Item ‘Questions - QC Manager Answers Define Project Quality Plan, ‘SAEP-1154 Quality Plan: Document specifying which procedures and associated resources shall be applied by whom and when to a specific project, product, process or contract. {ISO 9000] _ What are the processes /stages related in defining Preventive actions? SAEP-1154 5.8.5.3 Prevent Potential Nonconformities a) Detect potential nonconformities. b) Identify the causes of potential nonconformities. ¢) Study the effects of potential nonconformities. d) Evaluate the need to take preventive action. @) Develop preventive actions to eliminate causes. 4) Take preventive actions when they are necessary. g) Record the results achieved by preventive actions. h) Examine the efficiency of the preventive actions. What is a Quality Policy? Quality Objectives? ‘What is the function of a QMS Quality Policy-Top Managements expression ofits Intentions, directions and aims regarding Quality of its products and processes. Quality Objectives-a specified level of Quality that must be met by a product to be deemed acceptable. | ‘Can be defined as the managing of organizational structure, responsibilities, procedures, processes and Hera ete ene Imonagerent resources omplement the principles & action lines needed to achieve quality objectives of the organization Sch. Q. 7.5.3 CONTRACTOR, subcontractors, manufacturers and/or | suppliers shall document all non-conformities to Contract requirements, approved CONTRACTOR quality plan(s), iacontactor rae ineral | ppetion &test plans end racedues, CONTRACTOR 7 they inform the Client shall forward to COMPANY records of all recorded non- | I ecai conformities within 48 hours of Issue. . 7.5.4 CONTRACTOR shall investigate the root cause of nonconformities and initiate Corrective Actions to prevent recurrence of nonconformities maximum 7 days of the issue date | What SAEP is being referenced 6 when escalating NCR/ Project | SAEP-381 Project quality Issues Escalation Process Quality Issues? 7: How do you close NCR? | SAEP-1154, 7.5.4 CONTRACTOR shall investigate the root cause of honconformities and initiate Corrective Actions to prevent recurrence of nonconformities maximum 7 days of the issue date. Implementation of Corrective actions will require RFI, participation of PID to verify CA isin line with the Std, requirements or with approved Method of atatement..What Is an ITP? SAEP-1150 Inspection & Test Plan (I&TP): An I&TP is a document based on the detailed manufacturing, fabrication and construction program which identifies each process description, sets out the related sequence of activities to be inspected, examined and tested and lists the relevant approved procedures for a particular material, component, | assembly, or, in some cases, type of work, It shall include identification of requirements for documents, acceptance criteria to be used, who is responsible for what, the inspection survelllance to be performed and the type and level of inspection including hold, witness and review points of Contractor/Sub-contractor and Saudi Aramco. ‘Mandatory Hold What are the attachments in Sch. OF Sch.Q. ‘Attachment I CONTRACTOR and Subcontractor Quality Personnel Qualification Requirements Attachment Il COMPANY Standards and Procedures Containing Quality Requirements Attachment Ill Quality Requirements for CONTRACTOR Supplied Materials Attachment IV Quality Requirements for the Construction | Phase ‘Attachment V Summary of Quality System Deliverables ‘Attachment VI Project Specific Quality Requirements 10 ‘At what phases Internal audit is conducted as required per Sch. a Sch Q. | 7.3.2 CONTRACTOR shall submit a quality audit schedule to the Company Representative for review and approval within thirty (30) calendar days from the effective date of this Contract. As a minimum, full quality system audits | shall be carried out at fifteen Percent (15%) and sixty percent (60%) of completion stage for the Design, Procurement, and Construction WORK Phases. Contractor's audits may be rescheduled only with the concurrence of the Company Representative. Monthly Quality Management | Report—what are the quality items included in the report. Sch. Q. 7.7 Analysis of Data CONTRACTOR shall prepare and submit a monthly Quality ‘Management Report in a format acceptable to COMPANY | to demonstrate effective implementation of the CONTRACTOR's Quality System. The report shall include the following items as a minimum: 7.7.4 General tems: 2) Listing of quality audits completed (internal and Sub-contractor), in progress, and planned for the next month.'b) Status of open corrective actions for Non-conformance reports, audits and management reviews. ) Quality Personnel Listing by Discipline as specified in Paragraph 5.11. 4) Listing and status of engineering waivers requested 7.1.2 Design and Procurement Phase Items: 2) Listing of supplier surveys performed and results b) Planned surveys for the next month c) Listing of Pre-inspection Meetings conducted and planned for the next month d) Listing of supplier inspections performed and those planned for the next month 7.7.3 Construction Phase Items: a) Listing and disposition of all defective or rejected material or equipment received at jobsite by CONTRACTOR and subcontractor( s) 'b) Welding rejection rate reported in accordance SAEP-1160. A chart showing the historical performance during the project shall be included. 7.7.4 Narrative Section for Process Improvement Activities This section shall describe CONTRACTOR and subcontractor activities during the month to continually improve its processes, correct and eliminate non- conformities, prevent potential problems, and improve schedules, et. It shall include trend analysis for processes identified in paragraphs 7.1.1 and 7.4 of this contract schedule. Name some of the special Sch. Q, Welding/Brazing Nondestructive Testing (NOT) Positive Material Identification (PMI) & Color-Code Verification Heat Treatment & associated Hardness Testing Pressure Testing | welding, NOT, pressure testing. | What are some of the oo Process procedures? _| Coatings & Lining Gasket Installation Gap Control (Socket welds, thread engagement, back welding of threaded joints) Hot Taps (Cables) & Tie-ins Refractory installation HVAC Testing & Balancing TR Pipe Work “Name some of the | 13 Please see attached Sch. Q. Deliverables, Deliverables? What SAEP is referred for aq_| tacking & reporting of SAEP-1160, Section 6.1 Minimum Data Requirements See attached pdf.[ information contained in the report? a What important information is 15 | contained when accomplishing | SATR-W-2018, please see attached SAIC-W-2018 WRR Report SATR-W-2018 _ - —_ Sch.a. 5.27 CONTRACTOR shall submit Hydrostatic Test Packages prior to conducting hydrostatic tests of piping, pipeline and equipments for COMPANY review and approval, The hydrostatic test shall comply with SAES-A-004, SAES-L-150 and G! 002,102. The hydrostatic test package shall include but not limited to the following: + Hydrostatic Test Procedure. + Hydrostatic Test Diagram which shall include the limits of piping (Including test manifold) and equipment include each hydrostatic test, test pressures, test temperature, | as | Whatarethe contents ofa | tect fui ine flushing requirements, and safety hydrotest package? precautions, + Relief Valve datasheet and calibration records. | + Pressure gages and recorders calibration records. + COMPANY Safety Instruction Sheet and Pressure Test Report Form. * Copies of P&ID and isometric drawings of the piping. system to be hydrostaticaly tested. | * Piping spools control sheet with NOT extent and results + Prechydrostatic test check List. | + Re-instatement procedure and Check List, | + Bolting Control Sheet. + Gasket Verification Form. During the course of the construction phase, a major | standard violation was | committed by the contractor | and despite various renee QC Manager must bring the quality issue to SA Project communicated to the Inspection supervisor describing all in detalls of the contractor still refuses to committed std violation and PID will take the implement the corrective | necessary/serious action to correct the non-conformity. 17 | actions. While exhausting all ‘ SAPID Field Supervisor being the main counterpart of the the efforts within the i contractor QC Manager must interphase with PID with organization and with the client | regards to Quality. SA Interviewer Is keen to hear the contractor remain steadfast ea wer not to comply despite NCR has 7 been issued. Now, As a QC Manager what will you do and what will be your action/s to | pave the way to resolve the |standard violation? (Exhausting | 7 means the issue was brought to the higher management, _| SAMPT, operations et). item | Questions - QA Manager ‘Answers > Define and implement the overall QA strategic approach. > fiDefine and implement the overall QA tactical/operational approach. | > [Define and implement an efficient QA operating model to align with the company’s business goals, > tiManage teams across multiple geographic. locations, releases and projects. > [iManage and maintain the QA team budget. > BBulld the QA area/team, QA team structure, and QA roles and responsibilities based on the projects the QA group would be responsible to deliver. Build a strong QA team through better recruitment, retention, training, and performance | evaluation. > Set the overall QA test strategy that includes all the various types of testing being performed by the QA team. > biDetermine the scope of the overall QA team. based on all the business demand, run the business maintenance work, resource capacity and skill set. > Provide input from a testing perspective to the delivery release roadmap and project schedule plan, capacity, and deployment to production schedule > Maintain the QA team’s capacity planning, utlization and assignment allocations, etc. > Create and maintain the overall QA Project Plan and Statement of Work (SOW). What are the roles of a QA Manager? SAEP-1154 | quality Plan: Document specifying which procedures 2 | What isa Pap? and associated resources shall be applied by whom and when to a specific project, product, process or contract. {SO 9000]Mention an example ina Quality Policy? Refer to Approved CAT POP ‘What SAEP is referred as guidelines to Contractor's, SAEP-1154- Guidelines for Contractor's Quality Plan | Project quality Plan? What are the eight sections of apap? SAEP TSA Section 1 Scope (corresponds to section 1 of !SO 9001:2000 and section 5.1 of SAEP-1154) Section 2 Normative reference (corresponds to section 2 of ISO 9001:2000 and section 5.2 of SAEP-1154)) Section 3 Terms and definitions (corresponds to section 3 ‘of ISO 9001:2000 and section 5.3 of SAEP-1154) Section 4 Quality Management System (corresponds to section 4 of ISO 9001:2000 and section 5.4 of SAEP-1154) Section 5 Management Responsibility (corresponds to section 5 of ISO 9001:2000 and section 5.5 of SAEP-1154) Section 6 Resource Management (corresponds to section 6 of ISO 9001:2000 and section 5.6 of SAEP-1154) Section 7 Project Execution/Product Realization {corresponds to section 7 of ISO 9001:2000 and section 5.7 of SAEP-1154) Section 8 Measurement, Analysis, and Improvement {corresponds to section 8 of SO 9001:2000 and section 5.8 of SAEP-1154) Explain Management Responsibility & Product, Realization? ‘SAEP-1154 5,5 Management Responsibility 5.5.1 Management Commitment ‘The top management of (contractor) is committed to the development and improvement of the quality management system by: 1. Communicating the importance of meeting Saudi Aramco, regulatory, and legal requirements by (identify how this information is communicated). Establishment of a quality policy and objectives (identify ‘the quality policy and quality objectives for this project.) AiConducting management reviews in accordance with Paragraph [reference paragraph number} of this Quality Plan and Schedule Q. Ensuring the availability of necessary resources in accordance with Section [reference Section number] of this Quality plan. 5,7 Project Execution (Product Realization) 5.7.4 Planning of Project Execution ‘The (Contractor) shall plan and document the project execution process. The documentation for project execution is stated in paragraph 5.3.2 of this quality plan.The quality objectives for the (design, procurement, construction activities, etc.) are identified in (consider the contract, internal quality objectives, etc.) The (design, procurement, construction or Pre- commissioning) processes, documentation, resources, and facilities shall be established for this project. (Describe compliance with this requirement. Consider reference to other section of this Quality plan, including matrix or other data developed in Section 1, the resource loaded schedule, other documentation). Verification and validation are incorporated into the planning process as follows: (describe how verification and vali activities are incorporated. Consider design review, acceptance testing, planned inspections, approval, | etc. The resource loaded schedule may be used to identify, verification and validation activities.) ‘Acceptance criterla for the work will be developed where appropriate. Records attesting to conformity of process and resulting Work shall be maintained by (title). Records include: {Inspection reports and certificates {8 Disposition reports 8 Internal quality audit results and closures | Records of management reviews | Project acceptance by Saudi Aramco shall be documented by Mechanical Completion Certificate(s) (MCC). How many QMS do you know? 1SO 9000:2008 OMS Fundamentals & Vocabulary ISO 9001:2008 QMS - REQUIREMENTS ISO 9004:2008 OMS ~Guidelines for Performance 7 | Name One and explain briefly | Improvements 1S0 19011:2002 Guldelines on Quality & for | Environmental Management Systems Auditing SAEP-1154 or ISO 9001:2008 5.4 Quality Management System 5.4.4 General Requirements in order to implement the QMS, the (contractor) has developed the following matrix that identifies: the process Re neny TOMS. | needed to ensue effective operation and control ofthe processes; availablity of information necessary to support the effective operation and monitoring of these processes; methods of measurement, monitoring, and analysis needed in order to implement those actions that will | | achieve planned results and continual improvement |g _ | Whatare the deliverables ‘Sch. Q, as per attached in the email. mentioned in atta. V of Sch Q? SAEP-1150 10 | What isan ITP? Inspection & Test Plan (18TP): An I&TP is a document based on the detailed manufacturing, fabrication andit What is Quality Assurance? construction program which identifies each process description, sets out the related sequence of activities to be inspected, examined and tested and lists the relevant approved procedures for a particular material, component, assembly, or, in some cases, type of work. It shall include identification of requirements for documents, acceptance criteria to be used, who is responsible for what, the inspection surveillance to be performed and the type and level of inspection including hold, witness and review points of Contractor/Sub-contractor and Saudi Aramco. Mandatory Hold Part of Quality Management focused on fulfiling Quality Requirements, = 2 What is Quality Control? Part of Quality Management focused on providing confidence that Quality requirements will be fulfilled, 3 4 ‘What is an Internal / audit? What is a Non Conformity? | Contractor: How long you have to wait before you Inform the Client officially? What information is included in the letter? 150 9004:2008 clause 3.9.1 — checking What & How the Company operates VS. What and How they say they do, evaluating the methods used to determine if objectives and customer requirements are met and reporting results where actions are taken to conform with the methods and criteria and identify possible improvements. Sch.Q 7.5.3 CONTRACTOR, subcontractors, manufacturers and/or suppliers shall document all non-conformities to Contract requirements, approved CONTRACTOR quality plan(s), Inspection & test plans, and procedures. CONTRACTOR shall forward to COMPANY records of all recorded non- conformities within 48 hours of issue. 7.5.4 CONTRACTOR shall investigate the root cause of nonconformities and initiate Corrective Actions to prevent recurrence of nonconformities maximum 7 days of the issue date. 15 | What is an Inspection ‘Assignment Package (1AP)? | following documents as appli Sch. Q 3.15 CONTRACTOR shall compile and forward to the Company Representative no later than twenty-one (21) calendar days prior to the pre-Inspection meeting and start of any fabrication, ether at the prime supplier or @ major sub-supplier, one electronic version on compact disc (CD) of the CONTRACTOR's Inspection Assignment Package, and forward to COMPANY one complete set via e-mall. For Inspection Level 4, CONTRACTOR shall submit the Inspection Assignment Package fourteen (14) days before final inspection. 3.15.1 The Inspection assignment package shall include the bk 3.15.1.1 A complete copy of the CONTRACTOR's purchase order including Change Order(s} or subcontract, material requisition, and attachments 3.15.1.2 Copies of sub-suppliers applicable purchaseAt what inspection level project orders (If these are not available, CONTRACTOR shall provide them to the Company Representative upon placement by the supplier) 3.15.1.3 Applicable COMPANY standards (SAMSS/SAES) 3.15.14 Inspection requirements as specified in the applicable COMPANY Form 175 3.15.1.5 Inspection assignment sheet specifying the approved inspectors) that will perform the inspections 3.15.1.6 Inspection and Test Plans 3.15.1.7 The level of CONTRACTOR inspection (as required by SAER-1972 or Attachment VI to this Schedule "Q") 3.15.1.8 Agenda for each pre-inspection meeting where appropriate. Sch. Q. Inspection Level 1, Only final inspection is required prior to pre-inspection meeting? 16 | material/s be in order for lap | UPS be generated? ping. ‘Sch. Q. _ 3.15 CONTRACTOR shall compile and forward to the Company Representative no later than twenty-one (21) calendar days prior to the pre-inspection meeting and start of any fabrication, either at the prime supplier or a major How many calendar days are ee 17 | fetutuntortoecheduting a | b-supller of the CONTRACTOR's Inspection Assignment | Package, and forward to COMPANY one complete set via e- ‘mall. For Inspection Level 1. CONTRACTOR shall submit the Inspection Assignment Package Fourteen (14) days before final inspection