MUMBAI TRANS HARBOUR LINK PROJECT

PACKAGE II

Non-Conforming Item Control Procedure

1 19.10.2020 As comment J.S.SEOK S.E.YUN C.K.PARK

0 23.03.2020 First Issue J.S.SEOK S.E.YUN C.K.PARK

REV DATE DESCRIPTION WRITE CHECK APPROVAL

Document No: DWST-MTHL-QP-009

Non-Conforming Item Control Procedure

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Non-Conforming Item Control Procedure

Document No.: DWST-MTHL-QP-009 REV. 1 PAGE 2 of 13

REVISION LOG

REV. NO. REV. DATE REVISED PAGE REVISION DESCRIPTION

0 23.Mar.2020 All First Issued

1 19.Oct.2020 7, 9 ,11,12 As comment

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Non-Conforming Item Control Procedure

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TABLE OF CONTENTS

1.0 PURPOSE .....................................................................................................................................................4

2.0 SCOPE ..........................................................................................................................................................4
3.0 DEFINITION ..................................................................................................................................................4
4.0 RESPONSIBILITY .........................................................................................................................................4
4.1 Project Quality Assurance (QA) Manager / QA Engineer ..................................................................5
4.2 Project Quality Control (QC) Manager / QC Engineer ......................................................................5
4.3 Quality Control (QC) Inspector ..........................................................................................................5
4.4 Manager of responsible Party / Team .............................................................................................................. 5
4.5 Responsible Party / Team.................................................................................................................................. 5
5.0 CONTROL OF NON-CONFORMING ITEMS ................................................................................................5
5.1 Identification ......................................................................................................................................5
5.2 Segregation.......................................................................................................................................5
6.0 NON CONFORMANCE REPORT (NCR) ......................................................................................................6
7.0 CORRECTION AND CLOSE OUT OF NCR ..................................................................................................6
8.0 REGISTRATION OF NCR .............................................................................................................................6
9.0 Defect Trend Analysis and Quality Improvement ...........................................................................................7
10.0 RECORDING OF NCR FORM ....................................................................................................................7
10.1 NCR Numbering System...................................................................................................................7
10.2 Discipline Code .................................................................................................................................7
10.3 Cause Code of NCR .........................................................................................................................7
11.0 APPENDIX ...................................................................................................................................................9
(Exhibit – 1 : NCR Control Flow Chart) ......................................................................................10
(Exhibit – 2 : Hold / Reject Label) ............................................................................................... 11
(Exhibit – 3 : Non-conformance Report (NCR)) .........................................................................12
(Exhibit – 4 : NCR Register) .......................................................................................................13
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1.0 PURPOSE

This procedure is to define the roles, responsibilities and processes surrounding the reporting, recording
and resolving of identified or discovered non-conformances.

2.0 SCOPE

This procedure describes the methodology of controlling non-conforming items found during MTHL
Project package II execution to provide a process for the identification, reporting and documentation of
nonconformities reported or discovered through observation, surveillance, notified inspection at
assembly and erection site.

3.0 DEFINITION

The definitions of terms included in this procedure are as below;

a) Non-Conformity : Non-fulfillment of a requirement

b) Non-conformance Report : Report of detected nonconformity

c) Correction : Action to eliminate a detected nonconformity

d) Corrective Action : Action to eliminate the cause of a detected nonconformity or

other undesirable situation to prevent recurrence

e) Preventive Action : Action to eliminate the cause of a potential nonconformity or

other undesirable situation to prevent occurrence

f) Deviation : Action to depart from the originally specified requirements of a prod-

uct prior to realization

Deviation to the Owner specification is not-acceptable. The disposition of product non-conformities shall
be categorized into four (4) basic types, as follows:

a) Concession : Should be for using alternate method/technique as defined in the original accepted
proposal

b) Rework/Repair : Action on a nonconforming product to make it acceptable for the intended use

c) Scrap/Reject : Action on a non-conforming product to dispose of its original usage.

d) Return : Return the non-conforming product to supplier

4.1 RESPONSIBILITY

All personnel are responsible for identifying and reporting any actual materials, equipment, services,
or processes and that would result in a level of quality outside of accepted or established standards
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in effect establishing that everyone is responsible for quality.

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4.2 Project Quality Assurance/Control Manager

Is responsible for:

- Developing the non-conforming item control procedure

- Issue / review/approval and distribution of the Non-conformance Report (NCR)

- Maintaining NCR Register, disposition, tracking and closeout

- Carrying out Defect Trend Analysis of NCR during first year of project

- Carrying out Corrective Action / Preventive Action Process (where applicable)

4.3 Quality Control (QC) Inspector

Is responsible for:
- Identification and reporting of Non-conforming items

- Preparation of the NCR report.

- Re-verification of correction and close out of NCR

4.4 Manager of responsible Party / Team

Has a responsibility of controlling nonconformities per the accepted disposition of the Non- conform-
ance Report (NCR) for their assigned areas and disciplines.

4.5 Responsible Party / Team

Is responsible for:

- Bringing to the attention of the QC inspector any in process non-conformance.

- Prompt corrective action and correction of non-conforming item

- Requesting the verification of correction to Quality Control Inspector

- Preventive action

5.0 CONTROL OF NON-CONFORMING ITEMS

5.1 Identification

When QC Inspector detects, suspects or is informed of the existence of the non-conforming item, he
shall investigate the non-conformity and report to Project QC Manager.

Non-conformities may be identified through a number of means. General observations, surveillance,

formal or casual inspections may all identify non-conformities.
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5.2 Segregation

Once, a non-conforming item is identified by QC Inspector, he shall stop the use or operation of the item
by segregating if possible, and attaching the "Hold" or “Reject” label for guarantee or marking.

Only the QC Inspector shall remove the label/marking once the disposition has been approved and
the corrective action, if required, has been implemented satisfactorily.

The engineer / foreman in charge of the item in Construction Department, Material Management
Department or other Departments are responsible for segregation of the non- conforming item.

QC Inspector shall also ensure that the Non-conforming item has been segregated to the designated
area or identified.

6.0 NON CONFORMANCE REPORT (NCR)

All NCR submissions must be filled out by the originator on the established NCR format.

QC Inspector shall describe the actual condition of non-conformance with back-up data (i.e. documental
evidence or picture and etc.) with the NCR report

Project QC Manager shall decide the necessary disposition action through investigation and discussion
with Construction & Engineering Manager as necessary.

The disposition shall be approved and should include the expected disposition date to be proposed
by Project QC Manager and CONTRACTOR.

7.0 CORRECTION AND CLOSE OUT OF NCR

When the disposition of NCR is approved, the copies of NCR shall be distributed to QC Inspector,
and relevant parties. Relevant parties (including Responsible Department) will be designated by QC
Manager based upon NCR details.

Correction of the non-conforming item shall be made in accordance with the approved disposition. QC
Inspector shall check the correction, and report the verification result to Project QC Manager when the
correction is completed and verified.

Project QC Manager shall attach the back-up documents, if necessary, to the NCR and close it out with
verification by CONTRACTOR.
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CONTRACTOR acceptance to the corrective action(s) or correction performed is required to close out
the NCR.

8.0 REGISTRATION OF NCR

Project QC Manager is responsible for registering, filing and controlling NCR.

Once the NCR is issued, information related to the NCR shall be registered in the "NCR Register"

NCR Register with disposition status shall be reported to CONTRACTOR weekly.

9.0 Defect Trend Analysis and Quality Improvement

Defect trend analysis will be carried out by QC Manager every 3months before Performance Review
Meeting. Sorted cause code will be utilized for quick recall of defect type for analysis purpose.

10.0 RECORDING OF NCR FORM

10.1 NCR Numbering System

MTHL – NCR - OOO

10.2 Cause Code of NCR

Code Description of Cause

C01 Drawing revision/Modification/drawing err

C02 Defective workmanship/Materials/Equipment
C03 Transit damages
C04 Mishandling of items at site
C05 Improper storage
C06 Inspection error
C07 Approved procedure/FQP/QAP not followed
C08 Natural Calamities
C09 Inadequate Inputs/Resources/QA system/Materials
C10 Others
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11.0 APPENDIX

Exhibit - 1 : NCR Control Flow Chart

Exhibit - 2 : Hold Label / Reject Label
Exhibit - 3 : Non-Conformance Report (NCR)
Exhibit - 4 : NCR Register
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(Exhibit – 1 : NCR Control Flow Chart)

Quality Manager Quality Inspector Responsible Dept. Owner

Identification of
Non-Conformance * DTJV/GC finding NC
shall be handled with
Stop the Operation same flow of this.
Segregation
Labelling of Hold/Rej.

NCR Preparation
(Actual Condition)

NCR Disposition/
Registration of NCR

Review/Approvall of
NCR Disposition

NCR Distribution Correction

Confirm of
Close of NCR
Correction

Review/Approval of
NCR Closure

Distribution of Removal of
Closeout NCR Hold/Reject Label

Analysis the NCR and establish the plan of

replapce prevention

Implementation

Report the result

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(Exhibit – 2 : Hold / Reject Label)

"HOLD LABEL"

"REJECT LABEL"
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(Exhibit – 3 : Non-conformance Report (NCR))

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Legend TATA PROJECTS LIMITED
Gray Auto filled fields
ANALYSIS OF NON CONFORMITY CUM RESOLUTION REPORTS / FIELD OBSERVATION RECORDS / FIELD INSPECTION NOTES UPDATED UPTO July- 2020
peach Drop downs fields

Mismatch of
Proposed Civil drawing Defective Mishandl Approved Inadequate
NCR - Name of the Open/ Actual Date of Rework Cost borne Drawing
NCR/FOR/FIN Rejected/ Agency Completion Rework cost with Workmanship / Transit ing of Improper Inspectio Procedures / Natural Inputs /
S.NO NCR/FOR/FIN No Description Discipline Major / NCR Type Root Cause Details Issued by Vendor / WIP/ Completion of Details of Correction Done Preventive Action by Revision /
Date Rectifiable Responsible date of (Rs.) Mechanical / Materials / Damages items at Storage n Error FQP / QAP Calamity Resources /
Minor Subcontractor Closed Resolution TPL / Subcontractor Modification
Resolution Electrical Equipments sites not followed QA Systems
drawing

1 1 03.06.2016 Curing bunds are not prepared for curing of raft Civil Major Structural Rectifiable Curing done by providing hessain cloth. FQE Closed 03.06.2016 04.06.20169
Document No.:

Shuttering board for PCC works collapsed during

2 2 10.06.2016 Civil Minor Structural Rectifiable Shuttering redone immediately and continued concreting FQE Closed 11.06.2016 11.06.2016
concreting

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(Exhibit – 4 : NCR Register)

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