audit report-2 signed

Audit reportOrganisation Emirates Beton Readymix LLCAudits (ZA): QMS 58003123; EMS 58003124; OHSAS 58003125

A00F207e - Audit report-2.dot Page 1 of 12 Rev. 04/01-2014

Master Data of OrganisationName of Organisation Emirates Beton Readymix LLC

Name of corporate group(in case of group certification)

Street Nad Al Sheba

Postcode / Town / Country P.O. Box 111576 Dubai / UAEContact Lorraine BautistaE-Mail [email protected]/Fax +971 04 320 9204/ 05/ 06/ 07 +971 04 320 9322Language englishScope Description Design, Production & Supply of Ready-mix Concrete

more description regarding scope in annex

Industry / Scope (EA) 16R3

Audit profileStandards under contract /Audit type

ISO 9001 : 20082. Surveillance audit

ISO 14001 : 20042. Surveillance audit

OHSAS 18001 : 20072. Surveillance audit

---:---

Manual: Revision / Issue EB- IMS-M,Rev.4,Dtd.01.07.12

Surveillance mode Yearly surveillance

Audit team leader / responsible Lokesh Ganapa (A)Audit team Joval Esteves (B)

Technical expert - Trainee

Multi-site-organisation All sites are listed in:Audit Reference Data Sheet seperate ListingAudit program/ATEAMultisite-certification (Sample)

Shift operation no shift operation



Audited StandardsISO 9001 : 2008 2. Surveillance audit

Exclusions: Nil Revision Manual: EB- IMS-M,Rev.4,Dtd.01.07.12Audit team leader: Lokesh Ganapa (A) Audit number(ZA): QMS 58003123;EMS 58003124; OHSAS 58003125Certificate number: 44100/104/116100427 Valid until: 07.05.16

ISO 14001 : 2004 2. Surveillance auditExclusions: Nil Revision Manual: EB- IMS-M,

Rev.4,Dtd.01.07.12Audit team leader: Lokesh Ganapa (A) Audit number(ZA): QMS 58003123;EMS 58003124; OHSAS 58003125Certificate number: 44100/104/116100427 Valid until: 07.05.16

---: 2007 2. Surveillance auditExclusions: Nil Revision Manual: EB- IMS-M,

Rev.4,Dtd.01.07.12Audit team leader: Lokesh Ganapa (A) Audit number(ZA): QMS 58003123;EMS 58003124; OHSAS 58003125Certificate number: 44100/104/116100427 Valid until: 07.05.16

--- :Exclusions: Revision Manual:Audit team leader: Audit number(ZA):Certificate number: Valid until:

Audit-DetailsSites DubaiAudit date 22.02.15 23.02.15Audit duration 3,58 person days on site including

0,00 person days for stage 1 audit (separate report)

Details for Stage 1 AuditStage 1 -Audit not necessary.Duration Stage 1 0,00 person days on siteDate Stage 1 audit on site -



Distribution/Confidentiality/Rights of ownership/Limitations/Responsibilities

This report is sent to the certification body or bodies, the members of the audit team and the auditrepresentative of the organisation. All documents (such as this report) regarding the certificationprocedure are treated confidentially by the audit team and the certification body. This audit report remainsthe property of the certification body.

An audit is a procedure based on the principle of random sampling and cannot cover each detail of themanagement system. Therefore nonconformities of weaknesses may still exist which were not expresslymentioned by the auditors in the final meeting or in the audit report.

The responsibility for continuous effective operation of the management system always rests solely withthe audited and certified organisation.

Salvo clause:The audit report will be left to the organisation at the end of the audit - subject to approval by thecertification body. The independent release process may cause modifications or additions. In these casesa modified revision will be sent to the audited organisation.

Annex/EnclosuresAnnex/corresponding audit documentation

Questionaire(s) / Checklist(s)Additional annexes, number



Summary of resultsISO 9001 ISO 14001 OHSAS 18001 ---

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4.1 2 4.1 1 4.1 14.2 2 4.2 1 4.2 15.1 1 4.3.1 2 4.3.1 25.2 1 4.3.2 1 4.3.2 15.3 1 4.3.3 2 4.3.3 25.4 2 4.4.1 1 4.4.1 15.5 1 4.4.2 2 4.4.2 25.6 2 4.4.3 1 4.4.3 16.1 1 4.4.4 1 4.4.4 16.2 2 4.4.5 1 4.4.5 16.3 1 4.4.6 2 4.4.6 26.4 1 4.4.7 2 4.4.7 17.1 1 4.5.1 1 4.5.1 17.2 1 4.5.2 2 4.5.2 27.3 1 4.5.3 1 4.5.3 17.4 2 4.5.4 1 4.5.4 17.5 2 4.5.5 2 4.5.5 27.6 1 4.6 2 4.6 28.1 18.2 28.3 18.4 18.5 17.5.2 E

Obligatory elements from ISO17021:2011 Section 9.3.2.1 Audited Resulta) internal audits and management review; 2b) review of actions taken on nonconformities identified in previous audit; 2c) treatment of complaints; 1d) effectiveness of the system to achieve the certified client's objectives; 2e) progress of planned activities aimed at continual improvement; 1f) continuing operational control; 2g) review of any changes including system documentationh) use of marks and/or any other reference to certification.audited: = audited sections of the standard;Result: 1 = fulfilled; 2 = basically fulfilled / potential for improvement; 3 = not fulfilled / nonconformity ; - = not applicable / excluded.Details are listed in the section "Detailed results. Fields with a coloured background are obligatory elements in every audit.

Obligatory elements from A00VA02a) Are temporary sites (i.e installation sites, project locations etc.) available? yes nob) Which one are visited? DubaiPlease enter the reasons for the selection in Summary / explanation of results



Organisations profile

Emirates Beton is a ready mix concrete company engaged in the design, production and supply ofready mix concrete. It was established by a group of dynamic, motivated and experienced people withover 20 years of pioneering work experience in the ready mix concrete industry, to provide highquality products and services.Cementitious materials are stored in watertight metallic silos. The capacity of silos range from 100to150 tons.There are separated tanks for each type of admixture, fresh water and chilled water.Chilled water tanks are insulated with sprayed foam. Each water tank has a capacity of 20,000 gallonsand each admixture tank has capacity of 20,000 Liters.Each concrete batching plant is supported with a dedicated Flaked Ice Plant and Chiller, which canproduce enough ice and chilled water to produce up to 2000m3 of temperature controlled concrete perplant per day.In order to ensure speedy, effective and time bound delivery, Emirates Beton maintains a fleet of 60mixer trucks with Scannia chassis and Baryval drums and one of the largest fleet of pumping andplacing equipments available in the ready mix market in Dubai. Emirates Beton has the professionallytrained and skilled staff, who have done the mix design,production and quality control and pumping ofthe prestigious high- rise constructions in Dubai.The Scope of Certification of the integrated management system is Design, Production & Supply ofReady Mix ConcreteThe other basic details of the Organisation as established in the contract were verified and found tobe satisfactory. The number of effective employees in the Organisation is 60. The Organisation hastwo units operating in Dubai, UAE. However, the unit operating at Nad Al Sheba only is offered forCertification.The quality related activities/ processes are: Management Function ( Top Management, Managerial functions and dept heads) Tender review & customer related process. Procurement & Stores. Administration Human Resources & Training /Legal requirements. Operations including Production, Maintenance (Batching plant), workshop and Health &Safety Department. Design and Development Quality Assurance/ Quality ControlThe environmental related activities and the related aspects are: Movement of transit vehicles dust generation & consumption of fuel. Handling of raw materials/aggregates dust and particulate pollution operation of machinery/ movement of heavy vehicles - noise Concrete production waste water discharge Maintenance works oil spills/ leaks Administrative process consumption of water and electricity Batching plant energy depletion, water consumption, dust generation Truck washing waste water generation. Water treatment plant generation of empty chemical containers. Day- to- day activities resulting in generation of solid wastes, liquid wastes and hazardous wastes. Storage of diesel and re-fuelling of vehicles: fire and depletion of resources/ spills etc. Operation of Generator dust generation/ fuel consumption. Operation of compressor - noiseThe Health and safety activities and the related hazards are: Production- batching plant dust generation Charging of admixtures/ aggregates dust generation Movement of vehicles dust generation and generation of noise. Maintenance works electrical hazards, plant erection / maintenance -fall from height. Welding works hot surface, smoke/gas Storage and handling of diesel fire. Movement of transit mixtures incidents. Concrete pumping hazards at the client site. Hazards from the various chemicals handled.



Summary / explanations of results

The Audit was carried out in a random sampling basis to fall in line with the scope of the certificationas per the audit criteria ISO 9001:2008, ISO 14001:2004, OHSAS 18001:2007. The Processes wereaudited as planned in the audit plan (Refer Audit Plan).

The plant is shifting from Nad al sheba location to Jebel ali location, both locations have been auditedfor operational fitness and all documentation has been evidenced at old location

The results/Summary is as follows:

Overall system implementation and maintenance was found to be effective

Implementation of policy commitments was found to be appropriate

With reference to the above statement, the tools for continual improvement such asObjectives, Internal audits and Management review can be utilized effectively to demonstrateimprovement

The overall demonstration of the Quality, Environmental and Health & Safety Management systemwith reference to the audit criteria of ISO 9001:2008, ISO 14001 : 2004 and OHSAS 18001:2007 iseffective and the Auditors here by recommend the organization for maintenance of thecertificates of ISO 9001:2008, ISO 14001:2004 and OHSAS 18001: 2007.

The effectiveness of the actions for the IPs to be verified in the next surveillance.



Conclusion

Taking into account the size and structure of the organisation, the products/services supplied andthe process used, the organisation has basically demonstrated that it operates its managementsystem in order to ensure fulfilment of its own requirements, the requirements of its customers andthe relevant legal requirements.

This includes in particular: The policies from 06.02.10, objectives and their implementation in the organisation The processes which exist in the management system and their interaction The management system documentation The recording system The resource management The measuring and analysis (management review from 16.10.14, audit planning from 2014,

audit report(s) from 28.09.14 - 29.09.14 and examples for indicators) The continual improvement process

also the implementation and the effectiveness of the management system and the processes forproviding services/production/product realisation were assessed by the audit team by means of on-site inspection and examination of documents on a random sample basis.

Nonconformities, observations and the potential for improvement are described in the "DetailedResults" section.



Detailed results

The evaluation of the audit results basically follows the scheme shown below:

Stage Classification MeaningNC A Nonconformity A 1. Non-fulfillment of one or several requirements of the

management system standard or2. A situation which gives rise to considerable doubt as to the

capability of the customer's management system to achievethe desired results

NC B Nonconformity B All other nonconformitiesPI Potential for improvement Items which would allow optimisation of the management system

in relation to the requirements of the relevant standard. It isrecommended that the company implements these items.

GP Positive aspects/Good Practice

Positive aspects of the management system worthy of specialmention (see also point 4.3 if applicable)

CM Comments Special situation and information to be traced in next auditFollow-up action(*):Follow-up Audit or action plan

No. NC A Area /Process Standard:clauseFollow-upaction * Set date

Nil

No. NC B Area /Process Standard:clauseFollow-upaction * Set date

Nil

No. PI Area / Process Standard:clause1. Exclusions should be mentioned in IMS manual IMS Manual ISO 9001 4.2.22. Sequence & Interaction between processes is

not evidenced in IMS manual,IMS Manual ISO 9001 4.2.2

ISO 14001 4.1OHSAS 18001 4.1

3. Outsourced processes and respective controlsare not lilsted in IMS manual,

IMS Manual ISO 9001 4.1

4. Accountability topic should be added to IMSmanual

IMS Manual OHSAS 18001 4.1

5. Impacts of products should be covered in aspectimpact studies (Like In process product &Finished products, e.t.c)Ref: production aspect & Impact study, dated:22.09.14, doc no: EB-EMS-P01-F01, rev:0

Aspect & Impactstudy

ISO 14001 4.3.1

6. Bio medical waste, E-Waste, Glass, Bulbes &Tubes e.t.c could be added to aspect & impactstudies at respective area studies


ISO 14001 4.3.1

7. Disposing waste to authorised dubai municipalityscrap vendor to be mentioned in controls ofaspect & impact studies at all applicable areasRef: production risk assessment study, dated:15.08.13, doc no: EB-OHSMS-P01-F01, rev:0


ISO 14001 4.3.1



No. PI Area / Process Standard:clause8. Human behavioural risks could be included in

Risk assement studies at all applicable activitiesRef: production risk assessment study, dated:15.08.13, doc no: EB-OHSMS-P01-F01, rev:0

HIRA Study OHSAS 18001 4.3.1

9. Residual risk factor to be made afterimplementing control for each identified riskRef: production risk assessment study, dated:15.08.13, doc no: EB-OHSMS-P01-F01, rev:0

HIRA Study OHSAS 18001 4.3.1

10. Data tracking and analysis of data of all KPIs arenot evidencedRef: Number of LTIS, Nearmiss reportingpromotion, use of recycled plant

Objectives, targets &programmes

ISO 9001 5.4.1ISO 14001 4.3.3OHSAS 18001 4.3.3

11. Effectiveness check of corrective and preventiveactions taken for NCR to be made andimplemented

Corrective andpreventive action

ISO 9001 4.2.2ISO 14001 4.1OHSAS 18001 4.1

12. Permit to work should be introduced to otheractivities like confined space working, working atheight (Based on application)

Operational control OHSAS 18001 4.4.6

13. Forklift driver qualification is required to few moreoperators


14. Bio-medical waste should be consideredseperately to dispose it to authorized vendor andthis waste should be segregated from all watses


ISO 14001 4.3.1

15. Energency mock drill for environmentalemergencies could be made as per frequencymentioned in EB-HSEMS-P04 procedure

Emergencypreparedness andresponse

ISO 14001 4.4.7

16. Air monitoring to be made at DG Set &Production area

Operational control ISO 14001 4.4.6

17. Noise level should also be checked during nightshiftsAll points the noise level is above 85 dB Anaction plan to be made by applying ELARP

Operational control ISO 14001 4.4.6

18. Detailed instruction to be made for cleaning ofdrinking water storage tank with detail records ofcleaning


19. MR topic is not evidenced in audit plan of 2014 Internal audit ISO 9001 8.2.2ISO 14001 4.5.5OHSAS 18001 4.5.5

20. Results of evaluation of compliance to becovered in management review

Management review ISO 9001 5.6ISO 14001 4.6OHSAS 18001 4.6

21. Rootcause analysis, corrective and preventiveaction should be defined to avoid repetition ofmaintenance problems in rapair and servicerequisition form

Maintenance ISO 9001 7.5

22. Evaluation of complaince is not evidenced as perIMS manual (Twice in a year)

Evaluation ofcompliance

ISO 14001 4.5.2,OHSAS 18001 4.5.2

23. Ear plugs or ear muffs usage at high noise areas Operational control OHSAS 18001



No. PI Area / Process Standard:clauseare not followed by staff 4.4.6

24. Training records / certificates to be retained byHR department

HR ISO 9001 6.2ISO 14001 4.4.2OHSAS 18001 4.4.2

25. Environmental management system focussedtrainings to be provided

Training ISO 9001 6.2.2ISO 14001 4.4.2OHSAS 18001 4.4.2

26. Rating criteria as well as records retention forsupplier selection to be improved

Purchase ISO 9001 7.4

No. GP Area / Process Standard:clause1. Management committment Top management ISO 9001 5.1

ISO 14001 4.1OHSAS 18001 4.1

2. Well maintained documentation in sales Control of documents ISO 9001 4.2.3ISO 14001 4.4.5OHSAS 18001 4.4.5

3. Detailed HSE training plan from HSE functionand regular toolbox talks

HSE Training ISO 14001 4.4.2OHSAS 18001 4.4.2

No. CM Area / Process Standard:clause



Management of non-conformities

Nonconformities were not found - the procedure can continue.

Nonconformities were found.

In case of non-conformities:Follow-up Audit:On-site review and evaluation of the introduction, implementation and effectiveness of guidedcorrection and corrective actions for previously identified non-conformities.

or

Action Plan:The auditors is a scheduled plan of action with the serial number of the finding, root causeanalysis, the corrections (to stop the error), and corrective action (for retraction of the fault) tosubmit.

Verification of effectiveness:On a Follow-up Audit:By submission of documents:Evidence of the effectiveness of correction and corrective action is to explain to the deadline setby the Audit Team Leader submission of documents.In the next audit:The final proof of the effectiveness of the corrections and corrective actions will be reviewed inthe next regular audit.

Auditor in Charge:The audit team leader directs the non-conformities as needed to the responsible auditor forprocessing.

audit report-2 signed

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