PROCESS CONTROL

Quality Management System

PROCESS CONTROL

CONTENTS

1.0 PURPOSE & SCOPE

2.0 DEFINITIONS

3.0 FLOWCHART

4.0 PROCEDURAL TEXT

5.0 REFERENCES

6.0 ATTACHMENTS

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reserved in respect of it. This document may not be reproduced or disclosed in any manner
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PT Thiess Contractors Indonesia expressly disclaims any responsibility for or liability arising from the
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Revision Status

Issue/ Date Revision Description By Checked Checked Approved

Rev.

A2 June 97 Original Issue R.Liong RW RW DGS

A3 October 99 TMS Review ES RL BAM

A4 May 00 TMS Intranet Version ES RW RL BAM

A5 Nov 00 TMS Review ES RO BAM

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Quality Management System

1.0 PURPOSE AND SCOPE

The purpose of this procedure is to control production of the product in a formal
systematic manner:, by which production/process is monitored and controlled by the
application of Management (Quality) Plans, Project Procedures, Work Procedures and
Inspection and Test Plans.
This procedure shall apply to all projects undertaken by the company and to those
processes identified as critical to quality, where the absence of such procedures would
adversely affect quality.

2.0 DEFINITIONS
System Procedures (SP) Procedures describing the
operating system (ie. the Rule book) by which
PT. Thiess Contractors Indonesia carries out
its business.

System
Procedures are produced by each Business
Unit for their individual Business Unit/Project
use.

Project Procedures (PP) Procedures, normally modified

System Procedures (SP), developed on a
project to incorporate project specific details.

Work Procedures (WP) Work Procedures define the

sequential method of production detailing
criteria for workmanship, equipment to be
utilised, verification activities and related
authorities/ responsibilities.

Inspection and Test Plans (ITP) A document of formalised plan

describing how, when and where the
characteristics of products/works will be
inspected, tested or measured to provide
evidence that design, regulatory and
contractually specified requirements have
been met.

Special Processes For work of which the

results cannot be fully verified by subsequent
inspection and testing, and where continuous
monitoring and/or compliance with
documented procedures is required to ensure
that the specified requirements are met.

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 PROCESS CONTROL
Quality Management System

QAE / System Engineer The project person(s)

nominated by the Project Manager to be
responsible for the establishment and
management of the Project Systems and QA
regime (or specific part/function thereof).

Risk Management The set of ongoing

management and technical activities for
ensuring that risks are effectively identified,
understood, and minimised to a reasonably
achievable, tolerable level. The activities
include feedback mechanisms and continuing
performance monitoring.

3.0 FLOWCHART

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Quality Management System

3.0 FLOWCHART
TCI-OPS-SP003-FC3.1/A1 TCI-QUC-SF001
TCI-QUC-SF012 TCI-QUC-SF013
Process Control INCOMING INSPECTION
CHECKLIST
VERIFICATION PROCEDURAL
CHECKLIST CHECKLIST

TCI-OPS-SP005
PROCESS CONTROL
ENSURE INCOMING
PP
MATERIALS / PRODUCTS
COMPLY WITH SPECIFIC
FILE SUITE OF MANAGEMENT PLANS PM/QAE REQUIREMENTS, PRIOR TO USE
DETERMINED AT THE CONTRACT / INSTALLATION
HANDOVER MEETING IN PMS TCI-QUC-SF001
FOLDER(S) INSPECTION & TEST
PLAN
IMPLEMENT THE APPROVED PP
TCI-TEN-SP001 WORK PROCEDURE /
TENDER AND SUBCONTRACT PACKAGE QAE/PE
CONTRACT REVIEW REINSURE WP IF NECESSARY AND
CONTINUE MONITORING OF PROCESS
DETERMINE IF ANY SPECIFIC PPR's PM/QAE
OR MODIFICATIONS TO SP's ARE
REQUIRED IDENTIFY, ORGANISE AND QAE/PE
CONDUCT AUDITS PP
COMPLETE WORK / SUBCONTRACT
INSPECTIONS AND TESTS
WITHIN THE WORK CYCLE PACKAGE
IAW THE ITP
PM
BREAKDOWN THE PROJECT INTO
SEPARABLE PARTS OR ELEMENTS
OF WORK / TRADES QAE/PE
COLLATE ALL DATA FROM AUDITS,
COMPLETE PROCEDURAL QAE/PE PROCESS CONTROL INSPECTIONS,
CHECKS / SURVEILLANCE AS PRODUCT INSPECTION AND TESTS ETC
THE WORKS PROCEED AND DETERMINE IF WORK IS IN
CONFORMANCE WITH SPECIFICATION
QAE REQUIREMENTS
DETERMINE TRACEABILITY
REQUIREMENTS - BOTH CLIENT
AND THIESS

QAE/PE
MONITOR THE PERFORMANCE
TCI-PRO-SP001 OF THE PROCESS. MONITOR
PROCUREMENT OF SUBCONTRACTOR
PRODUCTS AND SERVICES PERFORMANCE BY
SURVEILLANCE AND AUDIT DOES THE WORK
NO
CONFORM?
PM/PP
DEVELOP AND DOCUMENT AS A
PPR, A UNIQUE LOT NUMBERING
SYSTEM AND APPLY TO PROJECT YES
TCI-OPS-SF006 TCI-OPS-SF016
DOCUMENTATION COMPLIANCE
PROCESS CONTROL
CHECKLIST AUDIT CHECKLIST
QAE
TCI-OHS-SP019
FILE RECORDS IAW PROJECT
RISK MANAGEMENT
FILING INDEX

DETERMINE RISK FROM WORK PP

ELEMENTS AND RECORD.
IDENTIFY QP's, ITP's AND TCC-DOC-SP01
SURVEILLANCE PROCEDURES IS THE PROCESS / DOCUMENT AND
AND/OR CHECKLISTS AS SUBCONTRACTOR RECORD CONTROL
REQUIRED. YES
OPERATING
SATISFACTORILY? PM/QAE
DISPOSITION NON /PE
CONFORMANCE
TCI-ENV-SP001
TCI-OPS-SF014
ENVIRONMENT PLANNING
RISK ASSESSMENT
AND RISK MANAGEMENT
NO
TCI-QUC-SP005
CONTROL OF NON -
PM/QAE/PE QAE/PE CONFORMING PRODUCT
APPROVE, REGISTER AND REVIEW PROCESS SUBCONTRACTOR
ISSUE PP'S / WP'S / ITP'S / WORK METHODS AND ISSUE CAR IF
CHECKLISTS NECESSARY. REVIEW WP METHODS AND
AMEND IF NECESSARY. IF METHODS ARE
OK - ENSURE GREATER ADHERENCE TO
METHODS. IF ADHERENCE TO METHODS
TCI-ADM-SP001 IS OK REVIEW ACCEPTANCE CRITERIA.
DOCUMENT AND RECORD
CONTROL LEGEND

PM PROJECT MANAGER
QAE QUALITY ASSURANCE ENGINEER
PP PE PROJECT ENGINEER
COORDINATE NECESSARY
PP PROJECT PERSONNEL
DOCUMENTATION AND CONDUCT PMS PROJECT MANAGEMENT SYSTEM
WAB's AS APPROPRIATE. RECORD QP SPECIFIC WORK PROCEDURES
ISSUE OF CONTROLLED DOCUMENTS IAW IN ACCORDANCE WITH
SP SYSTEM PROCEDURES
PPR PROJECT PROCEDURES
WP WORK PROCEDURES
ITP INSPECTION AND TEST PLANS
TCI-ADM-SF001 WAB WORK ACTIVITY BRIEFING
DOCUMENT TCI-OPS-SF007 CAR CORRECTIVE ACTION REQUEST
DISTRIBUTION WAB CHECKLIST PROCEDURE REFERENCE
REGISTER FORM REFERENCE

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4.0 PROCEDURAL TEXT

4.1 General

4.1.1 The application of a Project Management (Quality) Plan developed in

accordance with TCI-OPS-SP001 "Preparation of Management (Quality)
Plans" is the primary mechanism used to assure both company and Client
quality requirements are met.

4.1.2 All projects as a minimum shall develop, implement and maintain a Project
Management (Quality) Plan The Project Management (Quality) Plan
requirements are identified and acknowledged by the Project Manager
during a Contract Handover Meeting conducted in accordance with TCI-
TEN-SP001 "Tender and Contract Review".

4.1.3 As the key document providing a systematic and controlled mechanism for
process control the Project Management (Quality) Plan makes reference to
the project sub-plans, project procedures, work procedures and inspection
and test plans applicable to the project.

4.1.4 Due to the confidentiality of project specific/technical documentation, the

project procedures, work procedures and inspection and test plans shall be
separated from the main body of the Project Management (Quality) Plan and
titled "Manual of Work Procedures" in accordance with TCI-OPS-SP001
"Preparation of Project Management (Quality) Plans".

The "Manual of Work Procedures" is not submitted to the Client unless

otherwise specified in the contract.

4.2 Project Procedures

4.2.1 The Project Manager shall ensure that the requirements for Project
Procedures (PP's) are identified in section 3.4 "Procedure Index" of the
Project Management (Quality) Plan.

4.2.2 The Quality Assurance Engineer (QAE) shall prepare Project Procedures in
accordance with the format requirements of TCI-QUA-SP002 "Preparation
and Control of Procedures".

Project Procedures shall be maintained in the "Manual of Work Procedures"

as defined in the Guideline for Project Management (Quality) Plan TCI-
OPS-GL001.

4.2.3 Numbering of Project Procedures shall be in accordance with the

requirements set out in TCI-QUA-SP003 "Numbering and Identification of
Quality System Documents".
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4.2.4 Where existing Quality System Procedures do not adequately address

project specific requirements, and the change required is minor and does not
warrant compilation of a Procedure, the QAE shall add project specific(s)
by means of addenda to the system procedure in Section 5 -Specific Process
Control Requirements of the Project Management (Quality) Plan.

4.3 Work Procedures

4.3.1 The Project Manager shall identify those processes which affect the quality
of the product and for which a Work Procedure (WP) shall be prepared.

i.) (i) Where the project is essentially executed by subcontracted trade

packages, the Project Manager shall determine the extent to which work
procedures apply.

ii.) (ii) The Purchasing Officer shall ensure that procurement documents
prepared in accordance with TCI-PRO-SP001 - "Procurement of
Products and Services", reflect appropriate requirements for process
control.

4.3.2 Typical work procedures (commonly known as method statements) may

include:

Excavation and Embankment Fill; Concrete Construction; Structural

Steelwork; Brickwork and Blockwork; Building Finishes; Pipelaying and
associated operations.

4.3.3 The Project Engineer/Quality Assurance Engineer (QAE) in conjunction

with the project superintendent and or supervisor shall plan and prepare the
work procedures (method statements). The work procedure shall define all
the construction activities and shall include the following:

(i) sequence of operations;

(ii) types of plant and equipment to be used;

(iii) necessary controls over working environments;

(iv) special work methods to be employed;

(v) materials;

(vi) batches and/or lot identification;

(vii) standards and tolerances acceptable in the workmanship;

(viii) to whom authority and responsibility for inspection, test and control
points has been delegated;
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(ix) any handling and storage packaging and shipping requirements. The
Project Manager shall review and approve the work procedures.

4.3.4 The Project Manager or nominee shall, where appropriate undertake a

prestart briefing with the workforce, Form TCI-OPS-SF007 - "Work
Activity Briefing Checklist", to ensure the understanding of the Work
Procedure and to deploy resources and allocate responsibilities using form
TCI-OPS- SF008 - "Action Plan".

4.3.5 The Site Engineer shall issue the approved work procedures to all relevant
project personnel, controlling the distribution by implementing TCI-ADM-
SF001 - "Document Register", or equivalent computer based register.

4.3.6 The QAE and/or the Project Engineer, shall evaluate the implementation of
the work procedures during the manufacture/ construction/installation
process or whenever unsatisfactory results are obtained, to ensure
compliance with the specified requirements, in accordance with form TCI-
OPS-SF006 - "Process Control Checklist". The frequency of the evaluations
shall be determined by the Project Manager.

4.3.7 Where the evaluation of work procedures demonstrate an inability to

comply, or the implementation may lead to defective work, the Project
Engineer/QAE shall in conjunction with supervisory personnel, revise and
issue an amended work procedure.

The QAE shall ensure all related quality documents, ITP, Checklists etc.
reflect, where appropriate, changes to work procedures.

4.3.8 Where there is a need to provide an objective evidence of

conformance from a product or service to the agreed standard or
specification, a formalised plan of Inspection and Testing (ITP) shall be
established. The purpose of the Inspection and Test Plan (ITP)/Checklist is
to assemble in one document all the testing and inspection requirements
(including subcontract requirements) in the sequence in which they will be
performed together with the documentation to be used to record the results,
relevant to a particular operation or element of work.
The responsibility and preparations of ITP shall be in accordance to TCI-
OPS-SP002”Preparation of Inspection and Test Plan”

4.4 Special Processes

4.4.1 Where special processes, (refer to Definition) including any

supplier/subcontractor requirements for Special Processes, have been
identified the Project Engineer/QAE or Subcontractor shall prepare a special
work procedure. Special work procedures are generally qualified versions of
standard work procedures.

4.4.2 Discretion shall be exercised if the supplier operates a certified quality

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system and for remote location work whereby the Project Manager may
accept previous work history and/or referral by other purchasers as proof of
acceptability of facilities.

5.0 REFERENCES
TCI-OPS-SP001 - Preparation of Project Management (Quality)
Plans
TCI-OPS-SP002 - Preparation of Inspection and Test Plan
TCI-TEN-SP001 - Tender and Contract Review
TCI-QUA-SP003 - Numbering & Identification of Quality System
Documents
TCI-ADM-SF001 - Document Register
TCI-OPS-SF006 - Process Control Checklist
TCI-OPS-SF007 - Work Activity Briefing Checklist
TCI-OPS-SF008 - Action Plan

6.0 ATTACHMENTS
Not Applicable to this procedure

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