Professional Documents
Culture Documents
: PEB-QP-J0B-
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CONTENTS
1 - SCOPE
2 - APPLICATION
3 - INTRODUCTION OF THE WORK
4 - MANAGEMENT COMMITMENT
5 - ORGANIZATION
6 COMMUNICATION
7 ENGINEERING AND DESIGN
8 - DRAWING AND DOCUMENT CONTROL
9 PURCHASING
10 MANUFACTURING PROCESS
11 - SPECIAL PROCESSES
12 PRODUCT IDENTIFICATION AND TRACEABILITY
13 MARKING AND CUTTING PROCESS
14 BULD UP MEMBER AND FITTING PROCESS
15 WELDING PROCESS
16 FINISHING PROCESS
17 BLASTING PAINTING PROCESS
18 INSPECTION AND TESTING
19 CONTROL OF NONCONFORMING PRODUCT
20 CORRECTIVE AND PREVENTIVE ACTION
21-STORAGE, PACKING, AND DELIVERY
22 -QUALITY RECORDS
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0. REVISION STATUS
0 Initial release
Signature
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1. SCOPE
2- APPLICATION
CUSTOMER :
NAME OF PROJECT :
DESCRIPTION OF ITEMS:
WORK VOLUME:
PERIOD OF MANUFACTURING:
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4. MANAGEMENT COMMITMENT
The management of PEB Steel Buildings Co. Ltd. has fully committed to
meeting all the specified requirements on time with high degree of quality.
The manufacturing and quality system requirement described in this
quality plan is based on PEB STEEL and international standards, design
and technical specification, and other contractual requirements.
All our employees are responsible for comply with this quality plan and for
the quality of work carried out on the manufacturing process of structures,
services and performance.
Operation Director, Mr. Adib Kouteili is responsible and has the authority
to organize, maintain and administer this quality plan and to ensure its
effective implementation.
Further all other key staff of our factory is given the responsibility and
authority to identify any problem and implement solutions to those
problems and to control the product quality at all stages of manufacturing.
This includes preventing dispatch defective, nonconforming and
unsatisfactory products to customer until satisfactory corrective action has
been taken.
Each process group is required to implement this quality plan in each area
of their responsibility.
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5. ORGANIZATION
QC SUPERVISOR &
QUALITY DEPT. HEAD INSPECTORS
SHIPPING /PURCHASING
SUPERVISOR &
LOGICSTIC & PURCHASING FOREMAN
MANAGER
CUSTOMER SERVICE
CUSTOMER SERVICE ENGINEER/SUPERVISOR
DIRECTOR
MANAGER
Mr. ADIB KOUTEILI
ACCOUNTANT
CHIEF ACCOUTANT
IT SUPERVISOR IT TECHNICIANS
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6- COMMUNICATION
Mr.Adib Kouteili
Director
Ho Chi Minh City Office
Unit 701, 7th Floor, City Plaza,
60A Truong Son St.,
Tan Binh Dist, HCMC
Tel: (84) 8 847 5475 / 997 5975
Fax: (84) 8 847 6476 / 9975157
7.1 PEB design department shall take the responsibility of the following related to:
a. Design development
b. Identifying and documenting any statutory and regulatory requirements
c. Review of the selection of design input requirements
d. Resolving incomplete, ambiguous or conflicting requirements
e. Documenting the design output
f. Design calculations
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g. Design analysis
h. Design reviews
i. Design verification
j. Design validation
7.2 Acceptance criteria and identifying any crucial design requirements for the main
frame and other structures shall be the responsibility of customer.
7.3 Any design modification required by design department or customer during the
manufacturing process, a written instruction shall need to be issued through
PEBs Customer Service Department so that the modification can be embodied
in the final product.
8.1 Planning Engineer shall establish and maintain a project document list showing
the latest revision status of the documents and it shall be readily available to
preclude the use of invalid/superseded documents.
8.2 Any superseded document retained for reference by the user and it shall be
communicated to the Planning Engineer. Planning Engineer shall identify those
documented to clearly differentiate from current version of documents by means
of stamp SUPERSEDED and RETAINED BY USER.
8.3 All the engineering documents which include PEB design, drawing and detailed
engineering drawings, connection details, engineering specifications and product
drawing or shop drawings shall be reviewed, controlled, managed, maintained,
issued revised and recalled by the Panning Engineer.
8.4 Design drawing list shall be based on drawing number and showing the status of
revision and date of receipt from the PEBs Customer service department. The
Engineer in-charge shall ensure that all the information provided in the design
drawings is very clear, complete and legible.
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8.5 If any unclear, portion of the design drawing shall be clouded and marked as
HOLD in design drawing. No engineering work shall be carried out on
HOLD until it is released by PEBs design dept. with appropriate information.
8.6 Upon receipt of revised design drawing from PEBs design dept. the Planning
Engineer shall update the drawing list for new revision and he will ensure that
the revised portions have been clouded clearly, having the revision mark in a
triangle at every place of revision.
8.7 The new revised information shall be compared with existing drawing to identify
the changes or modification. If any discrepancy or conflict is found, it shall be
reported to PEBs design dept. immediately.
8.8 Upon receipt of new revision, the existing drawing shall be SUPERSEDED
and the new revision drawings shall be distributed to all the processes area
concerned and the old revision drawing shall be withdrawn from all the process
concern.
8.9 If any design revision received after issue of shop drawing to the production
process, the Planning Engineer shall communicate this information to the
production process and request them to hold the production process of such
items.
9.1 Purchasing department of PEB shall ensure all the materials, welding consumables
and paint material purchased from approved manufacturer/supplier to confirm the
specified requirements of design drawing and international standards.
9.2 All of the steel materials shall be procured for the main frame structure by PEB
STEEL purchasing department and delivered to the factory at Vung Tau city.
Purchasing department in-charge in Factory will coordinate with Head office to
procure other consumables such as: Welding electrode & Wire, Paint and thinner,
Tools, Safety devices and accessories etc.
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9.3 Purchase order/Sales contracts shall be described and defined clearly the material
to be purchased. All the purchasing information shall be defined and documented
in the purchase order/sales contract.
9.4 Prior to order being placed to any supplier or manufacturer, purchasing
department Head shall ensure the adequacy of the specified purchase requirement
by communicating with the supplier or manufacturer.
9.5 Prior to release purchase order/sales contract to the supplier, the purchasing
Documents shall be verified by the end user in the company who made the
Requests and it shall be reviewed by the Planning.
9.6 All the materials, consumables and paints from the supplier or manufacturer
shall be verified and inspected to ensure that the materials meet specified
purchase requirements. All the verifications and inspection activities shall be in
accordance with the company in-coming material receiving inspection and test
procedure.
The company has identified various processes that involve in the manufacturing
of mainframe structures:
Marking / cutting
Build up of members
Fitting / assembly
Final Welding
Secondary and Sundry Parts
Sheeting, Panel and Trims
Surface Treatment and Painting
Buyouts
Loading /Delivery
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Welding
Surface treatment and painting
NDT
12.1. Identification of parts shall be followed in accordance with PEB STEEL design
and shop detail drawings.
12.2 Planning and Production Manager in consultation with other concern
departments shall establish the identification of each item based on design and
contract requirement.
12.3 Upon completion of marking and prior to start cutting every parts, the
identification number of the particular parts shall be written by means of
crayons/paint in accordance with drawing and part list.
12.4 Prior to start blasting of items, blasting team shall prepare the metal tags with
hard punched identification number of the particular items and hang on the
product by mean of steel wire to avoid missing of the tags during blasting.
12.5 Identification of completed product and logo of company shall be stenciled by
paint on the surface of connecting parts so that it will not appear on the final l
structure.
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13.2 Prior to start marking, cutting plan showing allotment of the component on the
ordered materials shall be made to minimize the losses and surpluses.
13.3 Application to the center punch in the marking shall be minimized except for
those areas where marking can be completely erased afterwards by means of
drilling, coping or welding.
13.4 As much as possible, original heat number which is stamped by mill must be
retained and marking should be avoided on the identification numbers. Only on
un-avoidable circumstances, the original plate heat numbers shall be transferred
by means of hard punch at unusable corner of the material.
13.5 The cutting face of each member shall be perpendicular to the axis line unless
otherwise specified on the drawing.
13.6 Cut face shall be free from remarkable uneven notch or slag attachment. In case
of occurrence of notch, such part shall be welded and finished to flatness by
means of grinder.
14.1 Fitter shall inspect the items visually for any surface damages, bends and
deformation. If so, it shall be properly corrected in accordance with shop detail
drawings.
14.2 It is the responsibility of fitter/QC Supervisor to verify the size, thickness, hole
details, hole diameter, spacing and number of holes. The contact surfaces of the
components shall be free of burrs and foreign materials that would prevent solid
seating of the part.
14.3 All the edge preparation and site assembly profile on both main members and
components shall be carried out prior to start fitting and in accordance with shop
drawing.
14.4 Assembly work shall be carried out with suitable tools and equipment, such as
surface plate, positioners, jacks, lever blocks, chain blocks and strong backs.
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14.5 All full penetration weld joints of fitting shall have minimum root gap of 3mm
and the edge preparation strictly in accordance with shop drawing.
14.6 The fitter performing the tack welding shall be qualified for the process in
accordance with the applicable welding procedure specification.
14.7 Electrode for tack welding shall be in accordance with the specification and as
per the approved welding procedure.
15.1 All the welding process shall be in accordance with the approved welding
procedure specification (WPS) and procedure qualification record (PQR).
15.2 All the welders to be engaged in this work should have approved welder
performance qualification test certificates.
15.3 Prior to the welding, all welding joint surfaces shall be clean and dry condition.
Rust, paint, dust, grease or any other foreign particles shall be cleaned by
mechanically using wire brush or grinding.
15.4 When the pre-heat is required as per WPS, pre-heating temperature of the base
metal shall be of 100-1200C and shall be checked by temperature crayon.
15.5 Welding gaps or bevels must be accurately controlled over the entire joint during
welding operation.
15.6.1 Consumables such welding electrodes, flux etc. to be used shall be as per
standards. Deteriorated or spoiled consumables should not be used.
15.6.3 Weld testing equipment should be in good operating condition and be handled
by the well trained staff.
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15.7.1 The weld groove should be free from dirt, rust, oil, slag or any other foreign
particles which affect the quality of the weld.
15.7.3 The fit-up, gap, orientation, welding position, method and sequence of
assembly all should be as per approved welding procedure.
15.7.4 Tack welds should be of adequate size, length and pitch.
15.7.5 Fittings, clamps, fixtures, etc. should not interfere with welding
15.7.7 Slag should be thoroughly removed from each pass in multi-pass arc welds and
spot welding electrodes should be dresses periodically.
15.8.1 Cleaning and visual inspection of welding includes: Final weld appearance,
final weld size, extent of welding, dimensional of accuracy, amount of
distortion, surface cracks, undercut, overlap, exposed porosity, unacceptable
weld profile, and roughness of the weld face.
16.1 Welding slag and spatter must be cleaned properly and use wire brush or power
brush as post cleaning operation.
16.2 If any undercutting or porosity found during cleaning, mark the spot by means of
crayons and report to welding supervisor for repair and ensure the repair has
been done in accordance with the standard and acceptable level.
16.3 If any crater observed, note down the welder identification number which is
written near the welding and call the same welder for repair.
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16.4 All the bolt holes must be clean and trimming by means of grinder, round file
and reamer if in case necessary.
16.5 All the cutting edges must be grind smooth and all the sharp edges must be
radius and smooth.
16.6 All the gas notches must be rebuilt by (touch up) qualified welders and grind
smooth.
16.7 Any bend, deflection and deformation of member out of tolerance should be
corrected by means of heating and cooling methods.
17.1 Prior to start painting blasted surface shall be cleaned by dry compressed air and
ensure the surface is dust free.
17.2 The following area shall be covered by masking tape to avoid painting:
17.3 Each container of paint shall be clearly marked or labeled to show paint
identification date of manufacture, batch number, analysis of contents,
identification of all toxic substance and special instruction.
17.4 All ingredients in any container of paint shall be thoroughly mixed before use and
shall be agitated often enough during application to keep the paint uniform.
17.5 The type of thinner shall comply with paint manufacturers instructions. Correct
amount of thinner to be added to particular application when the use of thinner is
permissible, thinner shall be added slowly to paint during mixing process.
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17.6 The equipment used for painting application shall be suitable for the appropriate
purpose and coating system and shall be capable of properly atomizing the paint
to be applied.
17.7 All the paint pot shall be equipped with suitable pressure regulators and gauges.
17.8 Paint shall be applied in a uniform layer with overlapping at the edges of the
pattern. During application, the painting spray gun shall be held perpendicular to
the surface which will ensure that a wet layer of paint is deposited on the surface.
The trigger of the gun should be released at the end of each stroke.
17.9 The air caps, nozzles and needles shall be those recommended by the paint
manufacturers of material being sprayed and equipment being used.
17.10 Traps or separators shall be provided to remove oil and condensed water from air. The
traps or separators must be of adequate size and must be drained periodically during
operations.
17.11 The pressure on the material in the pot and of the air at the gun shall be adjusted
for optimum spraying effectiveness.
17.12 The pressure on the material in the pot shall be adjusted when necessary for
changes in elevation of the gun above the pot. The atomizing air pressure
17.13 When spraying the spray gun should be held from 250 mm to 350 mm from the
surface and maintained perpendicular to the surface throughout the stroke. At the
end of each pass, the gun trigger should be released.
17.14 For airless application, the distance should be from each spray pass should
overlap the previous one by 50%, and where possible, a cross hatch technique
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should be used. This requires a duplicate series of pass at 90o to the first to
ensure complete and uniform coverage.
17.15 Paint shall not be applied when the temperature of steel or the paint is below 4o C.
17.16 Paint shall not be in rain, wind, fog, mist or when the steel surface temperature is
less than 3o C above the dew point.
17.17 Paint shall not be applied when the relative humidity is above 80%. The
manufacturers instructions shall be followed regarding the acceptable humidity
range for the particular paint.
18.1.1 All the materials shall be inspected against the specified material specification
and the mill certificate.
18.1.2 Upon receipt of materials/products, storekeeper shall verify the quantity, number
of packing, type of materials, general appearance of materials and conformance
against the requisition order, purchase documents, packing list and delivery
order. He shall also make arrangements to request Q.C Inspector for receiving
inspection.
18.1.3 Q.C Inspector shall carry out the following visual inspection upon receipt
Of materials:
General appearance
Corrosion or pitting conditions
Conformance to the purchase order
Material identification (heat number) conformance to the Mill certificate.
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18.1.5 Material shall not be used for production until it has been inspected or verified as
conforming to specified requirements.
18.2.1 In-process inspection shall be carried out in all stages of process in order to verify
the conformance of the product against drawings and technical specification.
18.2.2 Product shall be hold until the required in process and test have been completed
and shall be released for next process, only after acceptance by QC inspector.
18.2.3 If any part or item found nonconformity during in-process inspection and test
shall be identified, segregated and hold until the items to be re-inspected and
accepted by QC inspector.
a) The in- process inspection during marking and cutting process shall include:
b) In-process inspection during marking and cutting shall be carried out by the
marking/cutting group leader and the Q.C Supervisor / Engineer may
witness the transfer of heat number when necessary.
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c) Appropriate corrective action shall be carried out within the period stated in
the NCR reports. Upon completion of satisfactory corrective action, the
same item shall be re-inspected again in accordance with the requirements.
d) If any items are not in conformance with the requirements after necessary
repair and re-inspection, QC Engineer shall fix REJECT label and
separate the item from the assembly line and further investigation to be
conducted for the failure.
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c) Any welding defect noticed by the QC Engineer who shall mark the
defective area and subsequently the welding supervisor shall take necessary
corrective action.
a) The equipment shall not be dispatched or handed over to customer until all
the activities specified in this work plan/quality plan, inspection & test plan
including applicable records and documents have been satisfactorily
completed.
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19.2 Al the non-conforming product shall be segregated from the routine process or
from the conforming items. If the parts or items are heavy and too big, a
HOLD label shall be fixed until the appropriate corrective action taken.
19.3 Any item or part number that has been repaired, reworked and modified shall be
re-inspected prior to it being released to further process or dispatch. Re-
inspection and test records shall indicate the original rejection, disposition and
the result of the re-inspection.
19.4 Upon completion of correction action, QC Engineer shall verify the effectiveness
of the corrective action and records in the non-conformance report. NCR shall be
closed once the corrective action is completed and satisfied.
19.5 QC Engineer shall ensure that product which does not conform to the specified
requirements is prevented from further processing or dispatch to the customer.
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20.1 The QC Engineer shall be responsible for the execution of proposed corrective
action for any customers complaint or comments and he is also responsible to
submit the appropriate corrective action reports to customers representative
when required.
20.2 Corrective action shall include the documenting/recording both cause and
proposed appropriate corrective action needed to eliminate the cause of non-
conformities.
20.3 The concerned action party shall report when the corrective action has been
completed and the QC Engineer shall verify it.
20.4 If QC Engineer determines the non-conformance is minor and the effect of non-
conformities does not affect the performance of the product, it shall be
recommended to use as it is without any corrective action.
20.5 In case of product non-conformity is considered as major the QC Engineer shall
recommend for repair the product to meet the requirements. In such case, the
repair method and acceptance criteria shall be documented in the non-
conformance report.
21.1 Storage
21.1.1 Appropriate designated storage areas for raw materials and the equipment shall
be planned in advance in order to prevent damage or deterioration.
21.1.2 After painting, the product shall be kept in open yard on the stable steel skid
beams and there shall not be any deflection in the middle.
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21.2.2. All threads of bolt and nuts including any exposed parts should be coated with
rust preventive grease or oil to prevent corrosion during storage.
Marking and identification shall be done clearly on the equipment and other
packages and shall be in accordance with requirements, which is stated in
contract or technical specification.
21.4 Delivery
21.4.1 Products shall be delivered to the Project site based on schedule and instruction
to delivery from Customer Service Department (PEB STEEL).
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