
analysis and design of structure and / or in the drawings. This will further be
substantiated by maintaining the input-output analysis record as per R-2/7.

Validation of the design and development of the part and whole structure will be
done wherever necessary and planned.

Any change in design and development, if necessary as per customer's
requirement or own requirement, shall be carried out. The change so done shall
be reviewed and verified as required and records shall be maintained to this
effect in the form of notes/correspondences or changed design & drawings.

Outsourcing of design activity: Design of any structure during tendering or
execution stage may be outsourced. BU HOD Engineering will decide whether
the Design / Design Review / Design Verification will be carried out In-House or
engaging outside Agency. In case it is decided that the Design related activity will
be carried out through outside Agency, BU HOD Engineering or any person
authorized by him shall prepare the Design development plan. Review and
verification may also be outsourced. In such cases BU HOD Engineering or any
persons authorized by him will coordinate these processes and necessary
supporting documents of Review or Verification by the Service Provider will be
maintained. During the tendering stage, BU HOD-Proposal shall provide
information to BU HOD-Engineering to evaluate the requirement of outsourcing.
During execution stage, Contract Manager or Project-in-Charge shall provide
necessary details, such as, schematic drawing, loadings, material availability at
site etc to BU HOD-Engineering to facilitate decision making for outsourcing.

After a decision has been taken to outsource the design, the same shall be
communicated to HOD-Proposal/Project In charge who shall then prepare





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 7


Version 1.0 Page 5 of 8
ITD Cementation India Ltd
Subcontract Indent for outsourcing the design activities. Indent shall then be sent
to HOD Engineering for approval. Delegation Authority for approval of Work
Orders related to Sub-contracting of Design related activities shall be as follows:











Sub Contracting
Value Up To
(Lakh)
Authority Level
Signatory I Signatory II
<5 BU HOD Engg. Project In Charge / BU HOD Coml.
>5 but <100 BU HOD Engg + BU HOD
Coml.
Vice President
>100 but <250 BU HOD Engg. + BU HOD
Coml.+Vice President
Director
>250 Director Managing Director

Performance of the service provider for outsourced design activities shall be
monitored and controlled by BU HOD Engineering as per delivery of design
(R 1/7).

BU HOD Engineering shall assess the performance of consultant during design
delivery process (DS-1/7). Performance analysis will be based on observations
on review and verification of various design elements/activities carried out by
consultant. Observations on review and verification shall be recorded in R-1/7.
Observations on input-output analysis recorded in R-2/7 shall also be the basis
for consultants performance analysis. Summary of performance of each
consultant shall be maintained by BU HOD Engineering for future reference as
per R-3/7.

6.0 CROSS REFERENCES

ISO 9001 : 2000 Clause 7.3 Design and development of product
IMS Manual Section 4.7

7.0 RECORDS

R 1/7 : Review and verification plan for design
R 2/7 : Input-Output Analysis
R 3/7 : Design consultant performance record

8.0 RECORDS AVAILABILITY

R 1/7 : BU HOD Engineering
R 2/7 : BU HOD Engineering
R 3/7 : BU HOD Engineering

9.0 RECORD RETENTION
As per procedure P-2.























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 7


Version 1.0 Page 6 of 8
ITD Cementation India Ltd

DATA SHEET - DS-1/7: CRITERIA OF PERFORMANCE ANALYSIS OF CONSULTANTS

Score criteria Sl.
No.
Evaluation Parameter
Good Satisfactory Poor
1 Experience on design of similar structures. 5 3 1
2 Adequacy of number of engineers and
draftsman available to take up the job.
5 3 1
3 Adequacy of softwares available relevant to
job.
5 3 1
4 Capacity of organization to take up the job
based on turn over of the company in the
last three years.
5 3 1
5 Capacity of organization to take up the job
based on works in hand in comparison to
persons available.
5 3 1
6 Familiarity and experience in the specific
geographical area.
5 3 1
7 Track record on past projects 5 3 1


ACTION TO BE TAKEN ON THE BASIS OF SCORE

1. Find out the average score evaluation parameter and score criteria mention above.
2. Take appropriate action as follows:

Sl.
No.
Average score Action to be taken
1 5 to 3.5 Continue with the consultant
2 3.5 to 2.5 Take appropriate action as reducing the workload, keep the
name in standby list.
3 Less than 2.5 Not to be opted for job.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 7


Version 1.0 Page 7 of 8
ITD Cementation India Ltd

RECORD - R-1/7 : REVIEW & VERIFICATION PLAN FOR DESIGN

Project Code & Name: Date :
Scope of Design
Reference


Sr
No
Activity & Design
Particulars
Responsibility Target
Date
Status Remarks/
Observations





HOD Engineering

RECORD - R-2/7 : INPUT & OUTPUT ANALYSIS

Project Code & Name: Date :
Scope of Design
Reference


Sr.
No.
Input Analysis For Design

1. Functional and Performance requirements
2. Statutory and regulatory requirements
3. Information derived from previous similar designs
4. Additional requirement for carrying out Design

Output Analysis For Design


1. Meet the requirement for Input
2. Information for purchasing materials
3. Product acceptance criteria
4.
Characteristics of the structure that are essential for its
safe and proper use


Design Verification


Design & drawings have been reviewed with respect to the Input information and found to
be in order.


HOD - Engineering






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 7


Version 1.0 Page 8 of 8
ITD Cementation India Ltd

RECORD - R-3/7 : DESIGN CONSULTANT PERFORMANCE RECORD


BU :

Sr
No
Date Name of
Consultant
Scope Of
Assignment
Including J ob No.
Address, Phone
/ Fax etc.
Observations
on
Consultants
Performance
Date of
Introduction








BU HOD Engineering























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 8


Version 1.0 Page 1 of 15
ITD Cementation India Ltd














PROCEDURE P 8 - PURCHASING


















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR COMMERCIAL






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 8


Version 1.0 Page 2 of 15
ITD Cementation India Ltd

1.0 PURPOSE

To provide documented procedures so that purchased materials and vendors
conform to the specified requirements.

2.0 SCOPE

This procedure is applicable to the purchase of Critical and Important Items only
as in Material Procurement Plan as referred in DS-2/11. For other items (except
administrative items e.g. utensils, personal items, kitchen items, bedding ,
stationary etc) clause no. 5.3 to 5.10 and 9.0 to 10.3 shall be referred.

3.0 RESPONSIBILITY

Direct responsibility for this procedure shall be with Corporate Purchase Head.
Responsibility of providing items to project sites will lie with HOD Purchase for BU
purchase, Project In-charge for purchase at Project site and Import including
Custom Clearance with Import In-charge. Capital Purchase, Cement, Steel,
Bitumen, Furnace Oil, Light Diesel Oil, Import Substitution matters etc. shall be
responsibility of Corporate Purchase. For Spare Parts & Plants direct
responsibility shall lie with Corporate Purchase while Assisting responsibility shall
be with HOD Plant.

4.0 DEFINITIONS

Vendors -- This term includes Suppliers of Items & materials.

Critical and Important Items -- These items significantly impact the final product
quality and is part of the permanent works handed over under a contract.

Capital Purchase -- Assets of the company like plant and machinery, capital
purchases capitalized in the books of account or specifically treated as such as
per the company procedure.

BOQ -- Bill of Quantity as per awarded tender / contract

MOU Memorandum of Understanding between Vendor and Purchaser

5.0 PROCEDURE

5.1 After award of the Contract a list of the purchased products required for that
project along with their lead time for procurement shall be prepared. This shall be
part of Quality Plan as referred in DS-1/11. This will specify whether a particular
material shall be purchased from site, BU or Corporate Office. This Material
Procurement Plan shall be prepared by the Project - In charge in concurrence with
Corporate Purchase Head. However for projects of short duration this may be
prepared in the Kick Off meeting itself in concurrence with Corporate Purchase
Head.























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 8


Version 1.0 Page 3 of 15
ITD Cementation India Ltd

5.2 Project execution/Store In charge shall prepare Stores Purchase Indent ( SPI,
indicating the Contract or Location, Date, Full item description, Specifications,
Quantity to order) for those materials which are to be purchased from depot or BU
Office or Corporate office or at site itself. Except for all critical and important items
(non stock items), Depot In charge shall check the availability at area depot and
forward the Indent to Corporate Purchase Head / HOD Purchase for Procurement
action after consultation wherever required with Corporate Plant Head. This shall
then be sent to HOD-Purchase or BU purchase or Depot In charge or Site
Purchase In charge for subsequent action. A Purchase Indent in the form of
memos / verbal messages / fax / e-mail should not be entertained. However, in
case of emergency, indent in the above form shall be accepted giving proper
justification. Enquires against such Indent shall be issued but no orders shall be
placed until receipt of proper purchase indent.

5.3 In order to ensure control and regulation of purchase activity proper enquiry
shall be floated to the vendors available in the existing vendors list and to the
probable vendors as per clause 6.0. Enquiries are required to be floated for all
Critical and Important items. However, in case of routine standard, and day-to-day
items written enquiries may or may not be floated.

5.4 Repeated enquiries need not be floated in following cases also.
a) Where rate contracts exist.
b) Where MOUs exist.

5.5 In the event of a single response to any enquiry due to any of the following
reasons :
a) Paucity of time / less reaction time available with purchaser.
b) No other Manufacturer / dealer has quoted in spite of follow up.
c) Supplier is an OEM (Original Equipment Manufacturer) .

Negotiations should be held with the party and approval to be taken.

5.5 The Quotations / Offer received in writing or telephonically should be entered on a
Comparative Sheet. However Comparative Sheet need not be made in the
following cases

a) The number of quotations to be compared are less.
b) Terms and conditions of all the quotations are same and only Basic price or
all inclusive price is varying.
c) There are only one or two small value items per quotation.

5.6 Negotiations should be carried out with maximum numbers of parties to get the
best rates, best commercial terms and the delivery period. The same is to be
recorded on Comparative Sheet in case the comparative sheet is prepared and in
case the comparative sheet is not prepared it is to be recorded on the quotations
or Indent and signed.

5.7 Purchase Order containing all purchasing data shall be raised as per format R-
1A/8 and R-1B/8 and distributed as per marking in the P.O. copies.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 8


Version 1.0 Page 4 of 15
ITD Cementation India Ltd

White Copy
(original)
- To the supplier.
Yellow Copy - Accounts department / Bill passing section.
Green Copy - Purchase department.
Pink Copy - Site / Store / receiving section.

Delivery schedule shall be stipulated in the terms and condition of Purchase
Order. The authorized persons shall do review and approval of purchase order.

5.8 Supply of materials, services, etc. will be monitored with respect to its completion.
Delivery, Specification, etc. against the Purchase Order shall be verified and
controlled at the receipt points i.e. Depots / sites.

5.9 Any amendments to Purchase Order shall be in the same format and contain
reference to the original P.O.

5.10 PO follow up shall be done in Purchase Register as per R- 6/8 and it shall be
responsibility of Site Store In charge at Site / Depot In charge at depot.

6.0 VENDOR APPROVAL

Existing vendors as on dated 15.04.03 who have been approved by virtue of past
experience shall be listed in R 3/8. Each depot and BU office shall maintain
such list. Similarly, a list of approved vendors for a specific project site shall be
prepared in R - 3/8 by Purchase In charge at Site and a copy of the same is to be
forwarded to HOD Purchase for record. While approving a new vendor, a
questionnaire as given in R - 2/8 for Vendors shall be prepared. On the basis of
such information, the HOD - Purchase or Purchase In Charge / Engineer
Commercial at site shall decide whether or not to give sample order. First order to
vendor shall be considered as sample order. Only after getting the report of
sample order it would be decided whether to register the Vendor or not and the
reasons for this approval or rejection shall be recorded under remarks. However
the other competitors can be considered for further enquiries.

7.0 VENDOR EVALUATION & DEREGISTRATION

Performance of the vendors shall be assessed by the Project In-charge for site
receipt and Depot In charge for store receipt from the various records of supply as
per R - 5/8. This evaluation shall be done once in six months or twice for the
project of duration less than a year. The criteria used would include performance
with respect to quantity, quality and delivery time as per DS 1/8. A copy of the
same to be sent to HOD Purchase quarterly.

8.0 VERIFICATION OF PURCHASED PRODUCT

Whenever it is required to verify purchased product at the vendors premises the
verification arrangement and the method of products release shall be specified in
the Purchase Order.























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 8


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ITD Cementation India Ltd
As may be specified in the Quality Plan for Inspection & Testing as per R-1/12
vendor shall conduct the necessary Inspection / Testing and furnish the relevant
Test Certificate.

If contractually agreed, customer or his representative shall be afforded the right
to verify the purchased products at vendors or companys premises. Such
verification shall not be used by the company as evidence of effective control of
quality by the vendor.

9.0 EMERGENCY PURCHASE FROM SITE

For purchasing materials to meet emergency requirement at site not exceeding
Rs.20 lakh the Site Purchase In charge shall get the approval of the Project-In
charge for the same as per R-4/8 and proceed with procurement. This copy of R-
4/8 shall be sent to HOD-Purchase for transaction value more than Rs 5 lakh.
Purchase Order shall be made subsequently for all such Purchase. This
emergency purchase shall also include emergency purchase of materials to be
arranged from Depot / BU Office/Corporate Purchase .

10.0 CASH PURCHASE

10.1 This provision is provided only at site/ depot to meet the urgent, immediate
material requirements which arise at site and not meeting those requirements can
cause a delay in execution of major jobs at site. This provision is to be used very
discretely by the Project In charge/Depot In-charge judging urgency in his
capacity. However cash purchase can be done for bill value of less than Rs 5000
per transaction where no PO is required and same transaction cannot be
repeated in a week for the same item.

10.2 Procedure to be followed for Cash purchase :

a) Cash Purchase is to be initiated on a SPI with a clear endorsement by
Project In-charge/Depot In-charge recommending so.
b) Since there shall be no P.O. for such a transaction following records are to
be maintained :
i) Cash Purchase register with site Purchase In-charge/Cashier at Depot
clearly indicating the SPI No., item description, quantity received,
checkers slip no., cash memo no. details, amount expended as per
cash memo, signature of purchase, cashier and Project In-
charge/Depot In-charge against each purchase.
ii) Cash Memo clearly indicating whether paid/ unpaid.
iii) Receipt from party if paid or stamp of paid on cash receipt.
iv) Relevant checkers slip of material having received in the local stores.
v) The inspection/ acceptance of the material at the time of each
purchase shall be treated as final and binding on the site/ depot.

11.0 REPEAT ORDER

11.1 Repeat orders, without calling for fresh quotations may be placed against previous
purchase order within a period of one year of its issue or six months from the date
of completion of supply. No repeat order shall be placed for higher price on early





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 8


Version 1.0 Page 6 of 15
ITD Cementation India Ltd
delivery consideration. Also, no repeat orders shall be placed for those items
where market prices fluctuate periodically.

11.2 Repeat orders shall be placed as per the financial delegation of powers. Repeat
orders shall be released with the provision:

i) The quantity to be ordered in each subsequent order does not exceed
100% of the quantity originally ordered. For quantities that exceed 100% of
the quantity originally ordered, fresh quotation should be invited as per
purchasing procedure.

ii) It should be ensured at the time of placing repeat orders that there has
been no downward trend in the price since the placement of the original
orders. Suitable remarks on the price comparison sheet shall be made by
the Site Purchase In charge / Project In charge / HOD Purchase as the
case may be.

12. CROSS REFERENCES

ISO 9001:2000 Clause No. 7.4 Purchasing
IMS Manual : Section 4.7

13. RECORDS

R 1/8 : Purchase Order
R 2/8 : Questionnaire for Vendor Evaluation
R 3/8 : List of Approved Vendors
R 4/8 : Emergency Purchase Register

14. RECORDS AVAILABILITY

R 1/8 : BU HOD Purchase / Site Purchase Officer
R 2/8 : BU HOD Purchase / Site Purchase Officer
R 3/8 : BU HOD Purchase / Site Purchase Officer
R 4/8 : BU HOD Purchase / Site Purchase Officer

15. RECORDS RETENTION

As per Procedure P-2.























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 8


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ITD Cementation India Ltd

DATA SHEET : DS- 1/8 : CRITERIA FOR PERFORMANCE ANALYSIS OF VENDOR

CRITERIA OF PERFORMANCE ANALYSIS OF VENDOR


Parameter Good Satisfactory Poor
Quantity As per PO Delivered 20 % less Delivered more than 20 %
less
Quality Exactly as per PO
specification
--- Lot Rejected
Time Schedule As per PO Delay less than 20 %
of Scheduled time
Delay more than 20 % of
Scheduled time



Score Description
100
If Vendor received all GOOD in all three categories

90
If Vendor received two GOOD and one satisfactory

80
If Vendor received one GOOD and two satisfactory

70
If Vendor received two GOOD and one poor

60
If Vendor received one GOOD and two poor

50
If Vendor received two SATISFACTORY and one POOR

40
If Vendor received one SATISFACTORY and two POOR

30
If Vendor received all POOR


ACTION TO BE TAKEN ON THE BASIS OF SCORE

1. Find out the total SCORE.
2. Find out the average SCORE per ORDER per ITEM of particular VENDOR and take
appropriate action as follows :


Sl. No. Avg. Score Action To Be Taken
1 Till 60 Continue the Vendor
2 Less than 60 & till 40 Give Warning Letter
3

Less than 40 Deregister the Vendor























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PROCEDURE P- 8


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ITD Cementation India Ltd
DATA SHEET DS 2/8 : PROCUREMENT AUTHORITY



AUTHORITY LEVEL : All Purchase Orders must be signed by two authorities. Level of authority for signing
purchase order is given below :


PROCUREMENT PURCHASE ORDER SIGNATORIES

Authority Level Type of
Procurement
Landed Value
Upto (without
escalation )
( Rs. )
Signatory 1 *
Commercial /
Procurement
Signatory 2
Projects
5,00,000 Site Purchase In Charge / Site
Comm. Head
Project In Charge
25,00,000 BU Purchase HOD / BU
Comm. HOD
Contract Manager
50,00,000 Corp Purchase Head Vice President
1,00,00,000 Corp Purchase Head Director
Purchase
Product




10,000,000 and over Director

Managing Director
1,00,00,000


Corp Purchase Head

Director


Capex
1,00,00,000 and over

Director

Managing Director
1,00,00,000 Import Manager Director
Imports
1,00,00,000 and above Director Managing Director
10,00,000 Corp Purchase Head Vice President
50,00,000 Corp Purchase Head / Vice
President
Director
Single
Vendor
50,00,000 and above Director Managing Director

* In consultation with respective BU Head Corporate Purchase Head shall identify Site Purchase
In Charge, Project In Charge and Contract Manager for different projects.






















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PROCEDURE P- 8


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ITD Cementation India Ltd


RECORD - R 1A/8 : PURCHASE ORDER SUPPLIERS COPY

PURCHASE ORDER

Must be quoted on all Invoices,
Advice Notes and

Order No.


Date


Your Ref.



Please supply the following goods to us at / carry out the following work :

For and on behalf of
Skanska Cementation India Ltd.


SPI No./ Cont. No. Quantity Unit Item Code & Description Unit
Price Rs.
Value
Rs.





















Rupees :

Where practicable all stores items, including spare parts, accessories, fittings, tools etc. should be
clearly labeled with the description. Makers part No. and stores code number.
It is also important that Stores Code Number appears on all packing notes advice notes and
Invoices.

Acknowledgement Price acknowledgement to the below address B.S.T. 400020 S-689 Dt. 01-04-96

Advice Notes One copy to consignee, one copy to the below
address
C.S.T. 400020- C 620 Dt.01-04-96

Invoices In duplicate to the below address
Suppliers Copy

Printed on : Page No :
Registered Office : Apeejay House, Dinshaw Vachha Road, Mumbai 400 020.























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 8


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ITD Cementation India Ltd


TERMS & CONDITIONS OF ORDER

1) The execution of this order shall be deemed to be an acceptance of the conditions stated herein. This contract
shall be deemed to have been made in Kolkata/ Mumbai and shall be subject to jurisdiction of Courts in Kolkata/
Mumbai.

2) The Company will not be responsible or liable for any goods supplied in absence of written order nor its printed
official forms duly signed by one of its authorised officials.

3) The goods shall be delivered strictly within the time specified in the contract, the time being of the essence of the
contract.

4) The Vendors/ Suppliers shall be entirely responsible for loss or damage due to faulty protection and or insecure
packing. All packing material shall be the property of the Company.

5) The goods shall be subject to the approval of the Company and must strictly conform to workmanship, quality,
materials, construction, dimension, tolerances, performances and other details specified herein and in the
specification drawings or samples or as directed. Liberal factors of safety must be used throughout the design. If
in opinion of the Company any goods are defective and do not answer or comply with terms herein the Company
shall have the right to reject the goods and the Vendors/ Suppliers shall be liable to replace such goods or
compensate Company for the value hereof and also for all direct or indirect damage or loss to the Company
consequent therefrom.

6) The Company and its duly authorised representative shall at all reasonable times have access to the Vendors/
Suppliers premise or works to inspect the materials or workmanship of the goods during its manufacture. All goods
are subject to inspection and test if necessary but it is clearly understood that any such inspection shall not relieve
the Vendors/ Suppliers of their responsibility, any liability. Final testing of the goods shall be at the Companys site/
premises and only, after complete erection at the suppliers cost. Any failure or defect noticed shall be made good
or replaced by the Vendors/ Suppliers at their own costs and risk within the period specified therein. The Company
shall however have the option at the risk and cost of Vendors/ Suppliers to get any such defect rectified by any
other competent agency if the Vendors fail to rectify the defects time.

7) All machinery supplied shall be installed by the vendor at all Companys premises/ sites and shall be given trial run
by way of demonstration to the satisfaction of the Company entirely at the suppliers cost.

8) The Company shall have the right at any time or from time to time and any stage to make any alterations in the
design or specification of the goods and all terms herein contained shall apply to such alterations.

9) All order placed by the Company are strictly confidential. The Vendors/ Suppliers shall not publish or allow to be
published whatsoever any details concerning the goods without Companys previous permission in writing. All
designs specifications and drawings supplied by the Company shall be kept by the Vendors/ Suppliers in safe
custody and not shown or disclosed to any person save for the limited purpose of manufacturing the goods
comprised in the order. Such design, specifications and drawing shall be the property of the company and shall be
returned to the Company on demand and in any event upon the goods contained in this order being manufactured
and shall not be used by the Vendors for or in connection with the production of any goods whatsoever order than
goods ordered by the Company.

10) In case of any dispute the decision of the Company shall be final and binding on this Vendors/ Suppliers.

11) In acknowledging this order the Vendors are required to draw attention of the Company specifically to any
conditions contained in the order which he finds unacceptable and in absence of such notification the conditions
contained herein shall exclusively govern this order.

12) Delay in payments shall not entitled the supplier to claim any interest whatsoever.

13) The supplier confirms and agree the following :

a) Upon issuance of this purchase order with the terms and conditions printed over leaf, the supplier shall supply the
goods strictly on the terms and conditions of this purchase order only. The supplier confirms that in the event of
any dispute or difference, the same shall be referred to the Competent Courts in Mumbai alone.
b) The Supplier shall further confirm and agree that the supplier shall not under any circumstances and under any
eventually impose any fresh conditions of supply by any means or mode either orally or in writing such as but not
limited to imposing of any fresh conditions either orally or in the form of any written document, delivery challans,
letter. Invoice or any other like documents which imposes any fresh conditions of supply.

14) In the event the Vendor is within the status of Small Scale Industry (SSI) then to that effect the vendor shall
promptly notify the Company with its SSI registration number and shall make the said declaration while raising their
invoice(s).

15) The goods shall conform to the safety standards laid down in Building and Other Construction Workers Act 1996
and Rules 1998. Test certificate wherever required shall be furnished.

16) You shall meet environmental requirements as follows:





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 8


Version 1.0 Page 11 of 15
ITD Cementation India Ltd
Environmental Policy : Suppliers/Contractors supplying/working for ITD Cementation India Ltd shall familiarize
themselves with the Environmental Policy of the Company.

Training : Contractors who supply workforce at project sites shall ensure that induction training is given to all
workers, before commencement of work. Contractors shall seek advice of the Project In Charge for training
arrangements.

Training Effectiveness Assessment : Contractors shall ask the supervisory staff to assess effectiveness of
training in terms of work practices. Contractors shall give feedback on training need of workers to the Project In
Charge in first week of each month.

Environmentally Sound Work Practices : Contractors shall ensure following work practices are strictly adhered to
:

Waste Minimization : Wastage of raw material (cement, steel, sand, gravel, water, electricity, and diesel)
is avoided. Appropriate quality control is exercised in preparation , placing and curing of concrete.

Waste Management : Waste is deposited in the bins/locations identified for construction waste, metal
waste, plastic/rubber waste, food waste, used oil, waste cotton, miscellaneous scrap.

Noise Pollution Control : Appropriate PPEs are used by workers working in noisy areas, timely preventive
maintenance Plant/equipment supplied by the Contractor, and plant/machinery is not run in idle condition.

Air Pollution Control : Appropriate PPEs are used by workers working in dusty areas, dust emission is
minimized in transport and loading/unloading operations

Water Pollution Control: Wastewater generated in plant/machinery/vehicle/pipeline/ vessel/empty
containers washing, bentonite slurry, unused oil/paint is not discharged in source of water such as
stream/river/lake, or on good agricultural land, or any other place which can result in public nuisance.

Nature Conservation : Disturbance to nature due to cutting of trees, cutting/depositing soil, diversion of
flow of water, blasting operations, development of access roads is minimized.

Legal compliance : Contractors working for Skanska Cementation India Ltd shall strive to meet following legal
obligations :

Stone Crushers : Obtain Consent to Operate from State Pollution Control Board for stone crushers , and
operate the crusher in keeping with conditions stipulated in the Consent. (Air [Prevention & Control Of
Pollution] Act 1981 and Rules there under)

Diesel Generating Set : Ensure that minimum height of stack to be provided for generator sets meets the
requirement worked out as H =h+0.2x (KVA)0.5, H =Total height of stack in meter, h =Height of the
building in which the generator set is installed in meters, KVA =Total generator capacity of the set in
KVA (Central Pollution Control Board)
DG sets are provided enclosure to ensure that the maximum permissible sound level shall be 75 dB(A),
at 1 meter from the enclosure surface (Environment (Protection) second Amendment Rules, 2002)

Transport Vehicles : Obtain and maintain PUC certificate for transport vehicles. (Central Motor Vehicle
Act 1988 and Rules there under).

Lead Acid Batteries : Ensure that used lead acid batteries are collected before returned or sold to
registered dealers/recyclers (Battery (Management and Handling) rules, 2001)

Generation, storage, transport, disposal of Hazardous Waste : Obtain authorization from State Pollution
Control Board for handling and disposal of hazardous wastes. (Hazardous Wastes [Management &
Handling] Rules 1989.as amended in 2003)

Work practices at construction sites: Adhere to work practices as mentioned in the Building and Other
Construction Workers Act 1996 and relevant rules
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 8


Version 1.0 Page 12 of 15
ITD Cementation India Ltd


RECORD - R 1 B/8 : PURCHASE ORDER ACCOUNTS COPY

DELIVERIES EFFECTED AGAINST THE ORDER
Bill No. Date Amount C.S. No. Quantity



PURCHASE ORDER

Must be quoted on all Invoices,
Advice Notes and

Order No.


Date


Your Ref.



Please supply the following goods to us at / carry out the following work

For and on behalf of

Skanska Cementation India Ltd.


SPI No./ Cont. No. Quantity Unit Item Code & Description Unit Price
Rs.
Value
Rs.








Rupees :

Where practicable all stores items, including spare parts, accessories, fittings, tools etc. should be clearly
labeled with the description. Makers part No. and stores code number.
It is also important that Stores Code Number appears on all packing notes advice notes and Invoices.


Acknowledgement Price acknowledgement to the below address B.S.T. 400020 S-689 Dt. 01-04-96

Advice Notes One copy to consignee, one copy to the below
address
C.S.T. 400020- C 620 Dt.01-04-96


Invoices In duplicate to the below address
Accounts Copy

Printed on : Page No :
Registered Office : Apeejay House, Dinshaw Vachha Road, Mumbai 400 020.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 8


Version 1.0 Page 13 of 15
ITD Cementation India Ltd


RECORD - R 2/8 : QUESTIONNAIRE FOR VENDOR / SUPPLIER


INFORMATION TO BE FURNISHED

A. GENERAL

A.1 Name of the company and Office address :

A.2 a) Partners (if yes, give names) :

b) Public / Private Ltd. Company :

c) Proprietorship :

A.3 Basic business :

A.4 Date founded :

A.5 Highest single order value executed
& Name of the Customer :

A.6 Name and addresses of two reputed Customers/
Companies to whom reference can be made :

A.7 Is vendor ISO 9000 certified company ?

B. FOR MATERIAL SUPPLIER

B.1 Mode of Quality Control Check and Supervision,
Testing Facility / Certificates :

B.2 Total installed capacity at the factory :

B.3 Generator Facility ( if applicable ) :

B.4 Quality Control / Laboratory facilities :

Sample Order To be Placed / Rejected

Ref. PO. :

Follow Up : Approved or Rejected ( Put tick )

Remarks :

Prepared By Checked By Approved By

Site Purchase
In Charge
Site Commercial Head /
BU Purchase Head
Project In Charge /
Corporate Purchase Head























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 8


Version 1.0 Page 14 of 15
ITD Cementation India Ltd

RECORD - R 3/8 : LIST OF APPROVED VENDORS

Project No & Name :

BU No :

Critical Item Name :



Sl.
No.
Name Of The Vendor &
Address
Phone / Telex / Fax
Nos.
Date Of
Introduction
Applicable IMS
Q E S





* Put mark wherever applicable


Review Date : Corporate Purchase Head / Project In Charge





RECORD - R-4/8 : EMERGENCY PURCHASE REGISTER

No. :


Party :


Sl. No. Item Particulars & Specification Quantity Rate Amount Delivery Date








Prepared By :
Purchase In Charge
Approved By :
Project In Charge

Copy to : HOD Purchase ( if required )





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 8


Version 1.0 Page 15 of 15
ITD Cementation India Ltd


RECORD - R-5/8 : RECORD OF VENDOR EVALUATION

Party Name :


Item Description:




Comments Sl.
No.
PO Ref
Quantity Quality Delivery
Schedule
Total
Score
Action To be
Taken ( If any ) &
Remarks











Project In Charge


Copy To : Corporate Purchase Head



RECORD - R - 6/8 : PURCHASE REGISTER


PO
No.
Date Item
Particulars
Suppliers
Name
Purchase
Order
Quantity
Scheduled
Time
Scheduled
Quantity
Received
Quantity
Quality
( Ok / Not
Ok )
Actual
Delivery
Date







Approved By :

Project In Charge :























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 9


Version 1.0 Page 1 of 3
ITD Cementation India Ltd














PROCEDURE -P-9 : COMMERCIAL PROCEDURE


















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR COMMERCIAL






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 9


Version 1.0 Page 2 of 3
ITD Cementation India Ltd

1.0 PURPOSE

The purpose of this procedure is

a) To provide a method such that all commercial inputs are provided at tender
stage in order to properly identity the risk and benefits including accepted
deviation/qualification to the original tender conditions, as per company guidelines.

b) To handle all issues related to finalisation of subcontract including agreements
etc.

c) To finalise contract with customer and to monitor the contract performance by
proper inputs, reports including claim management, arbitration etc.

2.0 SCOPE

The scope of commercial function extends from the tender stage to the execution
stage and the post execution stage.

3.0 RESPONSIBILITY

Direct responsibility for implementation of this procedure shall be with HOD
Commercial. Functional responsibility of HOD Commercial and Commercial
Manager at Site ( Project Commercial) shall be defined at the time of starting of a
project.

4.0 DEFINITION

None Required

5.0 PROCEDURE

Tendering Stage

For major tenders of value more than Rupees 10 Cr, during pre-tender stage, the
Commercial department shall review the commercial conditions of a tender and
prepare a statement on salient bid conditions of the tender. The department shall
prepare pre-bid queries on the basis of tender conditions subsequent to this risk-
benefit areas of the tender are identified.

In case of tenders of value less than Rupees 10 Cr Proposal department shall
study commercial conditions of the tender. Salient conditions shall be discussed
with Commercial Department. Based on the discussion suitable deviation /
qualification shall be submitted in the tender and / or cost provision shall be made
in the estimate.

Contract Execution

On award of work, the Commercial Department shall review the Contract





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 9


Version 1.0 Page 3 of 3
ITD Cementation India Ltd
conditions with respect to the tender clauses, negotiation document and final
accepted conditions, prior to execution of the Contract agreement.

Subcontracting guidelines as circulated by Director Commercial ( Doc. Ref. No.
CD/A/SCG/01) and amended from time to time shall be applicable for engagement
of all vendors for execution of the Project. The site Commercial team prepares the
subcontract agreement of the major subcontractors with the help of BU
commercial team with respect to the terms and conditions of the original contract.

During execution, the Commercial Engineer / QSS department at site shall
prepare the invoices in terms of contract.

On the basis of invoices, the costvalue reconciliation for the projects shall be
undertaken at BU / site level on a monthly basis or quarterly basis.

Reconciliation report of debtors balances for the projects shall be done both at BU
and site level.

BU Commercial team with the help of Site Commercial team or vice versa shall
prepare claim towards extra / additional works undertaken, if any, or towards any
other issues pertaining to the project.

In the event of non-settlement of any dispute in an amicable manner, arising out of
the Contract between the Parties, the Commercial teams shall pursue the matter
for settlement through arbitration / court if felt necessary.

6.0 CROSS REFERENCES

ISO 9001:2000 Planning of Product Realization
IMS Apex Manual : Section 4.7

7.0 RECORDS

Nil
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 10


Version 1.0 Page 1 of 4
ITD Cementation India Ltd














PROCEDURE P-10 : PLANNING PROCEDURE



















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 10


Version 1.0 Page 2 of 4
ITD Cementation India Ltd

1.0 PURPOSE

The purpose of this procedure is to plan, programme and monitor progress of
project.

2.0 SCOPE

The scope of this procedure covers planning for all projects.

3.0 RESPONSIBILITY

The responsibility for implementation & maintenance of this procedure shall be as
under.

1) Project Engineer Planning To prepare the programme, to generate periodic
report and revise the programme as per requirement.

2) BU HOD Planning To monitor the project and suggest corrective action, if
any.

4.0 DEFINITION
None required

5.0 PROCEDURE

After award of each contract, Planning Engineer at project site shall study the
contract document, site visit report, drawing etc. Programme methodology and
Resource Deployment schedule prepared during tendering shall also be studied
and taken note of. Based on these and proposed methodology, Planning Engineer
shall prepare a detailed Time Program of work ( Network / Bar Chart / Quantity
Schedule )

Project in Charge shall approve the above detailed programme and forward the
same to BU HOD Planning for his concurrence.

Resource requirements shall be evaluated. Accordingly Store Purchase Indent
shall be raised for necessary procurement / arrangement by respective department.

Project Planning Engineer shall prepare Weekly Progress (R-1/10) that shall be
reviewed and approved by Project In Charge and copies shall be sent to BU HOD
Planning who shalll review the actual progress of work against the schedule
programme and monitor the progress. BU HOD Planning shall prepare the concise
statement of area of concern and his suggestions on corrective action (if any) shalll
be circulated to Contract manager and Project In Charge.

Project Planning Engineer shall review the programme periodically based on the
progress and incase he finds that there shall be delay in completion of the project
owing to any reason related to client, he shall request the Project In charge to take
necessary action to inform the reasons for delay to client in due course. Otherwise





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 10


Version 1.0 Page 3 of 4
ITD Cementation India Ltd
in consultation with Project In charge, BU HOD Planning shall crash the balance
activities to maintain the original date of completion of the contract and revise the
program accordingly. Extension of time shall be applied to client at appropriate time
depending on condition of contract. Revised programme shall be approved by
Project In Charge and copy shall be sent to BU HOD planning. The additional
resources required to fulfill the revised programme shall be evaluated for further
action.

6.0 CROSS REFERENCES

ISO 9001:2000 Planning of Product Realization
IMS Apex Manual : Section 4.7

7.0 RECORDS

R 1/10 : Weekly Progress Report

8.0 RECORDS AVAILABILITY

R 1/10 : BU Head Planning

9.0 RECORD RETENTION

As per Procedure P -2























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 10


Version 1.0 Page 4 of 4
ITD Cementation India Ltd


RECORD - R-1/10 : WEEKLY PROGRESS REPORT

Project Name : Contractual Commencement Date :
Location : Actual Commencement Date :
Contract No : Contractual Completion Date :
Progress Report For Week Ending : Expected Completion Date :

Total
Quantity
Quantity
up to
Last
Month
Quantity Planned
Revised
Quantity
Executed
Cumulative
till Date
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V
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Area of Concern Requirements






Project In Charge
Date
Site Planning Engineer
Date
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 11


Version 1.0 Page 1 of 13
ITD Cementation India Ltd














PROCEDURE P-11 : PROJECT EXECUTION

















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 11


Version 1.0 Page 2 of 13
ITD Cementation India Ltd

1.0 PURPOSE

The purpose of this procedure is to ensure that the Project Execution is carried out
in an organised manner.

2.0 SCOPE

The scope of this procedure is to cover all projects / works.

3.0 RESPONSIBILITY

Direct responsibility for implementation of this procedure shall lie with Project In
Charge.

4.0 DEFINITION

None required

5.0 PROCEDURE

Review Before Acceptance Of Contract

After getting work order from customer through proposal department, the contract
manager shall review it and differences, if any, shall be resolved with customer.

Initial Mobilisation Period

After award of work, the contract documents shall be collected by Project In charge
from Contract manager. Before actual start of construction work, following activities
shall be carried out.

A Kick Off Meeting (KOM) shall be held within 15 days after award of contract.
Contract manager, Project In charge, HOD Plant, HOD Purchase, BU HOD-Safety
& other HODs as required shall attend the KOM. The guideline agenda for KOM is
given in DS-1/11. Minutes of KOM shall be recorded. Site-specific Quality Plan
shall be prepared within 30 days from the date of KOM as per guideline given in
DS-2/11. Site specific Environmental Plan shall be prepared as per DS-3/11.Site
Safety plan shall be prepared prior to start of execution as per DS-4/11.

Master indent for the stock items shall be raised by the project site for arranging all
necessary materials & plants. This shall be arranged by BU office / depot.

Method statement for carrying out the work shall be prepared for construction
activities. Method statement shall consider environmental aspects and health &
safety risks.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 11


Version 1.0 Page 3 of 13
ITD Cementation India Ltd
Collection of drawings & documents from the customer shall be made and initial
survey shall be carried out.

In case the scope of contract includes design and development of permanent
structures, initiation of the same shall be done as per procedure P-7

Planning of the project will be carried out by the Planning Engineer as per P-10.

Quality Plan for Inspection and Testing & Calibration of equipment shall be done
as per P -12 & P -14 respectively.

Environment Plan for monitoring key parameters of environmental performance
and calibration of environmental performance monitoring / measuring instruments
shall be prepared as per procedures P-13 and P-14 respectively.

Project Execution Stage

Construction activities shall be planned as per R -1/11.

Construction shall be carried out according to the planning done as per the
procedure on project planning (P-10).

Qualified and / or experienced personnel shall carry out all the construction
activities.

Maintenance of the equipment shall be carried out as per the Procedure P-15

Product shall be inspected as per Procedure P-12. Inspection, measuring and
Test equipment shall be calibrated as per Procedure P-14.

Nonconforming products shall be controlled as per P-16 and necessary corrective
and preventive actions shall be taken as per P-17.

Handling and storage of different products shall be as per P-18.

In case of any major inadequacy of resources during the execution of the project
the same shall be intimated to Contract Manager by Project in charge.

Any amendment to contract during the post award period shall be recorded by
Project In Charge.

Overall performance of various activities along with implementation of IMS of a
project site shall be reviewed monthly by the Project in Charge and all concerned.
Suggested checklist for Monthly Site Review Meeting and Site Safety Committee
Meeting are provided in data sheet DS-5/11. Minutes of Site Review Meeting shall
be sent to MR and AMR at BU level. Corporate Safety Head and Corporate





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 11


Version 1.0 Page 4 of 13
ITD Cementation India Ltd
Environment Head. Minutes of Site Safety Committee Meeting shall be sent to
Corporate Safety Head, Contract Manager and BU HOD Safety. Site shall send
periodic/monthly reports to all concerned as per DS-6/11.

Concrete mix is one of the In Process material for which identification system
exists. Any other material, if required for a specific project, can be included in this
category.

Concrete mix is identified as specified in the quality plan for project execution,
which shall be maintained by the supervisor at work of destined structure under
construction.

Part of final structure as may be applicable shall be identified / marked with
reference number relating to the drawing.

Traceability shall be maintained for the Cement. Any other material as felt
necessary can be included in this category for specific project.

Cement can be traced back from any point of using concrete upto the supply stage
through various records.

Site store shall be maintained as per P-18.

For winding up, plants & stock items shall be sent to other location as decided by
Contract Manager. Unused Customer supplied product, if any, shall be returned.
Scrap materials, if any shall be disposed off. All IMS records shall be controlled as
per P-2.

After complete winding up of the Project, Contract Manager shall prepare and
submit the Contract Performance Report (CPR) along with detailed analysis of
causes for any adverse deviations and suggestions on corrective / preventive
actions needed to BU Head and the HOD Proposal for future use.

Selection of subcontractors for any outsourced construction activities shall be done
as per P-9. Outsourcing of construction activity shall be planned and included in
site-specific quality plan. Performance of the subcontractors shall be monitored
and controlled for quality, safety and time frame as per terms and condition
specified in the work order by the Project In Charge. A safety clause for
subcontractors (Document SC-B) shall be enclosed with each purchase order and
same shall be endorsed as accepted by the subcontractor prior to start of work.

On completion of project, the Project In Charge shall assess safety performance of
the sub contractor as per the guideline given in data sheet DS-7/11.
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 11


Version 1.0 Page 5 of 13
ITD Cementation India Ltd
6.0 CROSS REFERENCES

ISO 9001:2000 Planning for Product Realization
IMS Apex Manual : Section 4.7

7.0 RECORDS

R-1/11: Construction activity plan
R-2/11 : Amendment status-Quality/Environment/Safety Plan

8.0 RECORDS AVAILABILITY

R-1/11 : Project In Charge
R-2/11 : Project In Charge

9.0 RECORDS RETENTION

As per procedure P-2.
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 11


Version 1.0 Page 6 of 13
ITD Cementation India Ltd

DATA SHEET - DS-1/11 : GUIDELINES FOR KICK-OFF MEETING


Step 1: Mention date, time, Venue, Persons Present, Project Name, Tender No in the
Minutes of Meeting.

Step 2: Following issues shall be part of agenda:
a. Plant requirement & their dispatch
b. Material requirement.
c. Commercial / accounts matters.
d. Stores at site.
e. Laboratory at site.
f. Schedule of construction programme.
g. Estimation (if Required)
h. Workshop equipment & office furniture.
i. Electricity, water, accommodation
j. Local problems if any.
k. Safety & Health Issues;
Nomination of Safety Officer
Immediate and subsequent requirement of safety stores. Transfer of stores
from other sites if possible.
Control of sub contractors
Major anticipated hazards, risks and control measures
Safety training of staff and workmen


Suggested Format for Minutes of Meeting :

Sl.
No.
Agenda Decisions Action Plan Target
Date
Responsibility Follow up








Note: This format can be changed based on the requirement.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 11


Version 1.0 Page 7 of 13
ITD Cementation India Ltd

DATA SHEET DS-2/11 : ELEMENTS OF PROJECT QUALITY PLAN


Sl.
No.
Activity Elements Reference Documents /
Responsibility
Copy to be
Forwarded To
1 List of Personnel for Site
Organization
Based on DS-5/QM BU-Head
2 Details of Construction Activity

Project In Charge -------
3 Time Program for Project Execution
(Master Plan / Bar Chart / Quantity
Schedule )
Project In Charge HOD-Planning
4 Material Procurement Plan

Project In Charge HOD-Purchase
5 Plan for Subcontracting including
services

Project In Charge HOD-Commercial
6 Inspection & Test Plan

R -1/12 ----------
7 Plan for Calibration of Instruments

R - 1/14 ----------
8 Plant Requirement Plan

Project In Charge HOD-Plant
9 Plan for Design Delivery of
Temporary and Permanent Structure
( If any )

Project In Charge HOD-Engineering


Quality records shall be maintained as per formats given in the system document. However, if
format (s) other than that given in this system document is followed, the same shall be approved by
the Contract Manager and must be included in Quality Plan of that project.


A register containing details of all drawings giving receipt of new drawings, revisions and also the
issue of drawings for site use / to subcontractors, is to be maintained.























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 11


Version 1.0 Page 8 of 13
ITD Cementation India Ltd

DATA SHEET - DS- 3/11: ELEMENTS OF PROJECT ENVIRONMENT PLAN

Sl.
No.
Acti vity Elements Reference
Documents
Responsibility Copy To Be
Forwarded To
1 IMS Policy IMS Section 2.0 Project In Charge
2 List Of Personnel For
Site Organization
(Organogram)
IMS Apex Manual
Annexure I

Project In Charge
3 Site Environment &
Scope of Work
Contract Document Project In Charge
4 Environmental Risk
Assessment (ERA)
IMS Procedure P-3 Project In Charge
5 Legal and Other
Requirements
IMS procedure P-4 Management
Representative

6 Environment
Objectives And Targets
IMS Policy
Risk Register
Views of Interested
Parties
Project In Charge BU AMR
7 Improvement
Programmes
IMS Procedure P-5 Project In Charge/MR
8 Responsibility and
Authority
IMS Apex Manual
Annexure V

Project In Charge/MR
9 Training IMS Procedure P-19 Corporate HRD Head,
Corporate Environment
Head, Project In Charge

10 Communication IMS Procedure P-21 Project In Charge
11 Operational Control
Procedures
Environmental
Operational Control
Procedures
Project In Charge
12 Document Control IMS Procedure P-1 Project In Charge
13 Emergency
Preparedness and
Response including
important telephone
numbers
IMS Apex Manual
Section 4.8
Project In Charge
14 Measuring and
Monitoring
Environmental
Parameters
IMS Procedure P-13 Project In Charge
15 Inspection & Audit

IMS Procedure P-20

BU AMR and Project In
Charge
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 11


Version 1.0 Page 9 of 13
ITD Cementation India Ltd

DATA SHEET - DS- 4/11: ELEMENTS OF PROJECT SAFETY PLAN

Sl.
No.
Acti vity Elements Reference
Documents
Responsibility Copy To Be
Forwarded To
1 IMS Policy IMS Section 2.0 Project In Charge
2 Site Health & Safety
Policy
IMS Section 2.0 Project In Charge
3 List Of Personnel For
Site Organization
(Organogram)
IMS Apex Manual
Annexure I

Project In Charge
4 Site Environment &
Scope of Work
Contract Document Project In Charge
5 Occupational Safety
And Health Risk
Analysis (OSHRA)
IMS Procedure P-22 Project In Charge
6 Legal and Other
Requirements
IMS procedure P-4 Management
Representative

7 Health & Safety
Objectives And Targets
IMS Policy
Risk Register
Views of Interested
Parties
Project In Charge BU HOD Safety
8 Improvement
Programmes
IMS Procedure P-5 Project In Charge/MR
9 Responsibility and
Authority
IMS Apex Manual
Annexure V

Project In Charge/MR
10 Training IMS Procedure P-19 Corporate HRD Head,
Corporate Safety Head,
Project In Charge

11 Communication IMS Procedure P-21 Project In Charge
12 Operational Control
Procedures
Safety and Health
Operational
Procedures (SHOP)
Project In Charge
13 Document Control IMS Procedure P-1 Project In Charge
14 Emergency
Preparedness and
Response including
important telephone
numbers
IMS Apex Manual
Section 4.8
Project In Charge BU HOD Safety
15 Site Rules Project In Charge
16 Measuring and
Monitoring OSH
Performance
IMS Procedure P-11/
DS-5/11
Project In Charge
17 Inspection & Audit

IMS Procedure P-20

Corporate Safety Head,
BU HOD Safety,
Project In Charge, Safety
Auditor

18 Safety Committee
Meeting
Legal Register Project In Charge BU Head,
Corporate Safety
Head, BU HOD
Safety

Safety records shall be filled up, submitted and maintained as per DS-5/11. Format(s) other than those given
in this document, if required by the clients, may be filled up but these must be included as part of the Safety
Plan of the Project.

























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 11


Version 1.0 Page 10 of 13
ITD Cementation India Ltd


DATA SHEET - DS-5/11 : CHECK LIST FOR MONTHLY SITE REVIEW MEETING &
SAFETY COMMITTEE MEETING

Sl. Agenda Points
QMS
1 Project Planning. Refer Sl No 3 of DS 1/11
2 Material Procurement. Refer Sl No 4 of DS 1/11
3 Subcontracting Requirement. Refer Sl No 5 of DS 1/11
4 Plant Requirement. Refer Sl No 8 of DS 1/11
5 Design Requirement for Permanent & Temporary Structure. Refer Sl No 9 of DS 1/11
6 Vendor Evaluation. Refer R-5/8
7 Customer Complaints. Refer - R-2/17
8 Status on analysis of Performance Indicator of processes: Engineering, Commercial,
Purchase, Planning, Project Execution, HRD, Plant & Office of Management

EMS & HSMS
1 Legislative Compliance (Status and action plan) Refer R-2/4
2 Performance Report on Improvement Program (IP)
3 Requirement of additional IP, if any.
4 Requirement of additional Operational Control Procedure (OCP), if any.
5 Objectives and Targets
6 Monitoring & Measurement Non-Conformance including Corrective Action. Refer R-2/13
7 Sub-contractors staff induction training
8 Views of Interested Parties
9 Mock Drill status

QMS & EMS & SHMS
1 Corrective and Preventive Action status, based on Customer Complaint & Product Non-
Conformity. Refer - R-1/17.
2 Status of Non-Conformities of Internal Audits. Refer R-2/20
3 Customer Feedback (Quarterly)
4 Any problems in implementation of QMS, EMS & HSMS.
5 Any other pertinent points

Agenda Points for Site Safety Committee Meeting
1 Review of the previous minutes
2 Communication from corporate / BU, if any. (Alerts, policy letters etc.)
3 Legislative Compliance
4 Observations of the safety Committee / Safety officer
5 Key Safety Issues
6 Sub Contractors performance & key performance indicator (DS 6/11)
7 Any Other Point.























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 11


Version 1.0 Page 11 of 13
ITD Cementation India Ltd
DATA SHEET - DS-6/11 : SAFETY PERFORMANCE INDICATOR

Site shall complete under mentioned forms to report activities and monitor
performance:-

Sr.
No.
Details Of The Activity /
Output
Frequency of
Reporting /
Completion
Responsi
bility
Format
For
Report /
Exercise
Copy To
1 Occupational safety and
health risk analysis
(OSHRA)
Before the
commenCeme
nt of work /
after any
change
Project In
Charge
RA-01 --
2 Immediate reporting of
injuries and dangerous
occurrence and near
misses
Immediately
after the
incident
Safety
Officer
SR 1

BU Head,
Corporate Safety
Head, BU HOD
Safety
3 Site safety and health
inspection report form

Monthly Safety
Officer
SR 2 Corporate Safety
Head, BU HOD
Safety
4 Average daily manpower
form

Monthly Safety
Officer
SR 3 -Do-
5 Details of injuries /
dangerous occurrence
form (Inquiry Register)

Monthly Safety
Officer
SR 4 -Do-
6 Toolbox talk form Monthly Safety
Officer
SR 5 -Do-
7 Induction training form Monthly Safety
Officer
SR 6 -Do-
8 Expenditure on treatment
of injuries form

Monthly Safety
Officer
SR 7 -Do-
9 Senior management
inspection form
After the visit Safety
Officer
SR 8 -Do-
9 Monthly safety summary
data sheet
Monthly Safety
Officer
SR 9 -Do-
10 Standards and inspection
forms for working at
heights
Fortnightly Frontline
Engineer
SCL 1 BU HOD Safety
11 Standards and inspection
forms for scaffolds

Weekly Frontline
Engineer
SCL 2 BU HOD Safety
12 Standards and inspection
forms for plant and
machines

Fortnightly Frontline
Engineer
SCL 3 BU HOD Safety






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 11


Version 1.0 Page 12 of 13
ITD Cementation India Ltd
Sr.
No.
Details Of The Activity /
Output
Frequency of
Reporting /
Completion
Responsi
bility
Format
For
Report /
Exercise
Copy To
13 Standards and inspection
forms for cranes and
lifting devices

Fortnightly Frontline
Engineer
SCL 4 BU HOD Safety
14 Standards and inspection
forms for excavation

Fortnightly Frontline
Engineer
SCL 5 BU HOD Safety
15 Standards and inspection
forms for temporary
electrification
Fortnightly Frontline
Engineer
SCL - 6 BU HOD Safety
16 Standards and inspection
forms for piling
Fortnightly Frontline
Engineer
SCL 7 BU HOD Safety
17 Fortnightly checklist Fortnightly Safety
Officer
SCL 8 BU HOD Safety
18 Investigation of injuries
and dangerous
occurrence
Next day of
the incident
Project In
Charge
SCL 9 Corporate Safety
Head, BU HOD
Safety
19 J ob Safety Analysis Form On
commenceme
nt of new task
Frontline
Engineer
SCL - 10
20 Authorisation certificate
for crane operators and
vehicle drivers
Monthly Project In
Charge /
Plant
Engineer
SCL - 11
21 Walkabout report Weekly

Project In
Charge
SR 10 Corporate Safety
Head, BU HOD
Safety
22 Subcontractors
assessment form DS
Monthly Project In
Charge
SR 11
SR 12
Corporate Safety
Head, BU HOD
Safety






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 11


Version 1.0 Page 13 of 13
ITD Cementation India Ltd

RECORD - R-1/11 : CONSTRUCTION ACTIVITY PLAN


Sl No Activities Activity Code Reference Method
Statement No.
Reference Data
Sheet No.
Reference
Record Format
No.






Project In Charge





RECORD - R-2/11 : AMENDMENT STATUS QUALITY / ENVIRONMENT / SAFETY PLAN


Amendment
No.
Date of
Amendment
Communic
ation
Reference
Brief Description of Amendment Signature of
Project In Charge





























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 12


Version 1.0 Page 1 of 4
ITD Cementation India Ltd















PROCEDURE P-12 : INSPECTION & TESTING



















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 12


Version 1.0 Page 2 of 4
ITD Cementation India Ltd

1.0 PURPOSE

The purpose of this procedure is to ensure meeting of the specified requirements of
the relevant products and materials at all stages of construction.

2.0 SCOPE

The scope of this procedure covers all relevant materials and products.

3.0 RESPONSIBILITY

Direct responsibility for implementation of this procedure at project sites shall be of
Project In Charge and at Area laboratory it shall be of BU HOD-Engineering.

4.0 DEFINITION

None required

5.0 PROCEDURE

General

All inspections and tests at any stage shall be done by trained personnel.

All inspection and tests shall be done by calibrated or verified instruments as
discussed in the Procedure P-14 on monitoring and measuring devices.

In no case materials / products shall be used for further processing until it is cleared
as per Inspection & Test plan. In case of emergency, it may be released with proper
documents for positive recall procedure.

Where the product fails to pass any inspection and /or test, action shall be initiated
as per the procedure for Control of Nonconforming Product ( P-16 ).

For any project, Project In Charge in consultation with Contract Manager shall
prepare the Inspection & Test Plan as per R-1/12 for inspection and testing to be
performed for receiving, and in process stages of the project.

The acceptance criteria for all incoming materials, to be specified in Inspection &
Test Plan ( R-1/12 ), shall either be based on laboratory test results, manufacturers
test certificates or visual inspection.

Test results shall be maintained as per specimen formats given in Quality Plan for
Inspection & Testing.

Necessary guidelines for method of inspection shall be kept at site.

After completion of a project (or a part of it), the as made drawing and /or
completion certificate / report shall be prepared and preserved as Final Inspection
Record.





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 12


Version 1.0 Page 3 of 4
ITD Cementation India Ltd

Subcontracting to external testing agencies for carrying out certain tests /
inspections may be done. Companys approved testing agencies shall only be
allowed to conduct such tests. A testing agency shall be approved if it possesses
certified equipment with known valid relationship to nationally or internationally
recognised standards. Method of selection of such agencies shall follow Purchase
Procedure P-8.

Selection of institute/reputed testing house for any outsourced inspection and
testing activities shall be done as per P-9. Outsourcing of inspection and testing
activity shall be planned and included in site-specific quality plan. Performance of
the institute/reputed testing house shall be monitored and controlled for quality and
time frame as per terms and condition specified in the work order by the respective
authority.

6.0 CROSS REFERENCE
ISO 9001:2000 Clause 7.4 - Purchasing
IMS Apex Manual : Section 4.7

7.0 RECORDS
R-1/12: Inspection and test plan

8.0 RECORDS AVAILABILITY
R-1/12 : Project In Charge

9.0 RECORD RETENTION
As per procedure P-2

























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 12


Version 1.0 Page 4 of 4
ITD Cementation India Ltd
RECORD R-1/12: INSPECTION & TEST PLAN



Project No : Date :


Material
( In Coming/
In Process)


Name
of Test
Parameter Norm Frequency Sampling
Point
Reference
Format No.
Responsibility Remarks
( Test
Location
etc.)









Project In Charge























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 13


Version 1.0 Page 1 of 4
ITD Cementation India Ltd












PROCEDURE P-13 MEASUREMENT & MONITORING OF
ENVIRONMENTAL PARAMETERS


















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 13


Version 1.0 Page 2 of 4
ITD Cementation India Ltd

1.0 PURPOSE

This procedure shall be followed for measurement and monitoring of parameters
that reveal the performance of operations in terms of environmental quality.

2.0 SCOPE

The procedure shall be applicable to measurement and monitoring to be carried
out at:
Project Sites;
Depots; and
BU/Corporate Offices.

3.0 RESPONSIBILITY

Project In charge at sites, Head Depots, and Administrative officer in
Corporate/BU offices shall be responsible for ensuring that requisite measurement
and monitoring is carried out.

4.0 DEFINITIONS
Nil

5.0 PROCEDURE

Project In charge at sites, Head Depots, and Administrative Officer in
Corporate/BU offices shall identify aN Environment and Monitoring Coordinator to
list parameters for measurement and monitoring based on:
Significant aspects identification;
Occupational safety and Health Risk Assessment;
Legal and Non-Regulatory Requirements;
Operational Control Procedure(s); and
Improvement Programme(s).

Monitoring Coordinator in consultation with Corporate Head Environment shall
prepare Measurement and Monitoring Plan using format R-1/13.

Project In charge at sites, Head Depots, and Administrative officer in
Corporate/BU offices shall review and approve Measurement & Monitoring Plan
and allocate resources for the same.

Monitoring Coordinator shall arrange for measurement and monitoring and keep
records of the same.

Monitoring Coordinator shall identify non-conformances in format R-2/13. He shall
bring non-conformance to the notice of In-Charge for recording Corrective &
Preventive action in R-2/13.

Corrective & Preventive Action shall be recorded in format R-2/13 and
implementation shall be reviewed in Site MRM.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 13


Version 1.0 Page 3 of 4
ITD Cementation India Ltd
6.0 CROSS REFERENCES
ISO 14001, Clause No. 4.5.1
OHSAS 18001, Clause No. 4.5.1
IMS Appex -Manual: Section 5.1

7.0 RECORDS
R-1/13: Measurement and Monitoring Plan
R 2/13: Measurement and Monitoring Non-Conformity Report

8.0 RECORDS AVAILABILITY
R-1/13, 2/13- for Site/Depot/Office Project In Charge / Head Depot / Head
Administration
R-2/13 for BU - AMR BU
R-1/13 for Corporate Corporate Head Environment and Corporate Head Safety

9.0 RECORD RETENTION
As per procedure P-2























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 13


Version 1.0 Page 4 of 4
ITD Cementation India Ltd

RECORD R-1/13 MEASUREMENT AND MONITORING PLAN


Project No : Revision No : Date :


Sr No Requirement Parameters Number of
Samples
Frequency
I. Legal
Requirement




II. Significant
Aspects







III. Operational
Control
Procedures




IV. Improvement
Programmes






RECORD R-2/13 MEASUREMENT & MONITORING NON-CONFORMITY REPORT


Project No : Month :

Sr No Characteristic Details Of Non-
Conformance
Probable Reasons For
Non Conformance





























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 14


Version 1.0 Page 1 of 7
ITD Cementation India Ltd

















PROCEDURE P-14 : MONITORING & MEASURING DEVICES















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 14


Version 1.0 Page 2 of 7
ITD Cementation India Ltd

1.0 PURPOSE

The purpose of this procedure is to ensure that all the instruments used for
inspection, testing and measurement are properly identified and controlled to the
extent to suit the requirement and to ensure that instruments used for monitoring
Environmental performance, Operation Controls, Objective & Targets are
calibrated & records maintained.

2.0 SCOPE

The scope of this procedure is limited to those equipment, which are used to
demonstrate the conformance of product & performance of Environment to the
requirements as specified in various records as referred in Inspection & Testing,
and Environmental procedures.

3.0 RESPONSIBILITY

Direct responsibility for implementation of this procedure at project site shall be
with Project In Charge. HOD Engineering and Corporate Head Environment shall
be responsible for Area Laboratory for monitoring equipment to determine product
conformity, Environmental performance monitoring equipment & OHS monitoring
equipment, respectively.

4.0 DEFINITION
None required

5.0 PROCEDURE

Concerned Project In Charge shall identify the equipments under his control to be
calibrated and shall inform to the concerned person responsible for calibration of
the equipment.

The calibration or verification of all relevant inspection, measuring and testing
equipment directly affecting Quality / Environment shall be done regularly or prior
to use as per schedule.

Calibration or verification from outside agency shall be against certified equipment
having a known valid relationship to internationally or nationally recognized
standards. Where no such standards exist, basis used for calibration shall be
recorded.

Calibration or verification shall be done against certified equipment or
measurements. The agency shall furnish necessary documents in this respect as
may be applicable which shall be maintained by respective QA Engineer /
Laboratory Officer & Safety Officer in case of Environmental parameters.

A list of all inspection, measurement and test equipment in use at sites and Area
Laboratory (other than master equipment as maintained in R-2/14) shall be
included in Quality / Environment as per Calibration plan R-1/14. A list shall be
kept separately indicating place of use or issued persons name by the QA





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 14


Version 1.0 Page 3 of 7
ITD Cementation India Ltd
Engineer at site / Safety Officer in case of EHS equipment.

Guidelines for selection of master instruments at Area office or at site are given in
DS-1/14. List of master instruments available at Area laboratory / site laboratory
shall be maintained as per R-2/14.

All equipment under use shall be calibrated against Master equipment of Area
Laboratory or outside agency. For any special instrument, specific work instruction
for calibration is to be specified in Quality / Environment / Safety Plan.

In case an equipment/ instrument is found to be malfunctioning or suspected so, a
red X mark shall be given in the tag /label/ sticker attached to the equipment
/instrument.

An annual calibration schedule shall be prepared and maintained as per Record
R-3/14 showing duration and frequency of calibration.

Project In Charge shall ensure that calibration of all equipments is carried out
within due date. Calibration status for all the necessary equipment / instruments
shall be indicated on the equipment / instrument by the tags/ labels/ stickers as per
the format shown in TL -1/14, wherever the size of equipment/ instrument allows
For smaller size of equipment/ instrument, calibration status and correction factor
shall be displayed on board as per TL -2/14 or shall be kept with Project-in-Charge
/ QA Engineer / safety Officer. The correction factors, if any, shall be readily
available to user(s) of the instruments

An equipment / instrument shall be re-calibrated before schedule if found to be
malfunctioning or suspected so. Calibration status shall be considered null and
void in such cases and the equipment shall not be used until re-calibrated.
Equipment-wise calibration record shall be maintained at R-4/14.

If any Inspection, Measuring and Test equipment is found to be out of calibration,
validity of previous inspection and test results, found with the aforesaid equipment
in last 24 hours, shall be assessed and necessary corrective action shall be
initiated.

All the calibrated instruments shall be safeguarded from adjustments, which would
invalidate the calibration setting. Proper handling, preservation and storage of the
calibrated instruments shall also be ensured to maintain this accuracy and fitness
for use.

Selection of institute/reputed testing and calibration house for any outsourced
calibration activities shall be done as per P-9. Outsourcing of calibration activity
shall be planned and included in site-specific Quality / Environment / Safety Plan.
Performance of the institute/reputed testing and calibration house shall be
monitored and controlled for quality and time frame as per terms and condition
specified in the work order by the respective authority.

6.0 CROSS REFERENCE
ISO 9001:2000 Clause 7.6
IMS Apex Manual : Section 5.1





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 14


Version 1.0 Page 4 of 7
ITD Cementation India Ltd

7.0 RECORDS
R-1/14:Inspection, measuring & test equipment calibration plan
R-2/14:List of calibrated master equipment
R-3/14:Annual calibration schedule & follow up
R-4/14:Calibration record

8.0 RECORDS AVAILABILITY
R-1/14:Project In Charge for project site, BU HOD Engineering for Area Laboratory
R-2/14: Project In Charge for project site, BU HOD Engineering for Area
Laboratory
R-3/14: Project In Charge for project site, BU HOD Engineering for Area
Laboratory
R-4/14: Project In Charge for project site, BU HOD Engineering for Area
Laboratory

9.0 RECORDS RETENTION
As per procedure P-2























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 14


Version 1.0 Page 5 of 7
ITD Cementation India Ltd


DATA SHEET DS-1/14 : GUIDELINES FOR SELECTION OF MASTER EQUIPMENT


Sl.
No
Name of Equipment /
Instrument
Range Frequency of
Calibration
Least Count
1 Measuring Tape 0 to 30m Yearly 1mm
2 Steel Scale

0 to 30cm Yearly 1 mm
3 Deflectometer

30mm & 50mm Yearly 0.01 mm
4 Pressure Gauge 0 - 60kg / cm
2
Yearly 20 PSI
0 - 280 kg/cm2 Yearly 10 kg/cm2
0 - 600 kg/cm2 Yearly 20 kg/cm2
5 Hydrometer

1 1.20 Yearly 0.01
6

Standard Weights 10 kg, 5kg, 2kg, 1kg
500 gm, 200gm,
100gm, 50 gm, 20
gm, 10 gm, 5 gm, 2
gm, 1 gm
Yearly -
7 Pan Type Balance 1 gm 15 Kg Yearly 1 gm
8 Leveling Instrument - Yearly -
9

Theodolite - Yearly -
10

Slide Calipers 6 Yearly 0.01mm
11

Thermometer 0
o
150
o
Yearly 1
o
C
12

Stop watch - Yearly 0.1 sec.
13

Measuring Cylinder /
Can
1000ml, 500ml,
250ml, 100ml, 50 ml
Yearly 10ml, 5ml, 2ml
14

Mud Balance - Yearly 0.01gm/cc

































INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 14


Version 1.0 Page 6 of 7
ITD Cementation India Ltd
RECORD R-1/14 : INSPECTION, MEASURING & TEST EQUIPMENT CALIBRATION PLAN

Location : Date :


Sl
No
Name of
Equipment /
Instrument
Identification
No.
Range Least
Count
Frequency of
Calibration
Place of Calibration






Laboratory Officer / QA Engineer / Safety Officer


RECORD R-2/14 : LIST OF CALIBRATED MASTER EQUIPMENT

Location : Date :

S
l

N
o

N
a
m
e

o
f

E
q
u
i
p
m
e
n
t

/

I
n
s
t
r
u
m
e
n
t

I
d
e
n
t
i
f
i
-
c
a
t
i
o
n

N
o

R
a
n
g
e

A
c
c
u
r
a
c
y

N
a
m
e

o
f

O
u
t
s
i
d
e

C
a
l
i
b
r
a
t
i
o
n

A
g
e
n
c
y

/

A
r
e
a

L
a
b
F
r
e
q
u
e
n
c
y

o
f

C
a
l
i
b
r
a
t
i
o
n

L
e
a
s
t

C
o
u
n
t

C
o
n
t
r
o
l
l
e
d

C
o
n
d
i
t
i
o
n

M
e
t
h
o
d

O
f

C
a
l
i
b
r
a
t
i
o
n



(
W
I

R
e
f
.
)

A
c
t
i
o
n

T
o

B
e

T
a
k
e
n

F
o
r

U
n
s
a
t
i
s
f
a
c
t
o
r
y

R
e
s
u
l
t





Laboratory Officer / QA Engineer / Safety Officer

RECORD R-3/14 : : ANNUAL CALIBRATION SCHEDULE & FOLLOW UP

Year:


Location
:
Area Laboratory : / Contract No :


Sl
No
Equipment
Description
Identification
No
J an Feb Mar Apr May J un J ul Aug Sep Oct Nov Dec





Laboratory Officer / QA Engineer / Safety Officer





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 14


Version 1.0 Page 7 of 7
ITD Cementation India Ltd


RECORD R-4/14 : CALIBRATION RECORD

Equipment : Identification No :


Sl
No
Date of
Calibration
Range Least
Count
Due date of
Next
Calibration
Signature Of
Responsible
Authority
Remarks




Laboratory Officer / QA Engineer / Safety Officer


TAG/LABEL TL-1/14 : CALIBRATION STATUS FOR LARGER EQUIPMENT


Instrument:
Identification No:
Date of Calibration:
Next Due Date:
Calibrated Range:
Least Count:



Laboratory Officer / QA Engineer / Safety Officer


TAG/LABEL TL 2/14 : CALIBRATION STATUS FOR SMALLER EQUIPMENT

Project Location : Contract No:

Sl
No
Instrument
Identification
No. / Type
Calibration
Done On
Next Due
Date
Calibrated
Range
Calibrated
Least Count
Signature
Laboratory
Officer / QA
Engineer /
Safety Officer

























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 1 of 47
ITD Cementation India Ltd

















PROCEDURE P-15 : PLANT














VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 2 of 47
ITD Cementation India Ltd

1.0 PURPOSE

The purpose of this procedure is to ensure arranging plants as per requirements of
the project sites and carrying out necessary maintenance for all major plant and
equipment.

2.0 SCOPE

The scope of this procedure is limited to provide plants and equipment at project
sites and relevant site maintenance activities for major plants and equipment.

3.0 RESPONSIBILITY

3.1 Direct responsibility of this procedure shall be with Corporate Plant Head.
Responsibility of providing plants to project sites and maintenance of Plants at
Depots will lie with HOD Plant. Responsibility for carrying out necessary
maintenance at Project Site will be with Engineer Plant maintenance.

4.0 DEFINITION

4.1 Major Plant : Major Plants are considered as those whose purchase value /
replacement value is high, breakdown maintenance is very expensive and time
consuming and they are not easily available for hire at local market.

5.0 PROCEDURE

5.1 Requirement for plant and equipment shall be determined by project site and
necessary indents for this will be raised by them. Deployment from internal
sources i.e. from central depot and other project site(s) and from external hire or
new purchase shall be made by HOD Plant.

5.2 Incase of any new purchase and inspection of hiring plant (major) from outside
source Purchase Procedure (P-8) will be followed.

5.3 Lists of group of Major Plants are given in DS- 1/15. Detailed list of all plant along
with the identification number shall be available with Engineer -Plant maintenance
for a specific project.

5.4 Particulars of maintenance frequency are given in DS - 2/15.

5.5 Engineer - Plant Maintenance shall maintain a list of machinery used at a
particular site as per the format shown in R-1/15. This shall be updated as when
necessary.

5.6 Records of weekly maintenance and periodical maintenance records shall be kept
in format R -2/15.

5.7 Monthly plant report shall be prepared as per the format shown in R-3/15 and shall
be sent to HOD plant..






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 3 of 47
ITD Cementation India Ltd
5.8 Records of breakdown and overhauling maintenance shall be kept in Monthly
Plant Report i.e. R-3/15 .

5.9 The monthly plant report maintained at site shall contain particulars of general
activities as well as of major repair / overhaul / modifications and remarks on
requirements of special protocols to be followed, if any.

5.10 Plant transfer from site to site shall also be recorded in R 3/15.

5.11 Condition of plant transferred to site shall be verified through monthly plant report.
Necessary action shall be initiated on unsatisfactory performance.

5.12 Plant Inspection : Plants will be inspected for its health by chief of inspection or a
designated representative on the guidelines drawn in Inspection Report Formats
started from R INS/1. Site for inspection will be selected by HOD Plant. Report
should be maintained for plants mentioned in DS-1/15 as per the formats
mentioned above.

5.13 Purchase of Maintenance Spare shall be done based on the actual requirement
and a reasonable stock holding. Procurement activities of Spare Parts will be as
per Procedure P-8.

6.0 CROSS REFERENCE
ISO 9001:2000 Clause 7.1
IMS Apex Manual : Section 4.7

7.0 RECORDS
R-1/15 : Monthly Consolidated Plant Statement
R-2/15 : Weekly Plant Report
R-3/15: Monthly Plant Report
R-INS/15 : Inspection Reports

8.0 RECORDS AVAILABILITY
R-1/15: Plant Engineer at Project Site
R-2/15: Plant Engineer at Project Site
R-3/15: BU HOD Plant
R-INS/15 : BU HOD Plant

9.0 RECORDS RETENTION
As per procedure P-2.
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 4 of 47
ITD Cementation India Ltd
DATA SHEET : DS 1/15 : LIST OF OF MAJOR PLANT


1 Batching Plant
2 Transit Mixer
3 Tipper / Dumper
4 Concrete Pump
5 Excavator Tata Hitachi ( EX-200,100,60 )/ L-T Poclain (CK-170/90)
J CB Loader / Excavator
6 Crane Tata 320 Crane
Tata TFC -280 Crane
Hydra Crane
Hind 101 MK
7 Compressor : 250 cfm and above.
8 Pilling Winch : 7
1
/
2
Ton Capacity
9 DP Rig with Winch
10 Rotary Rig RT-3 ST
Cem Drill
HY-40
11 Stone Crusher
12 Hot Mix Plant
13 Wet Mix Plant
14 Asphalt Sensor Paver
15 Wet Mix Paver
16 Pile Driving Hammer Delmag
BSP Rig
Walker Rig
ICE
PTC
17 Genset : : 50 KVA and above
18 Vibroflots with Power Pack


DATA SHEET DS -2/15 : PERIODIC MAINTENANCE OF MECHANICAL COMPONENTS OF MAJOR
PLANTS

1) DAILY ( Once Within 24 Working Hours ) As Per OEM Guidelines
2) TYPE A : ( 50 Hours Maintenance ) As Per OEM Guidelines
3) TYPE B : ( 250 Hours Maintenance ) As Per OEM Guidelines
4) TYPE C : ( 500 Hours Maintenance ) As Per OEM Guidelines
5) TYPE D : ( 1000 Hours Maintenance) As Per OEM Guidelines

Note: Depending upon the nature of plant maintenance activities OEM guidelines are different for
each type of plant.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 5 of 47
ITD Cementation India Ltd

RECORD : R 1/15 : MONTHLY CONSOLIDATED PLANT STATEMENT


MONTH ENDED :

CONTRACT NO. :

LOCATION :

P
l
a
n
t

D
e
s
c
r
i
p
t
i
o
n

C
.
C
.
L

C
o
d
e

N
o

T
y
p
e

P
l
a
n
t

R
e
c
e
i
v
e
d

A
t

S
i
t
e

P
l
a
n
t

T
r
a
n
s
f
e
r
r
e
d

T
o

O
t
h
e
r

S
i
t
e

O
r

C
.
C
.
L

D
e
p
o
t

N
u
m
b
e
r

o
f

d
a
y
s

P
l
a
n
t

a
t

S
i
t
e

W
o
r
k
i
n
g

D
a
y
s


A
v
l
.

H
r
s
.

R
u
n
n
i
n
g

H
r
s
.

I
d
l
e


H
r
s
.

B
/
D

H
r
s
.

W
i
l
l

B
e

R
e
q
u
i
r
e
d

A
t

S
i
t
e

T
i
l
l

R
e
m
a
r
k
s

C.N
No
Date Place C.N No.
&
Date






1. Reason of B/D and rectification action to be written in remarks column
2. Column No. 4, 5, 6 & 7 to be filled up only at the time of receiving or transferring the Plant.


Engineer Plant Maintenance























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 6 of 47
ITD Cementation India Ltd

RECORD : R 2 /15 : WEEKLY PLANT REPORT


Contract
No.


Due At
Cumulative
Running
Hrs. [ Crh ]


Type A :
Type B : Prime Mover
Type B : Plant
Type C :
Type D :
Prev. Cumm. Running Hrs. =

Running Hrs.- This Month =
Month:

Plant:

CCL. No.:

Location:


Running
Hours
Maintenance Type *
D
a
t
e

Daily CRH
B
r
e
a
k
d
o
w
n

H
r
s
.

N
a
t
u
r
e

O
f

B
r
e
a
k
d
o
w
n
Spares
Replaced
(use
addnl.
sheet if
required)
S
i
g
n
a
t
u
r
e

Type
-A
Type
-B
Type
-C
Type
-D
R
e
m
a
r
k
s















Not for Quality Record purpose :

** This is to be maintained daily and this report shall reach plant manager within 15days of expiry
of the reporting month.
In case of type A, B, C, D maintenance not done on schedule date the reason may be
mentioned in the remarks column.

























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 7 of 47
ITD Cementation India Ltd

RECORD : R 3/15 : MONTHLY PLANT REPORT

PLANT CODE NO

MONTH YEAR


PLANT UNIT LOCATION CONTRACT NO


WORKING HOURS :
For Previous Cum This Month Total Cum Cum Hrs Last O/H


SERVICING - MAINT. AFTER LAST O/H COMMISSIONED :
Carried Out For Schedule
Hrs
Due At Cum hrs
Date Cum Hrs
Next Due At Cum Hrs.


CHANGE OF PRIME MOVER IF DONE :
DATE : REASON :
Last
Overhauled
Prime
Mover
Ex
Plant
Code
No
SL
No
Mak
e
Type
Model
H.P R.P.M
Date Cum
Hrs
Cum
Working
Hrs To
Date
Remarks
Withdrawn
Installed

PLANT TRANSFER :
Received From or Sent To : LOCATION : CONTRACT NO :
Date CN No. & Date Cum Working Hrs. Remarks


CONDITION OF :
Legend Good Rectified Under Repair Not Applicable

Bed / Foundation / Anchor Bolt, Bed frame
Under Carriage etc.
Brake, Clutch, Levers, Pedals, Linkages etc
Rope Drum, Rope, Rope attachment,
Lubricant etc
Bearings, Bushing, Lubrication, General up
keep cleaning etc

Hoist boom Pullies, Hoisting System Radiators, Coolers, Ventilation etc
Drive transmission system CPTO, Chain
Sprocket coupling, V Belt etc.
Electrical wiring controls, Motor starter,
Switches, cables etc

Crawler, Steering, Road wheels, Tyre etc. Safety guards, Devices, Alarms, Limit
Switches etc


PARTICULARS OF BREAKDOWN / OVERHAUL / REPAIR : PLANT IDLE
Date
From To
Nature / Remarks From To Reason
Plant
Prime Mover

Particulars Of Repair / Overhaul / Modification Etc. Carried Out And Other Remarks :





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 8 of 47
ITD Cementation India Ltd

RECORD R-INS-1/11: INSPECTION REPORT OF BATCHING PLANT

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date

Plant Side Condition Action to be taken by site
Overall appearance
Boom/Dragline bucket/ wire ropes
Main control cabin & scrapper
operator cabin

Operating & Control system
Electrical Motors
Electrical system
Mixing Drum
Gear Boxes
Structurals
Compressor
Drum rollers & Boom rollers
Brakes
Winch Drums
Chains & Sprockets
Screw conveyor
Functions of Weighihg System
Any Other system

Condition of Safety System :

Remarks :-


Signature of Site Plant In
Charge
Signature of Person
Assisting Inspector
Signature of Inspector






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 9 of 47
ITD Cementation India Ltd
RECORD R-INS-2/15 : INSPECTION REPORT OF BATCHING PLANT
(60 M AND ABOVE)

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date

Plant Side Condition Action to be taken by site
Overall appearance
Feeding hoppers (nos.) / Belts (sizes)
/ Rollers etc.

Weight hopper Yes / No
Main control cabin
Operating & Control system
Operating & Control system /
S0ftware system

Electrical Motors &Gear boxes /
Geared motors

Electrical system / Wiring herness
Mixing Drums / Type of mixer
Structurals
Compressor
Drum rollers & Boom rollers
Brakes
Winch Drums
Cement ( Type of Cement One / Two
/ Three )

Silo system
Cement loading arrangement
Pneumatic and / or bag splitter

Water - Weight / Volume
Admixture - One / Two / Three
Any Other system
Associated units :- Capacity Type Remarks
Chilling Plant
Ice Plant





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 10 of 47
ITD Cementation India Ltd

Condition of Safety System :

Remarks :


Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 11 of 47
ITD Cementation India Ltd
RECORD R-INS-3/15 : INSPECTION REPORT OF CONCRETE PUMP

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date

Plant Side Condition Action to be taken by site
Over all appearance
Tyres
Cabin
Hydraulic motors
Hydraulic hoses
Pumping cylinders
Rams
Stroke of concrete pump
Hyd.pump pressure
Agitator
Water pump
Compressure unit
Cup body & gate valve
Pipes & clamps
Plunger condition
Electrical system
Any other system























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 12 of 47
ITD Cementation India Ltd

Prime-mover Side Condition Action to be taken by site
Oil pressure in Low Idle
Oil pressure in High Idle
Fuel pump
Injectors
Radiators
Water temperature
Oil temperature
Back compression / Blowby


Condition of Safety System :-

Remarks :-


Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 13 of 47
ITD Cementation India Ltd

RECORD R-INS-4/15 :INSPECTION REPORT OF TRANSIT MIXER ( MIXING DRUM )

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date


Plant Side Condition Action to be taken by site
Overall appearance
Drum
Hydraulic Pump
Hydraulic Motor
Roller
Any other systems
Primemover Side Condition Action to be taken by site
Oil pressure , in lLow idle
Oil pressure ,in Hifg Idle
Fuel Pump
Injectors
Radiator
Water temperature
Oil temperature
Back Compression / Blowby

























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 14 of 47
ITD Cementation India Ltd
INSPECTION REPORT OF TRANSIT MIXER ( CHASSIS )

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date


Chassis Side Condition Action to be taken by site
Overall appearance
Tyres
Cabin
Transmission System
Electrical System
Steering System
Suspension System
Any other systems
Primemover Side Condition Action to be taken by site
Oil pressure , in lLow idle
Oil pressure ,in Hifg Idle
Fuel Pump
Injectors
Radiator
Water temperature
Oil temperature
Back Compression / Blowby



Condition of Safety System :-

Remarks :-


Signature of Site Plant In Signature of Person Assisting Signature of Inspector





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 15 of 47
ITD Cementation India Ltd
Charge Inspector
RECORD R-INS-5/15 : INSPECTION REPORT OF TIPPER / DUMPER

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date

Chassis Side Condition Action to be taken by site
Overall appearance
Tyres
Cabin
Transmission System
Lifting System
Hydraulic System
Tipper / Dumper Body
Auto Electrical System
Steering System
Suspension System
Any other systems
Primemover Side Condition Action to be taken by site
Oil pressure , in lLow idle
Oil pressure ,in Hifg Idle
Fuel Pump
Injectors
Radiator
Water temperature
Oil temperature
Back Compression / Blowby

Condition of Safety System :-
Remarks :-























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 16 of 47
ITD Cementation India Ltd
Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector

RECORD R-INS-6/15 : INSPECTION REPORT OF COMPRESSOR

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date


Plant Side Condition Action to be taken by site
Overall appearance
Condition of tyres
Condition of Cabin
Max air pressure, at no load
Comp,oil pr. ,at no load
Air temp., at no load
Air discharge pr., at full load
Air temp., at full load
Condition of Operating & Control
system

Condition of Compressor Unit
Condition of Other System
Primemover Side Condition Action to be taken by site
Oil pressure (in low idle)
Oil pressure (in high idle)
Fuel Pump
Injectors
Radiator
Water temperature
Oil temperature
Back Compression























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 17 of 47
ITD Cementation India Ltd

Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 18 of 47
ITD Cementation India Ltd

REPORT R-INS-7/15 : INSPECTION REPORT OF D G SET (ABOVE 50 KVA)

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date


Primemover Side Condition Action to be taken by Site
Oil Pressure (In Low Idle)
Oil Pressure (In High Idle)
Engine Mounting
Auto Electrical System
Fuel Consumption
Smoke
Black Compression / Blowby
Electronic Grovenor & Actuator
Tempareture
Radiator
Fuel Pump
Injector
Plant Side Condition Action to be taken by Site
Coupling & Bearing
Meggar Value of Stator & Rotor
AVR
Condition of Generator Control Unit
(Synchronising unit)

Any Other System

Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 19 of 47
ITD Cementation India Ltd
RECORD R-INS-8/15INSPECTION REPORT OF LOADER CUM EXCAVATOR ( TYRE MOUNTED )

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date

Plant Side Condition Action to be taken by site
Overall appearance
Tyres
Cabin / Roll Over Protection
Max hyd.oil pressure, at no load
Max.hyd.oil pr. ,at full load
Max.hyd.oil temp., at full load
Transmission system
Operating Contols
Hydraulic pumps
Hydraulic Controls
Hydraulic cylinders
J acks
Wheel brakes
Buckets
Auto Electrical System
Any other systems
All the greasing points
Primemover Side Condition Action to be taken by site
Oil pressure (in low idle)
Oil pressure (in high idle)
Fuel Pump
Injectors
Radiator
Water temperature
Oil temperature
Back Compression / Blowby





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 20 of 47
ITD Cementation India Ltd

Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 21 of 47
ITD Cementation India Ltd

RECORD R INS-9/15 : INSPECTION REPORT OF LOADER ( TYRE MOUNTED )

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date

Plant Side Condition Action to be taken by site
Overall appearance
Tyres
Cabin / Roll Over Protection
Max hyd.oil pressure, at no load
Max.hyd.oil pr. ,at full load
Max.hyd.oil temp., at full load
Transmission system
Operating Contols
Hydraulic pumps
Hydraulic Controls
Hydraulic cylinders
J acks
Wheel brakes
Buckets
Auto Electrical System
Any other systems
All the greasing points
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 22 of 47
ITD Cementation India Ltd

Primemover Side Condition Action to be taken by site
Oil pressure , in no load condition
Oil pressure ,in full load condition
Fuel Pump
Injectors
Radiator
Water temperature
Oil temperature
Auto Electric Sensors
Back Compression / Blowby

Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 23 of 47
ITD Cementation India Ltd

RECORD R-INS-10/15 : INSPECTION REPORT OF CRAWLER CRANE

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date

Plant Side Condition Action to be taken by site
Overall appearance
Boom/ Hook block (with Latch) / Wire
ropes

Cabin
Brakes & Clutches
Gears & Pinions
Cam clutch function
Drums
J ack Shaft / Magnetorque System
P.T.O./ Gear Box
Operating & Control system
Electrical system - Working lights &
Horns, Boom end light,Limit Switches,
Swing warning horn with light and any
other electrical system.

Availaility / Condition of angle
indecator, Load chart

Other System























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 24 of 47
ITD Cementation India Ltd

Primemover Side Condition Action to be taken by site
Oil pressure (Low Idle)
Oil pressure (High Idle)
Fuel Pump
Injectors
Radiators
Water Pump
Condition of Smoke
Back Compression / Blowby

Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 25 of 47
ITD Cementation India Ltd

RECORD R-INS-11/15- INSPECTION REPORT OF EXCAVATOR ( CRAWLER MOUNTED )

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date

Plant Side Condition Action to be taken by site
Overall appearance
Cabin
Superstruture
Pump Device
Swing Device
Center J oint
Control Valves
Hydraulic pumps
Hydraulic oil pressure, at no load
Hydraulic oil pressure, at full load
Hyd. Controls
Hyd. & Fuel Tanks
Reduction gear boxes
Control Systems
Eletrical Systems
Front End Attachment
Hydraulic Cylinders
Bucket
Track / Lower
Upper Rollers
Lower Rollers
Front Idlers
Travel Device
Track Chains
Pipings






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 26 of 47
ITD Cementation India Ltd
Hoses
Any other Systems

Primemover Side Condition Action to be taken by site
Oil pressure (in low idle)
Oil pressure (in high idle)
Fuel Pump
Injectors
Radiator
Water temperature
Oil temperature
Back Compression / Blowby

Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 27 of 47
ITD Cementation India Ltd

RECORD R-INS-12/15 : INSPECTION REPORT OF TYRE MOUNTED CRANE

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date


Plant Side Condition Action to be taken by site
General appearance
Boom/Hook Block (With latch/ Wire
rope)

Cabin
Wire Ropes
Gear Pinions
Brakes & Clutches
Hyd. System
Hoses/ Hyd. Cylinder
Transmission
Operator & Control System
Drive Shafts
Electrical system, Working Lights &
horns, Booms and Lights and any other
electrical systems

Availability Condition of angle indicator
& Load Chart

Other systems
Guards























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 28 of 47
ITD Cementation India Ltd

Primemover Side Condition Action to be taken by site
Oil Pressure (Low Idle)
Oil Pressure (High Idle)
Fuel Pumps
Injectors
Radiators
Water pump
Condition of smoke
Back Compression / Blow by
safety systems
Special note:-
1. Third party, Valid Inspection report
available with the Plant :- Yes / No

2. Trained Helper and Competent
Operator are with the Plant :- Yes / No

3. S.W.L.(In Basic Boom) marked in
bold letter :- Yes / No


Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 29 of 47
ITD Cementation India Ltd

RECORD R-INS-13/15 : INSPECTION REPORT OF ROTARY RIG

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date


Plant Side Condition Action to be taken by site
Overall appearance
Cabin / Roll Over Protection
Max hyd.oil pressure, at no load
Max.hyd.oil pr. ,at full load
Max.hyd.oil temp., at full load
Transmission system
Operating Contols
Hydraulic pumps
Hydraulic Controls
Hydraulic cylinders
Rotary Gear Box
Gear Ol Pump
Universal J oint
Kelly
Auto Electrical System
Any other systems
All the greasing points























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 30 of 47
ITD Cementation India Ltd

Primemover Side Condition Action to be taken by site
Oil pressure , in no load condition
Oil pressure ,in full load condition
Fuel Pump
Injectors
Radiator
Water temperature
Oil temperature
Auto Electric Sensors
Back Compression / Blowby

Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 31 of 47
ITD Cementation India Ltd

RECORD R-INS-14/15 : INSPECTION REPORT OF BSP RIG

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date


Plant Side Condition Action to be taken by site
Overall appearance
Lader
Racking beam
Wire Rope
Cathead / Sheaves
Hammer Guide
Valva Head
Pneumatic Seals / J oints
Hammer
Pulling link
Operating & Control system
Other System

Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 32 of 47
ITD Cementation India Ltd

RECORD R-INS-15/15 : INSPECTION REPORT OF D. P. RIG

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date


Plant Side Condition Action to be taken by site
Overall appearance
Mast
Bottom Frame
Wire Ropes
Breaks & Clutches
Gears & Pinions
Hammer Catcher
Hammer Drum
Extraction Drum
Miscellanies Drum
Drive Shaft
Cathead / Sheaves
P.T.O
Operating & Control system
Electrical system
Guards
Other System























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 33 of 47
ITD Cementation India Ltd

Primemover Side Condition Action to be taken by site
Oil pressure , in no load condition
Oil pressure ,in full load condition
Fuel Pump
Injectors
Radiator
Oil Cooler
Water Pump
Smoke
Back Compression / Blowby

Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 34 of 47
ITD Cementation India Ltd

RECORD R-INS-16/15 : INSPECTION REPORT OF CRUSHER PLANT (JAW)

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date

Plant Side Condition Action to be taken by site
Overall Appearance
Hopper
Motors
Motor Pulley
Fly Wheel
Level of J aw Crusher
Damping Pad
Structure
J aw
Toggle Plate Bearing
Other System

Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 35 of 47
ITD Cementation India Ltd


INSPECTION REPORT OF CRUSHER PLANT (CONE)

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date


Plant Side Condition Action to be taken by Site
Overall Appearance
Motors
Motor Pulley
Level of Cone Crusher
Structure
Lubrication System
Dust Sealing System
Electrical Cables & Components
Other System


INSPECTION REPORT OF CRUSHER PLANT (BARMAC)

Plant side Condition Action to be taken by Site
Overall Appearance
Motors
Hopper
Structure
Electrical Cables & Components
Level of Barmac Crusher
Rotor Body























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 36 of 47
ITD Cementation India Ltd

Plant Plant Side Condition Action to be taken by site
Motor
Gear Box
Coupling
Belt
Pulleys
BC 1
Rollers
Motor
Gear Box
Coupling
Belt
Pulleys
BC 2
Rollers
Motor
Gear Box
Coupling
Belt
Pulleys
BC 3
Rollers
Motor
Gear Box
Coupling
Belt
Pulleys
BC 4
Rollers
Motor
Gear Box
Coupling
Belt
Pulleys
BC 5
Rollers
Motor
Gear Box
Coupling
Belt
Pulleys
BC 6
Rollers
Motor
Gear Box
Coupling
Belt
Pulleys
BC 7
Rollers
Motor BC 8
Gear Box





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 37 of 47
ITD Cementation India Ltd
Coupling
Belt
Pulleys
Rollers
Motor
Gear Box
Coupling
Belt
Pulleys
BC 9
Rollers
Motor
Gear Box
Coupling
Belt
Pulleys
BC 10
Rollers
Motor
Gear Box
Coupling
Belt
Pulleys
BC 11
Rollers
Motor
Gear Box
Coupling
Belt
Pulleys
BC 12
Rollers
Motor
Gear Box
Coupling
Belt
Pulleys
BC 13
Rollers
Motor
Gear Box
Coupling
Belt
Pulleys
BC 14
Rollers
Motor
Gear Box
Coupling
Belt
Pulleys
BC 15
Rollers






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 38 of 47
ITD Cementation India Ltd
Motor
Vibratory System
Screen
Pulleys
Screen
Station - 1
Other System
Motor
Vibratory System
Screen
Pulleys
Screen
Station - 2
Other System
Motor
Vibratory System
Screen
Pulleys
Screen
Station - 3
Other System
Motor
Vibratory System
Screen
Pulleys
Feeder
Other System

Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 39 of 47
ITD Cementation India Ltd

RECORD R-INS-17/15 : INSPECTION REPORT OF ASPHALT MIXING PLANT

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date


Feeding System Condition Action to be taken by Site
Tank No 1 Asphalt
Tank No 2 Asphalt
Tank, Furnace Oil
Tank, Thermic Oil
Tank, HSD
All Pipe Line (Asphalt, FO, Hot Oil
& HSD) & Valves

Hot Oil Burner (Motor 0.75 KW)
Hot Oil Circulation Pump (Motor
7.5 KW)

Sub Motor 7.5 KW
Four Cold Bin
Cold Bin Screen, Liner & Structure
Cold Bin Feeder Conveyor Belt (4
Nos)
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 40 of 47
ITD Cementation India Ltd

Feeding System Condition Action to be taken by Site
Cold Bin Motor 3.7 KW (4 Nos)
Eddy Current coupling Variable
Speed Motor (4 Nos)

Worm Gear Reducer
Horizontal Conveyor
Horizontal Conveyor Motor 5.5 KW
Horizontal Conveyor Gear Reducer
Slant Conveyor
Slant Conveyor Motor 7.5 KW
Slant Conveyor Gear Reducer
Type - FHB & Ratio - 1/20

All carrier & Returner Roller,
Pulley, Sprocket & Chain

Dryer : Tire ring, Tire ring Support,
Inner liner

Dryer Motor 15 KW (4 Nos)
Supporting Roller & Side Roller of
dryer

Dryer Gear (4 Nos)
Turbo Bolwer Motor 30 KW
Dry Cyclone
Duct
D.C. Dust Screw, Motor - 2.2 KW
Main Burner
Hot Elevator
Hot Elevator Bucket & Chain
Hot Elevator Motor 22 KW
Filler Silo
Filler Screw Motor 3.7 KW
Filler Rotary Feeder Motor 1.5 KW
Filler Elevator Bucket & Conveyor
Belt Motor 3.7 KW

Screen Vibrator Motor 22 KW
Screen
Hot bin Separation & Liner
Weighing System (Aggregate,
Asphalt & Filler)

Load Cell 2 Tons (3 Nos) 0.5 Tons
(5 Nos)

Mixer
Mixer Liner, Arms Tips, Mixer
Motor 45 KW (2 Nos) Gear Box

Asphalt Spray Pump Motor 15 KW
Discharge Gate
Cabin





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 41 of 47
ITD Cementation India Ltd
Electrical System
Electronic System
Monitor with Controlling System
Air Condition System
Printer
Bag Housing Condition Action to be taken by Site
Bags
Exhaust Fan Motor 132 KW
Dust Discharge Screw Motor 0.55
KW

Bag Transfer Motor 3.7 KW
Sequential Timer
Pneumatic System Condition Action to be taken by Site
Air Compressor I / R Model : 15 T,
Motor : 15 KW

Air Compressor I / R Model : 2545
T, Motor : 9.3 KW

Air Dryer Type :HLN - 006 - 4, Max
P.R: 12.5 Kg / Cm2

All Air Cylinder
All Solenoid Valve
All F.R.L Unit

General Condition Action to be taken by Site
V' Belts
Pulley
Chain
Sprocket
Limit Switch
Level Gauge
Temperature Gauge
Thermocouple



Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 42 of 47
ITD Cementation India Ltd

RECORD R-INS-18/15 : INSPECTION REPORT OF PAVER FINISHER

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date

Plant side Condition Action to be taken by site
Overall appearance
Condition of hopper
Conveyor plate
Conveyor chain
Augers & Shaft
Screed- Plate
Tamper blade
Vibration on paving
Track shoe
Track roller
Sensing systems
Auto electrical systems
Hydraulic system
Primemover side Condition Action to be taken by site

Screed plate heating system
Paving speed
Oil pr. (In Idle)
Oil pr. (In high idle)
Fuel Pump
Injectors
Radiators
Water pump
Condition of smoke
Back compression / Blowby
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 43 of 47
ITD Cementation India Ltd

Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 44 of 47
ITD Cementation India Ltd

RECORD R-INS-19/15 : INSPECTION REPORT OF PTC

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date

Plant Side Condition Action to be taken by site
Overall appearance
Frame, Canopy & Doors
Main Pump
Auxiliary Pump
Hydraulic Hoses
Hydraulic Oil Cooler
Hydraulic Motor (Vibrodriver)
Vibratory Gearbox (Vibrodriver)
Suspention Yoke (Vibrodriver)
Clamping Head
Hydraulic J acks (Clamping Head)
Operating & Control system
Electrical system
Guards
Other System























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 45 of 47
ITD Cementation India Ltd

Primemover Side Condition Action to be taken by site
Oil pressure , idle (1200 RPM)
Oil pressure , (2300 RPM)/ no load
Fuel Pump
Injectors
Radiator
Oil Cooler
Water Pump
Electrical system
Smoke
Back Compression / Blowby

Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 46 of 47
ITD Cementation India Ltd

RECORD R-INS-20/15 : INSPECTION REPORT OF DIESEL HAMMER

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date

Plant Side Condition Action to be taken by site
Overall appearance
Y' Hitch Assy. Wth Chain & Anchor
Wire Rope & Roller Assy.
Starting Device
Latching Mechanism & Rope
Ram
Anvil
Fuel Pump
Injectors
Smoke
Lube Oil Pump & Drive Hsg. Assy.
Grease Fittings
Cathead / Sheaves
Leader
Racking beam
Guide Angles/ Clips & Fasteners
Helmet & Dolly
Operating & Control system
Guards
Other System
Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 15


Version 1.0 Page 47 of 47
ITD Cementation India Ltd

RECORD R-INS-21/15 : INSPECTION REPORT OF STABILIZATION PLANT ( W.M.M. )

Name of project - Inspection date from / / to / /
S.C.I.L No. :-
Plant details :
Make/ Model Sr. No.
Working Hrs. as on / /
Last O/H Hrs. Last O/H date
Primemovers details :
Make/ Model Sr. No.
Last O/H Hrs. Last O/H date


Plant Side Condition Action to be taken by site
Feeder - 1
Feeder - 2
Feeder - 3
Feeder - 4
Gathering Conveyor
Vibration Screen
Charging Conveyor
Liner Pugmil
Shaft of Pugmil
Arm of Pugmil
Tips of Pugmil
Gear box of Pugmil
Water Pump
Long load out conveyor

Condition of Safety System :-
Remarks :-

Signature of Site Plant In
Charge
Signature of Person Assisting
Inspector
Signature of Inspector



























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 16


Version 1.0 Page 1 of 5
ITD Cementation India Ltd













PROCEDURE P-16 : CONTROL OF NON CONFORMING
PRODUCT


















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 16


Version 1.0 Page 2 of 5
ITD Cementation India Ltd

1.0 PURPOSE

The objective of this element is to ensure that the material / product showing
deviation detected on any quality aspect specified by the customer or the
companys policy shall be considered non conforming and shall be prevented from
unintended use or installation, or taken up for appropriate corrective and
preventive action before installation and /or usage.

2.0 SCOPE

This procedure shall cover materials / products relating to Incoming, In Process
and Final stage covering all works.

3.0 RESPONSIBILITY

Direct responsibility for implementation of this procedure shall be with Project In
Charge for Incoming & In Process material and with Contract Manager for
Final product.

4.0 DEFINITION

Nil

5.0 PROCEDURE

Any Incoming, In Process or finished product shall be deemed non-conforming for
any deviations of its Inspection and test results, from the required specifications as
detailed in the QMS documents.

All the non-conforming materials shall be identified as per the method discussed in
Procedure P-12. All detected nonconformity shall be brought to the notice of
Project In Charge by the person detecting the Non Conformity.

Disposition of nonconforming materials shall be decided from data sheet DS-1/16
by the respective authority.

The nature of the nonconformity & any subsequent actions taken shall be recorded
in R-1/16. In case, Non conformity is detected after use has started, necessary
actions shall be planned & taken by the Project In charge appropriate to the effect
on potential effect of the nonconformity. Record of the action taken including
Correction, Corrective & Preventive actions shall be maintained in R-1/16.

Reworked products shall be re-inspected and results of re-inspection shall be
recorded as per R-1/16.

6.0 CROSS REFERENCE
ISO 9001:2000 clause no. 8.3
IMS Apex Manual Section 5.3






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 16


Version 1.0 Page 3 of 5
ITD Cementation India Ltd
7.0 RECORDS
R-1/16 : Record of non-conforming product and corrective & preventive action

8.0 RECORDS AVAILABILITY
R-1/16 : Project In Charge

9.0 RECORD RETENTION
As per procedure P-2























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 16


Version 1.0 Page 4 of 5
ITD Cementation India Ltd

DATA SHEET DS-1/16 : DISPOSITION OF NON CONFORMING MATERIALS


Sl
No.
Material / Product Method Of Disposition Disposition Authority
1.0 Incoming Materials

1.1 Cement a) Change concrete mix ratio. Project In Charge
b) Use the same in enabling work.
c) Return to the vendor.


1.2 ReinforCement Steel Return to the vendor Project In Charge


1.3 Stone Chips Return to the vendor or use after re
gradation or other enabling works.
Project In Charge


1.4 Sand Return to the vendor or use after re
gradation or other enabling works.
Project In Charge

1.5 Other items Return to the vendor or other
enabling works.
Project In Charge

2.0 In Process Materials

2.1 Concrete Mix Use in enabling work or reject Project In Charge

3.0 Final Product ReplaCement of members /
Rectification / Reconstruction, as
appropriate

Contract Manager


Note : Any Nonconforming products may be accepted at any stage with or without
concession if approved by client.























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 16


Version 1.0 Page 5 of 5
ITD Cementation India Ltd

R-1/16 : RECORD OF NON CONFORMING PRODUCT & CORRECTIVE & PREVENTIVE ACTION

Project : Date :


Disposition Rework
D
a
t
e

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)

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.

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o
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.

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&

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n






Copy : AMR at BU Project in Charge / Contract Manager
Contract Manager
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 17


Version 1.0 Page 1 of 5
ITD Cementation India Ltd














PROCEDURE P-17 : CORRECTIVE & PREVENTIVE ACTION
PROCEDURE
















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 17


Version 1.0 Page 2 of 5
ITD Cementation India Ltd

1.0 PURPOSE

The purpose of this procedure is to prevent recurrence of non-conformities as well
as occurrence of potential non-conformities in order to ensure continual
improvement in the Integrated Management System.

To investigate non-conformances, initiating corrective & preventive action to
mitigate Environmental Impacts & OHS risks.

2.0 SCOPE

The scope of this procedure covers all actual / essential non-conformities related to entire
Integrated Management system. These non-conformities may be related to system or
product. Any customer complaints shall also be considered as non-conformities.

3.0 RESPONSIBILITY

Project In Charge at sites, Head Depots, BU Administrative Heads shall be
responsible for implementation & maintenance of this procedure for any customer
complaints, product & system nonconformities.

4.0 DEFINITION

Correction /
Disposition Action
: Action taken for detected NC.

Corrective Action : Action taken to prevent occurrence of detected NC in
future.

Preventive Action : Action taken to prevent occurrence of any perceived
NC, which has not occurred yet.

Non conformities : Non-fulfillment of any requirement related to product,
system or customer.

5.0 PROCEDURE

Corrective & Preventive Action

On detection of any non-conformity through Integrated Management System Audit
(Internal / External), concerned responsible person shall take necessary Corrective
& Preventive action ( CAPA ) & record the same in respective NCR ( R-3/20).
Effectiveness of action taken shall be assessed by Internal Auditors & recorded.

Environmental Non-conformance situation may arise due to any or all of the
followings:
Non-fulfillment of the legislative and regulatory requirements;.
Deviations of key characteristics of operation or activities having significant
impact on the environment;
Deviation from environmental OCPs; and





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 17


Version 1.0 Page 3 of 5
ITD Cementation India Ltd
Lack or inadequate remedial measures/ corrective action for earlier detected
non conformity.

Environmental Non-conformance, recorded in R-2/13, shall be reviewed by the
Project In Charge to determine the causes of NC. He shall determine the
appropriate CAPA (s) as needed, record the same in R-2/13, implement the same
& review the results of action taken.

OSH Non-conformances situation may arise due to any or all of the followings:
Non-fulfillment of the legislative and regulatory requirements;
Deviation of Key Characteristics of operation or activities leading to enhanced
risk to life equipment, material.;
Deviation from safety and health OCPs; and
Lack or inadequate remedial measures/ corrective action for earlier detected
non conformity.
OSH Non-conformance, recorded in R-2/13, shall be reviewed by the Project In
Charge to determine the causes of NC. He shall determine the appropriate CAPA
(s) as needed, record the same in R-2/13, implement the same & review the
results of action taken.

CAPA for Non-conforming product(s) shall be taken by the disposition authority as
mentioned in DS-1/16 of P-16 & the same shall be recorded in R-1/16.

CAPA for Customer complaints shall be recorded in R-1/17.

Project In Charge shall also determine the potential non-conformities, if any, &
their causes. Record shall be maintained in R-1/17.

Trend of product non-conformities & customer complaints shall be analyzed &
reviewed by Contract Manager.

Project In Charge shall send a copy of corrective and preventive action report to
the MR for the following action:
Requirement for any change in the documented procedure resulting from the
corrective & preventive action
Adequacy of such action with respect to the particular nonconformity.

Customer Compliant

Any customer complaint received by the Project In Charge or by BU Administrative
Heads (in case of BU office) shall be registered in R-2/17. This complaint may be
in the form of correspondence or verbal instruction.

Necessary action shall be taken and recorded.

Records of resolution of the customer complaint shall also be maintained in R-
1/17.























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 17


Version 1.0 Page 4 of 5
ITD Cementation India Ltd
6.0 CROSS REFERENCES
ISO 9001:2000 Clause 8.5.2 & 8.5.3
ISO 14001:2004 Clause 4.5.3
OHSAS 18001:1999 Clause 4.5.2
IMS Apex Manual Section 5.3

7.0 RECORDS
R-1/17 : Non-conformities and corrective and preventive action
R-2/17 : Customer complaint record

8.0 RECORDS AVAILABILITY
R-1/17 : Project In Charge for project sites, Head Depots, BU Administrative
Heads
R-2/17: Project In Charge

9.0 RECORDS RETENTION

As per procedure P-2.

























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 17


Version 1.0 Page 5 of 5
ITD Cementation India Ltd

RECORD R-1/17 : NON CONFORMITIES AND CORRECTIVE & PREVENTIVE ACTION (CAPA)


Corrective &/or
Preventive Action
Sl.
No
Source of NC
( Customer
Complaint /
Potential NC )
Date Particulars of Customer
Complaints ( with
reference, if any ) /
Potential Non-conformity
Actual &/or
Potential
Causes
Proposed Taken



Copy MR Project In Charge
Contract Manager
AMR at BU




RECORD R-2/17 : CUSTOMER COMPLAINT RECORD

Project :

Customer Complaint
No. Dated Communication
Reference
Details
Handling
Responsibility
Action Taken Signature of
Project
In Charge


























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 18


Version 1.0 Page 1 of 7
ITD Cementation India Ltd













PROCEDURE P-18 : STORES



















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




FINANCE DIRECTOR & SECRETARY






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 18


Version 1.0 Page 2 of 7
ITD Cementation India Ltd

1.0 PURPOSE
The purpose of this procedure in to ensure that Materials are stored and preserved
in the designated storage areas or stock room as applicable to prevent
deterioration.

2.0 SCOPE
The scope of this procedure is limited to handling and storage and preservation of
all relevant materials and Products.
3.0 RESPONSIBILITY
Direct responsibility for implementation of this procedure shall be with Central
Depot In Charge for Central Stores and with Site Store In Charge for Project Store.

4.0 DEFINITION
Direct material Those materials that will form component of permanent work.
5.0 PROCEDURE

Storage and Preservation

All incoming major direct project specific materials shall be inspected and
accepted as per P-12 before issue by the receiving person. All other materials
received at store shall be inspected as per P.O. specifications. All the materials
shall be inspected only at the first receipt point.

Particulars of the inspected (including visual inspection) and accepted incoming
materials from supplier shall be recorded in checkers slip as shown in R-1/18 . List
of authorised personnel for inspection at site shall be available with Project In
Charge.
When the materials are received, the particulars shall be recorded in the stock
register /Kardex as shown in R - 2/18. For direct material e.g. Cements, sand
stone chips, reinforcement steel & structural steel shall be consumed from their
stock areas directly by the concerned Activity Engineer. Stock records shall be
updated periodically by actual measurement of work completed.
Storage systems for different items shall be as follows:
a) Cement shall be stored in a covered shed whose plinth level is above
ground level and shall have a clearance from the wall. Cement shall be
placed on a hard base while storing in a covered shed.
b) Steel reinforcement bars and structural steel shall be kept on support above
ground level.
c) Secondary containment shall be provided for diesel and lubricants
d) Same type of gas cylinders shall be secured and stacked vertically in a shed
with separation for empty and filled cylinders
e) Gas cylinders shall be stored away from POL storages
f) Fire extinguishers shall be provided near inflammable material storages
g) Storage system of other items will be decided based on their requirements
to prevent deterioration.





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 18


Version 1.0 Page 3 of 7
ITD Cementation India Ltd
For other materials Store In-charge shall issue the items as required by engineers
and stock record shall be updated on day-to-day basis.
Preservation shall be as follows :
a) Cement shall be preserved for 3 months from week of manufacturing, beyond
that it should be re-tested and based on results, appropriate decision shall be
taken by Project In charge.
b) Preservation for other items will be decided based on requirements.
After due inspection, accepted material shall be taken into the stores and same to
be noted in checker slip as referred in R-1/18. In case of rejection, the materials
will be returned to the supplier immediately along with Debit Note and it shall be
noted in R-1/16.
For any customer-supplied product also checkers slip shall be made and a list of
items shall be maintained with Project In charge. The details of customer-supplied
product shall be mentioned in Quality Plan as referred in Procedure No. P-11.

6.0 CROSS REFERENCE
ISO 9001: 2000 Clause 7.5.5
IMS Apex Manual Section 4.7

7.0 RECORDS
R-1/18 : Checker Slip
R-2/18 : Kardex

8.0 RECORDS AVAILABILITY
R-1/18 :Stores In Charge
R-2/18: Stores In Charge

9.0 RECORDS RETENTION
As per procedure P-2
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 18


Version 1.0 Page 4 of 7
ITD Cementation India Ltd


RECORD R-1/18 : CHECKERS SLIP

CHECKERS SLIP


NO


LOCATION : DATE :




Price Amount Date
Recei ved
Rail
Post etc.
Consignor Description
Of Materials
Stores
Code
No.
Quantity Unit
Rs P Rs P


















Container Detail Supplied Against Order No Attached / Incomplete
Delete which is not
applicable

The Above Received
In Good Condition


Checkers Signature
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 18


Version 1.0 Page 5 of 7
ITD Cementation India Ltd


R-2/18-A: STOCK REGISTER / KARDEX

LOCATION:

CONTRACT NO :




S T O C K R E C O R D


RECEIVED ISSUED STOCK DATE
REF.
NO
QTY. UNIT
REF.
NO
QTY. UNIT
QTY
PRICE
UNIT
PRICE

























DESCRIPTION
_____________________________________________
CODE NO
______________























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 18


Version 1.0 Page 6 of 7
ITD Cementation India Ltd


R-2/18-B: STOCK REGISTER / KARDEX





S T O C K R E C O R D


LOCATION : BIN NO : UOM :



RECEIVED ISSUED STOCK DATE
REF
NO
QTY UNIT
PRICE
REF
NO
QTY UNIT
PRICE
QTY UNIT
PRICE























DESCRIPTION : CODE NO :























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 18


Version 1.0 Page 7 of 7
ITD Cementation India Ltd


R-2A/18-C : STOCK REGISTER / KARDEX





S T O C K R E C O R D


Location BIN No
Report Generated For The Period
Stock Quantity Prior To This Period UOM
Average Price Of This Stock
Value Of This Stock


Recei ved Issued Stock Date
Ref
No
Qty Rate Value Ref
No
Qty Rate Value Qty Rate Value
















Final Values

Item Name

Item Code Code























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 19


Version 1.0 Page 1 of 13
ITD Cementation India Ltd














PROCEDURE P-19 : HUMAN RESOURCES


















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 19


Version 1.0 Page 2 of 13
ITD Cementation India Ltd

1.0 PURPOSE

The purpose of this procedure is as follows:

a) For personnel on Companys regular rolls To induct employees with
necessary competency and assess their competency level on a yearly basis;
and

b) For personnel on Companys project-based rolls (including workmen) To
induct employees with necessary competency and provide awareness training
on Integrated Management System

To make the employees of ITDCem at each relevant function and level aware of the
various requirements of Integrated Management System.

To ensure that contractors working on behalf of ITDCem are able to demonstrate
that their employees have requisite awareness of Companys Integrated
Management System.

2.0 SCOPE

The scope of this procedure covers all personnel who are directly involved in the
construction activities and / or related to this Integrated Management System as
discussed in the documented Procedures.

3.0 RESPONSIBILITY

Direct responsibility for implementation and maintenance of this procedure shall lie
with Corporate HR Head.

4.0 DEFINITION

Competency Level : Minimum qualification and experience required for doing a
particular activity.

5.0 PROCEDURE

Training For Employees On Regular Company Rolls

5.1 Necessary education, experience, skills (as job descriptions) and any other
requirements (including training) for each job positions are given in DS 1/19.

5.2 Assessment of competency level of employees will be done on yearly basis through
Performance Appraisal Form by Corporate HR Head with necessary assistance
from HOD HRD of respective BU. The information collected will be used by
Corporate HR Head to identify training needs.

5.3 For specialized training of technical subjects, safety and environment, training
needs shall be identified by Corporate/BU HOD concerned.





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 19


Version 1.0 Page 3 of 13
ITD Cementation India Ltd

5.4 Once the training needs of above employees are identified, the training programme
shall be planned and necessary training shall be provided as per training calendar.
Other suitable action may also be decided and taken instead of giving training. This
shall be done by HOD HRD in consultation with BU Head.

5.5 The effectiveness of action(s) stated as per cl. 5.3 shall be assessed through the
process of annual performance appraisal carried out in the following year.

Awareness Training For Employees On Regular Company Rolls & Employees
On Company Project-Based Rolls (Including Workmen)

5.6 Awareness programme for the employees shall be conducted at every Project site
preferably once in six months. The programme will cover the following aspects:

The importance of conformance with the quality / environmental / safety policy and
procedures with the requirements of the Integrated Management System.

Their roles and responsibilities in achieving conformance with the Management
Policy.

The significant environmental aspects (actual or potential) of their work activities
and the environmental benefits of improved personal performance.

The potential consequences of deviations from specified operating control
procedures regarding Environment and Safety Management Systems.

5.7 Awareness programmes shall be conducted at various levels differently. The
content, time, location, mode of presentation and faculty for the awareness
programmes shall be decided keeping in view the targeted audience.

Awareness Training Of Contractors Employees

5.8 At the time of award of work the contractors shall be asked to conduct requisite
induction training/ awareness programme for their employees in consultation with
respective Project In charge. The training programme would emphasise on the
Company Policy, Objectives and Targets of ITDCem and safety precautions to be
taken at site.

5.9 Project-In-Charge shall ensure that the contractors or their personnel are aware
and follow the requirements of environment, health and safety.

6.0 CROSS REFERENCES
ISO 9001:2000 Clause 6.2.1 and 6.2.2
ISO 14001:2004 Clause 4.4.2
OHSAS 18001:1999 Clause 4.4.2

7.0 RECORDS
R-1/19 : Training Record






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 19


Version 1.0 Page 4 of 13
ITD Cementation India Ltd
8.0 RECORDS AVAILABILITY
R-1/19 : Corporate Head HR for Training at Corporate Level, Site Safety and
Environment officer for site level training

9.0 RECORDS RETENTION
As per procedure P-2
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 19


Version 1.0 Page 5 of 13
ITD Cementation India Ltd

DATA SHEET : DS 1/19 JOB PROFILE FOR WORKMEN & STAFF

A ) WORKMEN

Sl.
No.
Designation

Years Of
Experience
Education
J ob-Description Any Other
Requirement
1 Operator ( Winch /
Compressor /
Pump / Generator)
3 Nil Erect the rig pile boring, lifting
of materials with the help of
winch, pile concreting,
identification of soil, starting
and stopping the prime-mover
of the winch, compressor /
pump / generator; reading the
gauges / meters. Laying water /
air bentonite lines & operating
valves.
Operational
knowledge
2. Helper ( Rig /
Dumper / Transit
Mixer)

1 Nil Assisting in erection of rig or
helper to the driver of Transit
Mixer, fuel / water / oil top up,
give signals to driver / operator
and maintain cleanliness.
---
3. Mechanic 5 Class- VIII To repair plants & equipment.

To have the
knowledge of
the
mechanism of
all plants
4. Electrician 3 SSC Cable laying, installation of the
electric panel box, connecting
to electrical equipment, testing
the electrical equipment to
diagnose electrical faults in
lines up to 440V, setting up of
ELCBs.

Certificate
holder
5. Welder 3 NIL Cutting of structural steel & re-
bars and welding of re-bars
and steel structures.

Qualified and
/ or
experienced.
6. Concrete Mixer
Operator
2 ---- Operating the mixer & weigh
batcher feeding.

Operating
knowledge
7. Concrete Batching
Plant Operator
3 SSC Reading the panel of batching
plant and feeding the
ingredients of concrete in the
batch preparation desired,
starting and stopping of
Batching plant.

---
8. Crane Operator 5 Class - VI Starting and stopping the crane
engine, changing the wire
ropes, loading the wire ropes,
loading & unloading of
Knowledge of
minor repairs.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 19


Version 1.0 Page 6 of 13
ITD Cementation India Ltd
Sl.
No.
Designation

Years Of
Experience
Education
J ob-Description Any Other
Requirement
materials. Capable of reading
the load chart.

9. Excavator Operator 3 Class -VI Operating all types of
excavators (crawler or tyre
mounted) loading the
excavated earth in trucks /
trippers.

Licence for
heavy vehicle
driving in
case of tyre
mounted.
10.




Dumper Driver,
Truck Driver,
Transit Mixer Driver
3 Class - V Driving dumpers, trucks, heavy
vehicles.
Driving
license for
heavy
vehicles.
11. Lab Assistant - Site 3 Class V Collecting & storing material
samples from the site for
testing, operating instruments
& handling cube testing.



---
12. Concrete Pump
Operator
3 Class V Operating the concrete pump,
laying lines, cleaning the
pipeline in case of choking.


---
13. Workmen for misc.
works (They
may carry out
works of other
designation on job
to job basis.)
a) Semi-skilled
b) Skilled




3
5




Elementary
School





---

B) SUPERVISORY STAFF

TECHNICAL (WITH DIPLOMA / DEGREE IN ENGINEERING)

S.No. Designation Education Years of
Experience
J ob Description Any other
requirement
1. Assistant Engineer Diploma in
Engineering
2 years J ob Description (function-
wise) indicated below
-
2. Engineer Diploma /
Degree in
Engineering
4 years (For
Diploma) &
1 year (For
Degree)
- do - -
3. Senior Engineer - do - 6 years (For
Diploma) &
3 years (For
- do- -






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 19


Version 1.0 Page 7 of 13
ITD Cementation India Ltd
Degree)
4. Assistant Manager
(Executive)
- do - 8 years (For
Diploma) &
5 years (For
Degree)
- do - -
5. Deputy Manager
(Executive)
- do - 10 years
(For
Diploma) &
7 years (For
Degree)
- do - -

Job Description

a) Operations Functions
Project Management / Execution
1. Project Manager / Section Head / Activity Supervisor (Project Site) Ensure quality execution of
the entire project cost-effectively and profitability as per schedules and standard plan.
2. Surveyor (Project Site) Ensure demarcation of area allocated to execution as per standard
design and plan.
3. Design, Engineering and Temporary Works Coordinator (Project Site) Ensure design and
engineering of project as per contract terms and conditions for temporary and permanent
structures

Planning
1. Planning (Business Unit) -- To prepare baseline construction schedule as per contract
requirement in consultation with Business Unit Head and Planning Head at business unit;
Support the Planning Unit at Project; Monitoring of Projects.
2. Planning (Project Site) Prepare completed break-up of the baseline project schedule prepared
on award of project including identifying and detailing of resource requirement; Monitor and
report progress vis--vis baseline planning; identify deviations and suggest corrective action.

Commercial / Procurement
1. Insurance / Risk Management (Corporate) Assess the risk involved in various areas of
business / construction activity and provide for maximum risk cover in a judicious manner;
Process Insurance claims and realize them to recuperate the loss caused to maximum extent.
2. Commercial (Business Unit / Project Site) Commercial Management of contracts,
identification and record of all items of variation and additional work under a contract, pricing
and realization of financials and time claims.
3. Procurement (Corporate) Ensure smooth, cost effective, quality and right quantity of
procurement as per procurement plan of the Company.
4. Procurement (Business Unit / Project Site) Support to ensure procurement of required items
to sites under the Business Unit with respect to rate contract and through bulk purchases as per
set quality standards adhering to the procurement plans / schedules and vendor development.

Technical Services
1. Technical Services (Business Unit) Provide technical support and services such as designing
and engineering for temporary and permanent works, Quality Control / Quality Assurance and
ISO Support, R & D and technical trouble-shooting.
2. Quality Assurance / Quality Control (Project Site) Ensure standard quality of materials and
output through out the process of execution by scientific tools and procedures.

Marketing / Business Development





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 19


Version 1.0 Page 8 of 13
ITD Cementation India Ltd
Estimation & Tendering (Business Unit) Part of a Team to estimate and plan costs and time of a
project with respect to its contract conditions, drawings and Bill of Quantities; Present / submit
tender to the client.
a) Support Functions
Safety
Safety (Business Unit/ Project Sites) Ensure implementation of Corporate IMS Policy in an
effective manner across the Business Unit / Project Sites.


Environment

Environment (Business Unit/ Project Sites) Ensure implementation of Corporate IMS Policy in an
effective manner across the Business Unit / Project Sites.


Plant

1. Plant In-charge / Engineers (Project Sites) Implement plant policies for achievement of Site
Plant objectives by way of smooth functions / operations of plants across the Workshop and
Project Sites by way of preventive and break-down maintenance.
2. Logistics and Transport Ensure timely and cost effective mobilization / demobilisation of
plants, tools, materials etc. in a smooth manner.

Stores

Stores (Depots / Project Sites) Ensure smooth operations / flow of materials, plants, spares and
consumables at sites (including spares, tools and shuttering) through stores and inventory
management.

TECHNICAL (WITHOUT DIPLOMA / DEGREE IN ENGINEERING)

S.No. Designation Education Years of
Experience
J ob
Description
Any other
requirement
1. Technical Assistant S.S.C. / I.T.I.
/ B.Sc.
4 years J ob
Description
(function-wise)
indicated
below

2. Assistant
Superintendent
- do - 6 years - do - -
3. Superintendent - do - 8 years - do -
4. Senior
Superintendent
- do - 10 years - do-
5. Assistant Manager
(Executive)
- do - 12 years - do -
6. Deputy Manager
(Executive)
- do - 14 years - do -

Job Description
a) Operations Functions
Project Management / Execution
1. Section Head / Activity Supervisor (Project Site) Ensure quality execution of the entire project
cost-effectively and profitability as per schedules and standard plan.
2. Surveyor (Project Site) Ensure demarcation of area allocated to execution as per standard
design and plan.





















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 19


Version 1.0 Page 9 of 13
ITD Cementation India Ltd

NON-TECHNICAL

S.No. Designation Education Year of Experience J ob
Description
Any other
requirement
1. Site / Office
Assistant
S.S.C. 4 years J ob
Description
(function-wise)
indicated
below
-
2. Assistant Officer - do - 6 years - do - -
3. Officer S.S.C. /
Degree in
Commerce /
Arts / Science
8 years (For S.S.C.
& 3 years (For
Degree)
- do - -
4. Senior Officer - do - 10 years (For
S.S.C) & 5 years
(For Degree)
- do- -
5. Assistant Manager
(Executive)
- do - 10 years (For
S.S.C) & 7 years
(For Degree)
- do - -
6. Deputy Manager
(Executive)
- do - 12 years (For
Diploma) & 9 years
(For Degree)
- do - -

Job Description
a) Support Functions
Finance & Accounts
1. Finance & Accounting Support (Corporate) To assist Corporate Finance and Accounts function in
all day-to-day operational matters.
2. Finance & Accounts Support (Business Unit) To assist Business Unit Finance and Accounts
function in all day-to-day operational matters.
Human Resources / Administration
1. Human Resources (Corporate / Business Unit) Assist the Corporate / Business Unit Human
Resource function in implementing HR-related policies; handle day-to-day operations matters
relating to human resources.
2. Administration (Project Site) Assist the Project Head in carrying out day-to-day operational
matters relating to site administration and all statutory compliances.
Information Systems
Server / Systems Administrators (Corporate / Business Unit) Plan and control day-to-day operations,
monitor and improve operational efficiency of the servers; advice on selection, implementation,
operation and maintenance of different types of systems;
Safety
Safety (Business Unit/ Project Sites) Ensure implementation of Corporate IMS Policy in an effective
manner across the Business Unit / Project Sites.
Environment
Environment (Business Unit/ Project Sites) Ensure implementation of Corporate IMS Policy in an
effective manner across the Business Unit / Project Sites.

























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 19


Version 1.0 Page 10 of 13
ITD Cementation India Ltd
COVENANTED MANAGERS

Sl
No.
Designation Education Years of
Experience
J ob Description Any other
requirement
1. Manager / Senior
Manager
Degree in
Engineering
9 to 12 years J ob Description
(function-wise) indicated
below
-
2. Asst. General Manager
& Dy. General Manager
- do - 14 to 16
years
- do - -
3. General Manager - do - 18 years - do- -
4. Vice President - do - 20 years - do- -

Job Description
a) Operations Functions

Business Unit Head

Strategize business processes, resources and systems of the business unit and implement them for
achievement of business, functional and corporate goals on a month-to-month basis as per budget /
target for the year.

Improvement Projects

Ensure Improvements in standards of Quality, Environment and Safety and monitor effective
implementation of such standards on Company-wide basis in line with ISO & OHSAS 18001
Certification.
Project Management / Execution

Project Director / Project Manager / Section Head (Project Site) Ensure quality execution of the
entire project cost-effectively and profitability as per schedules and standard plan.

Planning

1. Planning (Business Unit) -- To prepare baseline construction schedule as per contract
requirement in consultation with Business Unit Head and Project Manager; Support the Planning
Unit at Project; Monitoring of Projects.
2. Planning (Project Sites) Prepare completed break-up of the baseline project schedule prepared
on award of project including identifying and detailing of resource requirement; Monitor and report
progress vis--vis baseline planning; identify deviations and suggest corrective action.

Commercial / Procurement

1. Commercial (Corporate / Business Unit) To ensure effective commercial and claims
management of all contracts.
2. Legal (Corporate) Advise concerned on all legal issues having financial / contractual
implications from pre-tendering to realization of claims; Provide consultation to management for
long-term legal strategy for the business.
3. Commercial (Project Site) Commercial Management of contracts, identification and record of all
items of variation and additional work under a contract, pricing and realization of financials and
time claims.
4. Procurement (Corporate) Ensure smooth, cost effective, quality and right quantity of
procurement as per procurement plan of the Company.
5. Procurement (Business Unit) Ensure procurement of required items to sites under the Business
Unit with respect to rate contract and through bulk purchases as per set quality standards
adhering to the procurement plans / schedules and vendor development.
6. Procurement (Project Site) Ensure procurement of required items as per set standards adhering
to the procurement plans / schedules and vendor development.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 19


Version 1.0 Page 11 of 13
ITD Cementation India Ltd

Technical Services

1. Technical Services (Business Unit) Provide technical support and services such as designing
and engineering for temporary and permanent works, Quality Control / Quality Assurance and ISO
Support, R & D and technical trouble-shooting.
2. Quality Assurance / Quality Control (Project Site) Ensure standard quality of materials and
output through out the process of execution by scientific tools and procedures.
3. Design, Engineering and Temporary Works Coordinator (Project Site) Ensure design and
engineering of project as per contract terms and conditions for temporary and permanent
structures

Marketing / Business Development

1. Marketing (Corporate) Development of new markets; Brand Building & Development; Client
Relationships Management; Client and Project Database Management and Prequalification
support to Sales; Competition Analysis.
2. Business Development (Business Unit) Maximise market share in concerned market segments
identified by way of Key Account Management; Submit Pre-qualifications to ensure healthy work-
in-hand position.
3. Estimation & Tendering (Business Unit) Estimate and plan costs and time of a project with
respect to its contract conditions, drawings and Bill of Quantities; Present and submit tender to the
client.


b) Support Functions


Finance & Accounts / Secretarial

1. Finance & Accounts (Corporate) Ensure adequate funding at right time to projects; company
with audit requirements and accounting standards pertaining to all accounting practices;
consolidate and prepare final accounts; Forex Management; Treasury Management; Exercise
control over accounting by way of budgetary controls, variance analysis, auditing etc.; To ensure
comply with the provisions of Tax Laws.
2. Management Accounts (Corporate) Timely preparation of desired level of information accurately
that is suitable for management decisions; Adhere / facilitate to achieve organizational/group
goals and policies with respect to business profitability, wealth-creation and value addition.
3. Finance & Accounts (Business Unit) Ensure accurate and timely compilation of accounts and
management information; effective fund management of business unit and to ensure cash
positiveness of contracts; Statutory compliances.
4. Company Secretary (Corporate) Timely filing of all statutory returns / information / documents;
comply with Corporate Law regulations and keep abreast the management of new changes in
corporate laws and advise / consult on their implications.

Human Resources / Administration

1. Human Resources (Corporate) Build, promote and nurture a performance-based, productive
and humane organizational climate and culture; ensure majority of employees are motivated;
design and lead administrative policies across the company through a facilitative approach.
2. Human Resources (Business Unit) Assist Corporate Human Resource in implementing HR-
related policies; handle day-to-day operational matters relating to human resources under the
jurisdiction of business units; ensure compliance with labour laws.
3. Administration (Corporate / Business Unit) Implement administration-related policies; handle
day-to-day and operational matters.

Information Systems

Information Systems (Corporate) Overall responsibility for the planning and control of IT systems
activities.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 19


Version 1.0 Page 12 of 13
ITD Cementation India Ltd

Internal Audit

Internal Audit (Corporate) Conduct Management Audit to ascertain compliance with standard
management practices for better corporate governance; advise management on issues of concern
emerged out of internal audit; implement the action plan of measures / suggestions by External
Internal Auditors.

Safety

1. Safety (Corporate) Design a comprehensive IMS Policy for the entire organization and drive its
implementation through various measures to build a Safe Work Culture.
2. Safety (Business Unit/ Project Site) Ensure implementation of Corporate IMS Policy in an
effective manner across the Business Unit / Project Sites.

Environment

Environment (Corporate) Design a comprehensive IMS Policy for the entire organization and drive its
implementation through various measures to build an effective compliance with Environmental issues.

Plant

1. Plant Head Strategize business processes, resources and systems of Plant Business Unit and
implement them for achievement of business, functional and corporate targets / goals of each
quarter by smooth functions / operations of plants and stores across the organization.
2. Central Workshop / Plant Controller Implement plant policies for achievement of Site Plant
objectives by way of smooth functions / operations of plants across the Workshop and Project
Sites.

* Educational Qualifications may be relaxed considering work experience

























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 19


Version 1.0 Page 13 of 13
ITD Cementation India Ltd


RECORD : R 1/19 : TRAINING RECORD


BU Level ( if BU office ) ( 1 / 2 / 3 ) :
Name Of The Project :
Contract No.
Topic of Training :
Date of Training :
Instructor :


Sl.
No
.
Name of Employee Signature Of Attendees Remarks




























Signature Of Instructor Date :



Project In Charge Date :

























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 20


Version 1.0 Page 1 of 8
ITD Cementation India Ltd














PROCEDURE P-20 : INTERNAL AUDIT

















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 20


Version 1.0 Page 2 of 8
ITD Cementation India Ltd

1.0 PURPOSE

The purpose of Internal Audit (IA) is to determine compliance of implementation of
the laid down Integrated Management System with the requirements of standard
and effectiveness of the implemented system vis--vis the management Objectives
& Policy.

2.0 SCOPE

The scope of this procedure covers Integrated Management System of the
organisation.

3.0 RESPONSIBILITY

Chief Internal Auditor (IA) shall be directly responsibility for implementation of this
procedure. Chief - IA shall be HOD Engineering of respective BU.

Assisting responsibility shall be with team of Internal Auditors.

4.0 DEFINITION

Nil.

5.0 PROCEDURE

Chief Internal Auditors shall be responsible for the planning & organising Internal
Audit, training of personnel for Internal Audit, maintaining relevant records and
taking appropriate follow up actions, as required.

Internal Audits shall be carried out only by personnel trained for such activities,
However, in no case the persons having functional responsibility in a specific area
or areas shall be allowed as an Auditor in his area or areas.

Each of the Processes/ Area covered in the Manual shall be audited as per the
frequency mentioned in DS -1/20.

While normally audit of each Process / Area shall be performed as per the
frequency given in DS-1/20, other factors that shall be considered to increase the
frequency of audit include the following:























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 20


Version 1.0 Page 3 of 8
ITD Cementation India Ltd
Possible external audit;
Major customer complaints, if any;
Discrepancy in records, if any;
Contractual requirements;
Significant changes in management, organization, Policy, product and
technology;
Changes in the Integrated Management System itself; and
Results of previous audits.


Chief-IA shall prepare Annual Internal Audit Plan (R - 1/20) in consultation with
Corporate Environmental Head & Corporate Safety Head. A copy of audit plan will
be sent to MR.

The Internal Audit Programme (R - 2/20) shall be communicated in advance to both
the concerned Auditor (s) and Auditee (s) by respective HOD Engineering for his
BU in consultation with Corporate Environmental Head & Corporate Safety Head. A
copy of audit plan will be sent to MR and who shall prepare the audit plan for the
Top Management and Corporate Heads. The audit plan shall be flexible to permit
change in emphasis based on audit findings and to permit effective use of
resources.

A non-conformity may occur due to any or all of the following:
Situation adverse to Product Quality / Environment / OSH;
Nonconformance to contract requirements;
Nonconformance to the IMS Manual, Procedure or Work instructions;
Nonconformance to the Standards ISO 9001 / ISO 14001/ OHSAS 18001;
Ineffectiveness of the implemented Integrated Management System; and
Lack of, or inadequate remedial measures / corrective action for earlier
detected nonconformity.

Any significant nonconformity shall be brought to the immediate attention of the
Management Representative by the Chief IA.

Discrepancies found in the audit shall be noted. Nonconformity report shall be
prepared as per R - 3/20 and shall be handed over to the Auditee to take necessary
action to close the nonconformity within the stipulated time period, after which the
follow-up audit shall be carried out to check the actual status. One copy of R - 3/20
& any other observations noted shall be sent to Chief IA.

Closing time of nonconformity shall be maximum forty-five days. In case the
nonconformity is not closed within stipulated period, this shall be brought to the
notice of Management Representative by Chief IA and another nonconformity shall
be raised.

Record of the Internal Audit, Nonconformance & Corrective Actions & verification
shall be maintained by respective Chief-IA.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 20


Version 1.0 Page 4 of 8
ITD Cementation India Ltd
Each round of audit conducted shall be summarized as per R - 4/20 by Chief IA.
This report shall be prepared after follow up audit for that Internal Audit and shall be
forwarded to MR.

6.0 CROSS REFERENCE
ISO 9001:2000 Clause No. 8.2.2
ISO 14001:2004 Clause No. 4.5.5
OHSAS 18001:1999 Clause No. 4.5.4
IMS Apex Manual Section 5.4

7.0 RECORDS
R-1/20 : Annual Internal Audit Plan
R-2/20 : Internal Audit Programme
R-3/20 : Non-Conformity Report
R-4/20 : Summary of Internal Audit Report

8.0 RECORD AVAILABILITY
R-1/20: BU HOD engineering and MR
R-2/20: BU HOD engineering and MR
R-3/20: BU HOD engineering
R-4/20: BU HOD engineering and MR

9.0 RECORD RETENTION

As per procedure P-2

























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 20


Version 1.0 Page 5 of 8
ITD Cementation India Ltd
DATA SHEET DS-1/20 : FREQUENCY OF INTERNAL AUDIT

Sl
No
Area Department/
Process
Procedure(s) To Be
Covered
Frequency
1 Corporate
Office
Directors Office, MR,
Commercial, Purchase, HR,
Marketing and Proposal,
Plant
IMS Apex Manual,
IMS Procedures : P-1,
P-2, P-3, P-4, P-5,P-6,
P-13, P-15, P-17, P-19,
P-20, P-21, P-22,
P-23
Once in 6
months
2 BU Office Document Control, Marketing
& Proposal, Engineering,
Purchase, Commercial,
Planning, Project Execution,
HR, Internal Audit

IMS Apex Manual,
IMS Procedures : P-1,
P-2, P-3, P-4, P-5,
P-6, P-7, P-8, P-9,
P-10, P-13, P-17, P-19,
P-20, P-21, P-22, P-23
Once in 6
months
3 Area Depot
(Including
Laboratory)
Document Control, Inspection
& Testing, Monitoring &
Measuring Devices, Plant,
Store
IMS Apex Manual,
IMS Procedures : P-1,
P-2, P-3, P-4, P-5,
P-13, P-14, P-15,
P-16, P-17, P-18,
P-19, P-20, P-21,
P-22, P-23
Once in 6
months
4 Project Site Document Control, Purchase,
Commercial, Planning,
Project Execution, Inspection
& Testing, Monitoring &
Measuring Devices, Plant,
Store, HR

MS Apex Manual,
IMS Procedures : P-1,
P-2, P-3, P-4, P-5,
P-7, P-8, P-10, P-11, P-
12, P-13, P-14,
P-15, P-16, P-17,
P-18, P-19, P-20, P-21,
P-22, P-23
Once in 6
months























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 20


Version 1.0 Page 6 of 8
ITD Cementation India Ltd

RECORD R-1/20 : ANNUAL INTERNAL AUDIT PLAN

Procedure Sl
No
Area
of IA
Main Relevant
Departme
nt /
Section
J
a
n

F
e
b

M
a
r

A
p
r

M
a
y

J
u
n

J
u
l

A
u
g

S
e
p

O
c
t

N
o
v

D
e
c














Chief - IA




RECORD R-2/20: INTERNAL AUDIT PROGRAMME

Time Auditor Audit
No
Area Of IA Place Of
Audit
Date
From To
Auditee
Leader Member (s)
Remarks

















Chief - IA























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 20


Version 1.0 Page 7 of 8
ITD Cementation India Ltd

RECORD R-3/20 : NON CONFORMITY REPORT

Audit No : Date Of Audit :
Area ( Office / Project Site / Depot ) : Department / Process :
NC No.
Standard : ISO 9001 - 2000 / 14001 2004 / OHSAS 18001-1999

To Be Filled By Auditor
Non-Conformity Observed


ISO 9001/ ISO14001 / OHSAS 18001 Clause Ref
Root Cause for Non-conformity
(Planning/Supervision/Resources/Other elaborate)

To Be Filled By Auditee During Audit
Corrective / Preventive Action Plan Target Date for NC Closure

Corrective / Preventive action proposed has been reviewed and agreed by the Auditor
Auditor :

Main Auditee :
Signature Of Auditor :

Signature Of Auditee :
To Be Filled By Auditor During Follow Up Audit
NC Status
(Closed /
Open)
Supporting Objective
Evidence, if NC Closed
Reason For Non Closure Of Open NC &
Revised Target Date For Closure

Name Of Auditor :
Signature Of Auditor :
Date :
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 20


Version 1.0 Page 8 of 8
ITD Cementation India Ltd
RECORD R-4/20 : SUMMARY OF INTERNAL AUDIT REPORT




Sl
No
Area ( Corporate
/ BU office /
Depot / Project
Site No.)
Date of
Audit
Department /
Process
Audited
Nos. of
Nonconformity
Detected
Summary
of NCs
No Of
NCs
Open
Remarks





































INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 21


Version 1.0 Page 1 of 2
ITD Cementation India Ltd














PROCEDURE P-21 : COMMUNICATION

















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 21


Version 1.0 Page 2 of 2
ITD Cementation India Ltd

1.0 PURPOSE

To facilitate receiving, documenting and responding to communication from internal
and external interested parties related to ITDCEMs IMS.

2.0 SCOPE

All pertinent communication with employees & other interested parties.

3.0 RESPONSIBILITY

MR / AMRs shall be responsible for effective implementation of the system.

4.0 DEFINITION

None required

5.0 PROCEDURE

External Communication

Environmental and OSH related communications received from statutory bodies (
SPCB, CPCB, MOE&F, RLC, CCE etc.) by any official should be available with
AMRs / MR and this shall be preserved.

MR / AMRs shall respond to the communication as necessary.

Environmental & OSH related communication with public shall be carried out
through appropriate means by AMR at site level

At the time of placing of order necessary instructions, with regards to environmental
& OSH requirements shall be communicated to suppliers and contractors.
Compliance shall be monitored and necessary action shall be initiated.

All these external communication shall be documented in communication register
by AMRs/MR.

Internal Communication

Each site shall properly preserve internal communication received with respect to
the IMS and suitable replies will be sent by MR / AMRs as applicable.

Internal communication includes displaying IMS Policy, Environmental & OHS
Objectives & Targets, Operational / Management Review Meetings,
communications regarding Internal Audits. Responsibility of maintaining these
communications lies with MR / AMRs as applicable.

MR / AMRs shall also take note of Environmental / OSH concerns of internal
interested parties & employees as & when required.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 22


Version 1.0 Page 1 of 15
ITD Cementation India Ltd














PROCEDURE P-22 :OCCUPATIONAL SAFETY AND HEALTH RISK
ASSESSMENT (OSHRA)

















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 22


Version 1.0 Page 2 of 15
ITD Cementation India Ltd

1.0 PURPOSE

This procedure shall be followed for Occupational Safety and Health Risk
Assessment (OSHRA) to:
Identify hazards associated with all ITDCem activities; routine / non routine
Assess risks to personnel, equipment and material out of the identified
hazards; and
Decide appropriate control measures to manage risk.

2.0 SCOPE

The procedure shall be applicable to all activities of ITDCem:
Project Sites;
Depots; and
BU/Corporate Offices.

3.0 RESPONSIBILITY

Project In charge at sites, Depots Head and Administrative Officer in
Corporate/BU offices shall be responsible for coordinating identification of
hazards, assessment of risk related to activities under ITDCem control and
activities of suppliers/contractors over which ITDCem has influence. Sites, Depots
and Offices shall prepare a risk assessment register.

Corporate Head Safety and BU HOD Safety shall provide technical support where
required, for identifying hazards and carrying out risk assessment.

Project In charge at sites, Depot Head and Administrative Officer in Corporate/BU
offices shall review Risk Assessment Register.

4.0 DEFINITIONS

Accident: undesired event giving rise to death, ill health, injury, damage or other
loss

Critical Task: Task which has the potential to produce major loss to people,
property, process, and / or environment when not performed properly.



Hazard: source or situation with a potential for harm in terms of human injury or ill
health, damage to property, damage to workplace environment, or a combination
of these.

Improvement Programme: Management programmes for achieving its
objectives.

Incident: Event that gave rise to an accident or had the potential to lead to an
accident.

Near Miss: an incident where no ill health, damage, or other loss occurs.






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 22


Version 1.0 Page 3 of 15
ITD Cementation India Ltd
Risk: Combination of the likelihood and consequence(s) of a specified hazardous
event occurring.

5.0 PROCEDURE

Risk assessment shall be carried out by a group nominated by Project In charge ,
Depots Head and Administrative Officer in Corporate/BU offices for all activities
likely to affect people, environment, material and equipment.

OSHRA shall be carried out as per Risk Assessment Process given below in
Paragraph 5.1.

5.1 Risk Assessment Process
The Process Of Carrying Out Risk Assessment Shall Be As Follows:
Listing Out Activities
Identifying Hazards
Evaluating Risk
Deciding Control Measures
Monitoring And Reviewing Assessment

5.1.1 Identifying Hazards

To systematically identify hazards that affect the safety and health of employees,
sub contractors and workers and all those affected by our activities, following five
key areas shall be considered: -
People
Equipment
Procedure
Work place (work environment)
Materials

5.1.2 Evaluating Risk
Risk will be evaluated based on a Risk Rating Score (RRS) as given below.

5.1.3 Risk Rating Score



Risk is essentially a combination of three factors:
The number of people that could be affected or extent of
exposure of property or equipment to the hazard
N
The severity of likely injuries that persons could suffer or
damage to the property / equipment
S

The likelihood of harm actually occurring
L
The overall risk shall be determined using the following formula:

Risk Rating Score (RRS) =N*S*L























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 22


Version 1.0 Page 4 of 15
ITD Cementation India Ltd



Rating for each of the above factors shall be considered as given below: -

Number of people affected /
exposure of property or
equipment to hazard
(N)
Severity / damage to
property or equipment

(S)
Likelihood of
Occurrence

(L)
Risk
Rating
Score
N*S*L
Factor Score Factor Score Factor Score
1-5 Persons /
Occasional exposure
(yearly)

1 Negligible /
<Rs. 10000
1 Improbable 0.5
6-50 Persons /
Seldom exposure
(monthly / weekly)

2 Minor / Rs.
10,000-
2,00,000
2 Remote 1
50+Persons / Daily or
continuous exposure

3 Major / Rs.
2,00,000
5,00,000
5 Possible 5
Public / Vulnerable
people

3 Fatal (Death) /
>Rs. 5,00,000
10 Likely 10
Certain 20


Explanation:
Negligible injuries include bumps, small cuts, abrasions etc.
Minor injuries include those injuries that could result in the time off work.
That is a person has to leave site for treatment.
Major injuries include broken limbs, injury to eyes, asphyxiation.
Improbable: Probability close to Zero
Remote: Unlikely
Possible: Could occur some times
Likely: No surprise that it will happen
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 22


Version 1.0 Page 5 of 15
ITD Cementation India Ltd

RISK
RATING
SCORE
ACTION TO BE TAKEN

<10
Risk acceptable


10-19
Risk is low. Action is required to reduce the risk, although low
priority. Time, effort and cost should be proportional to the risk.

20-49
Risk is medium. Action required soon to control. Interim measures
required in the short term. Significant time and effort may be
required to control the risk.

50-99
High Risk. Urgent action required, interim measures required.
Significant time and money may be required to control the risk.

100+
High Risk- totally unacceptable, Immediate action required to bring
RRS below 100 before work activity can continue.

A. Initial Risk Rating Score will be ascertained considering that control
measures are not in place or not properly exercised.

B. OSHRA shall be reviewed every six months to ensure that the degree of
risks have not changed or when new activities start or immediately after
occurrence of an incident.

C. On completion of OSHRA, details of control measures shall be entered
using format R-1/22 (Risk Assessment Form).

D. Critical task analysis is given in DS 1/22 and control measures are
incorporated in worksheet as per R 2/22.

6.0 CROSS REFERENCES

OHSAS 18001, Clause 4.3.1
IMS Apex Manual : Section 3.1

7.0 RECORDS

R-1/22 Risk Assessment Form
DS- 1/22 Critical Task Analysis datasheet
R- 2/22 Work sheet for control measures.

8.0 RECORDS AVAILABILITY

R-1/22, R-2/22 for Site/Depot/Office Project In Charge / Head Depot/BU
Administrative Head

9.0 Record Retention

As per Procedure P-2.
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 22


Version 1.0 Page 6 of 15
ITD Cementation India Ltd

DATA SHEET DS 1/22 -CRITICAL TASK ANALYSIS

Based on statistics of injuries and experience at site, activities pertaining to following
trades have been analysed for identifying critical tasks:-
(a) Vehicle/tractor/trailer driver
(b) Crane operator
(c) Electrician
(d) Pump/ Winch operator
(e) Driller
(f) Unskilled worker

Every task has to be examined for its criticality. Factors to determine task criticality
are as under:
Severity potential (S)
Frequency of exposure (F)
Probability of loss (P)

SEVERITY CRITERIA (S)

CRITERIA GRADING
PERSONNEL PROPERTY
No injury or illness Damage or other loss less than Rs
10000
0
Minor injury/illness without
lost time
Non-disruptive damage or other
loss of Rs 10000 Rs 2,00,000
2
Lost time injury/illness
without permanent
disability
Disruptive damage, or other loss of
Rs 2,00,000 to Rs 5,00,000 4
Permanent disability or
loss of life or body part
Extensive loss of structure,
equipment or material, or other
loss exceeding Rs 5,00,000
6



FREQUENCY CRITERIA (F)

Number of times task is performed by
each person

Number of
persons
performing task
Less than daily

Few times per
day
Many times per
day
Few (1 5) 1 1 2
Moderate Number
(6 20)
1 2 3
Many (>21) 2 3 3
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 22


Version 1.0 Page 7 of 15
ITD Cementation India Ltd



Probability (P)

Likelihood of loss occurring

- 1
Low probability of loss

0
Moderate probability of loss

+1
High probability of loss


CRITICALITY =S +F +P
If criticality (S+F+P) is more than 6, then the task is critical. Higher the number,
higher is the priority of the task.


CRITICAL TASK INVENTORY SHEET

Occupation: Vehicle Driver

S.No Task/Activity Major Loss/ Exposure S F P C Remarks
1. Forward driving and
parking
Injury to self or public /
vehicle overturning
4 2 -1 5

2. Reversing Vehicle running over /
crushing others
4 2 +1 7 CT
3. Maintenance and
running repairs
Minor injury
2 2 -1 3


Occupation: Crane Operator

S.No Task/Activity Major Loss/ Exposure S F P C Remarks
1. Moving crane Crane overturning/
crush injury
0 2 -1 1

2. Lifting load Failure of sling / Injury
to personnel
4 2 0 6

3. Moving with lifted load Failure of sling / Injury 4 2 1 7 CT
4. Maintenance and
repairs
Minor injury
2 1 0 3

5. Operating RT-3 Damage to equipment
/ Injury to personnel
4 2 -1 5

6. Operating grab Failure of wire rope
due to extra load /
Injury to personnel
4 2 +1 7 CT
7. Operating vibro Damage to equipment 4 2 -1 5
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 22


Version 1.0 Page 8 of 15
ITD Cementation India Ltd
Occupation: Electrician

Sr.
No
Task/Activity Major Loss/ Exposure S F P C Remarks
1. Earthing connection Minor injury 2 1 -1 2
2. Laying electrical circuit Minor injury 2 1 -1 2
3. Working on live circuit/
checking circuit
Electrocution
6 1 0 7 CT

Occupation: Unskilled Worker

Sr.
No
Task/Activity Major Loss/ Exposure S F P C Remarks
1. Manual handling Injury to self & others 4 3 -1 6 CT
2. Handling hazardous
substance
Diseases
4 3 0 7 CT
3. Guiding vehicles or
performing flagmen
duties
Injury to self
4 2 -1 5


Occupation: Pump/Generator/Winch Operator

Sr.
No
Task/Activity Major Loss/ Exposure S F P C Remarks
1. Starting and stopping Injury to personnel 4 1 +1 6 CT
2. Maintenance and
repairs
Injury or damage to
equipment
2 1 -1 2


Occupation: Driller

Sr.
No
Task/Activity Major Loss/ Exposure S F P C Remarks
1. Assembly of drilling
machine
Injury to self and
others
4 1 -1 4
2. Drilling Fall from height

Injury by compressed
air

4

4
2

2
0

0
6

6
CT

CT
3. Fishing for drilling bit Hit by spanner 4 1 0 6 CT
























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 22


Version 1.0 Page 9 of 15
ITD Cementation India Ltd

DATA SHEET DS-2/22:CRITICAL TASK ANALYSIS WORKSHEET




Department Mechanical
Occupation Vehicle Driver
Task Reversing of vehicle


No Task Steps Specific Loss
Exposure
Improvement
s/Suggestion
s
Recommended
Controls
1 Reversing from a
parked position

1a Driver starting to
reverse by getting
into the vehicle
Injury to personnel
sleeping/resting/stan
ding behind the
vehicle
Driver to check
underneath
and behind
before getting
into the vehicle
Driver to go
around the
vehicle
Helper to guide as
per norms
2 Vehicle being
reversed in
continuous
movement

2a Helper to
dismount from the
vehicle to go to
rear of vehicle
Injury to helper Helper to
move to the
rear of the
vehicle from
the front side
of the vehicle
Driver not to start
reversing till helper
reaches the spot and
signals
2b Start reversing Person/animal run
over
Reverse horn Vehicle to be
periodically checked
Helper to give
signals

Vehicle fall over from
height or on slope
Stopper to be
provided
Stoppers to be
periodically checked























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 22


Version 1.0 Page 10 of 15
ITD Cementation India Ltd

Department Mechanical
Occupation Crane operator
Task Operating Grab

No Task
Steps
Specific Loss
Exposure
Improvements/Suggestions Recommended
Controls
1 Positioning
of crane
Damage to
load
Crane to be positioned on
level and firm ground and as
near to the load as possible
Lift supervisor to
check the position
2 Lifting the
grab
Injury to
personnel
Area to be barricaded and no
person allowed inside
Crane helper to
check
3 Grabing Failure of wire
rope due to
excessive
load
Wire ropes to be periodically
inspected
Excessive pressure not to be
applied, incase hard
rock/obstruction encountered
grab to be withdrawn and
chiseling to be done
Mechanical engineer
to regularly inspect
the condition of ropes
Site supervisor to
ensure action on
encountering rock/
obstruction


Department Mechanical
Occupation Crane operator
Task Moving with lifted load

No Task Steps Specific Loss
Exposure
Improvements/Suggestions Recommended
Controls
1 Positioning
of crane
Damage to
load
Crane to be positioned on level
and firm ground and as near to
the load as possible
Lift supervisor to check
the position
2 Slinging of
load
Damage to
crane
Proper slings to be attached as
per the configuration of load
Lift supervisor to check
the position that the load
is within limit/capability
of the crane and the
slings are also of
adequate capacity and
are attached properly
3 Lifting of
load
Damage to
crane
Operator to lift the load slightly
off the ground and check the
"Load angle Indicator" to
ensure that the load is within
the safe working load at that
radius otherwise put the load
down and take corrective
action
Authorised
slinger/banksman to
give signal to the crane
operator
4 Lifting of
load
Damage to
crane and load
Injury to person
Load to be lifted gradually
No person to stay under the
load
Lift supervisor to check
Swing area of the crane
to be barricaded
5 Moving with
lifted load
Toppling of
crane
Injury to person
Path that the crane has to take
should be firm and level
No person in the path of the
moving crane
Lift supervisor to check
Helper to check























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 22


Version 1.0 Page 11 of 15
ITD Cementation India Ltd

Department
Mechanical
Occupation
Electrician
Task Work on live electrical circuit

No
Task
Steps
Specific Loss
Exposure
Improvements/Suggestions
Recommended
Controls
1 Identify
task

2 Working
on live
circuit
Loss of life Ensure the weather is dry
Ensure that the electrician is
not wet or is not perspiring
Work on live electric
circuit to be
permitted only on dry
days and during cool
hours
3 Touching
the live
wire
Loss of life Use rubber hand gloves and
insulated tools
All electricians to be
issued with rubber
hand gloves and
insulated tools
4 Touching
the live
wire
Loss of life Work on only one conductor,
ensure the other conductor is
visibly seperated



DEPARTMENT Mechanical
OCCUPATION Pump/ Generator/ Winch Operator
TASK Starting and stopping

No Task
Steps
Specific Loss
Exposure
Improvements/Suggestions Recommended
Controls
1 Starting
with
starting
handle
Injury to self Only trained operator/ helper
to start
Site supervisor to
nominate person(s) by
name who only will
start the machine
Adequate training to
be imparted























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 22


Version 1.0 Page 12 of 15
ITD Cementation India Ltd

Department
Operations
Occupation
Driller
Task
Drilling Holes

Sr.
No
Task
Steps
Specific Loss
Exposure
Improvements/Suggestions Recommended Controls
1











2










3
Working
from a
platform at
height /on
a hill slope








Drilling &
Cleaning
of the
drilled
hole using
compress
ed air





Fishing for
drilling bit
Injury to self due
to fall










Injury because of
flying particles


Injury by
compressed air
Hose or heavy
equipment



Injury to self due
to hit by spanner






Platform to be firmly
secured, have barricading all
around and toe boards
Worker to wear full body
harness firmly secured to
independent anchor

Net to be placed below the
platform protruding at least
1m on each side of the
platform

Minimum number of
personnel to be present.


Compressed air to be
gradually let in so that the
worker has full control over
the hose when the air comes
with full pressure

While operating the spanner
all personnel shall operate
from one side only


Platform to be thoroughly
checked for stability and
barricading before start of
work each day
Supervisor to ensure that
the worker wears the safety
harness and secures it

Supervisor to ensure net in
position



Equipment to be held firmly.
Use of goggles by all in that
area


Supervisor to check hoses
daily before start of work
Worker at the compressor
to be experienced and
trained

Only trained workers shall
be put on this operation
after being refreshed with
toolbox talk.























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 22


Version 1.0 Page 13 of 15
ITD Cementation India Ltd

Department
Execution
Occupation
Unskilled worker
Task
Manual Handling


No Task
Steps
Specific Loss /
Exposure
Improvements/Suggestions Recommended
Controls
1 Preparing
to lift items
Injury to persons
lifting
Line up persons involved in
lifting as per their height,
persons to be made to stand
alternately on either side of
load
Supervisor in control to
check
1a Preparing
to lift items
to lift items only when the
leader gives a command to
lift
Supervisor to give the
command "Uthao"
2 Putting
load on
left/right
shoulder
Hold the load firmly on the
shoulders
Supervisor in control to
check
3 Moving the
lifted load
from one
place to the
other
Every one should start
moving in the same direction
at the same speed
Supervisor in control to
move alongside
4 Lowering
the load on
reaching
the
destination

Every one should stop and
move their feet away from
under the load and be
prepared to keep the load
down
Supervisor to clearly
indicate the place
where the load is to be
kept, check that the
ground is alright and in
case load is to be kept
on dunnage the same
is in correct position
and then give the
command "Rakho"
5 Resting the
load on the
ground
Every one should lower the
load together and hold it till is
has firmly rested on the
ground
Supervisor to check
that the load is firmly
kept and then only give
the command to
release the hands
6 Straighting
up
Everyone should stand erect
without giving jerk to the
back
Supervisor to take the
team for next task























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 22


Version 1.0 Page 14 of 15
ITD Cementation India Ltd

Department
Execution
Occupation
Unskilled Worker
Task
Handling hazardous substances

No Task Steps Specific Loss /
Exposure
Improvements/Suggestions Recommended Controls
1 Coming in
contact with
Cement,
Bentonite,
Acids,
Batteries,
Additives
Injury to body
parts coming in
contact
Use of PPE Supervisor to ensure
regular use
Periodic medical
examination
2 Working in
areas where
hazardous
fumes/
particles etc
prevalent all
the time
Diseases due to
inhaling
hazardous
material
Use of PPE Supervisor to ensure
regular use
Periodic medical
examination


























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 22


Version 1.0 Page 15 of 15
ITD Cementation India Ltd

RECORD R-1/22 :RISK ASSESSMENT FORM

Site: System/Activity: Assessment Date:
Revision No. :
Reviewed By :
Group of
Assessors
______________
______________
______________

Reviewed On :


RISK RATING
SCORE
RESIDUAL RISK
RATING SCORE
SR
NO
TASK R/
NR
HAZARD HAZARD
EFFECT
N S L RRS
CONTROL
MEASURES
N S L RRS
REMARKS
(OCP/
IP/
CT)


R : Routine NR :Non-Routine RRS : Risk Rating Score N : Number S : Severity L : Likelihood
OCP : Operational Control Procedure IP : Improvement Programme CT : Critical Task


RECORD R-2/22 : CRITICAL TASK ANALYSIS WORKSHEET

Department
Date:
Occupation
Reviewed By:
Task
Approved By:

Sr.
No
Task Steps Specific Loss Exposure Improvements/Suggestions Recommended Controls




























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 23


Version 1.0 Page 1 of 4
ITD Cementation India Ltd














PROCEDURE P-23 : LEGAL COMPLIANCE EVALUATION


















VERSION NO. 1.0

ISSUE DATE 1 J ULY 2005




APPROVED BY




DIRECTOR & GENERAL MANAGER OPERATIONS






















INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 23


Version 1.0 Page 2 of 4
ITD Cementation India Ltd

1.0 PURPOSE

This procedure shall be followed for ensuring compliance with legal and other
non-regulatory requirements related to environmental aspects and occupational
safety and health risks.

2.0 SCOPE

The procedure shall be applicable to all activities of ITDCEM at :
Project Sites;
Depots; and
Offices.

3.0 RESPONSIBILITY

Project In Charges at Sites, Depots Head, and BU Head Administration shall be
responsible for ensuring compliance with legal and non-regulatory requirements
in areas under their control.

Information on compliance with legal and non-regulatory requirements shall be
compiled and submitted to Top Management through MR as follows:
Corporate Head Environmental : Environment;
Corporate Head Safety : Occupational Safety and Health Risks; and.

4.0 DEFINITIONS
Nil

5.0 PROCEDURE

Project In Charge at Sites, Depots Head, and BU HOD HR shall:

Obtain relevant permissions from regulatory authorities;
Ensure that the conditions stipulated in the permissions are strictly
adhered to;
Ensure that mandatory inspections are carried out and records are
maintained;
Ensure that mandatory measurement and monitoring is carried out and
records are maintained;
Ensure that mandatory information is displayed;
Ensure that PPEs as also infrastructure for hazard prevention and control
are provided; and
Ensure that relevant reports are sent and returns are filed on time.

Project Incharge shall maintain record of compliance in form R-1/23.

6.0 CROSS REFERENCES
ISO 14001, Clause No. 4.5.2
IMS-Manual : Section 5.2























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 23


Version 1.0 Page 3 of 4
ITD Cementation India Ltd
7.0 RECORDS
R-1/23: Legal Compliance Register

8.0 RECORDS AVAILABILITY
R-1/23 - for Site/Depot / Office Project In Charge / Head Depot / Head
Administration
R-1/23 for BU - AMR BU
R-1/23 for Corporate Corporate Head Environment and Corporate Head
Safety

9.0 RECORD RETENTION
As per Procedure P-2.























INTEGRATED MANAGEMENT SYSTEM PROCEDURES
PROCEDURE P- 23


Version 1.0 Page 4 of 4
ITD Cementation India Ltd

RECORD R-1/23 : LEGISLATIVE COMPLIANCE REGISTER

Project No /Depot : Date :

Sr.
No.
Identified Acts
& Rules
Regulatory
Agency
Obligation Compliance
Review

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