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PRE-ENGINEERED BUILDINGS DIVISIONVIETNAM – PEB

QUALITY SYSTEMMANUAL

(QSM-PEB)

Issued by:

MANAGEMENT REPRESENTATIVE

Approved by:

GENERAL DIRECTOR

QUALITY SYSTEM MANUAL Revision # 5

Date: 20.09.08

Section i Page ii of v

Table of Contents

Sect. No.

Ref.ISO9001

Revision Specification PageNo Date

IIiIii

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Table of contentsRecord of RevisionsCirculation list

iiivv

0.00.10.2 1.2

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IntroductionGeneral InformationScope and Application of this Manual.

112

1.01.11.2

1.2.11.2.21.2.31.2.4

44.14.2

4.2.14.2.24.2.34.2.4

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Quality Management systemGeneralDocumentation

GeneralQuality manual and internal documentsControl of documentsControl of records

3344445

2.02.12.22.32.4

2.4.12.4.22.5

2.5.1

2.5.22.5.32.6

2.6.12.6.22.6.3

55.15.25.35.4

5.4.15.4.25.5

5.5.1

5.5.25.5.35.6

5.6.15.6.25.6.3

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20.09.0820.09.0820.09.0820.09.0820.09.0820.09.08

Management responsibilityManagement CommitmentCustomer FocusQuality PolicyPlanning

Quality ObjectivesQuality Management System Planning

Responsibility, Authority and CommunicationResponsibility, Authority

Chief Operating OfficerGeneral DirectorOrganization

Management RepresentativeCommunication

Management ReviewGeneralReview Input, System Status Report

Review Output

77778881010101010101112121212

3.03.13.2

3.2.13.2.23.33.4

66.16.2

6.2.16.2.26.36.4

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Resources ManagementProvision of ResourcesHuman Resources

GeneralCompetence, Awareness and Training

Resources (hardware and software)Work Environment

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Date: 20.09.08

Section i Page iii of v

Sect. No.

Ref.ISO 9001

Revision Specification Page

4.04.14.2

4.2.14.2.24.2.34.3

4.3.14.3.24.3.34.3.44.3.54.3.64.3.74.3.84.4

4.4.14.4.24.4.34.4.44.5

4.5.14.5.24.5.34.5.44.5.54.6

77.17.2

7.2.17.2.27.2.37.3

7.3.17.3.27.3.37.3.47.3.57.3.67.3.7

7.47.4.17.4.27.4.3

7.57.5.17.5.27.5.37.5.47.5.57.6

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Product realizationPlanning of Product RealizationCustomer Related Processes

Determination of Product RequirementsReview of Product RequirementsCustomer Communication

Design And DevelopmentDesign and Development PlanningDesign and Development InputDesign and Development OutputDesign and Development ReviewDesign and Development VerificationDesign and Development ValidationDesign and Development ChangesDesign and Development Manuals

PurchasingPurchasing ProcessPurchasing InformationVerification of Purchased ProductOutsourcing

Production and Service ProvisionControl of Production and Service ProvisionValidation of Process for Production and Service ProvisionIdentification and TraceabilityCustomer PropertyPreservation of Product

Control of Monitoring and Measuring Devices

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5.2.15.2.25.2.35.2.4

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8.38.48.5

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Measurement, Analysis and ImprovementGeneralMonitoring and MeasurementCustomer SatisfactionInternal AuditMonitoring Measurement of ProcessesMonitoring Measurement of Product

In-Process Inspection & TestingFinal Inspection and TestingInspection and Test Records

Control of Nonconforming ProductAnalysis of DataImprovementContinual ImprovementCorrective Action and Preventive Action

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Date: 20.09.08

Section i Page iii of v

5 20.09.08 Annex 1, Annex 2 35


Date: 20.09.08

Section ii Page iv of v

Records of Revisions

# ISO Section

Rev. Item Date

1 00 First Issue 01.11.99

2 01 Minor Changes 02.07.013456

02030405

Minor ChangesEntire Quality Management System Manual

Logo changeMinor Changes,PIS added and Sales Territories

revised.

15.11.0224.12.0320.09.08


Date: 20.09.08

Section iii Page v of v

Circulation List

COPY ISSUED TO

1 General Director

2 Finance Manager

3 Marketing Manager

4 Production Manager

5 HR & Administration Superintendent

6 Purchasing Manager

7 Engineering Supervisor

8 Production Engineering Supervisor

9 Production Supervisor

10 Customer Service Manager

11 Shipping & Logistics Supervisor

12 Production & Material Control Supervisor

13 Plant Maintenance Manager

14 IT Acting Manager

15 QC Supervisor

16 Product Research & Development Supervisor

17 Adminstration Supervisor

18 I.E Supervisor

19 HR Supervisor

20 Production Foreman





25 Electrical Foreman

26 Mechanical Foreman

QUALITY SYSTEM MANUAL

Title: Introduction

Revision # 5

Date: 20.09.08

Section 0.1 Page 1 of 42

0.1 GENERAL INFORMATION

0.1.1 Introduction

Zamil Steel (ZS) is the largest manufacturer of Pre-Engineered Steel Buildings in the

Middle East and has the most diverse product line and expertise in this industry. The

Division manufactures pre-engineered steel buildings for factories, warehouses, workshops,

supermarkets, automobile showrooms, sports halls, distribution centers, aircraft hangars, car

parking sheds and any one, two or three storey building. Zamil Steel uses state-of-art-

hardware, software and machinery in the estimating, designing, shop detailing and

manufacturing of all its products.

0.1.2 Brief History

ZS was founded by A.H. Al-Zamil Group of Companies in 1976 as designer and

manufacturer of Pre-Engineered Steel Buildings and expanded into Structural Steel Work in

1984. The company’s main operation is based at Dammam’s first & second industrial

estates. The company has progressively expanded as a major steel fabricator in the region

greatly contributing to the phenomenal growth of the Saudi Arabian industrial sector and

has successfully completed numerous large and prestigious projects in the Kingdom of

Saudi Arabia.

0.1.3 Marketing Presence

Zamil Steel –Vietnam maintains its own sales and technical support staff in 17 sales

territories. These are in Japan, Manila, Yangon, Jakarta Mandalay, Kuala Lumpur,

Singapore, Bangkok, Malaysia, Cambodia, Vientiane, Johar, Pyinmana, Batam, Hanoi,

Haiphong Danang and HCMC ,strategically located through out Asia and 2 Liaison Centers

in Sydney and Shanghai, and offer the most superior technical and customer support in the

pre-engineered buildings industry.

0.1.4 Vietnam Manpower:

The Vietnam –PEB division currently employs a multinational work force of approximately

718 persons.


Title: Introduction

Revision # 5

Date: 20.09.08

Section : 0.2 Page 2 of 42

0.2 SCOPE AND APPLICATION

Zamil Steel Management has established the following scopes of its businesses:

“Design, Detailed Engineering, Manufacture and Supply of Pre-Engineered Steel Buildings”.

This manual (QSM-PEB) has been written and implemented in-line with the requirements

of the International Organization for Standardization ISO 9001.


Title: Quality Management System

Revision # 5

Date: 20.09.08


1. QUALITY MANAGEMENT SYSTEM

1.1 GENERAL

Zamil Steel has identified the processes needed for a QMS and determined the sequence

and interactions along with the method to operate and control these processes ensuring

availability of information to operate, measure, monitor, control and analyze the data,

taking action to achieve planned results and improvement.

Outsourcing

Currently Zamil Steel has some processes outsourced to outside organizations. Control

of such outsourced processes is described in sections 4.1, 4.4 of this Quality Manual

and related documents.



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Date: 20.09.08


1.2 DOCUMENTATION

1.2.1 General

1.2.2 Quality manual and internal documents

Quality Manual: The Pre-Engineered Buildings (PEB) Division has documented its policies as per the recommendations of ISO 9001 in the form of a “Quality System Manual” bearing the title QSM (PEB), generally referred to in this manual as “QSM”.

QSM is a document introducing Company, Company’s quality policy, organization structure, responsibilities, and authorities. Quality manual refers to procedures of quality system and introduces structure of documentation.

Company and Management Procedures: An approved standard format for the structure of a typical procedure shall be followed. Refer to Procedure # ZSM 01.03. A list of all revised procedures shall be issued as and when required. Work Instruction shall also be referred to as procedures.

Departmental procedures and Work Instructions: the documents describing in details how a particular work is performed at a particular stage, application scope of which is determined by scope of related Procedures or Instruction.

Records: documents that provide objective evidence of activities performed or result achieved.

Control of forms: forms are enclosed within procedures and work Instructions and are referenced in respective procedures and work Instructions.The issuance, amendment, revision and distribution of QSM and other procedures are controlled as per Procedure # ZSM 05.01.

Technical Drawings;Technical standards;Customer drawings;Customer specification;ISO9001.

Internal Documents External Documents

Design Manuals;Design Output Documents;Zamil Steel Standards



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1.2.3 Control Of Documents

General

The Project Information System (PIS) Contract Information Form (CIF), design input, engineering output drawings and approved working procedures are considered as Controlled Documents.Refer to Procedures # ZSM 05.01.

Document Approval and Issue

Controlled Documents shall be reviewed and approved by the concerned Manager/Supervisor and shall be distributed and made available to all relevant recipients. A Master List of all Controlled Documents shall be established and be readily available for reference showing the latest revision number of the drawings for a particular job or working procedures.

Document Changes

All Controlled Documents are subject to revisions, improvements and amendments and are issued by the originally designated issuing authority bearing the latest revision number.

Superseded and obsolete documents shall be removed from use. The issuer may retain a copy of the old document for reference purposes, which shall be marked “ Void” or “ Old for reference only” or “Delete”.

Related documents

ZSM 05.01- Document and Data Control

PR 05.13- Document and Data Control in Purchasing

CSD 05.01- Document Control

PC 05.01- Document control Production

SD 05.01- Documentation

SD 05.02- Control of Documents in Shipping

QCP 05.01- Document and Data control in QC Department

1.2.4 Control Of Records

General

Records shall remain legible, readily identifiable and retrievable. A documented

procedure is established to define the methods of identification, storage, protection,

retrieval and retention time, disposition of records.



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All documents and data specified in Section # 01 of this manual shall be treated as

records with the exception of ‘approved procedures’.

When required as per contract, the Quality ‘Dossier’ containing Mill Certificates,

Welding Procedures and Inspection Test Reports shall be treated as a quality record.

Record Retention

Cartons and bundles shall be marked with the date of ‘ disposal or destroy’ and shall

be maintained for a period of minimum one year.

The Administration Department shall check and confirm the safe and accurate

storage of records.

Related DocumentsZSM 16.01- Quality Records Of Various Depts.PR 16.08 - Maintaining Quality Record in Purchasing.

QCP 05.03- E-mail Query Procedure

CSD 05.01 – Control of Computerized Documents

MN 05.01 – Document & Data Records Keeping at PM Department


Title: Management Responsibility

Revision # 5

Date: 20.09.08

Section 2.1 – 2.4 Page 7 of 42

2. MANAGEMENT RESPONSIBILITY

2.1 MANAGEMENT COMMITMENT

Top management commits to the development and implementation of the quality management system and continually improving its effectiveness by

a) Communicating to all staff the importance of meeting customer as well as statutory and regulatory requirements;

b) Establishing the quality policy;

c) Ensuring that quality objectives are established at all relevant functions and levels;

d) Conducting management reviews; and

e) Ensuring the availability of resources.

It is the objective of Zamil Steel Buildings Company Limited to provide quality

products conforming to the agreed upon specifications of contracted jobs, in order to

satisfy our valued customers.

To achieve these goals, the company is vigorously implementing the International

Quality Management System ISO 9001 .

2.2 CUSTOMER FOCUS

Zamil Steel top management ensures that customer requirements are determined and are met with the aim of enhancing customer satisfaction.

2.3 QUALITY POLICY

It is the Objective of Zamil Steel (Pre-Engineered Building Division) to remain a

renowned supplier of Quality Products by:

Identifying Customer’s needs and expectations and ensuring their satisfaction.

Ensuring controlled processes are fully implemented and developed.

Complying with the requirements of the Quality Management System and

continually improving its effectiveness.

Establishing and communicating meaningful Quality objectives and performance

targets.

Ensuring the Quality Policy is well communicated and clearly understood by every

employee.



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Ensuring that non-conformities in the product and system are identified,

investigated, analyzed and improved.

Providing healthy and safe working environment.

Developing employee skills and increasing their contributions through effective

training.

Developing supplier relationships to obtain defect free material.

KHALID AL-ZAMIL

President Date: January 2004

“Plan –Do—Check—Act”

2.4 PLANNING

2.4.1 Quality Objectives

Zamil Steel top management ensures that quality objectives, including those needed to meet requirements for product, are established at relevant functions and levels within the Company. The quality objectives are measurable and consistent with the quality policy.

2.4.2 Quality Management System Planning

Zamil Steel top management ensures that

a) the planning of the quality management system is carried out by taking into account the requirements of ISO 9001 , Company’s management culture and processes, as well as the quality objectives;

b) Plans are established in advance to ensure the integrity of quality management system when changes are implemented.

c) Zamil Steel has identified the processes needed for the quality management system and applied them. The sequence and interaction of those processes are presented on the annex No 2 of this Quality System Manual. Besides, the interaction between processes is described by the reference between different documents and their layers and by defining communication channel between different departments and positions in their duties and responsibilities.

d) Criteria and methods needed to ensure effective operation and control of these processes are identified in respective chapters of this Quality System Manual and related Management Procedures, departmental documents.

e) Zamil Steel makes resources and information available to support the operation and monitoring of these processes.

f) Monitoring, measurement and analysis of these processes are made through Plan-Do-Check steps of PDCA cycle and in case of needs, actions are made to



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ensure achievement of planned results and continual improvement of these processes.

Related Documents:

ZSM 01.03 – Standard Format For Writing /Changing Of Policy/Procedures

PR 01.01 – Purchasing Department Policy and Procedure

PR 01.03 – Goals of Purchasing Department



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Date: 20.09.08


2.5 RESPONSIBILITY, AUTHORITY AND COMMUNICATION

2.5.1 Responsibility and Authority

Chief Operating Officer

The Chief Operating Officer of the Company is Senior Vice President. He reports to

the President of the company and is accountable to the Board of Directors.

General Director

The General Director has full authority over the overall performance of the Vietnam

PEB Division. He is responsible for the performance of the various departments:

Marketing, Sales, Operations, Engineering & Estimating (E & E), Customer Service

(CSD) and Quality Control (QC) and reports directly to the Vice President.

Organization

o Organization Charts

Figures QC # 1 to 9 in annex 1 show the various department organization charts.

o Responsibility and Authority

The responsibility and authority of employees are stated under individual

department procedures.

Related Documents:

Different departmental documents describing Duties and Responsibilities

Organization chart of different departments

2.5.2 Management Representative

The Quality Assurance & Continuous Improvement Manager (QACI Manager)

is the Management Representative for the implementation and maintenance of the

Quality System and reports directly to the General Director, Vietnam –PEB.

Responsibility of Management Representative:

a) Ensuring that processes needed for the quality management system are established, implemented and maintained,

b) Reporting to top management on the performance of the quality management system and any need for improvement, and



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c) Ensuring the promotion of awareness of customer requirements throughout the organization.

2.5.3 Communication

Zamil Steel top management ensures that appropriate communication processes are established within the organization and that communication takes place regarding the effectiveness of the quality management system.

Communication is taken place by means of staff meetings, reports, management meetings, information boards, memos, etc.



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2.6 MANAGEMENT REVIEW

2.6.1 General

Top management reviews quality management system to ensure its continuing suitability, adequacy and effectiveness. This review shall include assessing opportunities for improvement and the need for changes to the quality management system, including the quality policy and quality objectives.

Records from management reviews shall be maintained.

2.6.2 Review input, System Status Report

The Management Representative shall report periodically on the status of the quality

system to Management Committee for their review. The input to management

review shall include information on

a) Results of audits,

b) Customer feedback,

c) Process performance and product conformity,

d) Status of preventive and corrective actions,

e) Follow-up actions from previous management reviews,

f) Changes that could affect the quality management system, and

g) Recommendations for improvement.

2.6.3 Review output

The output from the management review shall include any decisions and actions related to

a) Improvement of the effectiveness of the quality management system and its processes,

b) Improvement of product related to customer requirements, and

c) Resource needs.

The Management Representative shall conduct Management Review meetings as

and when needed but at least once a year. The Strategic Management Meeting held

every month, where all Managers/Supervisors of the departments are usually

present, shall also be treated as Management Review Meeting.

Related Documents:

ZSM 01.04 – Management Review


Title: Resource Management

Revision # 5

Date: 20.09.08

Section 3.1 - 3.2 Page 13 of 42

3.1 PROVISION OF RESOURCES

Zamil Steel determines and provides resources needed

a) To implement and maintain the quality management system and continually improve its effectiveness, and

b) To enhance customer satisfaction by meeting customer requirements.

The needs in resources are systematically reviewed and analyzed in regular Management reviews and/or in ad-hoc reviews. Actions and decisions related to resource needs are included in management review output.

3.2 HUMAN RESOURCES

3.2.1 GeneralAll technical and office staff shall be recruited and trained to meet their respective job description and be competent on the basis of appropriate education, training, skills and experience.

3.2.2 Competence, awareness and training

Zamil Steel:

a) Determines the necessary competence for personnel performing work affecting product quality,

b) Provides training or take other actions to satisfy these needs,

c) Evaluates the effectiveness of the actions taken,

d) Ensures that its personnel are aware of the relevance and importance of their activities and contribution to the achievement of the quality objectives.

Records are maintained within the Administration Department.

o Training FacilityQuality Policies stated in this Quality System Manual shall be conveyed to all employees through various seminars, open forum discussions and Technical Training Programs.

o Hiring of Qualified StaffCandidates with appropriate experience and qualifications shall be employed. Further training, as deemed necessary, shall be the responsibility of the employee’s immediate Supervisor.

Related Documents:

ZSM 18.01– Training of StaffQCP 09.01 – Qualification of New WeldersADM 01.01 – Hiring Of Staff, OP 18.02 – Testing of Newly Hired WeldersDepartmental Training procedures


Title: Resource Management

Revision # 5

Date: 20.09.08


3.3 Resources (Hardware and Software)

Zamil Steel determines, provides and maintains the infrastructure needed to achieve

conformity to product requirements.

Buildings, workspace and associated utilities, all hardware and software (where

applicable) shall be reviewed periodically to ensure its adequacy and suitability to serve

the intended functions (refer to Engineering computer aids manual).

Related Documents:

MN 01.04 – New and Obsolete Equipment;

MN 09.01 – Planned preventive and corrective maintenance

CSD 05.01 – Control of Computerized Documents

MN 05.01 – Document & Data Records Keeping at PM Department

3.4 WORK ENVIRONMENT

Zamil Steel has determined production and servicing processes having critical impact

from work environment and their conditions/parameters are controlled to achieve

conformity to product requirements.

Related Documents:

Production and Material departmental procedures;


Title: Product Realization

Revision # 5

Date: 20.09.08


4.1 PLANNING OF PRODUCT REALIZATION

Zamil Steel has planed and developed the processes needed for product realization. Planning of product realization is consistent with the requirements of the other processes of the quality management system. Zamil Steel has determined:

o Quality objectives and requirements for the product set forth in inspection procedure and instructions of Quality Control department and respective design and development output documents.

o Processes, documents are established and resources specific to the product are identified and established/provided;

o Verification, validation, monitoring, inspection and test activities specific to the product and criteria for product acceptance are established and implemented;

o Records needed to provide evidence that the realization processes and resulting product meet requirements are identified in respective departmental procedures/instructions and are maintained.

A standard Quality Plan (QP), also referred to as the “Inspection and Test Program” (ITP), shall be adopted for each PEB jobs. A standard ITP shown in Appendix “A”.

The standard ITP shall be superseded if required by a Customer’s Approved ITP.

o Identification and Acquisition of Resources

All departments within the Vietnam –PEB division shall utilize the proper mix of skilled human resources and equipment.

o Updating Quality Control Techniques

The Vietnam – PEB Division shall customize its existing procedures and techniques to suit the requirements of a particular Project/Job. QC Department shall modify and re-issue the procedures in the revised ITP in the light of special requirements of a customer.

o Sub-Contracting of Special Testing. HDG and Sp.Painting.

QC may sub-contract a part or all testing requirements for a certain job to an Independent Testing Agencies, if required necessary as per customer’s approved Quality Plan.

QC shall monitor and maintain the record of all such tests.

HDG and some Special Paint jobs are sub-contracted as per the Quality Plan and the QC monitor and maintain the records of the results.



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4.2 CUSTOMER RELATED PROCESSES

4.2.1 Determination of Product Requirements

Three types of jobs are normally processed, which can be described as follows:

Simple Inquires (with no specifications from the Customer & Zamil Steel standard supplies): Most of times, estimation for such buildings are done by the Representative Offices without the involvement of the Head Office. In case of higher complexity of such standard buildings, Vietnam CSD and E & E shall provide assistance to Representative Office.

Simple Inquires (with no specifications from the Customer but with non-standard supplies): this includes;

- Special Paint- Non-standard/Inventory- Special Delivery/Discount- Or other Validation of Process for Production and Service Provision

In such a case, consultation with the Head Office is required. After approval, estimates shall be prepared by the Representative Office or by the E & E Department depending upon the complexity of the building.

Inquires with Customer’s specification – Estimates shall only be prepared at the Head Office. CSD shall thoroughly review Customer’s specification.

Representative Offices are responsible for the Project Information System ( PIS) Contract Information Form (CIF) once a job is finalized. This PIS/CIF shall include all the information of the Client’s requirement.

All assumptions, exclusions and deviations from Zamil Steel’s Standard Practices and Procedures shall be clearly mentioned in the PIS/CIF.

4.2.2 Review of Product Requirements

The comments on those specifications shall be sent to the Representative Office by the CSD.

The Sales Engineers shall clearly mention all non-standard specifications in the PIS/CIF for CSD to prepare additional necessary action that may require.

Review Procedures: when special requirements are received by the CSD after job entry, review shall be performed as follows:

By the CSD Engineers, in consultation with the CSD Supervisor or by the Estimating Engineers in consultation with Engineering Supervisor, comments and observation shall be sent to the Representative Offices directly.

If, in the opinion of the Engineering Supervisors, further approval or clarifications are required, the matter shall be presented to General Director for his advice through CSD Supervisor.



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CSD Supervisor may review on behalf of the General Director or partial involvement of some members through phone or emails. The summary of the comments shall be conveyed to the Representative Offices, for necessary action.

The Management shall only be convened upon the request of the CSD Supervisor to discuss a particular project, if he feels necessary.

Records:

The official job file shall be maintained at the CSD. The job file shall contain all records of the contract.

Review Changes

The Representative Offices in conjunction with the CSD shall maintain a record of all changes in the contract and revisions of the PIS/CIF. CSD Department shall issue a revised PIS/CIF to all concerned departments.

4.2.3 Customer Communication

Zamil Steel has determined and implemented arrangements for communicating with customers in relation to

a) Product information,

b) Enquiries, contracts or order handling, including amendments, and

c) Customer feedback, including customer complaints.

Related documents:ZSM 03.01- Procedure for Contract ReviewCSD- 05.01- Documents ControlCSD-03.01 - Procedure For Filling-In The (PIS/CIF);ZSM 14.01 – Corrective/Preventive Action RequestsPDB 14.01 – Processing of Customer’s Claim;PR 14.07 – Handling Claims;QCP 14.02 – Investigation of Customer’s Claim by Manufacturing& QC

ZSM06.01 – Selection and Evaluation of Raw-Material Suppliers/ Sub-contractors ( Foreign/Local)



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4.3 DESIGN AND DEVELOPMENT

4.3.1 Design and Development PlanningA standard plan for each design and development activity shall be followed. This plan is shown in Engineering & Estimating Procedures Manual under Section 4.3.3. This plan shall be updated, when appropriate, as design and development progresses.

Organizational & Technical InterfacesThe CSD shall receive input from the Representative Office via a Project Information System (PIS) or Contract Information Form (CIF). The CSD shall review the PIS/CIF in accordance with the workflow procedure contained in Section 4 of Engineering & Estimating Procedure Manual. The receipt of the PIS/CIF shall be acknowledged by sending a schedule information message from the CSD.

4.3.2 Design Input

Design Engineers shall prepare design calculations and drawings according to the information contained in the PIS/CIF and the E & E Department Manuals.

The Project Information System (PIS) or Contract Information Form (CIF) received from the CSD is the only source of input accepted by the E & E Department. Some supporting documents may be attached to the PIS/CIF to explain specific customer requirements.

Any clarification required by the E & E Department shall be communicated to the CSD in writing.

The E & E Department shall make revisions to the released designs based on a revised PIS/CIF form received from the CSD.

4.3.3 Design OutputAll design output documents shall be reviewed by an E & E Group Supervisors to make sure the design has been prepared in accordance with the latest PIS/CIF and the Standard Zamil Steel Procedures. The E & E Group Supervisors shall make sure that critical or crucial requirements are properly identified and considered in the design.

The output of the E & E Department consists of design calculations, erection drawings, shop drawings and bill of materials. These are prepared in accordance with the procedures contained in the following manuals.

E & E Procedures ManualThis manual contains the E & E Department organization chart, Job description for each position, qualification requirements for each position, work flow procedures, reports and internal forms.

Designing ManualThis manual contains guidelines and procedures for design calculations, material selection, codes requirements and specific requirements of certain major customers, end-users and approving authorities.



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Detailing ManualThis manual contains standard Zamil Steel detailing practices, detailing aid tables, manufacturing capabilities and limitations.

Computer Aids ManualThis manual contains instructional information for all the computer programs that are approved for use in the E& E Department.

4.3.4 Design and Development ReviewAll design process shall at appropriate stages be reviewed by qualified and competent engineers involved in all phases of design of a building. The E & E Group Supervisors shall confirm that all design phases have been reviewed by entering a password protected computer record. An evidence of the same shall always be available on the archived design package for a particular job.

4.3.5 Design and Development VerificationThe E & E Group Supervisor shall confirm that design results are verified with historical cases of similarly designed buildings and by utilizing his past experience to make sure that the design is realistic. The Group Supervisor shall record his verification on the same computer record.

4.3.6 Design and Development ValidationThe Engineering Supervisors shall study the validity of the design for the defined use and issue a certificate for validation of the design, if required by the customer.

4.3.7 Design and Development ChangesAll revisions shall go through the same process as in a new design to make sure that they have been documented, reviewed and reflected accordingly on the detailed drawings, if necessary. The resulting revisions of drawings shall be controlled. If needed as per contract, the revised design package shall be sent to the customer for his records.

RecordsAll records of Design and Development Inputs, Design and Development reviews, Design and Development verification, Design and Development validation, Design and Development changes are maintained.

4.3.8 Design and Development Manuals

Related Documents

E& E Procedures ManualDesigning ManualDetailing ManualComputer Aids Manual



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4.4 PURCHASING

4.4.1 Purchasing ProcessThe Purchasing Department is responsible for procuring all materials and services used in the fabrication and supply of Zamil Steel fabricated and supplied products in accordance with the purchase requisition. Refer to Procedure # ZSM 06.01.

The evaluation and selection of a new Supplier shall be as per Procedure # ZSM 06.01. A list of approved suppliers with assigned supplier/vendor numbers shall be available at the Purchasing Department and the performance of approved suppliers shall be maintained regularly.

4.4.2 Purchasing InformationThe requisitioning departments are responsible for providing the relevant specifications in their purchase requisitions. The Purchasing Department shall process the Purchase Orders in accordance with the purchase requisitions. The Head of the Purchasing Department shall review the contents of the purchase orders before signing it. In case, there is a difference of any sort with reference to the purchase requisition, he will confirm that the purchasing staff has obtained written concurrence from the requisitioner.

4.4.3 Verification of Purchased Product The QC Department shall inspect all incoming materials in accordance with the

applicable procedures. These procedures recognizes the specifications stated in the ZS Purchase Order as the acceptance criteria and incorporates the control exercised at the vendor’s premises as part of the receiving inspection process, where applicable. Inspection report shall be made available to the Purchasing, Quality Control, Production & Material Control and Finance Department.

Urgent Issue:In the event that incoming material is issued without a formal inspection the Production & Material Control shall keep an identification and traceability record for the positive recall of components manufactured from such materials in event that the identification of a significant non-conformance to the originally specified Purchase Order requires a recall of the material.

Incoming MaterialQC Department shall inspect incoming raw materials in accordance with the specifications and special requirements stated in the Purchase Order. Non-conformance shall be reported as per Procedure # ZSM 13.01. The Non-



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conforming material shall be pasted with a copy of NCR form or labeled with a sticker “ On Hold”.

Verification at Supplier’s premises:When specified in the Purchase Order, Purchasing Department shall arrange for the raw material or the product to be inspected at the Vendor’s premises by a QC Inspector. The inspector shall confirm the quality through an Inspection Report prior to the shipment by the supplier.

Customer verification of sub-contracted product:When specified in the Purchase Order, Zamil Steel shall arrange for the product to be inspected at the Vendor’s premises prior to shipment by a representative of the Customer.

4.4.4 OutsourcingThe evaluation and selection of a sub-contractor to perform a part or the whole of design, fabrication and other services shall be arranged by the Purchasing Department in coordination with concerned department. A list of approved sub-contractors shall be available at the Purchasing Department and the performance of approved sub-contractors shall be maintained regularly.

Suppliers

Supplier’s information is one of information the analysis of data shall cover.

RecordsRecords of the results of evaluations and any necessary actions arising from the evaluation shall be maintained.

Related Documents

ZSM 06.01 – Selection & Evaluation of Raw Material Suppliers (Foreign or Local);ZSM 10.01 – Acceptance Procedure For Incoming Raw Materials;PR 06.01 – Selection & Evaluation of Raw Material Suppliers;PR 06.03 – Purchasing Data;PR 06.04 – Expediting of Purchase Orders;PR 06.05 – Shipping Documents;PR 06.06 – Procurement of Equipment;PR 06.10 – Local Purchasing Ordering System;MDB 06.01 – Ordering Of Raw Materials;MDB 06.02 – Ordering Of Buyout Items;MDB 06.03 – Ordering Of Production Store Items (Paints, Reducers & Thinners);MDB06.04 – Ordering Of Production Store Items;MDB06.05 – Tracking Of Orders;CD 10.01 – Checking of Material at Site;CD 16.02 – Sub-Contracting Of Erection Work



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4.5 PRODUCTION AND SERVICE PROVISION

4.5.1 Control of Production and Service Provision

The Production & Material Control Group of the Operations Department shall be responsible for the production scheduling of ZS manufacturing. The Production & Material Control Procedure defines the process whereby shop drawings and bills of materials (BOM) output from the Engineering Group within E& E Department is released to the shop, scheduled in conformance with contractual delivery requirements, and that Validation of Process for Production and Service Provision (i.e. non-standard Quality Plan requirements, special manufacturing requirements, and/or special inspection criteria) are identified and controlled. Production & Material Control shall monitor the production status of all released-for-production components and ensure that revisions to in-production Engineering output are promptly released to the affected manufacturing processes

The Production & Material Control is responsible for all manufactured products. These products consist of built-up members, hot rolled members, cold-formed secondary framing members, roll formed roof, wall and liner panels, and sundry parts. These products are manufactured in accordance with the procedures (noted below) that identify the production machinery, processes, manpower skills, quality standards, tolerances and workmanship standards that are relevant to each particular product.

o Built-up/Hot-rolled Main Frame Components

The procedures outline the workflow, machines (with maintenance histories), in processing inspection criteria, job descriptions, and process validation inspection for all components manufactured from plates or from mill hot-rolled shapes.

o Secondary Framing Members

This procedure outlines the workflow, machines (with maintenance histories), in processing inspection criteria, job descriptions, and process validation inspection for all components either roll-formed or presses broken from hot rolled steel coil.

o Roll-formed Sheeting and Trim

This procedure outlines the workflow, machines (with maintenance histories) in processing inspection criteria, job descriptions, and process validation inspection for all components either roll-formed or press broken from hot-rolled cladding coils.

Related DocumentsDepartmental procedures and instructions;



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4.5.2 Validation of Process for Production and Service Provision:

Non-standard products and/or specific customer requirement may require the development of special manufacturing procedures. Zamil Steel shall develop such special process requirements and incorporate them within a job specific ITP. The special processes may include:

o Non-standard Requirement:

In the event that a particular joint required by design or in a specific contracted supply can not be performed using a standard Zamil Steel welding procedures, Operations and QC Departments shall develop a welding procedure which is either pre-qualified to AWS D1.1 or can be qualified under the conditions set-forth by that standard. Welder qualifications relevant to such a non-standard welding procedure shall be carefully reviewed to ensure conformance with AWS guidelines.

o Third Party Inspection

All manufacturing procedures noted above comply with the Zamil Steel Quality System. In the event that a customer shall require third party inspection, Quality Control shall accompany the nominated inspector and coordinate, as necessary, with CSD Engineer to ensure compliance with all contractual terms.

4.5.3 Identification And Traceability

o Product Identification

The identification of Zamil Steel supplied products shall be clear and unambiguous to ensure that the product is used as intended.

ZS always follows its own established product identification system as given in Procedure # ZSM 08.01.

o Traceability

The identification and maintenance of records enable Zamil Steel to maintain traceability of the material, design and test reports relating to the supplied products.

Traceability shall be as per Procedure # ZSM 08.01

Zamil Steel Pre-Engineered Buildings are uniquely designed structures requiring job specific component manufacturing. No components enter production as “general stock”; all are entered for a specific contract. As such, All Zamil Steel work-in process is marked with and is traceable through a unique part mark/job number designation. All inspection is conducted against actual job marked components.



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o Status With Respect To Monitoring And Measurement Results.

The assigned inspector if a particular stage of manufacturing shall record his observations on an Inspection or Test Report. Additional Non-Destructive Tests Reports, if required, shall be attached. If no inspection sign or NCR appears on a component, it is considered to be “ conforming” and released for further processing to the next stage.

In case a non-conformance is observed during the manufacturing process, the defect of component will be marked and the corresponding NCR number will be mentioned on the component to highlight the need of an appropriate Corrective Action.

The Inspection or Test Reports shall be reviewed by the QC Supervisor and by the Customer’s Representative, if contractually required. After the painting process if no NCR appears on a component, it will be considered as “ conforming” and released for shipment.

Related Documents

Documents of Production Planning And Control Group;Documents of Quality Control Department;ZSM 08.01 – Identification, Traceability Of Raw Materials & Finished Products;PDB 08.01 – Traceability Record Of Fitters & Welders;QCP 08.01 – Trace-Ability Of Plates;QCP 12.01 – Inspection And Test Status

4.5.4 Customer PropertyCurrently Zamil Steel does not receive any customer supplied materials, however received customer documents and information which are kept in confidence. In case the customer drawings, documents or specification contain ambiguous or conflicting provisions, Zamil Steel will discuss with client to resolve those provisions.

Related documents:ZSM 03.01- Procedure for Contract ReviewCSD- 05.01- Documents ControlCSD- 03.01 - Procedure For Filling-In The Project Information System (PIS) or Contract Information Form (CIF)

4.5.5 Preservation Of Product

o Handling

Products shall be handled by trained operators using cranes, forklifts, side loaders and trucks.



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o Storage

Products shall be stored in designated stocking areas. Protection during storage shall be ensured. Steel members shall be separated by wooden sleepers and stacked according to shape and weight. Goods shall bear permanent identification marks. Care shall be taken to protect finished surfaces. Approved repair procedures shall be followed to rectify accidental handling damage.

o Packaging

Due to the nature of the product manufactured by Vietnam-PEB Division, materials are typically not packed prior to shipment. Zamil Steel standard practice is to loose load mainframe components; bundle cold form and sheeting; and crate trims, and buyout store materials. (Each bundle or crate shall bear a unique pack number with a detailed packing list, which clearly identifies the contents of the package traceable to BOM quantity/description). Care is taken in loading loose goods to ensure that handling and transit damage is minimized; likewise bundled and /or crated material are loaded in such a manners as to ensure that the package and contents are not subject to damage during transit.

o Preservation

PEB supply is protected by shop coatings, cover sheets, and/or crating to ensure that materials remain in prime condition both while in yard storage prior to shipment and for a reasonable period of time at the site prior to erection. Site storage guideline is provided to customers and end users to ensure that material are preserved in prime condition until erected/installed. These guidelines describe proper off-loading techniques, segregation of materials, storage suggestions, and advice regarding site security to guard against theft and/or accidental damage.

o Delivery

Product shall be delivered in accordance with Shipping & Logistics Department Procedures.

Related documents:SD 15.01 - Loading & ReportingSD 15.02 - Back Orders & Back Orders ShipmentSD 15.03 - Daily Shipping ScheduleSD 15.05 - Back Orders & Back Orders ShipmentMDB 15.01 - Receiving & Storage Of MaterialsMDB 15.02 - Issuance Of Raw MaterialsMDB 15.03 - Issuance Of Buyout ItemsMDB 15.04 - Issuance Of Production Store Item (Timber)MDB 15.05 - Issuance Of Production Store ItemsMDB 15.06 - Issuance Of Consumables Items



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4.6 CONTROL OF MONITORING AND MEASURING DEVICES

o General

The QC Department is responsible for identification, maintenance of procedures and calibration for all measuring and testing equipment.

All instruments shall be frequently checked to ensure that these are within the calibration tolerance. Instruments shall be labeled with the date of last calibration and the signature of the calibrating inspector.

o Training

Users of the instruments shall be trained to detect adverse trends in measurement results and action taken to investigate the possible causes. Record of calibration and maintenance of the testing equipment shall be kept by QC.

o Control Procedure

Validity of previous results: Should any testing equipment be found out of tolerance during calibration, the QC shall review the measurement results and compare with the last calibration results. The validity of the previous results shall be assessed and action shall be taken to ensure that the products during the period in question comply fully with the contract requirements.

Frequency of Calibration of individual tool/equipment shall be established depending on the usage and the nature of the measurements. It shall be stated in the list of equipment requiring calibration.

Calibration shall be carried out with reference to a standard, which shall be traceable to a national, or an international standard, as applicable.

Ultrasonic Testing Machine shall be calibrated as per Section 6.18 and 6.21 of AWS D1.1 (1998).

All calibration shall be carried out under the environmental conditions and procedures specified in the manufacture’s instructions.

Ultrasonic machine and paint thickness gauge shall be calibrated with the standard block and shims arranged for this purpose only. Calibration shall be done prior to perform each set of testing and the instrument is adjusted accordingly. No stickers are required to be pasted on each instrument. The instrument shall be sent for repair and calibration only if they show no response to the usual calibration procedure. Only a representative sample shall be checked for measuring tapes.

All reference test equipment shall be stored and handled properly to preserve the fitness and accuracy of the equipment.

Related documents:ZSM 11.01 - Control Of Measuring & Test EquipmentsQCP 11.01 - Rockwell Hardness Tester (Eseway)



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QCP 11.02 - Procedure For 345-Digital Coating Thickness GaugeQCP 11.03 - Procedure For Measuring The Thickness Using Vernier CaliperQCP 11.04 - Procedure For Accurate Usage Of A MicrometerQCP 11.05 - The Usage Of Paint Adhesion Tester 'Elcometer'QCP 11.06 - Humidity Record (Thermo-Hygrometer)


Title: Measurement, Analysis, Improvement

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Section 5.1-5.2 Page 28 of 42

5.1 GENERAL

Zamil Steel plans and implements the monitoring, measurement, analysis and improvement processes needed

to demonstrate conformity of the product,

to ensure conformity of the quality management system, and

To continually improve the effectiveness of the quality management system.

This shall include determination of applicable methods, including statistical techniques, and the extent of their use (refer to Section 5.4 of this Quality System Manual).

5.2 MONITORING AND MEASUREMENT

5.2.1 Customer Satisfaction

As one of the measurements of the performance of the quality management system, Zamil Steel monitors information relating to customer perception as to whether the company has met customer requirements. Zamil Steel uses, as the case may from time to time be decided, such methods as questionnaire, telemarketing, customer direct contact or workshops for obtaining customer feedbacks.

Analysis of Data Related Customer Satisfaction

All customer feedbacks are analyzed and actions are taken for correction or improving Quality Management System effectiveness.

Management Review

Customer Feedback, as one of the input data, shall be analyzed and be included in the System Status Report prepared by Management Representative before management reviews.

Related Documents:

ZSM 14.01 – Corrective/Preventive Action RequestsPDB 14.01 – Processing of Customer’s Claim;PR 14.07 – Handling Claims;QCP 14.02 – Investigation of Customer’s Claim by Operations & QC Department

5.2.2 Internal Audits

o Responsibility

Management has appointed the Production Supervisor as the Lead Auditor to conduct Internal Quality Audits as per # ZSM 17.01. A qualified auditor working with other department shall audit QC Department.

o Regular Audits



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An audit program shall be planned, taking into consideration the status and importance of the processes and areas to be audited, as well as the results of previous audits. The audit criteria, scope, frequency and methods shall be defined as per procedure Internal Quality Audits as per # ZSM 17.01.

o Additional Audits

Management may require additional audits to verify implementation of new processes or to investigate identified deficiencies in the existing procedures/processes.

o Corrective Action

Internal Audit findings shall be conveyed to the concerned Department Manager/Supervisor. In the event that a deficiency is identified, the department Manager/Supervisor shall take appropriate action within an agreed upon time schedule.

o Follow-up of Corrective Action

Follow-up activities shall include the verification of the actions taken and the reporting of verification results.

o Management Review

The Management Representative shall present a periodic report of the implementation status of the quality system within the Division.

Records

Records of internal audits are maintained.

Related Documents

ZSM 17.01- Internal Quality Audits

5.2.3 MONITORING AND MEASUREMENT OF PROCESSES

o Monitoring And Measurement:

To demonstrate the ability of the quality management system processes to achieve planned results, Zamil Steel applies suitable methods for monitoring and, where applicable, measurement of processes.

o Analysis of Processes’ Monitoring and Measurement

Results (Data)

Respective Department Manager/ Supervisor and Management Representative analyze characteristics and trends of processes including opportunities for corrective/preventive actions.



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o Management Review

Process performance, as one of the input data, shall be analyzed and be included in the System Status Report prepared by Management Representative before management reviews.

o Corrective Actions:

When planned results are not achieved, corrective action shall be taken, as appropriate, to ensure conformity of the product.

5.2.4 MONITORING AND MEASUREMENT OF PRODUCT

o In-Process Inspection and Testing

The QC Department conducts two types of in-process inspections:

ZS Standard Quality Plan (Inspection & Test Program)

Steel components shall be inspected at a random basis at Dimensions, Welding and Painting stages of manufacturing. All measurement and testing shall be carried out to the extent stated in the Standard ITP.

Customer’s Approved Quality Plan

Any special inspection and testing requirements agreed by and approved by both the customer and Zamil Steel prior to actual production shall be followed.

Any required inspection technique not available at ZS (e.g., destructive mechanical testing or radiography) shall be sub-contracted to a recognized independent testing agency.

o Final Inspection & Release of Product Procedure

Documented process procedures included in-process inspection criteria at each manufacturing and finishing stage. The enforcement of these procedures is monitored by Zamil Steel’s Quality Control Department and as such ensures that the manufactured product conforms in all respects to the quality standards of this Quality System Manual.

o Product release

Unless otherwise contract permits, all actual final release of product is authorized only upon verification that the documented evidence of such inspection has been created and is available for examination. In case the contract permits, the final release of product is authorized by Quality Control Department, and by documented authorization from the customer.

o Inspection and Test Records



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All product inspection reports shall be available at the QC. All non-conformance reports (NCR) issued (with the disposition action undertaken) shall be maintained with the inspection reports.

o Analysis of Inspection results (Data)

The conformity to product requirements, through the development of processes and working procedures take in the chance of preventive action.

o Management Review

Product conformity, as one of the input data, shall be analyzed and be included in the System Status Report prepared by Management Representative before management reviews.

Related documentsQCP 10.01 - Inspection Of Hot Rolled Plates & Sections, Hot Rolled Black…QCP 10.04 - Inspection Of Pre-Painted Sheet CoilsQCP 10.06 - Visual/Dimensional Welding InspectionQCP 10.06 - Liquid Penetrate ExaminationQCP 10.07 - Magnetic Particle TestingQCP 10.08 - Ultrasonic TestingQCP 10.11 - Standard Painting InspectionQCP 10.14 - Final & Shipping InspectionQCP 10.18 - Checking The Weld Quality On Automatic Welding MachineQCP 10.26 - Dimensional InspectionQCP 10.40 - Specification, Codes & Tolerances For PEBQCP 10.41 - Procedure for Fabrication & Inspection of std. anchor bolts



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5.3 CONTROL OF NON-CONFORMING PRODUCTo General

The PEB Division shall record all non-conformances on Incoming Materials, Drawings and Manufacturing Processes.

o Fabrication Documents

Engineering shall be responsible for checking the accuracy of all fabrication documents.

o Goods in-Process

QC Department shall inspect and monitor the goods in process through all stages of production. Non-conformance shall be reported as per Procedure # ZSM 13.01.

o Review and disposition of the reported non-

conformance The concerned department shall validate the NCR and define the process to

resolve it. Disposition shall be reported. If required by the contract, the non-conforming product shall be reported for

concession to the customer. The record of actual measurements shall be maintained.

o The Management Representative shall analyze non-

conformances and shall provide periodic reports for the review of the management.

Records

Records of the nature of nonconformities and any subsequent actions taken, including concessions obtained, shall be maintained.

Related documents

ZSM 13.01 – Product Non-Conformities;PDB 10.01 – Repairing of the Mis-Fabricated Steel Structures;PDB 13.01 – Rectification Of The Pieces Pointed Out By QC;QCP 10.09 – Control Of Non Conforming Processed ProductsQCP 10.16 – Repairing of the Mis-Fabricated Steel Structures;



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5.4 ANALYSIS OF DATA

Zamil Steel determines, collects and analyses appropriate data to demonstrate the suitability and effectiveness of the quality management system and to evaluate where continual improvement of the effectiveness of the quality management system can be made. This shall include data generated as a result of monitoring and measurement and from other relevant sources.

The analysis of data provides information relating to

Customer satisfaction;

Conformity to product requirements;

Characteristics and trends of processes and products including opportunities for preventive action; and

Suppliers.

Statistical Techniques

Identification of NeedsWhere applicable, Statistical Techniques shall be employed to verify product quality characteristics.

ProceduresCustomer’s complaints (claims) and in-process non-conformance reports shall be statistically analyzed. Resultant information shall be used to monitor the quality of the product.

5.5 IMPROVEMENT

5.5.1 Continual Improvement

Zamil Steel continually improves the effectiveness of the quality management system through the use of the quality policy, quality objectives, audit results, analysis of data, corrective and preventive actions and management review.

Management Representative shall prepare System Status Report and send to top management on the performance of the quality management system and any need for improvement before Management Reviews.

5.5.2 Corrective And Preventive Action

o General

Zamil Steel shall determine and take actions to eliminate the cause of:

Existing nonconformities in order to prevent their re-occurrence; and

Potential nonconformities in order to prevent their occurrence.



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Corrective/preventive actions shall be appropriate to the effects of the potential problems.

The PEB Division shall follow the Procedure # ZSM 14.01 for Corrective and Preventive Action Requests (CAR).

The management undertakes to implement appropriate changes in the procedures.

o Corrective /Preventive Action

All customer complaints shall be recorded by the CSD. Immediate Corrective Actions shall be taken, if appropriate. Market feedback, other than complaints shall be referred to Marketing

Department for consideration and preparing recommendation. During reviews, Management may decide on Corrective Actions to be

undertaken by the concerned department or may refer such decision to the Marketing Department.

Corrective Action to address in process non-conformances may be undertaken by the concerned department, resulting in revision of existing procedures or implementation of a new procedure.

Corrective Action resulting from internal audits performed by the Management Representative or resulting from external audits shall be referred to management for consideration or implementation.

Suggestion from within or outside Zamil Steel shall be referred to Marketing Department for consideration.

Preventive Action Requests shall also follow the Procedure ZSM # 14.01.

o Review and verification Corrective/Preventive Action

The results of corrective/preventive actions are reviewed and verified to ensure their effectiveness

o Management Review

The status of Corrective and Preventive Actions shall be reviewed in the Management Meeting.

RecordsCorrective/preventive actions are recorded as required by ZSM # 14.01.

Related documents

ZSM 14.01- Corrective/Preventive action Requests.PR 14.07 - Handling Claims.PDB 14.01 – Processing of Customer’s Claim;QCP 14.02 – Investigation of Customer’s Claim by Operations & QC Department


Title: Annex1

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Organization chart Page 35 of 42


Title: Annex1

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Title: Annex 2

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Interaction of Processes Page 42 of 42

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Documents

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development review design

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