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Report
COMMERCIAL- IN – CONFIDENCE The contents of this report must not be disclosed to a third party without the agreement of the SAI Global Client
Number of Staff: 35
Shifts: Single
Audit Team Members(s): Vinod Khanna - Auditor, Arun Kumar Sinha - Lead Auditor
The purpose of this audit was to determine continuing compliance of your organisation’s
management system with the audit criteria; and its effectiveness in achieving continual
improvement and system objectives.
The audit revealed that Pentair Thermal Management India Private Limited is the Indian
subsidiary of the parent company in USA. Its main expertise lies in providing thermal solutions
to pipes carrying liquids and gases as well as storage tanks. One of the key areas where its
products find wide application is in oil pipelines both intra-plant as well as those from oil wells
or storage tanks to the processing units.
India office takes care of India and the Middle East. The company also provides design
support to its peer units in Europe, US and Japan. The principals provide bulk of the product
support particularly for heat tracing. Company also sources some products locally.
Nature of contracts broadly cover three categories i.e. engineering that is the design part,
project management and construction and finally product supply.
Both Mumbai and Noida facilities undertake the entire range of activities but broadly Mumbai
is primarily focussed on design whereas Noida is on projects. This however is not a watertight
distribution of work. Mumbai office also houses many management factions like HR .
Company’s design functions are software driven where the applying personnel have to feed
the input data and the design output parameters are worked out. Design software has got
validated over the years by its consistent performance. Design verification primarily involves
peer review for making checking the accuracy of calculations and feeding of the correct and
appropriate data.
Company’s operational systems are aligned with those of its principals in USA and are sound.
All the personnel displayed good knowledge of their subjects and there was ample evidence
of the implementation of the documented system
Some opportunities for improvement were also identified during the audit. These are
covered in the main body of the report. Definition of these terms is given in the general
information section of this report.
The audit team wishes to place on record his profound thanks to the client personnel for
their cooperation during the audit. The team also wishes to thank other remember of the
client organization for their powerful support during the audit
This audit was a stand-alone audit of the system(s) listed in the “Background Information”
section of this report as part of a multi -site certification.
The audit has determined that your management system has the ability to ensure the
organisation meets its identified applicable statutory, regulatory and contractual
requirements relevant to the scope of certification.
The audit has determined that your management system is effective in ensuring that the
organisation can reasonably expect to achieve its defined objectives.
The objectives of this audit have been fulfilled.
Recommendation
The recommendation from this audit is that your certification proceeds.
Audit recommendations are always subject to ratification by the SAI Global certification authority.
VK Khanna Auditor P -
Significant issues impacting on the Audit Programme. No significant issue impacting the Audit
programme.
Appropriateness of the certification scope. Site specific scope has been captured .
Scope remains unchanged. The organisation has defined and documented scope of their
quality management system. All activities, products and services within the scope are
included in the QMS. This was verified during the audit and there is sufficient evidence to
prove that that the scope is appropriate.
Noida facilities undertake the entire range of activities but broadly Mumbai is primarily
focussed on design whereas Noida is on projects.
Review of any changes. QMS has been upgraded as per the requirement of the ISO 9001:2015 Version.
Action taken on previous audit findings. Previous Audit findings have been addressed are adequately
closed .
Use of the certification documents and marks verified not being used at present on any document.
The organization has determined the organizational context and need and expectation of
the interested parties are being frequently monitored and reviewed during quality
management review meetings conducting bi annually in order to consistently provide
product and services which meet the customer and applicable statutory and regulatory
requirement Customer Employees , external Providers , Statutory and regulatory bodies .
Monitoring and review mechanism has been defined
Scope remains unchanged. The organisation has defined and documented scope of their
quality management system. All activities, products and services within the scope are
included in the QMS. This was verified during the audit and there is sufficient evidence to
prove that that the scope is appropriate.
Noida facilities undertake the entire range of activities but broadly Mumbai is primarily
focussed on design whereas Noida is on projects.
Leadership and commitment
Policy. Top management has established, reviewed and maintained a quality policy that is
appropriate to the context of the organisation and provides framework for setting objectives.
Policy includes commitment for continual improvement of the QMS. The policy is available
as documented information Quality policy has been formulated signed by the director .
Organisational roles, responsibilities and authorities. Senior management has ensured that
the Organizational roles and responsibilities of the staff are defined and communicated.
Planning
Risks and opportunities. The organization Risk Assessment process is driven through the
organization quality management review committee. Risk identification to monitoring of the
effectiveness of the actions taken to the identified risks are being continuously followed up
by the committee. Risk assessment is done for every project that is won and executed.
Business/Quality objectives.
Process-wise quality objectives based on performance indicators are being monitored
against monthly targets. Corresponding targets for the year
Proposal – conversion of proposal into orders –Target - 30 %. First Half – 57%, Second
Half – 17 %. Annual – 37%.
On time delivery of proposal – 95 % - 95 .9 %.
Project management. Gross margin improvement Target 2 % each month – 6.6 % Each
Month 2ND Review dec 2017.
Resource utilization Target 70% achieved 61% inter GBU.
Engg – Budget schedule variation. Target less than 5 % or 15 day – 7 days.
Procurement effective utilization of manpower – 60 % on projects- 64 %
Documented information.
The organisation has maintained documented information to effectively maintain the QMS.
Main processes have been identified. Each process gives process owner, inputs, activities
to be performed, controls and records required. Inter-action between processes has been
defined. Adequate documents have been generated to maintain the QMS effectively. A
number of SOP’s have been made for each process.
Communication. Internal communication normally take place by regular meeting, emails,
sharepoint, memos, notice board and intercom also use to communicate significant
decisions or information concerning the QMS or other business.
Operation and service delivery
Operational planning and control. The same was verified during audit of sales, Proposal, Projects
and construction, project controls processes are in place.
Requirements for products and services.
The organization has established, implemented and maintained a process to determine the
requirements for the products and services to be supplied to prospective customers.
Control of externally provided processes, products and services. System is in place to control
externally provided services whenever there is any need. Maintenance Services: AMC’s for
Fire equipment, IT services AMC, has been based on the service agreements
Outsourced services: Outsourced routine services SOS Payroll
Its primarily handled by the Design team who sit in Mumbai office.
Processes
Sales Interacted with Mr Sachin Pandita, Regular Visits are made to major customer
customers like EIL, Bechtel consultants , Track the leads .RFQ Queries , Pre bid
engineering .technical and commercial , L1 Criteria ,hit rate is monitored , Key Accounts ,
Customer feedbacks – 95 %. Customer complaints are also handled by the Sales team and
Project QSP -05 -08 IOCL Refinery , Vadodra,
Quality Objectives for the Sales department. MPO RMC , Major project offering risk
Assessment . Global Format is used . Company also participates in reverse bidding and
has won some projects .
Project Management.
Mr Akhlesh Dube and Mr MP Chandra are project team leaders. Project plan is made on MS
Projects. Material is procured as per the BOM. Material requirement is projected to Purchase
who then provision it as per the plan. Personnel requirement is worked out and apportioned
Resource planning on F-QSO-05-02. It takes care of both human and material resources.
Customer complaint. Saw incident report. Saw complaint from Phoenix Trading Co LLC dated
25 Aug 2017. Complaint was there is no reading display in TTDM-128. Cause was
manufacturing defect of the item ex-USA. Item replaced and case closed
Customer feedback from Tata Projects. All parameters are good and excellent, document No
F-QSP-05-08.
Proposal .
This process makes technical appraisal of the customer requirements and provides technical
inputs to the sales and marketing for the commercial proposal. The process is defined in
QSP-01.The main procedure is to identify potential business through sales leads and then
preparing, reviewing and submitting of bids to achieve sales as per business plan.
There are broadly following types of proposals depending upon customer requirements:
• P= Product supply
• EP= Engineering + product supply
IT. Objectives. Critical service request to be closed within 1 hour TAT /24 hours
Installation of software – TAT 5 days . Analysis of data could be done ascertain the present
achievement.
Server is located at the site Backups are taken on daily and weekly basis. Risk
Assessment is done , Anti viris Macfee is being used at the site.
Waste Management- Authorized E waste collector TES AMM collects the E waste like
laptops , keyboards and provides a certificate for the same valid till 3/2/2018 . Hard disk
are removed from the system before the disposal and these hard disks are maintained at
the facility.
Performance evaluation
Customer satisfaction is assessed by taking regular feedbacks from the customers at present
95 %.Customer satisfaction level. Feedback received from Tata Projects was seen,all
parameters are good and excellent, document No F-QSP-05-08.
Internal audits Internal Audit is done as per procedure QSP -07 R03, 2016 Internal Plan
F QSP -07 -04 R2 , frequency is twice in a year , Internal Audit plan April 2018 , Dec 2018
,
List of trained internal auditors are 5 as per ISO 9001:2008 to be upgraded to the new
standard ISO 9001:2015, QASPR 07-
ISO 9001:2015 Dec 2017 ,Processes/ Functions audited include top Management
Marketing, sales proposal, Engg , project management , construction , procurement, HR/
Training , IT and infrastructure and Admin , Quality EHS.
QSP -04 Procurement R3 , EHT Panel Supplier , Design team , Technical Approval by
design team ,ITP provided by the supplier IOCL Vadodra , Project manager .
Verification of purchased product - not clear observation raised during Internal Audit.
Proposal -3 observations – open , process flowchart, CBD Sheet Document Control,
Project management – observation , document control folder not prepared.
Management review is Chaired by Sales director , IHTS Middle East India, Last meeting
was in 26 July next meeting to be held in Feb 2018 it should take into consideration
effectiveness of action Taken to address the risk and opportunities .
26 July Agenda points discussed included, Audit results, Process performance, Customer
feedbacks.
Continual improvement.
Improvement projects are undertaken for continual improvement. Across all processes be it the
sales. Proposal, Projects /construction procurement.
a) Reason for break in calibration continuity, of instruments could be captured in the system. For eg
clampmeter Serial No 20221002 calibrated in July 2017 was calibrated in Nov 2017 that is
three months after it was due .Reason stated was that it was not in use for that period.
b) Internal inspection reports ,reports submitted by the suppliers on the basis of which the
verification is being done for eg Inspection report from Vidhyut controls India Pvt ltd, Project
Name 10238- 801 for electrical heat tracing panel may capture the PO Number and serial
numbers of instrument used for inspection
c) Root cause analysis for observations raised during Internal Audit could be done in detail for eg
one observation was pertaining for use of obsolete format by the project team but the root cause
for the same was not ascertained.
d) Customer complaints closure to be initiated after the acknowledgement from the customer end ,
regarding the suitability of the correction/ corrective action initiated on the same.
e) Training plan for the quarter could be released at the beginning of that Quarter. Internal Auditor
training request has been sent to HR department .
It is suggested that the opportunities for improvement be considered by management to further enhance the
company’s Management System and performance of the business.
Quality control