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Customer
Interested
Parties
Customer
Satisfaction,
Feedback and
Complaints
Management Processes
Establish/Review
Management Policy,
Customer Focus and
Statement of Commitment
to fulfillment of QHSE
Requirements
Identify Processes needed
for IMS, determine the
sequence & interaction and
criteria to ensure
effectiveness of these
processes
Determine requirement,
provide and ensure
availability of resources for
operation, monitoring,
measurement and continual
improvement of IMS
Continual Improvement
Employee
Suggestions and
Feedback
Internal
QHSE Auditing
Establish Responsibility,
Authority & Line of
Communication and
Appoint MR
Monitoring and
Measurement of IMS
Processes
Analysis of Data
Establish Means of
Internal/External
Communication regarding
effectiveness of IMS
*Receiving,
In-process & Final
Inspections
Control of
Nonconformance
Evaluation of
Compliance to Legal,
Statutory & other
requirements
Monitoring &
Measurement of HSE
Performance
Emergency
Preparedness
and Response
Accidents, Incidents
and Near-Misses
Project
Expediting
Corrective/Preventive Action
Conduct Management
1
Product Realization
Sales and Estimation
Resource Management
Determine Resource
Requirements Related
to Human Resources,
Infrastructure & Work
Environment
Provide Suitable
Infrastructure & Work
Environment
Evaluate Suitability of
Existing Resources
Recruit Human
Resources or arrange
Competent Personnel
Measure
Effectiveness of
Training
Determine Training
Needs & Provide
Engineering
Control Plan
Validate
Special
Processes
Assess HSE
Risks/Impacts
Plan HSE
Operational
Control
Evaluate &
Select Suppliers/
Subcontractors
Purchase/
Outsource
Products/
Services
*Verification of
Customer
Supplied,
Purchased &
Outsourced
Products
Control of
Records
Determine
Requirements of
Product
Identification &
Traceability
Production
Planning
Resource
Allocation
Job
Loading
Erection/ Installation and Other Works
Control of
Documents
Determine
Products to be
Supplied by
Customer
*Final
Inspection
*In-Process Inspections
Customer
PM-02
Rev.#
Rev. Date:
01-Feb-11
Process Owner :
Objective
To set and achieve SMART Objectives related to Quality, Occupational Health & Safety and
The above mentioned Inputs shall be discussed in the Management Review Meeting.
The possibility of improving the results shall be discussed and responsibilities
delegated to the concerned.
Objectives
SMART?
No
Yes
No
Results as
Planned &
effective?
Yes
Records
PM-03
Rev.#
Rev. Date:
1-Mar-11
INTERNAL COMMUNICATION
Input
EXTERNAL COMMUNICATION
Management Policy
Objectives,
Legal, Statutory & regulatory requirements
Input
Management Policy
IMS
HSE related aspects
Forward inquiries to MR
Immediate Superior shall make the
employee aware of the relevance and
importance of his/her activities, the
OH&S Hazards/Risks & Significant
Environmental Aspects/Impact related
to his/her activities and how he/she
contributes to the achievement of
IMS Objectives of PPE
MR to review the
correspondence and
discuss with the
Management
GM decides to
communicate?
NO
Employee Representative
shall communicate to employees
the decisions taken in the
meeting and laise between the
employees and the Management
team on all HSE related matters
Records of Communications to
be maintained with concerned
departments.
YES
MR to respond to external
party accordingly
MR or Delegate to
Communicate as decided
Records to be maintained
in MR office
PM-04a
Rev.#
Rev. Date:
18-Jan-12
NO
YES
YES
Any
opportunity for
Improvement?
NO
Management
Decision in Favor
of Implementation?
NO
YES
Records
Approved JCR
Completed CSS
End
Process Owner
Objective
PM-04b
:
:
Rev.#
Rev. Date:
18-Jan-12
Management Representative
To satisfy customer needs by appropriate handling of Customer Complaints and
Negative feedback
Inputs
Client
Investigate
Complaint
Justified?
NO
YES
Remedial Action
Satisfactory?
NO
YES
Any CAR
Raised?
YES
NO
Output
CAR Process
PM-05
Process Owner:
Objective:
Rev. #
Rev. Date:
18-Jan-12
Management Representative
To improve IMS by effectively implementing Employee Suggestions & Feedback Mechanism
Input
Is the
suggestion clear and
appropriate?
No
Yes
Yes
Any Alternate
Suggestion?
No
Does
The Management
Approve?
Yes
No
No
Results as
Planned?
Yes
Output
PM-06
Process Owner :
Objective
Rev.#
Rev. Date:
16-Jan-12
Maintenance Supervisor
:
Break-Down Maintenance
Input
Preventive Maintenance
Breakdown Reports
Maintenance Requests
Breakdown History
PM Schedule
Breakdown History
Input
Update /
Modify PPM
if required
Manpower Allocation
Study
Breakdown
History
Identify Required
Materials / Parts
PM-14a or PM-14c
No
Fixing/Reparing
Normal Operations
Confirmed?
Commissioning
Yes
Output
Conditioned Machinery
Maintenance Record
Updated Maintenance Schedule
Process Owner :
Objective
:
PM-07
Rev.#
Rev. Date:
16-Jan-12
Input
Identification of New
Devices needed for
Monitoring & Measurement
Raise PR for
Calibration
Register in Form
PPE/QF/IMS/390.
Devices Regularly
used or required for
current/upcoming use?
Yes
No
Stop
Purchaisng and/or the
concerned shall Review
the quotations & identify/
select suitable supplier
Agency to take
necessary action.
Yes
Yes
Results OK?
No
Approved?
No
Purchase to negotiate
with the agency and
take necessary action.
Results OK?
Yes
No
Output
Calibration Certificates
Results of calibration
Doc.#
PM-08
Process Owner(s) :
Objective
:
Rev.#
Rev. Date:
Inputs
Inquiry
Tender Specifications
Customer Drawings
Any Statutory/Regulatory Requirements
GM shall take
necessary
action in
coordination
with MM & SE
MM to Send
Queries to
Customer &
Receive
Clarifications
01-Mar-11
Information
Clear &
Explicit?
No
Yes
Yes
GM shall
forward the
Project
Information
and Summary
of Estimate for
the Review &
Approval of
DCM
No
Approved
by DCM?
Is approval
of Deputy
Chairman (DCM)
Required?
Yes
No
Yes
Inquiry within
PPE Scope/
Capability?
No
SE shall
Raise
Queries
and forward
to SMD
No
Management
Decides to
Decline?
No
Requirements
Complete &
Clear?
No
Yes
Yes
Management shall
discuss with
concerned & plan to
make Alternate
Arrangements
[extra resources,
process(es) or new
facilities etc.]
Yes
Yes
MM shall
forward the
decline letter
and keep the
Record for
Reference
Output
Records
Any SC/OS
Required?
MM shall
analyse
proposal
and find out
the reason
for failure.
The received
Order shall
be forwarded
to MM
MM shall
keep the
Record for
Reference
MM shall
Compare the
Order with the
PPE Proposal
No
Order same
as Proposal?
Yes
GM to Sign
the Contract
No
ES to Send Inquiries
to Approved
Subcontractors/
Suppliers and
Receive Quotations
SE to Prepare the Estimate & Proposal
taking inputs from concerned, as required
and forward to SMD for further action
Job
Awarded?
Output
Records
MM shall review the Proposal with the
General Manager (GM) in coordination
with the concerned
SE shall
take
necessary
action
No
OK to proceed?
Yes
Output
CIF
Contract Specifications
Customer Drawings
Statutory/Regulatory Requirements (if any)
PM-09
Rev.#
Rev. Date:
Process Owner :
Welding Engineer/Inspector
Objective
16-Jan-12
Contract Specifications
Engineering Drawings
START
Inputs
Is a new Welding
Procedure required?
No
STOP
Yes
Result Satisfactory?
Yes
No
No
Modification in pWPS
required?
Yes
Train Welders
on pWPS
Modify
Arrange TPI to
Witness
Carry out RT
Formally record PQR and WPS
No
Is RT acceptable?
Yes
Approved PQR
Approved WPS
Output
No
Results of Destructive
test acceptable?
Yes
STOP
PM-10
Rev.#
Process Owner :
Store Keeper
Objective
START
Inputs
Rev. Date:
1-Mar-11
Supplier to
take action.
QC to
distribute NCR
to concerned.
No
QC to raise NCR on
Supplier.
WCs acceptable?
Yes
Yes
No
Is re-baking required?
No
Outputs
Yes
STOP
MIR
SIV
WCs BAKING LOG
WCs ISSUE LOG
Etc.
PM-11
Rev.#
Rev. Date:
18-Jan-12
Process Owner
Objective
Input
1
1. Conduct Supplier/Subcontractor Audit where practical
2. Send Evaluation Questionnaires to prospective Suppliers/Subcontractors
Audit Results/Supplier
response to Evaluation
Questionnaire Satisfactory?
CPAR
Raise Corrective/Preventive
Action Request (CPAR) and
forward to the Supplier/
Subcontractor for Action
NO
YES
Add Supplier/Subcontractor
to Approved List
YES
NO
Monitor Suppliers'/Subcontractors'
for their Performance on compliance to
specified requirements, including product/
service quality, delivery schedules,
applicable regulatory/HSE requirements,
quality of relevant documentation & pricing
YES
Re-Evaluate
1
Performance
Satisfactory?
Action
Satisfactory?
Re-Evaluation
Required?
NO
Follow-Up
on CPAR
NO
YES
Output
PM-12
Rev.#
Rev. Date:
16-Jan-12
Inputs
Accident
Incident
Near Misses
Output
Accident /
Incident /
NearMiss
Report(s)
:
:
PM-13a
Rev.#
Rev. Date:
Inputs
YES
Design
Subcontracted?
Design Output
meets Design Input
Requirements?
Maintain Records of
Design Validation
YES
NO
Subcontractor to
Maintain Records
of Design Inputs
NO
Results of Design
Validation Satisfactory?
NO
YES
YES
Maintain Records
of Design Inputs
NO
NO
Carry Out
Design Validation
as Appropriate
YES
Subcontractor
to maintain
Records of
Review,
Verification &
Validation
SE to Determine &
Review Design Inputs
and Other Requirements
Subcontractor to Plan
and Carry Out Design
Development Activities
NO
Select Approved
Sub-Contractor
Any
Queries from
Subcontractor?
16-Jan-12
Client Approval
Required?
Formalize Internal
Approval and Distribute
No
YES
ES to Review
and Verify
Design Output
Carry Out
Design Works
Output
Submit to Client
through Projects
Department
Maintain Records
of Review &
Verification
Design Output
meets Design Input
Requirements?
NO
NO
Design Approved?
YES
NO
YES
PM-13b
Detailed
Drafting
DesignCalculations
DesignDrawings
PM-13b
Rev.#
Rev. Date:
16-Jan-12
ES to receive
required information
MTO Complete?
NO
YES
ES to raise query
to the Designer
NO
Documents
Complete, Clear
& Approved?
BOM
Authorize
BOM, release
& distribute
YES
Material Available
in Store?
YES
PM-15
NO
Carry Out
Detailing Works
Output
Check the
Detailing Output
Purchase Requisition
PM-14b
Detailing Output
Complete & Clear?
NO
Client Approval
Required?
YES
NO
Documents
Approved?
YES
Detail Drawings
Output
NO
PM-14a
Process Owner
Objective
Rev.#
Rev. Date:
01-Feb-11
: Purchasing Superintendent
: To ensure that all the fixed assets (whether general purpose, routine work related or project specific) are purchased in
conformance to the requirements determined, reviewed and approved by designated authorities.
Start
PR Accurate
& Complete?
Yes
No
No
SS shall check
the availability of
PR items in Stock
In Stock?
Yes
No
Yes
PS to Log the
PR & forward it
for review and
approval of GM
Requisitioner/RDH to
check the suitability of these
items for the intended use
Suitable?
Records Generated
PR, SIV, ISJ, ICN
(as applicable)
Stop
OK to
process?
No
Yes
OK to
process?
GM to forward
the PR for
Review &
Approval of
Vice Chairman
PS to Select (preferably 3 or
more) Suppliers from the
Approved List & send Inquiries to
them with complete information of
PR requirements
Yes
Quotations
Received?
Yes
No
PS to
Distribute
PR copies to
concerned
Supplier
to take
action
PS to
Follow-Up
with Supplier
Quotations
Accurate?
No
PS to take
necessary action
Yes
No
PO
Approved?
GM to review
approve the PO
Yes
Stores/Requisitioner/RDH to
receive Goods & verify for
Quality & Quantity of Products
PS to forward
the PO to
Supplier
Products
Accepted?
No
Yes
Yes
Documents
OK?
Yes
Records Generated
PR, PO, DN, LSR/ISR,
MI, SIV, ISJ, ICN
(as applicable)
Stores to issue/
handover the product
to Requisitioner,
update the Inventory
and distribute records
to concerned
End
Pre-Commissioning
OK?
No
No
PS to
coordinate with
Supplier
PM-14b
Process Owner
Objective
Rev.#
Rev. Date:
01-Feb-11
: Purchasing Superintendent
: To ensure that the raw material, semi-finished/finished products, services etc. are procured in conformance to the requirements
determined, reviewed and approved by designated authorities.
Start
Inputs
Approved Drawings
Material Take Off
Bill Of Materials
Engineering Superintendent
(EnS) shall review the PR for
accuracy and completeness
PR Accurate
& Complete?
Yes
No
No
SS shall check
the availability of
PR items in Stock
In
Stock?
Yes
QC Inspector shall
check the quality &
relevant documents for
these items in line with
the PR requirements
No
Suitable?
Yes
PS to Log the
PR & forward it
for review and
approval of GM
QC Inspector to
release the material
and generate
Material Inspection
Report (MIR)
SS shall offer
the available
items for QC
Inspection
Records Generated
PR, MIR, MTC,
SIV, ISJ, ICN
(as applicable)
Stop
OK to
process?
PS to raise query to
requisitioner & report to GM
No
Yes
PS to
Distribute
PR copies to
concerned
PS to Select (preferably 3 or
more) Suppliers from the
Approved List & send Inquiries to
them with complete information of
PR requirements
PS to take
necessary action
Quotations
Received?
Yes
No
Supplier to
take action
PS to Follow-Up
with Supplier
No
Quotations
Accurate?
Yes
No
GM to review &
approve the PO
PO
Approved?
Yes
Supplier to
take action
PS to forward
the PO to
Supplier
Products/
Services
Accepted?
No
Yes
PS to Distribute
PO copies to
concerned
Records Generated
PR, PO, DN, LSR/ISR,
NCR, MIR, BC/MTC, MI,
SIV, ISJ, ICN
(as applicable)
Stores/QC to verify
correctness and
completeness of necessary
documents
Yes
Documents
OK?
No
QC to Raise
NCR on
Supplier
QC to
Distribute
NCR copies to
concerned
PM-14c
Rev.#
Rev. Date:
01-Feb-11
: Purchasing Superintendent
: To ensure that all stock goods are purchased in conformance to the requirements determined, reviewed and approved
by designated authorities.
Start
PR Accurate
& Complete?
Yes
No
SS to modify/correct the
Purchase Requisition as necessary
Yes
OK to
process?
No
PS to instruct SS for
necessary action
PS to Select (preferably 3 or
more) Suppliers from the
Approved List & send Inquiries to
them with complete information of
PR requirements
PS to
Distribute
PR copies to
concerned
Quotations
Received?
No
Supplier to
take action
PS to take
necessary action
PS to compare each
Quotation against
requirements of PR
Yes
PS to Follow-Up
with Supplier
No
Quotations
Accurate?
Yes
No
PO
Approved?
Yes
Supplier to
take action
PS to forward
the PO to the
Supplier
Stores/QC to
Raise NCR on
the Supplier
Products
Accepted?
No
Yes
PS to
Distribute PO
copies to
concerned
End
Yes
Documents
OK?
No
Stores/QC to
Distribute
NCR copies
to concerned
PM-14d
Process Owner
Objective
Rev.#
Rev. Date:
22-Jan-12
Start
Inputs
Prepare
Subcontract
Document/
Order
Yes
Approved?
No
To be referred to
Tax Department?
No
Yes
Results
acceptable?
No
Yes
Records
Records
Outputs
Realized Services
Records of Take Over/Hand Over
(as applicable)
NCR
Input to
Supplier/Subcontractor
Records of
Inspections/Monitoring and
Input to
Supplier/Subcontractor
PM-15
Rev.#
Rev. Date:
1-Mar-11
Input
Purchase Requisition
Order Confirmation Letter
Delivery Note from Supplier
Prepare MIR
Consumables
Welding Electrodes
QC Check
Materials
NO
YES
Store at designated
Receive appropriate
Material Request From
IP-05
Ensure Materials are stored in a
suitable environment & safe
condition
Issue Materials as
required and log in the
Issue Materials
Output
Delivery Notes
Inspection Reports
NCR's If any
MSDS
Site Issue Note
Material Issue Note
Consumable Issue Note
PM-16
Rev.#
Rev. Date:
01-Mar-11
Process Owner :
Workshop Supervisor
Objective
To establish a procedure for the pre-fabrication and fit-up of product in line with approved drawings and contract
specification in order to meet the customer requirements.
Inputs
Information Clear
& Complete?
Receive
Clarifications
No
Yes
Query
Results OK?
No
Yes
Results OK?
No
Yes
NCR
Records
Welding
Inspection Reports
Cleared RFIs
PM-17
Rev.#
Rev. Date:
1-Mar-11
Process Owner :
Welding Supervisor
Objective
To establish a procedure for the welding of products in line with approved drawings and contract specification in
order to meet the customer requirements.
Inputs
Information Clear
& Complete? Approved
WPS Available?
Receive
Clarifications
No
Yes
Query
Foreman/Welder to Ensure
Completion of Welding, Cleaning
and Necessary Identification
Results OK?
Foreman/Welder to Complete
the Required Operations
No
Yes
Results OK?
No
Yes
Welding
Records
PM-18
Process Owner :
Objective
:
Rev.#
Rev. Date:
16-Jan-12
As per requirment of
contract/code/specification foreman to
plan and explain to operatives.
No
Is Surface
Preparation & weather
condition acceptable?
Yes
Yes
Acceptable?
No
Is Protective Coating
acceptable?
QC to raise NCR
Operations to take
necesary corrective action
No
Yes
Output
Painted Materials
Inspection Reports
DN,
PQR
L. (PPE)
16-Jan-12
PM-19
Process Owner :
Objective
:
Rev.#
Rev. Date:
1-Mar-11
Is excavation /boring
required?
Yes
No
Make arrangements/Perform
excavation/boring to required
degree/depth as contract/specification.
Is the reading
acceptable?
No
Yes
Commision the system
and apply for End
User/Client approval.
Document and
Record the
Approval.
Yes
No
Output
PM-20
Rev.#
Rev. Date:
16-Jan-12
Inputs
Yes
No
Is special preservation
and packaging required?
Yes
No
Prior to loading/dispatch,
a final inspection request
shall be raised to QC
Final
Inspection
Report
NCR
No
Inspection results
acceptable?
Yes
Product to be re-offered
for inspection
Record
(Photos)
Outputs
PM-21
Process Owner :
Objective :
Rev.#
Rev. Date:
18-Jan-12
Project Manager
To establish a standard procedure for receiving, proper storage and controlled utilization of products at site.
Inputs
Materials/Tools Indent
Delivery Note
Contract Requirements
No
Yes
Site Engineer/QC
Inspector shall raise
NCR and intimate
the concerned
NCR
Yes
No
Outputs
PM-22a
Rev.#
Rev. Date:
16-Jan-12
Input
Contract Specifications
Contract Drawings
QHSE Requirements
NO
Approved?
Follow Process
PM-14 (if req.)
YES
Follow Process
PM-15(if req.)
Follow Process
PM-16(if req.)
Follow Process
PM-17(if req.)
NO
Approved?
Follow Process
PM-18(if req.)
YES
Job involves
Site work?
YES
NO
Output
Project Completion Report
PM-22b
Process Owner :
Objective
:
Rev.#
Rev. Date:
1-Mar-11
Project Management
To establish a formal procedure covering all installation / erection activities carried out
Input
CIF
Specification
Drawings
No
QC Check Ok?
required to be
planted into
concrete?
Yes
Yes
PM-27
Process Owner :
Objective :
Rev.#
Rev. Date:
16-Jan-12
Input
Customer Complaints
Customer Satisfaction & Feedback
Supplier Performance Evaluation, Re-Evaluation
Employee Suggestion & Feedback
Human
Process/Method
Work Environment
Supplier
Evaluate Competence
PM-28 or
alternative
arrangements
NO
Competence
Ok?
Is CPAR
required?
NO
YES
YES
Raise CAR,
Investigate
Root Cause
NO
Update Objectives
as applicable
Results Ok?
YES
Update Records
& Closeout
Output
PM-28
Rev.#
Rev. Date:
16-Jan-12
Inputs
Immediate Superior shall make the employee aware of their roles & responsibilities, relevance
& importance of their activities, the OH&S Hazards/Risks & Significant Environmental
Aspects/Impacts related to their activities/behaviour, the benefits of their compliance to IMS
requirements & improved performance and potential Consequences of departure from specified
requirements and how they contribute to the achievement of IMS Objectives of PPE
Immediate Superior shall evaluate the QHSE performance of his/her subordinates periodically
on the basis of job requirements and results of daily output and identify any QHSE Training needs.
The HSE supervisor shall evaluate the HSE performance of the employees on regualr
as well as eventual basis and identify any HSE Training Needs
External or
In-House?
Output