QA Manager
Domus Lloyd Contracting Ltd
Total years of experience :27 years, 0 Months
Working as a Project QA Manager in YASREF
Offsite Pipelines-SP-2, Yanbu Aramco Sinopec Refining Company (YASREF)
Redundancy Pipeline - (YASREF)
PetroRabigh Pipelines Relocation Package (Remaining Works) - YASREF
YR-YASREF Clean Fuels Interface Facilities - YASREF
The responsibilities include:
• Preparation and administration of the project quality system documents such as Project Quality Plan, Inspection and Test Plans and QC forms.
• Prepare/Review Project Quality Procedures
• Review Non Conformance Reports prepared by Site Quality Inspectors
• Develop ITPs, Quality Procedures, Forms etc.
• Review ITP’s for various Vendors/Manufacturers & Fabricators
• Schedule internal audits and subcontractor audits as per the requirements of Schedule Q of the contract and approved audit schedule
• Review Purchase Order Requisitions for standards compliance, inspection levels and RVL compliance.
• Review Purchase Orders prior to placement for its adherence to the Purchase Requisitions Data.
• Review Inspection Assignment Packages for the applicable Saudi Aramco Standards & SAMSS, SA-175 forms, Inspection Levels, and the correctness of data.
• Review Pre-Inspection Meeting agenda and attend the meeting (where required).
• Resolve quality issues with the manufacturers.
• Review and approve Vendor documents like Quality Plan and Vendor ITP’s, Manage third party Inspectors and monitor ITP activities are covered.
• Review the Third Party Inspection reports of material carried out at the Stockists & Manufacturers place.
• Evaluation of suppliers/subcontractors quality system
• Review Supplier Pre-Qualification Documents for One Time Approvals.
• Carry out manufacturing shop visits.
• Coordinate with client Vendor Inspection regarding any vendor quality issues.
• Review & approve quality documents & Aramco submittals (Monthly Management Reports, Material Status reports, Two-week look ahead schedules, NCR summary reports).
• Identification and implementation of training requirements for the project personnel
• Supervision of procurement QC Supervisor
• Plan and prepare for project Internal Audits (at 15% & 60% for Engg, Procurement & Construction phases).
• Oversee preparation and submission of SPDPs, Project Record Books and Material FDRs and final documentation dossier.
As a Project QA Manager (SAP No. 70010440) from April 2009 to Jan 2012
Projects:
Bulk Plant Additional Capacity Phase II - North West and South West Regions (9 sites), Saudi Aramco (April 2010 - to Jan 2012)
De-bottleneck Condensate Systems Project, Haradh Gas Plant, Saudi Aramco (April 2009 - March 2010)
Upgrade Sanitary Waste Water Treatment Facilities (August 2008 - March 2009)
The responsibilities include:
• Preparation and administration of the project quality system documents such as Project Quality Plan, Inspection and Test Plans and QC forms.
• Review Project Quality Procedures
• Review ITP’s for various Vendors/Manufacturers & Fabricators
• Assign QA related tasks
• Verify and monitor the implementation of the project quality plan on sites
• Identify non-conformances through assessments
• Review proposed corrective & preventive actions
• Schedule internal audits and subcontractor audits as per the requirements of Schedule Q of the contract and approved audit schedule
• Review Purchase Order Requisitions for standards compliance, inspection levels and RVL compliance.
• Review the Technical Appraisal of all the material requisitions
• Review Purchase Orders prior to placement for its adherence to the Purchase Requisitions Data.
• Review Inspection Assignment Packages for the applicable Saudi Aramco Standards & SAMSS, SA-175 forms, Inspection Levels, and the correctness of data.
• Review Pre-Inspection Meeting agenda and attend the meeting (where required).
• Resolve quality issues with the manufacturers.
• Review the Third Party Inspection reports of material carried out at the Stockists & Manufacturers place.
• Review and approve Vendor documents like Quality Plan and Vendor ITP’s, Manage third party Inspectors and monitor ITP activities are covered
• Review & approve quality documents & Aramco submittals (Monthly Management Reports, Material Status reports, Two-week look ahead schedules, NCR summary reports).
• Evaluation of suppliers/subcontractors quality system
• Review Supplier Pre-Qualification Documents for One Time Approvals.
• Carry out manufacturing shop visits.
• Identification and implementation of training requirements for the project personnel
• Supervision of procurement QC Supervisors
• Plan and prepare for project Internal Audits ( at 15% & 60% for both Procurement & Construction phases)
• Oversee preparation and submission of SPDPs, Project Record Books and Material FDRs and final documentation dossier
The responsibilities include:
• Participate in Developing and Re-Engineering business processes of the company
• Assist in arranging ISO 9001 surveillance audits from Accreditation body and other 3rd Party Audits
• Preparation and Submission of Project Quality Manuals along with Tender Documents for the forthcoming projects.
• Assist in planning, scheduling and execution of internal quality audits, third party audits, audit administration and reporting, follow-up and closure of audit findings, Documentation and control of Quality Manual other quality related documents.
• Participate as an Auditor in company’s Internal Audit every six months
• Preparation, review, updating and distribution of the Project Quality Plan
• Support Projects in the implementation of Quality Management System
• Support in the preparation of Project Quality Control Procedures, Inspection and Test Plans and Forms for different disciplines.
• Conduct Sr. Management Review Meetings every six months on behalf of Management Representative (MR) on Project sites and apprise the top management of key issues, propose preventive actions and recommendation for continual improvement
• Attend Project kick-off meetings for new projects
• Visit project sites to support the project QC team in resolving quality issues with the construction team and the client as well
• Visit project sites to evaluate the project performance with regards to quality
Project: Saudi Kayan Polycarbonate Project, Saudi Kayan Petrochemical Complex, Jubail.
The responsibilities include:
• Preparation, review, updating and distribution of the Project Quality Plan.
• Issue of Project Quality Control Procedures, Inspection and Test Plans and Forms for different disciplines.
• Review of Quality documentations issued by SIS.
• Assignment of quality related tasks
• Review of Inspection Reports and Non-Conformance reports, if any.
• Evaluate Technical Appraisal of procurement products in line with project specifications.
• Determine and report to the Project Manager the principal causes of quality losses.
• Determine with the Project Manager where improvements are required and where necessary, recommending corrective actions.
• Managing Quality Control functions for the project including planning of Quality Control inspections and preparation of reports.
• Assign Quality Control personnel to various areas of activity. Monitor inspections progress; review inspectors reports and documentation.
• Monitor on day to day basis and review the deviations reported, if any, with the approved quality procedures.
• Review and approve as necessary quality related procedures.
• Monitor the content and consistency of subordinate’s daily inspection activities.
• Conduct Internal Audit of the organization.
Worked as a Mechanical Engineer in PetroRabigh Project Management Team (PMT) to oversee the Overall Construction & Inspection activities of 26 Tanks, of which 4 are of Cryogenic service and the remaining Atmospheric tanks, Spheres included.
The responsibilities included but not limited to:
• Supervise the Inspection team of 10 personnel.
• Supervision, Monitoring and Control of Mechanical, Construction and Welding works. Major welding includes CS, Nickel steel welding.
• Procurement Follow-Up
• Conducting and Managing Weekly Progress Meetings
• Review contractor’s weekly Two Week Look-Ahead schedules and Three month look-ahead schedules.
• Inspect and evaluate tests and procedures used in quality control program.
• Ensure that specified quality control inspections and functions are scheduled and performed.
• Verify that all required erection drawings, standards, procedures and project specifications have been received by Contractor.
• Review drawings for compliance with standards and specifications.
• Review materials for compliance with project specification.
• Direct the compilation of various reports pertaining to project activity, such as project pictures, monthly narrative status of construction, contractor performance reports, and damage to material or equipment.
• Advise contractor on timely preparation of Welding Procedures, Method Statements and Quality Assurance Documentation.
As a Senior Mechanical Inspector in Saudi Aramco Inspection Department (Projects Inspection Division, PID), I was assigned to various Saudi Aramco projects to provide QA support during design, procurement and construction phases of Refinery, Gas Plants projects. The project included piping and Valves, pipelines, plant equipment like pumps, heat exchangers, pressure vessels, tanks, condensate drums etc., Typical inspection activities comprised of welding, hydro testing, coatings, NDT, PWHT and monitoring entire construction activity to assure quality issues are not overlooked.
The responsibilities included but not limited to:
• Provide continuous support to SAPMT and Proponent to achieve high quality in the projects and meet SA standards and Scope of work.
• Monitoring of Contractor Quality System and its quality personnel team
• Reviewing the contractor’s Quality Manuals and Plans, procedures, ITP, Checklists, Hydrotest packages and Tie-in/hot tap packages.
• Review of EPC Contractor and Construction (sub-contractor) Quality personnel including QA/QC Inspectors, QC Supervisors, and QA/QC Manager resumes, conduct interviews and approve them for the project.
• Field monitoring of Quality activities like weld repair rates, electrodes storage conditions, independent test laboratories, certification of QA/QC personnel, Quality Plan, QA procedures, NDT activities etc., and attending weekly quality meetings.
• Inspection of Heat Exchangers, columns, pressure vessels and Tanks
• Reviewing design packages and co-ordinate with Vendor Inspection Division for procurement stage items.
• Participating in MCC walkthroughs and generating Exception Items List in coordination with SAPMT and proponent.
• Conducting Focused Assessments of all contractor’s quality activities, processes and personnel to ensure they are effective and implemented as planned.
• Ensuring the documentation at various stages of the project including MCC and pre-commissioning.
• Review and comment on revisions to the SAUDI ARAMCO and industrial standards.
• Review and comment on quality control program developed in construction contractors.
• Review Welding Procedure Specifications, Procedure Qualification Records & Issue Job Clearance Cards to welders.
• Perform design reviews to verify conformance to company standards.
• Write Inspection Reports, Non-Conformance Reports and makes Log Book entries of on-site inspection findings
• Train newly appointed SAUDI inspectors.
• Review inspection waiver request to ensure they accurately represent the condition described.
• Prepare Shop drawings for duct fabrication and installation details
• Assure the quality of the product and make corrective actions in case of defects.
• Discuss with the Production Manager in case of tough and critical jobs as to how the job has to be carried out without any hassles and held-ups.
• Check the welding quality visually in critical jobs and make sure that the welding has been done in accordance with the client requirement.
• Maintain all the records and document update and filing in accordance with the requirements of company’s quality policy and ISO 9002 and to assure that there is no non-conformance during internal/external audits.
• Prepare Corrective Action Report in case of non conformance for review and approval of the management
• Establish check/hold points during fabrication process for critical jobs for quality check.
• Prepare/review technical submittals based on SMACNA and DW144.
• Be present during project hand-over meetings and make suggestions, if any, for the smooth flow till the project completion.
• Duct designing and calculation of pressure losses in the duct Layout using Elite Software.
• Prepare and verify schedule of HVAC equipment and other Air Terminal devices
• Attend site coordination meetings with the clients
• Oversee and provide direction to personnel assigned to Projects
• Coordinate with the production, tagging and issuance of ducts and accessories
• Study of Engineering drawings for die development and its designing using AutoCAD and cost estimation for complete die development.
• Preparation of process sheet for die development.
• Follow-up to get the approval of process sheet from third party. Follow- up at various stages of die development to ensure work progress as per process sheet.
• On-line inspection of die at various stages to ensure quality.
• Supervision and guidance to machinists to get maximum efficiency.
• The assembly of die and final inspection w.r.t drawings and approval from customers.
• Trial of the tool and corrective measures if required.
• To discuss the quality standards of customers and to ensure that these standards are being met by being in touch with the clients QA Department.
• To inquire and study the latest development in quality assurance and Control. To study its feasibility w.r.t the working environment and to submit the report to management.
• To sketch the line of action for implementation of new techniques decided by management.
• To ensure that the quality policy of the company is implemented. This is done by conducting weekly meeting with the subordinates and counterparts of the other departments and to review the documentary feedback.
• Hold meetings with the concerned Departments to solve the quality problems and to assure the non-recurrence of such problems.