Professional Documents
Culture Documents
MATERIAL CONTROL
PROCEDURE
Date : 24/02/2015
Revision No : 0
Page 1 of 14
TABLE OF CONTENTS
SECTION
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
DESCRIPTION PAGE
PURPOSE
SCOPE
REFERENCE
DEFINITIONS
RESPOSIBILITY
PROCEDURE
6.1
GENERAL
6.2
MATERIAL RECEIVING AND INSPECTION
6.3
MATERIALS ON-HOLD
6.4
RESERVATION / STORAGE AND HANDLING OFALL MATERIALS
6.5
MATERIAL ISSUANCE
6.6
TRACEABILITY FOR ISSUED MATERIALS
6.7
STORAGE AND PROTECTION FOR IN-PROCESS PRODUCTS
2
2
2
2
2-3
3
3
3-5
5-6
6-8
8
8-9
9 - 11
SPECIAL REQUIREMENTS
RECORDS
11
11
FIGURE I to IV
12 14
APPENDICIES
APPENDIX I
APPENDIX II
APPENDIX III
APPENDIX IV
APPENDIX V
APPENDIX VI
APPENDIX VII
MATERIAL CONTROL
PROCEDURE
Date : 24/02/2015
Revision No : 0
Page 2 of 14
1.0
PURPOSE
This procedure is to clearly define the relevant requirements for material receiving,
handling, inspection, storage and traceability including its control of any nonconforming materials.
2.0
SCOPE
All material supplied by Client and p u r c h a s e d , intended to be used on a
particular project during the entire period of the project construction phase.
3.1
REFERENCES
- Requirement of ISO 9001 : 2008
- Clients specification
- ASME Sec II
4.0
DEFINITIONS
Material Receiving
Handling
Material Traceability
Storage
Material Control
PID
MIR
MIDR
PMT
5.0 RESPOSIBILITY
MATERIAL CONTROL
PROCEDURE
Date : 24/02/2015
Revision No : 0
Page 3 of 14
6.0 PROCEDURE
6.1 GENERAL
a. Receiving inspection guideline for mechanical, electrical and instrument items
are referring to Figure I & II.
b. Marterial receiving, issue and traceability flow chart, see Figure III.
6.2 MATERIAL RECEIVING AND INSPECTION
6.2.1 Material Receipt Verification and Inspection
6.2.1.1 General
QA/QC shall initially check/ Examine the actual physical condition of all
incoming materials and carryout verification for all corresponding
documents in compliance with the following:
Conformance to clients specification, code and Standard.
Quantity and type/grade of items received against Invoice/
Delivery Notes and/ or Purchase Orders/ PIDs.
Identification of items with Purchase Orders/ PIDs.
Visible damage of items.
Conformance to documents. (packing lists, Mill Cerificates, test
Certificates and Material Safety Data Sheets especially for
chemicals).
Any materials/ documents found not comply with the specified code,
specification code, specification and standard shall be automatically put on
hold.
The QA/QC shall be the inspection focal point and shall notify the relevant
Departments (QA/QC, Engineering and Production) to assist in the
receiving inspection.
6.2.1.2 Structural and Piping Materials
While carrying out inspection, the Material Contoller shall straight away
apply paint or metal marking on the item inspected.
Whenever practical, the Material Controller shall write on the material
Acc For accepted, Rej for rejected and On Hold" for deficient
material, Otherwise paint marking shall be applied at the edge of items
inspected as follows.
MATERIAL CONTROL
PROCEDURE
Date : 24/02/2015
Revision No : 0
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STATUS
SIGN
PAINT
MARKING
Accepted
Acc
Rej
On Hold
Green
Red
Yellow
Rejected
On Hold
MATERIAL CONTROL
PROCEDURE
Date : 24/02/2015
Revision No : 0
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6.2.3
6 . 3 M ATE R I A L S O N - H O L D
a) The material with following defections shall be put on hold:
Data in the mill certificate document are not available or doubtful.
Wall thickness/ schedule deficiency.
Physical damage.
Other issues as identified.
b) Materials on-hold shall be segregated at a designated bay/ rack until
further inspection/ verification can be carried out. The inspection/
verification shall be carried out only after necessary information comes to
be ready for reference in making justification of the deficient item.
c) In case of urgent circumstances, materials on-hold in the store can be
released when PMT produces the release note (Appendix V) duly signed
by Project manager to the store personnel.
d) To ensure effective identification and traceability of the released on-hold
material, upon receiving the release note from PMT and duly agreed by
clients shall adhere to the following:
To ensure all the relevant data are correctly filled up in the Release
Note.
To mark the Release Note number on material under release. The
Quarantine Tag shall be remained until the MIDR is closed out.
e) After confirmation of the material whether it is complying or non-complying
with the requirements, the Material Coordinator shall close the Release
note. Material which is confirmed non-compliance with the requirement
shall be removed from site and returned to stores quarantine area.
MATERIAL CONTROL
PROCEDURE
Date : 24/02/2015
Revision No : 0
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d)
e)
MATERIAL CONTROL
PROCEDURE
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6.4.3
MATERIAL CONTROL
PROCEDURE
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6.5
MATERIAL ISSUANCE
a) Material issuance shall be made by Material Requisition (Appendix VI) shall
Be raised by the Site Supervisor upon requesting any material.
b) Consumables and Materials which dip below identified Minimum Stock Level
(MSL) shall reordered by storeman by Material Requisition through the
Procurement Department.
6.6
General
It is the responsibility of the QA/QC Controller to ensure that the issue and
receipt of materials are properly documented. It is also their duty to ensure
that copies of documents are transmitted to the responsible personnel
involved in the control of materials and commencing from receipt.
6.6.2
MATERIAL CONTROL
PROCEDURE
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Revision No : 0
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6.6.3
6.7
General
a) All completed or in-process materials shall be
Kept at designated area and away from dirt, grease, paint
spray and other foreign matter.
MATERIAL CONTROL
PROCEDURE
Date : 24/02/2015
Revision No : 0
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6.7.2
MATERIAL CONTROL
PROCEDURE
Date : 24/02/2015
Revision No : 0
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8.0 RECORDS
All records generated from the time of material receiving and issuances during
the entire period of the project construction phase are to be kept
progressively by the designated party of the Long Wei Constructions Project
Team.
MATERIAL CONTROL
PROCEDURE
Date : 24/02/2015
Revision No : 0
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MATERIAL CONTROL
PROCEDURE
Date : 24/02/2015
Revision No : 0
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Revision No.0
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Initial
Inspection
Issue
MIR
Review
MIR
Review
MIDR
Accept
Reject
Store in
Designated Area
Joint
Inspection
Reject
Accept
Issue
MR
Return to
Supplier
Segregate to
Quarantine Area
Release to
production
No
Take Remedial
Action
Repairable?
No
Close
MIDR
ReInspection
Yes
Accept
Reject
Piping/ Str
Material?
Urgent
Material?
Yes
Yes
Produce
Release Note
Comply with
Requirement?
No
Yes
Release to
production
Deficiency
Cleared?
Fill-in Fit-up
Inspection Report,
Yes
Close
MIDR
No
Transfer to Cutting
Plan/ Drawings,
APPENDICES
Rev- 0
Appendix I
:
:
:
MIR NO.
DATE RECEIVED
P.O.NO.
DESCRIPTION
CERT NO.
Appendix II
Form
SUPPLIER :
Rev.
Material
Page
of
JOB NO.:
PO NO.:
DESCRIPTION :
No
Report No
Quantity
Order
Recv
Heat No.
Status
Acc / Rej
Remark
Remarks :
PREPARED BY
CHECK BY
WITNESS BY
QA/QC
QA/QC
Client Representative
Sign
Date
Name
Appendix III
Shipper
Report No. :
Pt. of Origin :
Rec. Points :
Date
Del. Carrier :
Unit No.
P.O. No.
F.O.B.
P.O. ITEM
MATERIAL
Remarks :
Proposed Recommendation :
Yes
Shipment Inspected on
Yes
No
Yes
No
Photos Attached
Yes
Yes
Delivery Document Att ached
No
No
Was Damaged or Loss Due to Poor Packing ? Lack of Precautionary Marks ? Other Reason ?
Explain :
Prepared By :
Closed Out By :
Material Coordinator
Date
Verified By :
Material Coordinator
Date
Client representative
Date
Appendix IV
HOLD
DO NOT USE
PROJECT
:
ITEM DESCRIPTION :
MARKS
ISSUED BY :
SIGNATURE :
DATE
No.
:
MIR
No.
INSP.
DATE
INSPECTED BY
:
:
Appendix V
TO
FROM
PROJECT
R.N. NO
DATE
DEFICIENCY
ITEM NO.
DESCRIPTION
QTY.
P.O.
DOC.
CAN BE
CORRECTED AT
MODULE
MAT'L
HEAT NO. OR
S/N
ISSUANCE
Project Manager
Name
LOCATION TO BE
INSTALLED
CLOSE OUT
REMARKS
CLOSE OUT
Material Controller
Name
MIDR NO.
Client Rep.
Name
Material Controller
Name
QA/QC Coordinator
Name
Client Rep.
Name
Date
Date
Date
Date
Date
Date
Appendix VI
MATERIAL REQUISITION
DATE
REQUIRED BY
PROJECT NO
REFER TO
ITEM
QTY
REMARKS :
DELIVERER TO :
DESCRIPTION
LOCATION
DRAWING NO.
REQUESTED BY :
SIGNATURE :
POSITION :
AUTHORISED BY :
SIGNATURE :
POSITION :
REMARKS :