PROCEDURE
CONTROL OF OPERATION AND NON CONFORMITY
DOC. NO.: DS-G-P03
REVISION : 2
PAGE 2 OF 9
7. PROCEDURE
7.1 CONTROL OF OPERATIONAL & NON CONFORMITY FOR QUALITY
FLOW
DETAILS
1. Respective personnel shall carry out the inspection
according to the Appendix 1, Inspection & Non
Conformance Plan.
1.
Carry
Out
Inspection
According To The Inspection &
Non Conformance Plan
2. Non
Conformance
Found?
RECORD
No
Yes
3. Verification
4. Isolate & Marking
5. Issue IN if required
6. Propose The Treatment Of Non
Conformance
Including
Concession / Dispose And
Corrective Actions
7. Implement Propose Correction
& Corrective actions
8. Re Inspection
9. File Record Into Project File &
Discuss In Management Review
2 & 3. If there is no non conformance found during the
inspection, respective Personnel shall sign on the
respective document and file all the relevant record
properly. However, If there is non conformance found
during inspection, PMT shall verify the non
conformance.
4. PMT shall isolate the non conformance products
and identify or mark properly to prevent authorized
used / further process.
5. PMT shall issue the Improvement Note, ( DS – G –
F01) refer to DS-G-P04 to respect department for
propose correction and corrective action.
6. Respect HoD shall propose the treatment of non
conformance including concession / dispose and
corrective actions and pass to PMT
7. Respective HoD shall implement the proposed
correction and corrective actions.
8. If re inspection required, respective personnel shall
carry out the inspection according to the Quality
Inspection & Non Conformance Plan.
9. If the re inspection satisfactory, PMT shall
 file all the relevant inspection record
 bring all the quality issue to management
review for further discussion.
Improvement Note, (
DS – G – F01)
PROCEDURE
CONTROL OF OPERATION AND NON CONFORMITY
DOC. NO.: DS-G-P03
REVISION : 2
PAGE 3 OF 9
7.2 CONTROL OF OPERATIONAL & NON CONFORMITY FOR SAFETY & HEALTH
FLOW
1.
Received
interested
parties
information
/
feedback
2.
Identified
significant Risks
3. Establish operation control
4. Train
/ communicate of
operation control
DETAILS
1 – 3. Establishment of operation control
The Steering Committee shall establish
the operation control documents to
minimize the incident, contamination, ill
health, injury and prevent pollution after
review the following
 information / feedback from
interested parties
 identified significant risks after
conduct JSA ( DS – H – F01)
 new / revised of applicable legal &
other requirements
 incident occurred
RECORDS
JSA
( DS – H – F01)
4. Train / communicate
The Steering Committee shall train /
communicate document to relevant
personnel include persons work on behalf.
5. Measurement & Monitoring
6. Internal Safety &
Health Issues
7. Control of Non Conformance
8.Review the need of corrective action
and risk assessment
9. Correct Actions
10. Review the effectiveness
11. Discuss In Management Review
5. Measurement & Monitoring
 Steering committee is responsible
for
implementation
of
the
monitoring and measurement
program.
 Respective
personnel
are
responsible for the monitoring
operations in their areas of
responsibility and for reporting any
conditions that might affect the
performance of health and safety
according to Appendix 2.
 The respective departments head
shall maintain review and compile
all the relevant information before
report to committee quarterly.
6 & 7. Control Of non conformance
The monitoring result shall be
acknowledged by respective HoD /
Steering Committee for deficiencies or
non-conformance
identified
during
monitoring and measurement and record
into Improvement Note (DS – Q – F01).
8 & 10. Corrective Action
The affected personnel shall review the
need of corrective action and JSA ( DS – H
– F01). Hence, carry out the corrective
actions and review the effectiveness of
actions taken as mentioned in DS-G- P04.
11. Management Review
Steering Committee shall bring all safety &
health issue to management review for
further discussion as DS-G- P05.
Improvement Note
(DS – Q - F01)
JSA
( DS – H – F01)
PROCEDURE
CONTROL OF OPERATION AND NON CONFORMITY
DOC. NO.: DS-G-P03
REVISION : 2
PAGE 4 OF 9
Appendix 1 : Quality Inspection & Non Conformance Plan
Step
No.
1
2
3
4
Description of Inspection Item
Receiving Inspection for
Hardware include
 Conduit and its fitting
& accessories
 Cable
 Fire Alarm & Devices
 Piping
 Fitting
 Cylinder
 Paint
 Chemical ( gas )
Receiving Inspection for
Equipment include
 Fire
Fighting
Equipment
 Other
measuring
equipment and tools
Receiving Inspection for
Cabinet, Cabinet Accessories
and Components
Engineering Workstations
Receiving Inspection
5
Outsource
Calibration
6
Outsource
Service & Maintenance
Control Document
(Spec./Dwg. No.)
Responsible Parties
Acceptance Criteria
Record
(Yes/No)
Non Conformance
Handling
Authorized
Method
personnel
Replenish
Project
Replacement
Manager
Return
DS
Client
Component delivered as per
quantity
ordered
without
physical damage.
W
R
Yes
Vendor Doc
Component delivered as per
quantity
ordered
without
physical damage.
W
R
Yes
Vendor Doc
Replenish
Replacement
Return
Project
Manager
Component delivered
quantity
ordered
physical damage.
Component delivered
quantity
ordered
physical damage.
Acceptable tolerance
as per
without
W
R
Yes
Vendor Doc
Project
Manager
as per
without
W
R
Yes
Vendor Doc
W
R
W
R
Yes
Calibration
Report
Yes
Service &
Maintenance
Report
Replenish
Replacement
Return
Replenish
Replacement
Return
Rework or
scrap
Rework
Service
Manager
Service personnel competency
Project
Manager
Service
Manager
PROCEDURE
CONTROL OF OPERATION AND NON CONFORMITY
DOC. NO.: DS-G-P03
Step
No.
Description of Inspection Item
REVISION : 2
Control Document
(Spec./Dwg. No.)
PAGE 5 OF 9
Responsible Parties
Acceptance Criteria
W
R
R
Outsource
Manpower & resources
Competency of
defined by client
8
Outsource
Design & Endorsement
Competency personnel
W
9
Design Review & Verification
I/O and Termination List
Configuration for Program
Development Internal Review
Application
Program
Development Internal Review (
Depend on project )
Comply
with
Software
Specifications
and
client
Database
HP
Function Logic emulation tests
are properly performed and
documented.
HP
11
System & marshalling cabinets
components installation work (
Fabrication Work )
HP
M
Yes
Eng Drawing
12
Internal Test
 System Power-up
 Network check
 Eng. Workstation check
 I/O Functionality test
Factory Acceptance Test (FAT)
Installation
Comply
with
respective
System
and
Marshalling Drawings. All
“Work Orders” are completed
and signed-off
All tests properly performed and
documented. All “Work Orders”
are completed and signed-off
HP
M
Yes
Factory
Acceptance
Test procedure
Rework
Re Configure
Redesign
Lead Engineer
All tests are properly performed
and documented.
HP
W
Rework
Re Configure
Redesign
Lead Engineer
All FAT documents properly
signed-off
by
authorized
personnel.
R
R
Yes
Factory
Acceptance
Test procedure
Yes
Factory
Acceptance
Test procedure
Ensure all
documents
being signed
Lead Engineer
13
14
FAT Acceptance Certificate by
client
or
Client
Non Conformance
Handling
Authorized
Method
personnel
Re recruit
HRA
personnel
7
10
worker
DS
Record
(Yes/No)
Yes
Sub Contractor
Claim
Drawing &
Rework
Specification
Endorsed
Documents
Yes
Review & amend
I/O &
I/O &
Termination list
Termination
List
Yes
Re Configure
Cause & Effect
Matrix
Rework
Redesign
Project
Manager
Lead Engineer
Lead Engineer
Lead Engineer
PROCEDURE
CONTROL OF OPERATION AND NON CONFORMITY
DOC. NO.: DS-G-P03
Step
No.
REVISION : 2
Description of Inspection Item
Control Document
(Spec./Dwg. No.)
PAGE 6 OF 9
Responsible Parties
Acceptance Criteria
DS
Client
Record
(Yes/No)
15
Composite Integration System
Test (CIST) with other system
integrated
All Communication and data
interchange with sub systems
are tested and working properly
HP
W
Yes
CIST procedure
16
Packing inspection prior to ship
out
W
W
Yes
Packing List
17
Site Inspection upon delivered to
site
Packing and labeling comply
with Procedure. Packing list is
complete.
Component delivered as per
quantity
ordered
without
physical damage.
W
W
18
Installation
and
Precommissioning include
 Conduit
 Cable Laying work
 Fire Alarm Equipment
 VESDA System
 Piping System (include
painting)
 Firefighting Equipment
All installation are properly
performed and documented
HP
W
Yes
DO
Material
Receiving
Inspection
DS-Q-F14
Yes
IFR Shop
Drawing
Inspection
Checklist
19
Commissioning
and
Acceptance Test (SAT)
Site
All tests are properly performed
and documented
HP
W
20
Pneumatic Leak Test for piping
work
HP
21
SAT Acceptance Certificate by
client
The system free from any
leakage and pressure maintain
during holding time
All SAT documents properly
signed-off
by
authorized
personnel.
R
Non Conformance
Handling
Authorized
Method
personnel
Rework
Lead Engineer
Re Configure
Redesign
Repack
Rework
Re label
Return for
rework
Back charge to
transporter /
insurance
HRA
Personnel
Lead Engineer
HRA
Personnel
Project
Manager
Rework
Redesign
Lead Engineer
Yes
SAT Procedure
Rework
Redesign
Lead Engineer
W
Yes
Leak
Test Procedure
Lead Engineer
R
Yes
SAT Procedure
Ensure all
documents
being signed
Ensure
document from
client
Lead Engineer
PROCEDURE
CONTROL OF OPERATION AND NON CONFORMITY
DOC. NO.: DS-G-P03
Step
No.
REVISION : 2
Description of Inspection Item
Control Document
(Spec./Dwg. No.)
PAGE 7 OF 9
Responsible Parties
Acceptance Criteria
DS
Client
All Commissioning works are
completed
and
successful
handover to client
Functional test after serviced
and maintained
Training effective carried out
R
R
Yes
SAT Procedure
R
W
R
W
R
R
M
M
Yes
Service Report
Yes
Training
Record
Feedback Form
Yes
Vendor Data
Book
Yes
Progress Report
Fortnightly
Report
Yes
Progress
Budget
22
Handover
Acceptance
(according to client requirement)
23
Service & Maintenance
24
Training To Client
25
26
Vendor Data Books include As
Built Document and final
documents
Project Progress
All documents has been review
by client and submitted as Final
Documentation.
According to the project
schedule & client requirement
27
Project Budget
According to the budget plan
M
W
28
Reliability Period ( warranty )
According
requirement
R
R
*HP: Hold Point
W: Witness Point
Record
(Yes/No)
M: Monitor
to
contract
R: Record Review
N : Notification
Yes
Certificate of
warranty
V – Verification
Non Conformance
Handling
Authorized
Method
personnel
Ensure
Project
document from
Manager
client
Rework
Service
Manager
Re training
Project
Manager
Rework
Resubmit
Project
Manager
Contingency
Plan
Project
Manager
Contingency
Plan
Project,
Solution Sales
& Finance &
Procurement
Manager
Project
Manager
Service
Replace
PROCEDURE
CONTROL OF OPERATION AND NON CONFORMITY
DOC. NO.: DS-G-P03
REVISION : 2
PAGE 8 OF 9
Appendix 2 : Safety & Health Verification & Non Conformance Plan
Factor
Purchased
(Chemical)
Criteria
Material
Safety Data
Within 5 years
English & Bahasa
Measurement
Method
Visual
Responsibility
Record
Every new Material
DCC
Safety Data Sheet
SDS Master List
New vendor
PMT
Procurement
Personnel
PMT
Evaluation
vendor
OH & S Performance Test
Internal air emission
Clean air
Boundary noise
Noise expose
Lab Test
Lab Test
Noise Test
Noise Test
Defined by vendor /
Client / Safety Head
Audiometric Test
Hearing
Hearing test
Depend on Noise
exposure report
HRA Personnel
Audiometric Test
Report
PPE
Safety in charge/
Safety Committee
Availability
Functionality
/
Condition
Availability
Expired Date
Pressure
Functionality
Break glass / Key
available
Availability
Content
Expiry date
Function
visual
Before depart to site
PMT
PPE
Checklist,
DS-H-F09
Exchange
Safety in charge/
Safety Committee
Visual
Monthly
Fire
Fighting
Committee
Fire
System
Checklist, DS-HF05
Change / replace
Fire
fighting
Committee
Visual
Monthly
First
Committee
First Aid Kit Change / replace
Checklist, DS- H- Refill
F06
First
Committee
Achievement
Visual
Quarterly
MR
Management
Revised MP
Programme, DSH-F02
Director
Fire System include
1) Fire Extinguisher
2) Emergency Exit
3) Keluar Sign
First Aid Kit
Objective & Management
Programme
and
Aid
New
Vendor
Evaluation,
DS- Q-F21
External
Test
report
Conformance
Responsibility
Respective HOD
Competency of Vendor
Protective
/
Non
Method
Only can use / sell
when SDS Obtained
/
Instruction
Re evaluate vendor
Vendor
Personnel
Equipment
of
Frequency
Liaise with vendor /
Client to reduce
HSE issue at vendor
or client site
Project Manager /
Purchasing
Personnel
Project Manager /
Safety in charge/
Safety Committee
Aid
PROCEDURE
CONTROL OF OPERATION AND NON CONFORMITY
DOC. NO.: DS-G-P03
REVISION : 2
Factor
Criteria
Electrical
Equipment
/Wiring System
Safety issue
Visitor / Vendor / worker
work on behalf
Reporting
Accompany
company staff
Working at night
Device Assembly
Dismantle
Installation process
Cable laying
Piping / Welding
Inspection & verification
( include FAT & SAT )
Staff
mobilization
/
Travelling
Office Safety
Incident
PAGE 9 OF 9
Measurement
Method
Visual
Condition
&
Function Test
Visual
Frequency
Responsibility
Record
Monthly For Office
Defined by PMT for
Project
Every time
Safety in charge/
Safety Committee
Site Inspection
DS- H-F07
Sufficient light
Weather
Safety
Safety
Electric
PPE in Used
Fire
(Whichever applicable
)
Visual
Every time
PMT / Safety in Site Inspection
charge
DS- H-F07
Ensure safety before
job started
Project Manager
Visual
During process
PMT / Safety in Site Inspection
charge
DS- H-F07
Ensure safety before
job started
Project Manager
Sufficient
travelling
time
Valid insurance
Safety
Wiring system
Electrical item
Evacuation route
Handle of patient
handle reporting
(
include
local
authorities )
Visual
Every Travelling
PMT
/
personnel
HRA Personnel
Visual
Yearly
Quarterly
Ensure
travelling
time
Valid insurance
Rectify the non
conformance
by
Visual
Inform immediate and
within 7 days from
incident
Safety In charge / Visitor
Safety Committee
Contractor
Logbook
Non
Method
Repair / Scrap
& Door always locked.
To Be accompanied
by company staff
HRA Insurance policy
Safety in charge
Site Inspection
DS- H-F07
Safety in charge
Incident Log DSH-F04
Report
to
Management / client
for the decision of
reporting
and
handling
Conformance
Responsibility
Safety in charge/
Safety Committee
Safety in charge/
Safety Committee
Safety In charge /
Committee
Safety In charge /
Committee