Quality Basic Concept

Quality Basic Concept
and Implementation
14 June 2006
Tripatra Fluor Consortium
QAQC Departement
TF Main Office-Duri, Sumatra
© Chevron 2005 DOC ID

Wellcome
to
Flexible Program Management

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Content:
What is Quality?
Quality in TF FPM Practice

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Quality:
What ?
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How do we make things better?

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CONTINOUS IMPROVEMENT
Quality begins with the PDCA cycle and an

understanding of variation --not with ISO 9001
DALE K. GORDON is director of quality and business improvement for Rolls-

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

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Plan : Identify an opportunity and plan for change.
Do : Implement the change on a small scale.
Check : Use data to analyze the results of the change and

determine whether it made a difference.
Act : If the change was successful, implement it on a wider

scale and continuously assess your results. If the change
did not work, begin the cycle again.

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ISO 9000:2000 defines:
System is :
“ a set of interrelated or interacting elements" (clause

3.2.1)
Quality Management System is:
"a management system to direct and control an

organization with regard to quality" (3.2.3)

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Process
Product Spec
&
Activities Customer
Needs
Knowledge
The system is a culmination of whatever the organization

says it is through the processes, activities and knowledge
it uses to meet product specifications and customer needs
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THE COST OF QUALITY
The “cost of quality” is NOT the price of creating a quality

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

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THE COST OF QUALITY
Every time work is redone, the cost of quality increases. Obvious

examples include:
 The reworking of a fabricated item.
 The retesting of an assembly.
 The correction of an invoice statement, report.
 The reworking of a service, such as welding, building,

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

quality were perfect contributes to the cost of quality.
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Quality:
Who ?
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QUALITY CONTROL AND QUALITY
ASSURANCE
Assurance:
The act of giving confidence, the state of being certain or the act of making
certain.
Quality assurance:
The planned and systematic activities implemented in a quality system so that
quality requirements for a product or service will be fulfilled.
Control:
An evaluation to indicate needed corrective responses; the act of guiding a
process in which variability is attributable to a constant system of chance
causes.
Quality control:
The observation techniques and activities used to fulfill requirements for quality.

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ASSURANCE
Function in quality can vary from one organization to another. Nevertheless, a few primary job
classifications are consistent, regardless of industry or organization:
 Analysts initiate and/or coordinate quality-related data from

production and service activities and report these data using
statistical techniques.
 Associates are involved in quality improvement activities or
projects but not necessarily full-time.
 Auditors systematically inspect and examine a quality system to
ensure compliance to requirements.
 Inspectors audit and report on materials, processes and products
using variable or attribute-measuring instruments and techniques,
to ensure conformance with the organization’s quality standards.

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ASSURANCE
 Quality engineers design, install and evaluate quality-assurance

process-sampling systems, procedures and statistical techniques; design
or specify inspection and testing mechanisms and equipment; analyze
production and service limitations and standards; recommend revision
of specifications when indicated; and formulate quality assurance
policies and procedures.
 Quality managers oversee the administration of quality, process
and/or business improvement efforts. They typically have authority over
a clearly defined area of the organization and a number of direct
reports.
 Specialists perform specific functions within a quality initiative, such as
statistical analysis or testing. They have extensive experience or
training.
 Technicians perform basic quality tasks to track, analyze and report on
materials, processes and products, ensuring they meet organizational
standards.

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Content:
Quality in TF FPM Practice

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KEY ISSUES
CPI & TF Management Expectations from Kick-off Meeting (20May05)
Mutual Expectation:
Safety, Cost and Quality

are the three key
elements to our success

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QUALITY BARS
Q
ytil a u Q
COS/ FPM
CS/
RC

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KEY ISSUES
Is FPM CONTRACTOR delivering
© Chevron 2005
 High Quality,
 Competitively priced work,
 Safely and on time
DOC ID
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?
Q
TF FPM QUALITY SYSTEM GENERAL
+
Operating
Proven System
Processes & Requirements
Procedures
The TF Quality Program is based on

the FLUOR Operating System
Requirements (OSR) and Tripatra’s
proven process & procedure

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PROJECT
EXECUTION
PLAN
Content of
TF Project
Execution Plan

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QUALITY
MANAGEMENT
SYSTEM
Quality Management
System is
the shared
responsibility of all
project team members
–
Engineer
Designer
Supplier/
Subcontractor,
Field personnel
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QUALITY
MANAGEMENT
SYSTEM
Content of
Quality
Managements
System
List of the forms

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QUALITY PLAN
Quality Plan establishes

top-level quality
assurance program
requirements –
References detailed
implementing
procedures, practice and
plans

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TF DELIVERABLES LIST
Content of
Quality
Managements
System
Contract
Deliverables
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HOW QUALITY IS ACHIEVED IN TF FPM
ORGANIZATION
FPM CONTRACTOR
TF TF TF CONST TF CONSTRUCTION
ENGINEERING SUPPLY CHAIN SUPERVISION/ EQUIPMENT
MANAGEMENT SUBCONTRACTOR
DESIGN
E P C CM
MAINTENANCE,
ENGINEERING PROCUREMENT CONSTRUCTION REPAIR,
RECONDITION
QUALITY
ACTIVITY QUALITY QUALITY
CONTROL/
QUALITY ASSURANCE/ CONTROL/ QUALITY
SURVEILLANCE
PLAN SURVEILLANCE ASSURANCE
QUALITY AUDITS

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QA/QC ORGANIZATION
This group is responsible for verifying the quality throughout all
FPM Contractor activities
Project QA/QC Manager
Charles J. Brazel
Technical Assistant
Lydia Fanny
Supply Chain Management
Audits Quality Assurance- Contract

M. Satir Hasibuan Zulkarnain H., Budi Purwanto
Sastro Kuncung Quality Assurance- Procurement
Kiagus Ismail Hamzah
Vendor/Supplier Quality Surveillance
Overall Quality System Control As required by WA
HO SLN SLS CEM HO & SLN

Quality Surveillance Quality Surveillance Quality Surveillance Quality Inspector NDE Coordination
Edward Delta Ananda Brammie D.K (vacant) Taufiq Rahman
SLS
QC Inspectors QC Inspectors QC Inspectors NDE Coordination
Construction
Equipment
Site Construction QC Surveillance & Testing Maintenance
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How Quality is cascaded down to TF
Subcontractor

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TF Subcontractor’s Quality Plan
All Subcontractors performing work on the FPM Project shall

implement specific Quality Program adequate for the FPM project
quality management needs and requirements
CPI User + DOA

FPM Contractor
TF Contracts TF QA/QC TF Subcontractor
Comply with
Tender Process •Review Quotation Exhibit-F
Develop •Pre Bid Meeting (Subcontractor’s
WAF -Exhibit F quality
-Specification requirement)
(CPI, Codes, etc) •Site Surveillance &
•Audits Specification

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Table of Contents
Quality Requirements for FPM Subcontractors
1.1 Quality Plan

1.2 Quality Objectives
1.3 Construction
1.3.1 Organization
1.3.2 Field Design Change Control
1.3.3 Purchasing
1.3.4 Document Control
1.3.5 Identification and Traceability of Equipment and Material
1.3.6 Inspection and Testing
1.3.7 Inspection, Measuring and Test Equipment
1.3.8 Quality Process Control
1.3.9 Inspection and Test Status Procedures & Reporting
Requirements
1.3.10 Control of Non-Conformance
1.3.11 Material and Equipment Receiving, Handling, Storage and
Maintenance
1.3.12 Quality Records
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DOCUMENT HIERARCHY
CTOP-400
Data Sheets
CPI Specification
TF FPM Specifications
Referenced Codes and Standards
Approved for Construction Drawings
Vendor/Supplier/Subcontractor Standards

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QUALITY : in TF FPM Practice
Contract Awarded Work Execution
1. Develop Quality Plan

1. Planning the 2. Develop Procedures Develops the
3. Develops the generic ITP
Work 4. Establish Quality Organization specific ITP
Executethe work
2. Work out the Implementation of
based on the
Plan the Quality Plan
specific ITP
3. Document your Quality Records Record Inspection

work Documentation and Test Report
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TF Subcontractor’s Quality Implementation
Share Quality Responsibility
TF Subcontractor
Quality Org
TF Quality Org
1. Develop Quality Plan
1. Review and approve Quality Plan
1. Planning the 2.
3.
Develop Procedures
Develops the generic ITP
2. Review Procedures
3. Review the ITP
Work 4. Establish Quality
4. Review Quality Personnel
Organization
Implementation of the 1. Quality Assurance

2. Work the Plan Quality Plan, Procedures, 2. Site Surveillance
ITPs 3. Priodically Audits
Records of Inspection and

3. Documenting Assure and Audit Quality
Testing Report, Projects
the work Records Documentation
Document

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When you are as the TF FPM Subcontractor

and get the Work Order/Requisition, what
will you do ?
Deliver the service in Quality

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TF FPM Subcontractor TF
Construction Services
Service Provider Customer
Control Control
No
Activities Reference/ Acceptance Hold/ Witness/
Spot Witness
Hold/ Witness/ Spot
Witness
Document Criteria

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TF FPM Subcontractor TF
Construction Services
Service Provider Customer
1. Planning the Work

Control
2. Work out the Plan Hold/ Witness/ Spot
Witness
3. Document Your Work

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In order to deliver the Quality

Service You have to:
1. Plan your work
2. Work your plan
3. Documentation

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1. Plan your work
- Read & Examine and socializes the Work Requsition
among the crew team
- Prepare Inspection and Test Plan (ITP) and socializes
among the crew team
- Prepare and/or develop work procedure
- Prepare other documents (JSA, GWP, etc)
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2. Work your plan
- Execute the work to follow the Work Requsition’s scope

- Execute the work to follow the Inspection and Test Plan
(ITP)
- Execute the work to follow the work procedure
- Work beyond the JSA, GWP,

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3. Documentation
- Progress Report on the Work Requsition’s scope

- Testing & Inspection Report based on the ITP
- Improve the work procedure based on the best practice
during the execution

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QUALITY : What ?
Then...
TF FPM will feel?
Satisfy
Happy to pay as the invoice
Happiness  Long term relationship

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END
Thank You
TF FPM hand in hand to reach our goal
Deliver the service On time,

Efficiently, Safe with high
Quality
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Content
Site Coordination with

Construction Group

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SITE COORDINATION
CPI Construction
Representative
CS
Sr. QC Inspector
Superintendent
QC Inspector CS Engineer
FPM Subcontractor
Coordination Line
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SITE COORDINATION
- Work Requisition Process Flow-
CPI User TF CS & PC TF QA/QC TF Subcontractor
Check SOW and data

Issue WR F002
completeness
Receive TF’s WR, and
review
No Data Received copy for
Complet info and quality
Data No
e? control
Complete
Yes implementation
?
No Re write a TF’s WR to Yes
Subcont, supervise job
Execute TF’s WR
and distribute copy to TF
Job PC, QC, HES
complete
No
d? TF’s WR
Get WR F002 completion Sign for QC Complete?
Yes approval from CPI acceptance
Yes
Compile Report and get

Sign for TF’s WR completion approval
Close by signing total completion
WR F002 and return to
Subcontractor Back up data for
invoicing

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SITE COORDINATION
- Inspection & Test Plan (ITP) Flow-
CPI User TF CS Engineer TF QC Inspector TF Subcontractor
Review Develop ITP
No Revise
Accept?
Yes
Get input from User and
User to identify CS to identify hold Copy and distribute to
CS on inspection
Yespoints
hold and witness and witness points CS & QC
and return to
points
Subcontractor
Supervise the Project Execution

project to follow Quality Control & ITP
the ITP & Surveillance Implementation
procedures based on ITP
Yes Yes Respond to NCR

Supervise the
corrective action NCR and implement
implementation corrective action
No
Surveillance Report

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SITE COORDINATION
- Request for Information (RFI) Process Flow-
TF Engineering TF CS Engineer TF QC Inspector TF Subcontractor
Initiate RFI
Received &
Review
Yes Need No
Design
Engineerin
g Support.?
Respond to RFI Respond to RFI
Accept and
Transmit to
Log Implement
Subcontractor
Get Info and

Copy to QC and
verify Log
log
implementation

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SITE COORDINATION
- Non Destructive Examination (NDE) Process Flow-
TF Subcontractor TF CS Engineer TF NDE Testing TF Subcontractor

Construction Coordinator NDE Service (SCI)
Check Job Receive order

Finished Job Review request and
Completion and
Execution Determine NDE &
Request NDE to
Requiring NDE order NDE Service Testing
TF QC Inspector
No
Verify Report Test Accept?
Yes
Instruct No
Repair the job Subcontractor to Job Pass QC?
repair the job Interpretation and
Report
Yes
Accept job
completion
Send copy to CPI
Regular reporting
for information
on data base,
Data Base Report weekly and
Evaluation monthly
Data Base Report
Evaluation

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Flexible Program Management