QA-QC PLAN

ORGANIZATION: -

PROJECT: -
LOCATION: -

PREPARED BY: - MR. SAGAR RASKAR. (AGM-QAQC)

APPROVED BY: -

DATE OF ISSUE: -
REVISION: -

1
 TABLE OF CONTENTS
1. QUALITY MANAGEMENT SYSTEM.
2. QAQC ORGANIZATION CHART.
3. QUALITY ASSURANCE PLAN.
3.1. PURPOSE OF QA PLAN
3.2. ROLES & RESPONSIBILITIES
3.3. PROCESS STANDARDIZATION
3.4. TRAINING & ORIENTATION
3.5. SUPPLIERS/CONTRACTORS QA
3.6. DOCUMENT CONTROLS
4. QUALITY CONTROL PLAN.
4.1. PURPOSE OF QC PLAN
4.2. ROLES & RESPONSIBILITIES
4.3. SCOPE OF QUALITY CONTROL
4.4. STANDARDS & SPECIFICATIONS
4.5. INSPECTION & TESTING PLAN
4.6. SAMPLING & BENCHMARKING
4.7. CHECKLISTS & DOCUMENTATIONS
4.8. NON-CONFORMANCE MANAGEMENT
5. QUALITY MONITORING & REPORTING. (QMR)
5.1. PURPOSE OF QMR PLAN
5.2. CONTINUOUS MONITORING
5.3. QUALITY REPORTING
6. RCA-5 WHY ANALYSIS, FISHBONE DIAGRAM.

2
 1. QUALITY MANAGEMENT SYSTEM (QMS)

I. Purpose:
The purpose is highlight the processes help for the QMS for continual
improvement & to determine the criteria & methods required to ensure
the effective operation & control of the identified process.

II. Scope:
The scope should include QMS must comply with relevant legal, regulatory
and industry specific standards that helps to achieve the organizational
quality goals.

III. References:
List of applicable codes, standards, specification & regulations that will be
adhered during the project - IS, BS, EN, A.S.T.M, ISO.

IV. Responsibilities:
QAQC Manager - Oversees the entire QAQC process & ensure adherence
to the plan.
Project Manager – Ensure that QAQC process integrated into the projects
daily operations & Coordinates between the departments.
QAQC Inspectors & Technician – Perform regular inspections, testing &
verification to ensure quality requirements are met.
Team Members – Each member responsibility for maintaining quality in
their specific task.
Contractors – Contractor should be responsible for to ensure the all work
is performed to the required standards, specifications and regulatory
requirement and also follow the QAQC methods, processes & procedure to
ensure that all project deliverables meet the required standards. This
involves periodic inspections at different stages of the work & verifying
that materials & workmanship meet define quality standards. Co-
ordination with site team & QAQC team.

3
V. Principles of QMS:
1. Customer Focus- Organizations depends on their customers
therefore should understand current & future customer needs, meet
customer requirements and strive to exceed customer expectations.
2. Process Approach- Results are achieved more effectively & efficiently
when activities are understood and managed as interrelated
processes that function as a coherent system. The process approach
involves the systematic definition and management of processes and
their interactions.
3. Leadership- Leaders establish unity of purpose and direction for the
organization. They should create and maintain the internal
environment in which people can become fully involved in achieving
the organization’s objectives.
4. Engagement of People- People at all levels are the essence of an
organization and their full involvement enables their abilities to be
used for the organization’s benefit. Involving employees in decision-
making & process improvement, it helps for quality of the output.
5. Factual Approach- Effective decisions are based on the analysis of
data and information. This principle emphasizes the importance of
using reliable data to make informed decisions that can be justified
and evaluated.
6. System Approach- Identifying, understanding and managing
interrelated processes as a system contributes to the organization’s
effectiveness and efficiency in achieving its objectives.
7. Relationship Management- Organizations manage their relationships
with interested parties, suppliers, partners, and other stakeholders.
Strong relationships can lead to increased efficiency, and improved
performance, and ensure that the supply chain operates smoothly.
8. Continual Improvement- This involves continuous improvement of
processes, products, and services, which is necessary for
organizations to maintain current levels of performance, adapt to
changes in their internal and external environments, and create new
opportunities.

4
VI. Objectives of QMS:
1. Customer Satisfaction: Increase the customer satisfaction score day
to day.
2. Process Efficiency: It involves enhancing procedures, reducing waste
and ensuring consistency to achieve the high quality outcomes
without rework and within time.
3. Waste Reduction: Decrease the material wastage in this year and will
do proper waste management.
4. Defect Rate: Lower defects rate in products and services day to day.
5. Employee Training: Ensure 100% of employees receive quality
management training.

VII. Quality Procedures in QMS:

Quality procedures in QMS are documented processes that guide how a
project will carry out its quality objectives, ensuring consistency and
control across operations.
Here key elements of Quality Procedures in QMS:
1. Document Control Procedure:
 Ensure all QMS documents are created, reviewed, approved,
distributed and updated systematically.
 Prevents unauthorized and outdated documents from being used.
2. Control of Records:
 Manages how records are created, stored, protected, retrieved
and disposed of.
 Helps maintain evidence of compliance and quality performance.
3. Internal Audit Procedure:
 Describes the methods for regularly assessing the QMS through
audit.
 Identifies area for improvement, evaluate compliance with the
QMS and ensures corrective actions are taken when necessary.

5
4. Non Conformance Control Procedure:
 Outlines steps to identify, document and address non-conforming
products and processes.
 Ensures corrective actions are taken to prevent recurrence.
5. Corrective Action and Preventive Action (CAPA) Procedure:
 Define how corrective and preventive actions are identified,
implemented and monitored.
 Addresses the root causes of nonconformities and prevents similar
issues in the future.
6. Risk Management Procedure:
 Establishes a method for identifying, assessing and mitigating risks
to product quality or compliance.
7. Supplier and Purchasing Control Procedure:
 Ensure suppliers meet quality requirements through evaluation,
selection and periodic review.
8. Customer Feedback and Complaint Handling Procedure:
 Provides a strategic approach to collecting, reviewing and
addressing customer feedback and complaints.
 Improves customer satisfaction by resolving issues and using
feedback for continuous improvement.
9. Employee Training Procedure:
 Ensures employees receive the necessary training and
demonstrate competence for their roles.

6
2.ORGANIZATION CHART.

YEN- QAQC ORGANIZATION CHART

(GM-QAQC)

(DGM-QAQC)

(AGM-QAQC)

SE- QAQC SE- QAQC ASE- QAQC

(RCC WORK) (FINISHING WORK) (LAB & PLANT)

ASE-QAQC ASE-QAQC JE-QAQC

(LAB & PLANT)

7
 3.QUALITY ASSURANCE PLAN.
3.1 Purpose:
The purpose of QA plan is to ensure that products or services meet the
customer requirements and comply with industry standards or regulations. It
set the foundation for achieving consistent quality by specifying quality
control & preventive measures.
QA focuses on the proactive steps taken to ensure that processes are
followed, minimizing the defects.

3.2 Roles & Responsibilities:

The QA plan should define the roles & responsibilities of all personnel
involved in QA activities.
 QAQC Manager- Oversee the entire QA process, develop policies and
ensure adherence to the plan.
 QAQC Inspectors- Perform check & audits to verify compliance with
standards and identify any areas for improvement.
 Project Manager- Ensure that QA procedures are integrated into day-
to-day operations.
 Engineering/Technical Staff- Follow the QA plan and ensuring that
process function correctly to meet quality standards.

3.3 Process Standardization:

 Implement & standardize the procedure, WMS & best practices for
project to ensure consistency in quality.
 SOPs is detailed, written instructions that outline the specific steps to
be followed to complete tasks in a consistent & uniform manner.
 SOPs ensure that processes are carried out the same way every time,
regardless of who perform the task.
 QAQC manager prepare the all WMS of the work activity and
approve/verify it from Senior managers of the QAQC.
 QAQC manager ensure that all SOPs are available & accessible to all
employees.

8
  QAQC manager ensure that all standard documents related to
processes such as WMS are properly managed & up to date.
 QAQC manager review & revise the documents whenever changes are
made to processes.
 QAQC team ensures that work process comply with WMS procedure &
contracts specifications and drawing.

3.4 Trainings & Meetings:

The QA plan should include strategy for training and ensuring the
competence of personnel involved in quality-related activities. Training
helps that all employees, contractors and suppliers understand the quality
standards and procedures they must follow.

Training & Meeting Program Element:

1.New Employee Training- Comprehensive on-boarding to introduce to
the quality standards & procedures.
2.Kick-Off Meeting- Prior to starting the work activities conducted this
meeting for Contractors & Staff, explain the detailed work procedure &
scope of work.
3.QAT-Subject Expert Training- Regular refresher subject expert trainings
to keep employees, contractors and workers updated and aware to
processes and standards.
4.Quality Review Meeting- It is essential to maintain control over the
quality processes, ensure continuous improvement and address any
quality related issues promptly.
5.On-Site Training- It is the part of continuous improvement strategy,
where employees and workers regularly updated on processes or industry
best practices.
6.MIS meeting- To ensure that quality standards are being met across
processes and systems & utilize MIS data for improvement in quality
performance. Also effectively supporting for decision-making and strategic
objectives.

9
 QAQC manager & inspectors ensure that all team members, contractors
are trained on projects quality standards, expectation & processes.
 QAQC manager conduct the Kick-Off Meeting Prior to starting the
work task with Contractors, Site engineers & PM.
 QAQC manager ensure the contracts document, mentioned work
procedure and scope of work.
 During the kick-Off meeting QAQC manager communicates the work
task quality requirement, work procedure as per WMS, required quality
documents, record keeping requirements, standard of workmanship,
awareness of critical quality requirements, work task quality inspection
checklists etc.
 QAQC manager conduct the weekly QRM with contractors, contractor
personnel’s & staff for reviewing the quality of work, process deviation
& any non-conformance.
 QAQC manager maintain the record of QRM in training tracker or
Quality control report.
 QAQC manager & team prepare the schedule of trainings for staff and
contractors and conduct/arrange the trainings according to schedule.
(i.e. On Job training, Subject Expert Training, Lessons Learned training,
Critical to quality training.)
 QAQC manager maintain the record of trainings in training tracker or
Quality control report.
 Each day QAQC team member will meet the QAQC manager and discuss
the daily progress report or quality regarding any issue.
 QAQC manager conduct the weekly meeting with staff for taking the
review of QA of material & approved process.

10
3.5 Suppliers/Contractors QA:
 Ensure that materials from suppliers & work performed by contractors
meets the project quality requirements.
 QAQC team will be responsible for evaluating all materials & goods
received as per approved specifications and determine their compliance
with the contract specifications prior to delivery on site.
 QAQC inspectors ensure the suppliers/contractors material when
arrived on site is as per approved specifications.
 QAQC inspectors check & verify the material as per approved
specifications by MTC, TDS, Field test & TPT.
 QAQC inspectors maintained the test records of supplier’s/contractors
material. (i.e. MTC, TDS, MIR, FTR, TPTR)
 After checking material from the QAQC inspectors then allowed for use.
 QAQC inspectors have authority to reject the material if material not as
per approved specification or found any defects and convey this
message to QAQC manager.
 QAQC inspectors maintain the record of material rejections.
 QAQC inspectors keep the records maintained of the material testing &
verified from QAQC manager.
 QAQC inspectors may stop the work activity if found the material not as
per approved specification and raised the NCR against contractor &
building engineer.
 QAQC manager coordinate with suppliers/contractors with quality
regarding matters/defects.
 QAQC manager ensure all materials received on site is inspected.
 QAQC manager ensure all materials testing is performed as per ITP.
 QAQC inspectors assist to QAQC manager regarding any material quality
issues.

11
3.6 Document Control:
 QAQC manager prepare all quality related documents and ensure all
document is review & formally signed off by designated authorities.
 QAQC inspectors ensures that all documents related to quality
processes are properly managed & updated.
 QAQC manager ensure that all hard copies of document are distributed
accurately and outdated versions are removed.
 QAQC inspectors shall inspect all materials received on site and these
material are acceptable as per contract specifications document are
comparable to PO. Receiving inspections shall be recorded & fill the
MIR.
 QAQC inspectors shall be aware of every stages of construction and
prior to start the new activity ensure that material have been approved
and maintained the documents.
 Supplier/Manufacturer may proceed the material inspection in advance
with the Witness Point of QAQC inspector and then proceed for further.
 Supplier may not proceed the work without witness by QAQC
inspector.
 After arriving the material QAQC inspectors filled the FTR, MIR as per
specifications and maintained record of TDS & MTC.
 QAQC inspectors send the material for TPI as per ITP for QA purpose.
 QAQC inspector check the material tags, labels & other markings for
traceability of the material.
 Document control system should be audited regularly to ensure
compliance with internal policies and external standards.
 Internal Audit should verify that –
-Only latest version of document are in use.
-Documents are reviewed & approved.
-Changes & revisions are clearly documented.
 Audit findings should lead to corrective actions if any compliance is
identified in the document control system.

12
  Internal audits findings will be reported to the senior QAQC
management and all improvement actions & follow-up will be done by
QAQC manager.
 QAQC manager will review all internal audit reports & interact with the
auditors for suitable corrective actions.
 Results of the internal audits are reviewed during the management
Review.

 Roles & Responsibilities in Document Control:

 QAQC manager- Responsible for overseeing document control within
the quality management system. Ensure all documents are reviewed,
approved and distributed according to QAQC protocols.
 Document Controller- Dedicated personnel tasked managing the
document control system, ensuring proper handling, storage and
access to all QAQC documents.
 Reviewers & Approvers- These individuals (often department heads or
quality leads) are responsible for reviewing and approving document
before release.
 End Users (Engineers, inspectors)- Personnel who use QAQC
documents for daily operations must ensure they are always using the
latest approved version of the documents.

 Benefits of Document Control in QAQC:

1- Improved Consistency. 2- Enhanced Compliance.
3- Error Reduction. 4- Efficient Auditing. 5- Traceability.

13
 Document Controlled in QA Plan:
 Following are the documents that are controlled in QA plan-
1. QAQC Plan
2. WMS/SOPs
3. ITP
4. Quality control Checklists
5. Concrete mix design
6. Concrete cube register
7. Concrete consumption tracker
8. Material Standard Specifications tracker
9. NCR Tracker
10. Observation tracker
11. CAPA reports
12. Audit reports
13. Training tracker
14. Waterproofing Leakage tracker
15. Shower Test tracker
16. Tile Slope tracker
17. Tile Hollowness tracker
18. Pressure testing tracker
19. Electrical continuity testing tracker
20. Electrical post supply checking tracker
21. Firefighting hydro testing tracker
22. MIR & FTR tracker
23. QC records TPT
24. Rolling margin tracker
25. Standard Deviation tracker
26. Material TPT cost tracker
27. Calibration records
28. MIS & MOM
29. PDP tracker
30. MTC & TDS records

14
 4.QUALITY CONTROL PLAN.
4.1 Purpose:
The purpose of QC plan is to ensure that every stage of production or service
delivery is monitored and controlled to meet quality standards. It helps to
identify defects, non-conformities or deviations early in process, allowing for
timely corrections & minimizing the risk defects reaching customers or
affecting project outcomes.

4.2 Roles & Responsibilities:

QC plan outlines the specific roles & responsibilities of personnel involved
in quality control including,
 QAQC Manager- Responsible for oversee the quality control activities
and ensures compliance with QC plan.
 QAQC Inspectors- Perform inspections, tests and verifications during
production or project executions.
 Project Manager- Ensure that quality control procedures are integrated
into day-to-day operations.
 QAQC Team- Ensures that the QC plan aligns with the overall QA
processes.

4.3 Scope of Quality Control:

QC plan specifying the areas that will be controlled and monitored
including,
1.Material
2.Equipment
3.Workmanship
4.Work Activity Processes
5.Services & deliverables.

It describes where QC needed across the project lifecycle from

procurement to final inspection & testing.

15
4.4 Standards & Specifications:
The QC plan must reference the Standards, Codes & Specifications that
the QC process will follow, which may include:
 Internal Standards- Company specific guidelines or product
specifications.
 Industry Standards- ISO standard, IS, ASTM, etc.

4.5 Inspection & Testing Plan (ITP):

ITP is key component of QC plan. It outlines the inspection points, testing
stages and verification activities to ensure that quality is maintained at
every stage of production or service delivery. It typically includes:
 Inspection Points- The stages where inspection occur (e.g. raw
material inspection, in-process inspection, final inspection)
 Test methods- The types of test to be performed.
-Visual inspection: Checking for visible defects like scratches,
deformities, colour or inconsistency.
-Dimensional Checks: Measuring the physical dimensions of the
product to ensure it meets design specifications.
-Functional tests: Testing the performance of the product to ensure its
operates as intended.
-Laboratory test: Physical & chemical material testing to verify the
compliance with specifications.
 Acceptance Criteria- The specific criteria that must be met for the
product, service or process to be considered acceptable.
 Responsible Personnel- Specifies who will perform the inspections &
tests.

16
 -The inspection & testing activities are conducted as indicated in the
ITPs.
-QAQC manager will ensure that proposed approved 3rd party
laboratories will comply with the contract specification requirements.
-The Quality team will ensure necessary co-ordination with the 3rd party
testing Laboratories. They will ensure adequate quantities of samples of
material are secured and delivered.
-All construction material received on site will be subjected to receiving
checks on site by QAQC inspectors to ensure these are as approved and
specified.

 Field Inspection Quality Control:

 Prior to starting the work QAQC team will check all materials, drawings,
procedures & other relevant matters regarding the work.
 All materials should be as per approved material specifications,
drawings & procedures to be of the latest revisions.
 All material & drawing which are approved are to be rejected and
removed from the work site.
 After completion of work engineer raised the RFI for checking.
 Task-Ready for Inspection: - Engineer raised the RFI for work is ready
for quality inspections and it verify that conditions conform to the
project quality requirement.
 WIP-Quality Inspections: - Engineer performs an initial work in process
inspection when the first portion of the work activity is completed.
 QAQC engineer verify the work checklists and maintained the all
inspections records.
 During inspection found any defects or deviation in work process then
QAQC engineer highlights it immediately.

17
4.6 Sampling & Benchmarking:
Use sampling techniques for testing materials & work quality to ensure
that what is being produced matches the predefined standards.
 Incoming material inspection- sampling materials from suppliers to
ensure they meet specifications before use in work.
 In-Process Inspection- Sampling during the production or service
delivery process to detect any deviations before the final product is
completed.
 Final Inspection- Sampling finished products to ensure that meet
customer requirements and regulatory standards before release.
*Benchmarking in Quality Control*
1.Internal Benchmarking- Comparing performance across the different
projects processes, products.
2.Process Benchmarking- Comparing & improving internal processes to
align with best in class practices. (E.g.- Sampling, inspection & testing
methods)
Define what we want to achieve through benchmarking such as:
- Reducing Defects.
- Improving Product Quality.
- Enhancing Process Efficiency.
- Reducing Customer Complaints.
A Sampling & benchmarking plan are essential components of an effective
Quality Control plan.
Sampling ensures that representative portion of products or services is
inspected to maintain quality.
While Benchmarking helps the organization set quality goals by comparing
its performance against industry standards or competitors.
Both plans contribute to achieving higher levels of product quality,
customer satisfaction and operational efficiency.
18
  Control of Mock-Up Construction:
1.Approval of mock-up must have a prior approval from the
management before starting of work. And make sure that there is
always an available of procedures for construction of mock-up before
starting the work.
2.When mock-up completed then inform and arrange the visit of each
department, Architectures, Consultants and management for review,
verify & approval purpose.
3.Mock-up sample is the representation of the proposed materials and
constructions so it must show the product to comply with the necessary
requirements, show the proposed aesthetic aspect and workmanship.
4.Mock-up sample is good comparison standard for remaining work.

4.7 Checklists & Documentations:

Use inspection checklists to ensure evaluation of work at each stage of
activity. Maintain detailed records of test results, non-conformance &
corrective actions.
It is the essential tools to ensure consistency, traceability & compliance
with quality standards.
Effective use of checklists ensures that critical tasks are not missed, while
documentation provides a clear record of inspections, test & corrective
actions for future reference or audits.

 Purpose of Checklists: -
1.Ensure that each stage of process is completed according to
predefined requirements.
2.Maintain consistency and prevent human error.
3.Provide quick reference tool for inspectors & quality personnel.
4.Act as an evidence of compliance with QAQC standards.

 Types of Checklists in QAQC Plan: -

 Civil Work Checklists.
 PEF work Checklists.
19
  QAQC manager prepare all activity work checklists according to
requirements.
 After preparing the all work checklists give it for review, verification and
approval purpose to PM & Senior QAQC management.
 QAQC manager ensure that all checklists are sign-off from senior
management team.
 Site PM ensure that all approved checklists are integrated in daily work.

 Documentation in QAQC Plan: -

Documentation provide detailed records of the entire quality process,
ensuring traceability, accountability and compliance.

 Purpose of Documentation: -
- To provide record of all quality related activities.
- To track progress & performance of quality control measures.
- To ensure traceability of products, processes and corrective actions.
- To support audits, customer review and regulatory inspections.

4.8 Non-Conformance Management:

It is the systematic process for identifying, documenting, addressing and
resolving deviations from the established quality standards or
requirements.
Non-conformances can occur in materials, processes, products or services
and need to be an effectively managed to ensure that quality is
maintained, corrective actions are taken and preventive measures are
implemented to avoid recurrence.

20
 Purpose of Non-conformance:
- Identify & control defective or non-compliant products, material or
processes.
- Mitigate Risk of defects reaching customers or causing further issues in
production or service delivery.
- Implement Corrective Actions to eliminate the RCA of NCs.
- Prevent Recurrence of non-conformances through preventive actions
and continuous improvement.

 Key Steps in Non-Conformance Management:

1. Identification of Non-conformance- the 1st step is identifying deviations
from quality standards. NCs may detected during:
 In-Process quality control checks.
 Final Inspection or test.
 Incoming material Inspection. (If applicable)

2. Site engineer raised the RFI of the work, QAQC engineer observed any
defects, process deviation during inspection then QAQC engineer give
observations accordingly.
3. QAQC engineer directly raised the NCs to building engineer &
contractor, depends on severity of issues, repeated observations and
observations are not closed within 2 days then this observation will be
converted into NCs.
4. Then Building In-charge/PM should be responsible for compliance and
mentioning the corrective & preventing action in Non-Conformance
report.
5. Process flow of Observations or issues-
Duration Process Flow
˃ 2 Days NCR
˃ 7 Days Yellow Card
˃ 14 Days Orange Card
˃ 28 Days Red Card

21
 5.QUALITY MONITORING & REPORTING.
5.1 Purpose:
Monitoring is the essential for tracking quality performance throughout
the project. It helps maintain accountability, support decision making and
foster continuous improvement. Regular and accurate reporting provides
insights into performance, identifies areas for improvement and supports
compliance with standards.

5.2 Continuous Monitoring:

QAQC teams continuously monitor quality performance through
inspections, audits and reviewing data from tests & checklists.
It helps to identify any variations from quality standards.

5.3 Quality Reporting:

QC reports document the results of inspections, testing & monitoring
activities. These reports include data on defects, process deviations, non-
conformance’s and corrective & preventive actions taken

Components of reporting:
1.Inspections Report- it is the results of quality inspections carried out
during various stages of production or service process.
2.Non-Conformance Report- NCR document instances where a product,
process or service does not conform to predefined standards or
specifications.
3.CAPA Report- Addressing non-conformance and ensuring continuous
improvement.
Corrective Actions taken to resolve non-conformance.
Preventive Action taken to avoid recurrence of similar issues.
4.Incident Report- It is formally record and accidents or non-conformances
that occur during a project production and services.
5.Audit Report- It may be internal or external audit. These reports
evaluate compliance with the QAQC plan, regulatory standards.

22
6.RCA – 5 WHY ANALYSIS & FISHBONE DIA.

23
24