PAR CAR NCR Presentation 1

PAR’s CAR’s and PAR’s CAR’s and NCR’sNCR’s

THETHE

PREVENTATIVE & CORRECTIVE PREVENTATIVE & CORRECTIVE ACTION PROCESSACTION PROCESS

PAR’s CAR’s & NCR’sPAR’s CAR’s & NCR’s

Contractors and its Sub-Contactors are Contractors and its Sub-Contactors are committed to use a (QUALITY committed to use a (QUALITY MANAGEMENT SYSTEM) (MANAGEMENT SYSTEM) (QMSQMS))

Based on the ISO 9000-2000 standard Based on the ISO 9000-2000 standard QMSQMS is defined as “ is defined as “ AA Management Management system to direct and control an system to direct and control an ORGANIZATONORGANIZATON with regards to with regards to QUALITYQUALITY””

PAR’s CAR’s & NCR’sPAR’s CAR’s & NCR’s

WHAT IS AN ORGANIZATION?WHAT IS AN ORGANIZATION?

CONSISTS OFCONSISTS OFPEOPLEPEOPLEPROCESSESPROCESSESMATERIALSMATERIALSEQUIPMENTEQUIPMENTRESOURCESRESOURCES

PAR’s CAR’s & NCR’sPAR’s CAR’s & NCR’s

WHAT DO THEY MEAN?WHAT DO THEY MEAN?

Documents to Control potential and actual Documents to Control potential and actual non-conforming products or processesnon-conforming products or processes

PAR - PREVENTATIVE ACTION REQUESTPAR - PREVENTATIVE ACTION REQUESTCAR - CORRECTIVE ACTION REQUESTCAR - CORRECTIVE ACTION REQUESTNCR - NON CONFORMANCE REPORTNCR - NON CONFORMANCE REPORT

PAR’s CAR’s & NCR’s PAR’s CAR’s & NCR’s

WHY DO WE NEED THEM?WHY DO WE NEED THEM?To allow tracking of any potential or actual non-To allow tracking of any potential or actual non-conformities or break down in a processconformities or break down in a processTo give us the opportunity to mitigate against To give us the opportunity to mitigate against risk by giving an early warning about non-risk by giving an early warning about non-conforming product conforming product To establish trends which can be monitored and To establish trends which can be monitored and allow an organization to focus on those areas of allow an organization to focus on those areas of a QMS which potentially may not meet the a QMS which potentially may not meet the required standardsrequired standards

RECIPIENT WEEK No PAR

Issued OPEN CLOSED Recipient week

CAR issued

open closed Issued by WeekNCR Open

OPEN CLOSED

Subcon 1 Subcon 5 27 1 1 Subcon 2 40 3 3

20 2 2 24 1 1 4321 1 1 45 1 1 Company 44 1 1

22 1 1 Subcon 6 21 1 1 Grand Total 4 431 1 1 Grand Total 4 1 334 1 136 3 1 2

39 2 1 140 1 141 1 142 1 143 2 245 2 2

Subcon 1Total 18 4 14

Subcon 231 1 1

Subcon 2 Total 1 1

Subcon 341 1 144 1 145 1 1

Subcon 3 Total 3 1 2

subcon443 1 1

Subcon 4 Total 1 1

Grand Total 23 5 18

PAR Status CAR Status

subcon1

NCR Status

PAR Status

0

1

2

3

4

20 21 22 31 34 36 39 40 41 42 43 45 31 41 44 45 43

Subcon 1 Subcon 2 Subcon 3 Subcon 4

CLOSED OPEN

PAR Issued

PAR’s CAR’s & NCR’sPAR’s CAR’s & NCR’s

What’s the difference???What’s the difference???

PAR’s and CAR’s are primarily used to PAR’s and CAR’s are primarily used to control a potential or actual BREAKDOWN control a potential or actual BREAKDOWN IN A PROCESS BEFORE OR DURING IN A PROCESS BEFORE OR DURING THE PROCESS.THE PROCESS.

NCR’s are used to identify a Non NCR’s are used to identify a Non Conforming Product and prevent it being Conforming Product and prevent it being included in the completed facilityincluded in the completed facility

PAR’s CAR’s & NCR’sPAR’s CAR’s & NCR’s

These are maintained as part of the Project These are maintained as part of the Project QMS and there use and implementation QMS and there use and implementation

are defined in Project Specificationsare defined in Project Specifications XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX PROJECT PROJECT

CORRECTIVE AND PREVENTATIVE CORRECTIVE AND PREVENTATIVE ACTIONACTION

XXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXX CONTROL OF NON CONFORMING CONTROL OF NON CONFORMING

MATERIAL AT SITEMATERIAL AT SITE

PAR’s CAR’s & NCR’sPAR’s CAR’s & NCR’s

DEFINITION?DEFINITION?

PAR (PREVENTATIVE ACTION PAR (PREVENTATIVE ACTION REQUEST)REQUEST)THIS DOCUMENT OUTLINES THE THIS DOCUMENT OUTLINES THE ACTIONACTION TO BE TO BE TAKEN TO ELIMINATE THE CAUSES OF TAKEN TO ELIMINATE THE CAUSES OF POTENTIALPOTENTIAL NONCONFORMITIES OF A PRODUCT, PROCESS OR NONCONFORMITIES OF A PRODUCT, PROCESS OR THE PROJECT QUALITY MANAGEMENT SYSTEM THE PROJECT QUALITY MANAGEMENT SYSTEM DURING ENGINEERING, PROCUREMENT, DURING ENGINEERING, PROCUREMENT, CONSTRUCTION AND MECHANICAL COMPLETIONCONSTRUCTION AND MECHANICAL COMPLETIONTHE KEY WORDS IS PREVENTATIVE !!!THE KEY WORDS IS PREVENTATIVE !!!

PAR’s CAR’s & NCR’sPAR’s CAR’s & NCR’s

DEFINITION?DEFINITION?

CAR CORECTIVE ACTION REQUESTCAR CORECTIVE ACTION REQUESTTHIS DOCUMENT OUTLINES THE THIS DOCUMENT OUTLINES THE ACTION ACTION TO BE TO BE TAKEN TO ELIMINATE THE CAUSES OF TAKEN TO ELIMINATE THE CAUSES OF ACTUALACTUAL NONCONFORMITIES OF A PRODUCT, PROCESS OR NONCONFORMITIES OF A PRODUCT, PROCESS OR THE PROJECT QUALITY MANAGEMENT SYSTEM THE PROJECT QUALITY MANAGEMENT SYSTEM DURING ENGINEERING, PROCUREMENT, DURING ENGINEERING, PROCUREMENT, CONSTRUCTION AND MECHANICAL COMPLETIONCONSTRUCTION AND MECHANICAL COMPLETIONTHE KEY WORD IS CORRECTIVE!!!THE KEY WORD IS CORRECTIVE!!!

PAR’s & CAR’sPAR’s & CAR’s

WHO?WHO?

RESPONSIBILITIES – RESPONSIBILITIES –

PROJECT KEY PERSONNELPROJECT KEY PERSONNELSM/PM – SITE MANAGER/PROJECT MANAGERSM/PM – SITE MANAGER/PROJECT MANAGER

DSM – DEPUTY SITE MANAGERDSM – DEPUTY SITE MANAGER

CM – CONSTRUCTION MANAGERSCM – CONSTRUCTION MANAGERS

FEM – FIELD ENGINEERING MANAGERFEM – FIELD ENGINEERING MANAGER

SQM – SITE QUALITY MANAGERSQM – SITE QUALITY MANAGER

MCM – MECHANICAL COMPLETIONS MANAGERMCM – MECHANICAL COMPLETIONS MANAGER

PAR’s & CAR’sPAR’s & CAR’s

WHEN?WHEN? PARSPARS NCR’s from Suppliers/Sub-ContractorsNCR’s from Suppliers/Sub-Contractors During surveillance or audit of the QA systemDuring surveillance or audit of the QA system Review of documents including Review of documents including

Correspondence or MoM from Correspondence or MoM from Company/Owner Company/Owner

Inter office CorrespondenceInter office Correspondence Quality Audit reports, Quality Audit reports,

PAR’s & CAR’sPAR’s & CAR’s

WHEN?WHEN? CARSCARS

Complaints or NCR’s from Complaints or NCR’s from COMPANY/OWNERCOMPANY/OWNER

NCR’s from Suppliers/Sub-ContractorsNCR’s from Suppliers/Sub-Contractors During surveillance or audit of the QA systemDuring surveillance or audit of the QA system

PAR’s & CAR’sPAR’s & CAR’s

HOW?HOW?

The Key Project Personnel issue the The Key Project Personnel issue the CAR/PAR to the CONTRACTOR CAR/PAR to the CONTRACTOR Responsible Manager or Sub-Contractor Responsible Manager or Sub-Contractor Responsible Manager requesting Responsible Manager requesting Preventative or Corrective ActionPreventative or Corrective Action

PAR’s & CAR’sPAR’s & CAR’sThe Responsible Manager The Responsible Manager INVESTIGATESINVESTIGATES the POTENTIAL or the POTENTIAL or ACTUAL CAUSE ACTUAL CAUSE The Responsible ManagerThe Responsible Manager DETERMINES DETERMINES the PREVENTATIVE or the PREVENTATIVE or CORRECTIVE Action needed to eliminate CORRECTIVE Action needed to eliminate the cause the cause IMPLEMENTSIMPLEMENTS the Preventative or the Preventative or Corrective Action and sends it to the Key Corrective Action and sends it to the Key Project Personnel who originated the Project Personnel who originated the PAR/CARPAR/CAR

PAR’s & CAR’sPAR’s & CAR’sThe Key Project Personnel forwards the The Key Project Personnel forwards the PAR/CAR to the Site Quality Manager for PAR/CAR to the Site Quality Manager for CONFIRMATIONCONFIRMATION of of CLOSE-OUT CLOSE-OUT who who logs it the Quality System and forwards it logs it the Quality System and forwards it to the CLIENT/OWNER for informationto the CLIENT/OWNER for informationRECORDS MAINTAINED IN THE RECORDS MAINTAINED IN THE CAR/PAR LOGCAR/PAR LOG

NCR’sNCR’s

DEFINITION?DEFINITION? NCRNCRTHIS DOCUMENT DEFINES THE CONTROL THIS DOCUMENT DEFINES THE CONTROL OF PRODUCTS AT SITE THAT ARE DEFINED OF PRODUCTS AT SITE THAT ARE DEFINED AS DEFECTIVE OR AS DEFECTIVE OR DO NOT CONFORMDO NOT CONFORM TO TO SPECIFIED REQUIREMENTS TO PREVENT SPECIFIED REQUIREMENTS TO PREVENT THE UNINTENDED USE IN THE COMPLETED THE UNINTENDED USE IN THE COMPLETED FACILITIESFACILITIESTHE KEY WORDS ARE NON-CONFORMING!!THE KEY WORDS ARE NON-CONFORMING!!

NCR’sNCR’s

EXAMPLES OF NCR’sEXAMPLES OF NCR’sThe product does not conform to a technical or The product does not conform to a technical or material requirement even if repair can restore it material requirement even if repair can restore it to a condition such that its function is unimpairedto a condition such that its function is unimpairedS/Contractor does not comply with requirements S/Contractor does not comply with requirements in construction documentsin construction documentsA product contains a major defect that prevents A product contains a major defect that prevents its useits useA product which is used without repair or reworkA product which is used without repair or reworkDamage to equipment during handlingDamage to equipment during handlingSerious discrepancy between construction Serious discrepancy between construction documentsdocuments

NCR’sNCR’s

WHO?WHO?RESPONSIBILITIES OVERALLRESPONSIBILITIES OVERALLTHE SITE FEMTHE SITE FEM IS RESPONSIBLE FOR THE OVERALL IS RESPONSIBLE FOR THE OVERALL CONTROL OF NCR’s AND DETERMINING or CONTROL OF NCR’s AND DETERMINING or AGREEING THE DISPOSITION AGREEING THE DISPOSITION CMCM IS RESPONSIBLE FOR CONTROLLING THE NON IS RESPONSIBLE FOR CONTROLLING THE NON CONFORMING PRODUCT(MATERIALS MANAGER IF CONFORMING PRODUCT(MATERIALS MANAGER IF NOT YET ISSUED)NOT YET ISSUED)SQMSQM IS RESPONSIBLE FOR CONTROLLING FOR IS RESPONSIBLE FOR CONTROLLING FOR AGREEING THE DISPOSITION WITH THE FEM AND AGREEING THE DISPOSITION WITH THE FEM AND ENDURING INSPECTION OF THE PRODUCT WHICH ENDURING INSPECTION OF THE PRODUCT WHICH IS REPAIRED/REWORKED or REPLACEDIS REPAIRED/REWORKED or REPLACED

NCR’sNCR’s

WHEN ?WHEN ?RESPONSIBILITIES IN THE FIELDRESPONSIBILITIES IN THE FIELDIF AN INSPECTOR/SUPERVISOR DETECTS IF AN INSPECTOR/SUPERVISOR DETECTS OR IS INFORMED OF AN NON CONFORMING OR IS INFORMED OF AN NON CONFORMING PRODUCT THEY SHALL INFORM THE PRODUCT THEY SHALL INFORM THE S/CONTRACTOR TO KEEP “AS IS” AND TO S/CONTRACTOR TO KEEP “AS IS” AND TO ISSUE AN NCR TO CONTRACTOR FEMISSUE AN NCR TO CONTRACTOR FEMTHE S/CONTRACTOR SHALL THE S/CONTRACTOR SHALL IDENTIFY/MARK/TAG THE ITEM AND TAKES IDENTIFY/MARK/TAG THE ITEM AND TAKES PRECAUTIONS TO ENSURE IT IS PRECAUTIONS TO ENSURE IT IS SEGREGATED FROM OTHER MATERIALSSEGREGATED FROM OTHER MATERIALS

NCR’sNCR’s

WHAT HAPPENES NEXT ?WHAT HAPPENES NEXT ?FEM RECEIVES NCR FROM COMPANY/OWNER OR FEM RECEIVES NCR FROM COMPANY/OWNER OR S/CONTRACTOR, DETEMINES DISPOSITION S/CONTRACTOR, DETEMINES DISPOSITION FOLLOWING REVIEW AND EVALUATION & FOLLOWING REVIEW AND EVALUATION & AGREEMENT WITH SQMAGREEMENT WITH SQM

REJECT & REPLACMENT WITH A NEW PRODUCTREJECT & REPLACMENT WITH A NEW PRODUCT REWORK/REPAIR TO MEET SPECREWORK/REPAIR TO MEET SPEC REPAIR AND RECLASSIFY FOR ALTERNATE USEREPAIR AND RECLASSIFY FOR ALTERNATE USE USE “AS-IS”USE “AS-IS” REPAIR & USE “AS-IS “ REQUIRE COMPANY REPAIR & USE “AS-IS “ REQUIRE COMPANY

APPROVALAPPROVAL

NCR’sNCR’s

CLOSE-OUTCLOSE-OUTSQM RECEIVES CLOSE OUT REPORT SQM RECEIVES CLOSE OUT REPORT TOGETHER WITH ANY INSPECTION TOGETHER WITH ANY INSPECTION RECORD/EVIDENCE AND ISSUES TO RECORD/EVIDENCE AND ISSUES TO CLIENT/OWNER/FEM/CMCLIENT/OWNER/FEM/CMFEM ISSUES RELEASE NOTICE FEM ISSUES RELEASE NOTICE THROUGH SQM TO ALL PARTIESTHROUGH SQM TO ALL PARTIESSQM MAINTAINS RECORD IN THE NCR SQM MAINTAINS RECORD IN THE NCR LOGLOG

PAR’s, CAR’s, NCR’sPAR’s, CAR’s, NCR’s

REMEMBER! -REMEMBER! - ALL OF THIS ALL OF THIS PAPERWORK IS RAISED TO IDENTIFY PAPERWORK IS RAISED TO IDENTIFY A FAILURE IN A PROCESS OR A FAILURE IN A PROCESS OR PRODUCT - THE PROJECT IS NOT PRODUCT - THE PROJECT IS NOT BUILT BY PAPER – BUILT BY PAPER – ITS BETTER TO ITS BETTER TO STOP FAULTS THROUGH GOOD STOP FAULTS THROUGH GOOD CONSTRUCTION PRACTISE AND CONSTRUCTION PRACTISE AND GOOD QUALITY CONTROL IN THE GOOD QUALITY CONTROL IN THE FIRST PLACE!!!!!!!FIRST PLACE!!!!!!!

QUESTIONS ?QUESTIONS ?