84501-9200-9P-009_R1

CONOCO INDONESIA INC. LTD. PROJECTS DEPARTMENT SPECIFICATION TITLE NON CONFORMANCE REPORTING PROCEDURE

DOCUMENT NUMBER

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DATE

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REVISION CONTROL SHEET LATEST REV

DATE ISSUED

PREPARED

REVIEWED

APPROVED

COMMENT

0

1 October 2002

B. Burn

R.Ford

A.McIntosh

Issued For Use

1

1 March 2003

B. Burn

C.Binks

A.McIntosh

Department Nam Change


DOCUMENT NUMBER

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DATE

84501-9200-9P-009

1

1 Mar 03

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TABLE OF CONTENTS

1. 2.

INTRODUCTION.................................................................................................... SCOPE ................................................................................................................

3.

RESPONSIBILITIES..............................................................................................

4.

DEFINITIONS AND ABBREVIATIONS ..................................................................

5.

RELATED AND REFERENCE DOCUMENTS .......................................................

6.

PROCEDURE ........................................................................................................

7.

REVISIONS ........................................................................................................

8.

APPENDICES..................................................................................................10-1


1.

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INTRODUCTION

The purpose of this DOCUMENT is to ensure the control of Non-Conformance o material and manufacturing processes.

Quality Assurance / Quality Control on the Project is the contractual responsibilit of the EPCI Contractor who must put into place a quality system that complie with the requirements of ISO 9000 standard and identifies, marks and segregate (whenever applicable) items that do not conform to specified requirements and prevents their inadvertent use on the Project.

These non-conforming items are recorded, reviewed, dispositions decided and approved by designated Company personnel. Remedial actions are taken and recurrence prevented.

The Company QC Department and Project Team must ensure that these step are carried out and that all necessary actions required to ensure the control o non-conforming products, i.e. materials, processes, procedures and actions, ar utilized.

In addition, this procedure will define the methodology in issuing, handling and filing of non-conformance reports within the Specific project

An integrated team approach with EPCI Contractor will be taken to avoi duplication of effort and eliminate inefficiencies. 2.

SCOPE

The scope of this procedure is to describe the systems for identification reporting, evaluation and disposition of non-conformance in relation to materials procedures, actions, processes and products that will be actioned during th fabrication, construction and installation of the Specific project

The procedure identifies in detail the necessary actions to be followed and th associated responsibilities for taking remedial action and maintaining records o all non-conformances and documentation.

Design changes arising from non conformance activities are not covered unde this scope and are subject to a site query system or a design change contro


3.

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RESPONSIBILITIES

The application of this procedure shall be the responsibility of the Compan Project QC department within the Company Project Team.

This procedure is relevant to material, process, fabrication, installation, pre commissioning and commissioning of all works executed on the Specific project

Non-conformance can be identified during receipt of material, process construction, installation, pre-commissioning and commissioning of work. Th Company QC Department will interface with the EPCI QA/QC Department t identify and control non-conformances.

It is the responsibility of all Project personnel in the above areas to assist in th identification of possible non-conformances and to promptly notify the departmental head/section lead and to the EPCI QA/QC personnel in charge o the inspection of a particular activity.

The EPCI QA/QC personnel in charge of the area or activity where the non conformance is discovered will be responsible for the preparation of a Non Conformance Report (NCR) or a Material Non-Conformance Report (MNCR). necessary, the Company QC Department personnel may assist in preparing th report and the development of proposals for remedial action and ways to sto recurrence of the problem. Company QC Personnel Responsibilities

During fabrication and construction activities regular inspections will take plac and it will be the responsibility of the Company QC department inspectors t ensure that the contractor highlights, informs, records and documents any no conformances against an applicable material, process, procedure or activity. This does not free the Contractor of any of his contractual responsibilities.

A copy of all MNCR/NCR’s will be maintained at site and copies will be sent Company Project QC Manager. The original is to be held by EPCI Contractor QA/QC Manager.

Contractor’s approved documentation, such as MNCR and NCR forms, will b utilized to avoid duplication of paperwork.

The Project and/or EPCI QC inspector responsible for the activity will b


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subsequent actions are recorded, distributed and retained within the Compan QC Department. Project Engineering Section

It is the responsibility of the appropriate discipline engineers in the Project t oversee the EPCI Engineering department and ensure that the constructio drawings, specifications, procedures and data sheets conform to contrac requirements. Project QC Manager

It is the responsibility of the Company’s Project QC Manager to liaise with th Contractor to report the applicable MNCR’s or NCR’s and their dispositions

It is the responsibility of the Company’s Project QC Chief Inspector to ensure tha a record of all MNCR’s & NCR’s and their dispositions are retained within th project filing system. 4.

DEFINITIONS AND ABBREVIATIONS

Except where explicitly stated otherwise, items in this reporting procedure sha have the following meaning:

“Action Party” shall mean a person or a group of people instructed to carry ou remedial actions to ensure a product can, by the use of additional approved repair procedures, achieve a condition which fulfils the specification. “CA” shall mean a Certifying Authority i.e., ”MIGAS”.

“EPCI Engineering Department” shall mean the Contractor’s EPCI Engineerin Department.

“EPCI QA/QC Department” shall mean the EPCI Contractors Department base at EPCI contractors main office.

“Material Non Conformance Report” or “MNCR” shall mean a report tha identifies, reports on, evaluates and decides on a disposition on a material tha will be actioned in the fabrication, construction or installation of the Specifi project


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“Non-Conforming Material” shall mean any material in which one or more o the specified characteristics does not conform to the specified requirements.

“Non-Conforming Process” shall mean a construction or fabrication proces that does not conform to specified process criteria which is used to bring an item into conformance.

“Non-Conforming Product” shall mean a departure from the qualit characteristics that result in a product, assembly or sub-assembly not meetin specified requirements.

“Overage, Shortage and Damage (OS&D) Report shall mean a report tha identifies any discrepancy from the purchase order requirements carried out o receipt of goods at Contractors/Sub-Contractors facility by Contractors/Sub Contractors material handling personnel.

“Remedial Action” shall mean the agreed action or actions that take place by person or organization responsible for the work or activity in which a non conformance has been identified and described within a MNCR or a NCR form.

“Repair” shall mean work that is performed on a non-conforming material o product by a process that is different from one that is normally used to initiall fabricate the material or product which brings it back to a state of conformance. “TPA shall mean a Third Party Agency.

“SPECIFIC PROJECT e.g.WHP-P Project” shall mean any activities carried ou on the Wellheads, Pipelines and Oil Offloading Buoy, during Engineering Procurement, Construction, Installation, Pre-Commissioning, Commissioning Hand-Over.

“Company QC Department” shall mean the Project Quality Control Departmen based at EPCI Contractors main office in Jakarta. 5.

RELATED AND REFERENCE DOCUMENTS ISO 9001 –1994 Model for Quality Production, Installation and Servicing.

6.

PROCEDURE

Assurance

in

Design/developmen


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6.2.2 Within the Project, material, documentation, and/or manufacturing processes which do not conform to specified and /or agreed requirements shall be detected identified as such and reported as quickly as possible on an NCR or MNCR. Thi non-conformance report will contain a clear description of the non-conformanc against material, process or documentation. If additional pages/documentation i required to support or describe the non-conformance such documents shall b listed in the reports as enclosures.

6.2.3 Each non-conformance report shall be forwarded to Company Project QC Department for evaluation, registration and further processing. Each report will be given a unique number, location of origin of report and party responsible for th non-conformance.

6.2.4 Materials used in any process within the Project shall be inspected by th Contractor and where possible, by the Company’s Project QC Inspectors. defective materials, or materials which do not conform to specified and /or agreed requirements, shall be reported and recorded through the MNCR system. A defective material will be reported on a MNCR form. 6.2.5 Materials identified through a MNCR shall be subject to close control such that: •

•

•

•

•

Their unauthorized or inadvertent use or mixing with conforming material is prevented. Materials identified as such will be immediately quarantined clearly marked as such, and moved to a designated quarantine area until a disposition has been agreed on.

Non-conforming items/material are identified in a unambiguous manner b Contractors material handling personnel and any materials that ar pending evaluation and approval of disposition by authorized personne shall be physically segregated from items which conform to specifications At this point, an OS&D Report shall be prepared where necessary identify any discrepancies with the Purchase Order (PO).

Where non-conforming items cannot be physically segregated from conforming items then controls shall be implemented such tha identification is unambiguous. Authorized personnel implement approved disposition and the inspection shall be carried out to original requirements.

Records are to be maintained which readily and positively identify the non conforming item or material and specify the nature and extent of the non conformance. Records shall also contain evidence that the repaired o


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that this would be a “one off” waiver and not a general relaxation of th specification. 6.2

Non-Conformity during Work

6.2.1 When initiating a non-conformance report the originator shall ensure that th following information is included in the report. •

Contractor/ subcontractor location.

•

Party responsible for the non-conformance.

•

Location and activity where the non-conformance occurred.

•

Brief and concise statement of the non-conformance with reference t controlling documents i.e. specifications, procedures and QA/QC plans o inspection and test plans.

•

Remedial action to prevent recurrence of non-conformity.

•

Recommended disposition proposal.

•

Identification of action party.

6.3

The application of a NCR or MNCR shall be restricted to individual items o process of major activity or repetitive defects on a large number of items o processes. It shall not be used to document individual defects, where remedia procedures are already established.

6.4

Disposition of Non-Conformity Each MNCR or NCR shall receive one of the following dispositions:

6.4.1 Accept As Is – This disposition shall be considered when the non-conformanc is deemed not to have a detrimental effect on design, use, safety or any advers conditions to the function/operation of the product or when rework is considere impractical or it will not improve the condition.

This type of disposition requires approval from Company’s QC Manager an TPA/CA, where applicable.

6.4.2 Repair – This disposition shall be considered when the non-conforming item material or process, by the use of additional approved repair procedures, ca achieve a condition which fulfils the specifications.


6.5

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Final Documentation

6.5.1 All original process- or production-related NCR’s and the NCR status log shall b retained in the Contractor’s QA/QC Department. Copies of all documentatio related to the issue and resolution of NCR’s shall be placed in the project as–bui dossier or data book.

6.5.2 On a monthly basis, the Company Project QC Manager will review the non conformance report status and its dispositions in order to identify any significan trends. Corrective actions taken shall be assessed in order to prevent th recurrence of non-conformities. QA/QC reports from Contractors production an fabrication/construction facilities shall include a summary of NCR’s raised or i process.

The Project QC Manager shall appraise all data on non-conforming material o process and the results will be presented at management review meetings. 6.6

The clearance of any disposition by the Company does not relieve the Contracto of any of his obligations and responsibilities under the contract.

7.

REVISIONS

This Procedure may not be revised unless approved by the Company Projec Manager. 8.

APPENDICES The following Appendix is an integral part of this procedure Sample MNCR Report Sample NCR Report Sample NCR Log Sample NCR Flow Sheet

845

PROJECT MATERIAL NON CONFORMANCE REPORT Reference Number

Revision

Date:

MNCR Serial number Page

Contractor PO No

MATERIAL DESCRIPTION PO Item No

Units

PROPOSAL

A = Accept As Is B = Repair C = Rejected

Quantity

No further Action Subject to corrective action New Material to be procured

REMARKS

PROPOSED BY

APPROVED BY

Original Copy

TPA

TPA

Name: Signature Date Copy

Stores Project

Copy

Check with Document Control for latest available Revision

845

PROJECT NON CONFORMANCE REPORT Reference Number

Revision

Date:


Contractor PO No

DESCRIPTION PO Item No

Units

Quantity

845

PROJECT NON CONFORMANCE REPORT Reference Number

Revision

Date:


Contractor PO No

DESCRIPTION PO Item No

Units

PROPOSAL

A = Accept As Is B = Repair C = Rejected

Quantity

No further Action Subject to corrective action New Material to be procured

REMARKS

PROPOSED BY

APPROVED BY

Original Copy

TPA

TPA

Name: Signature Date Copy

Stores Project

Copy


845

PROJECT NONCONFORMANCE REPORT LOG NON CONFORMANCE REPORT (NCR) LOG ACTUAL NCR ORIGINATOR NO.

AUDIT REF.

NCR ISSUE DATE

NCR ISSUED TO

DEFICIENCY

AGREED COMPLETION DATE

CORRECTIVE ACTION COMPLETION

DATE

845

PROJECT NONCONFORMANCE REPORT LOG NON CONFORMANCE REPORT (NCR) LOG ACTUAL NCR ORIGINATOR NO.

AUDIT REF.

NCR ISSUE DATE

NCR ISSUED TO

DEFICIENCY

AGREED COMPLETION DATE

CORRECTIVE ACTION COMPLETION

DATE


Contractor QA/QC

CII QA/QC

CII DISCIPLINE ENGINEER

A NCR or MNCR is identified by either Client or Contractor QA/QC Department Inform Client and prepare NCR/ MNCR with assistance from

Give instruction to QC

CII PROJ ENGINE

Contractor QA/QC

CII QA/QC

CII DISCIPLINE ENGINEER

A NCR or MNCR is identified by either Client or Contractor QA/QC Department Inform Client and prepare NCR/ MNCR with assistance from client when needed. Transmit to CII QC

Give instruction to QC Department

On receipt refer to engineering if applicable. Act on received advice from engineering

YES

Discipline Eng

Give advice on Query and report back to PE Prepare answer to NCR/MNCR c/w Action Plan

Record NCR/ MNCR and their disposition. Transmit to Contractor

Contractor carries out remedial work

Gain approval for action or "Accept as is"

Instruct QC to reinspect to original specification if OK sign off if not return to start of process

CII PROJ ENGINE

84501-9200-9P-009_R1

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