• 1
    Project initiation

  • 2
    Project development

  • 3
    Project execution

PROCESS CONTROL

OKSA Services Nigeria Limited operates a process control system whereby work instructions and procedures describe how jobs are to be performed, tested and inspected. In the absence of such procedures, process control procedures are established to avoid jeopardy in the quality of the work. At construction level, calculation notes, fabrication procedures and drawings, testing and inspection, procedures, etc. are established by specialist departments.

However, special process, such as welding, protective coatings heat treatment, NDT, etc. requires continuous or intermittent monitoring throughout.
Full performance to the procedure shall be obtained and proof by adequate and documented qualification of personnel equipment and process, calibration of equipment and monitoring of process parameter. It is to be that not only the technical aspect that has to be controlled but also aspects such as time, costs, safety, and environment. Controlling such a process and product aspect is achieved by checking that aspect relevant to process and product characteristics to standards during the execution process and to make necessary adjustment, as needed.

INSPECTION AND TRAINING

In order to ensure correct application of inspection during work on a contract or project, an inspection and testing concept is adopted. This applies to incoming goods; work in process and finished product, in accordance with contractual requirements. By this measure, it stipulates that each product or service progress via specified test and inspection schedule including all relevant documentation.
Product can only be accepted after being checked and certified as meeting the requirements. Test and inspection files must be kept on record and adequately documented. Non- conformance discovered during receiving inspection and testing in-process inspection and testing, final inspection and testing must be marked and dealt with in accordance non-conformance procedure.

INSPECTION, MEASURE & TEST EQUIPMENT

As a quality measure, OSNL has identified the need to ensure that measuring and test equipment used to determine the conformity of a part of the system or plant to the instruction specified or for the process control, is efficient by means of adequate periodic gauging.

Although a procedure has been developed for the management and control of these equipment, but as a standing order all equipment or device used for performance of work involving measuring, monitoring, recording inspection and testing shall be in an appropriate and documented calibration status.
Such equipment or device bears a unique identification reference, allowing full trackability to its unique relevant calibration documentation.

Calibration register, calibration reports and calibration certificates are always documented for reference and verification purpose at work site or base office. However, users are expected to carry our systematic and periodic checking to ensure that the instrument, equipment or devices are gauged. They will also ensure correct use of every piece of the equipment and make sure that the equipment or such device are kept or stored in a conducive condition.

INSPECTION AND TEST STATUS

As a quality assurance measure, the status of product tested is always identified by suitable means which indicate the conformance or non-conformance of the product with regard to the inspection and test performed.

This identification process of inspection and test status are maintained as defined inquality plan or documented procedures throughout the life cycle of the project. Usually, labels follow-up sheets, markings, routine sheets etc., are used in order to track progress of the scheduled test and inspection operation.

Delivery, use or installation of a given product will only be allowed if the product in question has successfully passed all test and inspection operations listed in the relevant schedule. Those equipment are also applicable to subcontracted works.

CONTROL OF NON-CONFORMING PRODUCT

OSNL has remarkably established and maintained a document system to ensure that product/services which do not conform to specified requirements are not used,
installed or carried out. The control measure provided for identification, documentation, evaluation/ segregation and disposition of non – conforming
product or annulment of non – conforming services. The deficiencies are communicated effectively.

The non – conforming procedure sufficiently outline the requirements and conditions involved in handling non-conformance. The responsibility and authority involved for review and disposition of non-conforming are defined in the procedure.
However, the analysis and handling of non-conforming include:

  • Declaration, management and control of non-compliance.
  • Identification and storage of non-complying item.
  • Corrective action and verification of corrective action.
  • Preventive action and verification action.
  • Non-compliance status moved to anomaly status and dole out report.

All reports shall be recorded, documented and filed in accordance with requirements contained in the record and documented control procedures.

CORRECTIVE AND PREVENTIVE ACTION

Corrective Action Requests (CAR) are issued when a condition arises that cause or may cause a non-conformance. The main objective is to initiate investigation into the cause of non-conformance and to implement preventive or corrective action to prevent reoccurrence of non-conformance. In some cases a series of reviews or audits may be carried out with a view to institute corrective and preventive measures. Procedures are available to emphasis the application of controls to ensure that corrective and preventive measures are taken and to make sure that they are effective. To ensure objective realization of corrective and preventive action, the relevant information is submitted to management for review.

HANDLING, STORAGE, PACKING, PRESERVATION, AND DELIVERY

All materials/items supplied, produced or utilized by the Company are given adequate handling, storage, packing, preservation and delivery facilities and attention. Various conditions are specified for various products, materials or items to ensure satisfactory quality requirements compliance. At all times, we shall transport using adequate facilities and instructions designed to minimize the possibility of damage or deterioration.

Item shall be preserved, coated or packed as relevant to prevent deterioration during storage, production or shipment. When contractually specified, this shall be extended to include delivery to destination. Any transit damage or loss of project/contract materials/product shall be documented and communicated to the client without delay. The company has been established and maintained to demonstrate achievement of the required product quality and the effective operation of the quality system.
Such records shall include data regarding audit of the quality system, calibration of test and measuring equipment, material certification, inspections, and examinations, concessions, corrective and preventive actions, training records, HSE reports and statistics, performance records reports etc.

The records shall be designed and maintained that they can be readily retrieved and analyzed. Retention period of records shall be established based on legal and/or contractual requirements and specified in the relevant procedures of work instruction.

INTERNAL QUALITY AUDIT

In order to check implementation compliance and efficiency of the organization’s quality system, periodic quality audits are carried out. The Quality Assurance is responsible for planning, scheduling and ensuring the actual implementation. He is also responsible for the management reports following audits except as regards on the Quality department itself, which are carried out by the general management or a duly appointed organization or body by the management.

For projects, the project quality plan includes project-oriented audit plan drawn up to ascertain compliance and ensure corrective and preventive actions as to rely on satisfactory completion and handover.

Once a year, the QA manager evaluates all audit reports drawn up in the particular year. Findings and any proposal unattended to improve the quality system are summarized in the audit evaluation report. This summary report is then discussed by the Management for action and closure.

SERVICING

In situations where servicing is specified in company, established procedures for performing, servicing and/or verifying that servicing has been carried out based on the contract/service requirements. The format will however be approved by the client.

COMPANY PROCEDURES

It is a system requirement that the purpose of ensuring methodical and uniformity of work leading to efficiency control of activities, procedures are generated and developed. Each discipline is responsible for the development of their unit, procedures are indexed and detailed in the company procedures manual. Quality management department will be responsible for QA/QC procedures. Contractors/subcontractors engaged in contractual obligation with OSNL will be required to submit their entire contract with the company and where necessary develop additional contract specific procedures.

In general, listed below are some of the procedures utilized in the execution of company’s activities:

  • Contract Review
  • Basic Design
  • Quality Audit Control
  • Quality Record
  • Document and Data Control
  • Inspection
  • Calibration of equipment
  • Training
  • Correction and Preventive Action
  • Product Identification and tracing
  • Invoice Processing
  • Drawing Procedures
  • Vehicle Control
  • HSE
  • Promotion/ Staff Motivation