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WORLD QUALITY DAY 12 NOV 15Ella Agbettor

SHEQ Foundation

… Quality is never the result of random but the output of a thought-out and organized effort…

World Quality Day – Brief History

World Quality Day is celebrated every 2nd Thursday in November and for 2015, it falls on Thursday November 12th. It is a day set aside to celebrate Quality and the benefits it gives to Organizations that implement it.

It was started in 1989 by the American Society for Quality (ASQ), European Organization for Quality (EOQ) and the Union of Japanese Scientists and Engineers (JUSE)

Changing customer perceptionsCustomer needs and expectations are constantly changing.

Awareness of new technology, legislation, competitor services creates new wants for customers.

Quality and valueValue is not a price tag but a measure of the benefits derived from

a product or service for what is given in return. It is how value compares with customer needs that signifies quality

What quality is notQuality is not perfection, a standard, a procedure, a measure or an

adjective. Quality does not exist in isolation – there has to be an entity. It is not a specific characteristic of an entity but he extent to which that characteristic meets certain needs.

Why Quality

Definition of Quality

Joseph Juran: He developed the 80/20 principle, advocated top management involvement and defined quality as “fitness for use”

W. Edwards Deming: He developed the 14 steps to Total Quality Management and advocated the Plan-Do-Check-Act cycle as basis for quality improvement

Philip Crosby: He popularized the concept of the cost of poor quality, advocated prevention over inspection and “zero defects”. He believed that quality is “conformance to requirements”

Quality is defined as the degree to which a product or service fulfils requirements.

ISO 9001 The ISO 9001 quality standard is the internationally accepted standard for quality management systems. What is ISO9001?ISO 9001 entails a systematic and orderly approach to manage your quality management system rather than the quality of your services or products.

QUALITY MANAGEMENT

Quality ManagementQuality Management: A process of creating and following up on policies andprocedures to ensure that a product meets the defined needs it was intended to meet from the Customer’s perspective.

Quality Management includes the following processes: Quality Planning: identify all relevant standards and requirements for the quality of the project and the product of the project. Quality Assurance: The process of verifying or determining whether products or services meet customer expectations. This process considers design, development, production, and services Quality Control: involves the examination of a product, service, or process to ensure that they meet specific requirements and are dependable, satisfactory, and financially sound. Quality Improvement: This is a feed back process that helps to provide information on lessons learnt as a basis for improvement in the next cycle of activities.

The Project Quality Team• In most projects, the Quality team is made up of:

The Quality Assurance Department and the Quality Control Department.

Quality Assurance is the process of verifying or determining whether products or services meet customer expectations

Quality Control is the detection of defects by means of inspectionGenerally, the overall goal of the Quality team is to ensure that the• products, services, or processes provided by the Contractor, meet• specified requirements and are dependable, satisfactory, and• acceptable to the customer.

This is achieved by use of:• International Standards such as ASME codes, AWS D1.1, European standards, etc.• Project procedures and specifications• Approved project drawings

Project Quality Team

Typical Steps to achieve Quality in Projects

• Relevant procedures and report formats are developed, reviewed and approved

• Prequalification of Contractors, Suppliers and Vendors to ensure their capabilities to execute the works, supply materials and equipment based on requirements.

• Inspection and proper storage of procured materials is performed.

• Welding Qualification are performed to get suitable welding procedures and welding personnel who can produce sound and acceptable welds.

• Calibration, maintenance and pre-mobilization of equipment.

• Actual fabrication and site erection works are carried out using the procedures and qualified personnel . Non-conformities are spotted and treated accordingly.

• At the end of welding works, Non Destructive Tests ( Visual, RT, MPI, DPI, UT) are performed to ascertain integrity of welds.

• Flushing and Pressure test (hydro or pneumatic) are performed as a further check for the integrity of entire pipe sections and process vessels

• Periodic Audit is performed on personnel, processes and systems to ensure that requirements and project objectives are being achieved.

• Appropriate documentation, is done for every step enumerated above. This documentation is validated by the Contractor and COMPANY representatives and it becomes binding.

Impact of Poor Quality in Projects

• Increased costs• Low morale• Low customer

satisfaction• Increased risks• Rework• Schedule delays

Customers Customers

Management responsibility

Resources Management

Product realisation

Mesurement , analysis and improvement

Requirements

Satisfaction

ProductOutputInput

ISO 9001

Promoting quality management , based on planning, measurement

and improvement, which delivers the following benefits :• Improved customer satisfaction • Reduced costs and improved profitability • Improvement and innovation • Identification and management of risk• Corporate care and responsibility

Benefits of Quality

Typical Quality Project Docs• Project Quality Plan (QP)

Per Schedule “Q”, Contractor is required to develop a project specific Quality Plan by which to run the project’s quality. (The QP is a living document; maintained by Contractor)

• Quality manual (QM)The document consisting of, or referring to, the recorded quality system procedure intended for the overall planning and administration of activities which impact the quality within an organization.

• Inspection and Test Plan (ITP)ITP is a quality document listing overall scope Quality Control activities (including inspections) referring to pre-developed Checklists (CICs) and Customer Inspection and Test Records (ITRs).

• Customer Inspection Checklists (CIC) Designed and developed for the CTIP, each checklist contains the complete Acceptance Criteria for each and every specific inspection activity check-item, per inspection work item, per discipline, eliminating the need to retrieve applicable standards for inspection point in question.

• Inspection and Test Records (ITR)Designed and developed to cover the contractor quality inspection testing requirements on equipment and systems, such as electrical, communication and mechanical installations. ITRs are referenced also in the ITPs as applicable.

• Quality Control Procedures (QCP)A QCP is a documented procedure detailing the processes necessary to complete a specific work activity (for fully meeting quality requirements).

Organizations using quality techniques can expect to be:• Profitable – with a healthy bottom line• Safe – compliant with legislation• Green – operating with reduced energy costs, an enhanced reputation

and better placed to respond to legislation• Improved – continually able to find ways to do things better• Fit for purpose – delivers on promises, the first time, every time• Innovative – identifies gaps in the market • Productive – creates positive results and delivers up to capacity• Efficient – eliminates wasteful practices • Sustainable – will be around for many years to come.

Organisations that practice quality

Quality should be designed in, rather than inspected out

Quality in different areas of society

EXAMPLE OF QUALITY IN DIFFERENT AREAS OF SOCIETY Meeting Customer Requirements Reducing Development Cycle Times Just In Time/Demand Flow Manufacturing Improvement Teams Reducing Product and Service Costs Improving Administrative Systems Training Reduce Chronic Waste Reduce Variation