Professional Documents
Culture Documents
Page
All
Date
Revise
1 year revalidation.
08-Apr-2013
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Table of Contents
Abbreviations .................................................................................................................................... 4
Definitions ......................................................................................................................................... 5
1.
Introduction ............................................................................................................................... 7
2.
Purpose .................................................................................................................................... 7
3.
Scope ........................................................................................................................................ 7
4.
Reference ................................................................................................................................. 7
5.
5.1.
Organization .................................................................................................................. 7
5.2.
Responsibility ................................................................................................................ 8
6.
7.
General Requirements............................................................................................................ 13
8.
9.
10.
11.
8.1.
8.2.
8.3.
8.4.
8.5.
10.1.
Purpose ....................................................................................................................... 14
10.2.
Applicability ................................................................................................................. 14
10.3.
10.4.
Responsibility .............................................................................................................. 15
10.5.
10.6.
10.7.
10.8.
10.9.
Reporting ..................................................................................................................... 16
10.10.
Dispatching ................................................................................................................. 16
Attachments ............................................................................................................................ 16
Attachment 1
Attachment 2
Attachment 3
Attachment 4
Attachment 5
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Abbreviations
DT
: Delivery Ticket
MIRC
MR
: Material Request
MSDS
MT
: Material Transfer
NCR
ONWJ
PO
: Purchase Order
PSCM
QA
: Quality Assurance
QC
: Quality Control
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Definitions
Corrective action
Disposition
Excess Materials
Inspection
determine conformance.
Marking
number, etc.
Material Certificate
specification.
Material inspector
Nameplate
PHE ONWJ
Non - conformance
Purchase Order
quantities.
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Stock Materials
Vendor
User
PSCM.
Visual inspection
without disassembling".
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1. Introduction
In order to accomplish the needs of its routine operation and projects, PHE ONWJ needs to
purchase materials and equipment that vary in types and classes, such as valves, flare tips,
fittings, consumables, spare parts, tubular, chemicals, and tools, which require specific
2. Purpose
The intent of this document is to avoid receiving / improper defect materials & equipment,
assure that the purchased materials & equipment are genuine, original, and also comply with
international code, company's purchase order and specifications, industrial standards and
3. Scope
This procedure covers the inspection of materials and equipment purchased by PHE ONWJ
and the mechanism of how materials & equipment shall be registered and identified to ensure
future traceability when entering and being dispatched from the Marunda Shorebase. Scope
test report, etc.), internal packing and marking inspection, Non Destructive Examination
4. Reference
1.
Any relevant company's specifications, standards, and codes determined by the company's
2.
3.
4.
Any related PHE ONWJ Material Purchase Specification issued by PSCM Department shall
be applied.
vocabulary.
Guidelines.
5.1.
Organization
Organization associated with the receiving materials & equipment inspection is shown as below:
QA/QC Team
QA/QC Lead
Assistant
Material Inspector
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It is the responsibility of the following parties to ensure that the purposes of this procedure are
achieved:
5.2.
Responsibility
Manage the acquisition and distribution of parts and supplies for project's needs, as
requested.
Direct a cost effective parts and materials procurement, inventory and distribution program.
Handle personnel matters including employee work schedules, staff training, and internal
operations of the Warehouse's, as well as establishing and monitoring applicable policies and
procedures.
Manage the selection of staff; provide or coordinates staff training; and conduct performance
evaluations.
Direct purchasing and materials warehouse staff; and monitor inventory levels and processing
procedures.
Establish and/or implement procedure regarding the handling, storage, packing and delivery
of purchased materials / equipment, to prevent from loss, damage, defect, deterioration and
misused.
Issue written application for inspection to Marunda Shorebase QA/QC Team on planned
Provide the supporting documents (purchase order, material certificates, etc.) required for
Recommend and assist in the implementation of unit goals and objectives; establish
schedules and methods for assigned parts operations; and implement policies and
procedures.
Plan, prioritize, assign, supervise, and review the work of staff involved in the receiving
activities.
Implement procedures for the receipt, storage, and shipment of materials / equipment.
Check the documents completeness and suitability, i.e. PO, MT, Material Certificate, Test
Report, etc.
If there are no Materials / Equipment or documentation discrepancies, signs the delivery ticket
and MR.
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Keep and manages all original supporting documents, including QAJQC verified MR
Certificate.
Initialize, stamp in red "Verified Copy", and sign the copies of QA/QC verified mill certificates,
Ensure all stock and non stock items which are sent from other warehouse or location are
located in transit area and should be accompanied by Material Certificate, DT, manifest and
SMT.
5.2.4. QA / QC Lead
Provide monthly reports to QA/QC Manager and ensuring key quality metrics for quality
Issues acceptance notice based on engineering judgment for non-conforming. materials &
equipment
Liaise with the other materials / equipment functions and departments within the company in
order to efficiently deal with any issues arising from material receiving inspection.
Conduct periodic audit or review to maintain and improve the performance of Marunda
Optimize the efficiency within the QA/QC Team by means of regular review of processes and
procedures.
Receive and review application for inspection from Marunda Shorebase Supervisor for
Ensure that adequate instructions, procedures, specifications, drawings, and all applicable
documents related to the order are issued or made available to the material inspection
personnel.
Check, monitor, and verify that all inspection activities are carried out in accordance to the
Ensure the inspection file is complete and ready for consolidating and up-dating of the vendor
data base.
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Review instructions, procedures, specifications, and other inspection related data issued to
them for adequacy, accuracy, etc. and report discrepancies or ambiguities to Material
Inspector Leader.
Review and verify documentation for conformance with specification / purchase order.
In case of deviation and if the materials / equipment do not correspond to PO or MR, hold the
Verify specification of the materials / equipment against technical documents and ensure any
Check nameplates / tags/part number to ensure the information thereon is complete and
correct.
As the acceptable of inspection result, mark each and every item with MIRC number. Raise
QA/QC verified mill certificate conforming the acceptable of the materials / equipment.
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Description of Activities:
1.
2.
Marunda receiving team receives the purchased materials and equipment that are delivered
Upon materials I equipment arrival, Marunda receiving team performs initial documents
verification (delivery order, technical documents, etc.) against the purchase order (PO).
3.
Based on Critical Material List (CML) issued by the Engineering Department, Marunda
receiving team shall select the materials & equipment that need to be verified and
inspected.
4.
In case the inspection by QA/QC team is not required, the material equipment will be
5.
Marunda receiving QA/QC team shall check the completeness of the certification
6.
Any materials and equipment which are delivered without proper certification or do not fulfil
the standard requirement as specified in PO, shall be rejected and returned to vendor.
7.
Inspector shall verify the certification documents and or calibration test report (as part of
8.
Inspector shall carry out inspection and test (where necessary) in accordance to the
applicable QA/QC procedure, standards / codes, and check list. Material Receiving
Inspection report (see attachment 5) shall be issued within 24 hours after the inspection
completed.
9.
If the documents provided are not correct or materials / equipment are not acceptable,
inspector shall issue the material receiving inspection report. The material receiving
inspection report shall be distributed to Marunda Receiving team within 24 hours after the
inspection, with copy to either Discipline Engineer or Technical Authority. Material inspector
lead will record it into the list of inspection report (see attachment 2). In case of materials /
10.
Marunda Receiving Team shall store (temporary) and tag-out the incorrect documentation
disposition shall be segregated and clearly identified using labels, tape or authorized
stamps as appropriate.
11.
If materials / equipment are acceptable, raise MIRC number. Stamp the acceptable
J6.
12.
Material inspector shall issue a material receiving inspection report for the acceptable
materials / equipment. The report and inspection records shall be distributed to Marunda
Receiving Team with copy to Material inspector Leader who will record it into the list of
13.
the authorized person shall issue a disposition concerning corrective action needed to be
taken against the non-conformance materials / equipment. In case a repair work is required
as a corrective action, inspector shall re-inspect the repaired materials / equipment (back to
14.
If the materials / equipment are rejected or shall be replaced, Marunda receiving team shall
15.
Marunda Receiving Team contacts the End-User and vendor informing the non-
16.
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17.
If the end user has agreed to accept material with a different specification from the PO or if
the non-conformance issue has been resolved, the Discipline Engineer/technical Authority
18.
Marunda Receiving Team shall store or deliver the acceptable materials / equipment
properly.
19.
Marunda Receiving Team shall maintain and compile all documents including non-
7. General Requirements
1.
All materials and equipment used in maintenance shall have passed inspection following
receipt at warehouse. The material inspector shall check all relevant certification for
2.
Any materials or equipment which is delivered without the specified certification or failing
inspection shall be rejected or held in temporary storage with clearly identified using labels,
3.
Items held in temporary storage required urgently for production purpose may be released by
agreement with the Discipline/Project Engineer and user. The discipline engineer shall issue
"acceptance notice".
4.
Original Materials & Equipment related documents shall be maintained by PSCM department
and distributed to personnel and locations where operations essential to the effective
5.
Immediately upon their arrival on site or warehouse, all materials and parts shall be located in
storage within their original packing, suitably protected from the weather and/or under
controlled ambient conditions as may be required by the nature of the materials. They shall be
inspected visually and tested whereas considerably required, and record shall be made for
6.
If damage or defect is found due to transportation process, material inspector shall raise NCR
based on the severity of defect, will decide whether to reject the defect item or ask vendor to
7.
After inspection, equipment shall be returned to weather protected storage with protection
8.
Marunda QA/QC Team shall ensure that excess materials with incomplete documentation are
not acceptable.
9.
Marunda Receiving Team shall not release excess materials with incomplete documentation
conversely. In this situation, all consequences related to those materials are the responsibility
of user.
8.1.
Review all technical documentations (material certificate, calibration certificate, inspection &
test records, brochure/catalogue, manual, manufacturer data record, drawing, etc.) for
Verify specification of the material or equipment against the above technical documents and
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8.2.
order.
Check the type of packing/inside shielding (plastic, cartoon, Styrofoam, etc.) to protect
material (spare parts) from impact, humidity and another may appear destructive sources.
8.3.
Identification Check
Check material's conformance to specification and ensure any traceability requirements are
complied with.
The inspector shall also check nameplates/tags, part number to ensure the information
8.4.
The Materials Inspector shall ensure conformance with the particular specifications. Key
checkpoints are:
8.5.
Other NDT techniques might be performed to enhance the confident level about materials
condition and compliance, such as Dye Penetrant (DP), Magnetic Particle inspection (MPI),
Radiography Testing (RT), Ultrasonic Testing (UT), X-ray, Eddy-Current, Acoustic Emission
9. Inspection Method
When appropriate, material inspectors will check the condition of every single item. If it is
considered not practical to perform 100% inspection, due to the amount of materials, Marunda
10.1.
Purpose
The purpose of this procedure is to specify how materials & equipment shall be registered and
identified to ensure future traceability when entering and being dispatched from the Marunda
Shorebase.
10.2.
Applicability
This procedure is applicable to all materials and equipment that requires certification as specified
10.3.
MIRC Register
MIRC Numbers are registered in the List of inspection Report in the form of MS Excel located
QAQC Activities Marunda Receiving QA/QC Inspection Report List. It can be viewed by
anyone (who has access to PHE ONWJ share folder) and edited PHE ONWJ QA/QC at Arkadia
Office and Marunda Shorebase QA/QC Team. An MlRC number covers all items within a single
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10.4.
Responsibility
It is the responsibility of PHE ONWJ QA/QC at Arkadia Office and Marunda Shorebase to update
and maintain the MlRC Register. It is the responsibility of Assurance Engineer to ensure this log is
maintained correctly.
10.5.
MlRC Number
MlRC Numbers are unique numbers that are to be issued to all incoming materials and equipment
that require certification in accordance with this procedure. MlRC Number will be marked on all
applicable materials / equipment by the Marunda Shorebase QA/QC Team using the appropriate
marking procedure.
10.6.
Material Marking
On satisfactory completion of inspection, the Material Inspector shall mark the MlRC Number
on all-applicable materials and equipment. This number shall be marked adjacent to the
heat/cast/serial number by paint marker, hard stamp, and either low stress or engraved
Loose small fittings and fasteners shall not be marked by using hard stamp, low stress or
engraved.
Hard stamping is permitted to tag all carbon and stainless steel parts except zirconium (due to
its notch sensitivity). For zirconium vibro-etching techniques should be used for identification
For heavy part, when it is im proper to be handled or lifted by using bare hand, the lifting
process shall use forklift or crane. Refer to MSB-El-GEN-07, lnstruksi Forklift untuk Bongkar
Muat, for lifting using forklift, and MSB-El-GEN-08, lnstruksi Operasi Crane untuk Bongkar
Prior to stamping, ensure the surface of part to be stamped is free from dirt, corrosion
product, etc.
The surface of part can be cleaned or sw ept by using bristle brush or steel brush w hen
needed.
Marking is performed by pressing the stamp onto the surface of part by using hammer with
10.7.
Attachment 2 is the MS Excel MlRC Register input form. The Material inspector shall input all
necessary data for each MIRC. This register will provide the link between the unique
heat/cast/serial number on the materials / equipment and the original Purchase Order Number.
10.8.
All material certificates shall be recorded in accordance with MlRC number. Stamp on the material
MlRC Number
PONumber
The Marunda Receiving Team shall hold all original material certificates at Marunda Shorebase.
Material certificates copies will be issued to other parties as necessary. Marunda OAIQC Team
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10.9.
Reporting
Starting 1' February 2007, the Material inspector Leader shall report the status of all incoming
materials inspected to Assurance Engineer on daily basis and to PSCM Leader on satisfactory
or Warehouse Supervisor who will jointly agree the remedial actions necessary in conjunction with
10.10. Dispatching
All certified materials and equipment being dispatched from the Marunda Shorebase will be
accompanied with copies of their original material certificates. These copies will be stamped in
red "Verified Copy" and signed by the Material Receiving Team at Marunda Shorebase. The
It is the Material Receiving Team responsibility to manage the receipt and storage of this
certification.
11. Attachments
1.
Attachment 1
2.
Attachment 2
3.
Attachment 3
4.
Attachment 4
5.
Attachment 5
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Attachment 1
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Project
NCR No. :
User
Project No. :
Contractor :
PO No.
Location :
DESCRIPTION OF CONFORMANCE
ORIGINATOR
Name
Signature
ROOT CAUSE/S
Title
Date
Documentation
Design
Material
Plant
Workforce errors
Supervision
Training
Subcontractor
Vendors
PROPOSED DISPOSITION
Survey
Accept as it is
Other
Repair / rework
Reject
Originator :
CONTRACTOR
Name
Signature
Title
Date
CORRECTIVE / ACTION
PREVENTIVE ACTIONS
COORECTIVE
Contractor Rep. :
Name
Signature
Title
Date
END
DISPOSAL ACTION
DISPOSITION
Comments
COMPANY
Signature
Title
Date
Name
Signature
Title
Date
Name
Signature
Title
Date
Name
ACKNOWLEDGED BY
QA/QC Manager /
QC/QA Coordinator :
Lead:
Project
Leader :
Tier
1:
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The following instructions will assist the originator. contractor, and company in filling out the form
as completely and accurately as possible in the effort of informing and resolving the Non
Conformances.
Project
Contractor
The organization which provides goods or services to the Company under terms specified in a
The product or material which subject to non-conformance against the requirements stated in PO
(Purchased Order).
NCR No.
The originator shall fill this blank prior to the submission of NCR Form.
Project No.
This blank shall be filled by originator with the number of project and/or the number of contract.
PO No.
Location
Originator
The personnel who first identifies the non-conformance and raise the NCR form.
group or team, and the date of submission, shall be entered by the originator.
Root Cause/s
The root cause/s of non-conformance shall be indicated by checking the appropriate box.
Proposed Disposition
Originator shall propose the disposition toward end user to accept as it is, repair/rework, or reject
the non-conformance.
Corrective Action
To prevent recurrence, the Non-conforming organization shall propose the corrective action.
Company
End user shall fill this blank with recommendation and requirement headed for contractor to
Acknowledged By
QA/QC Manager / Lead and Tier 1 shall show their awareness regarding the on conformance by
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Attachment 2
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Attachment 3
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Attachment 4
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Attachment 5
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Project Title
Project Title
Project Location
: OMWJ
ONWJ
Marunda
Shorebase
Vendor
Date of Inspection
Reference
DESCRIPTION
Brand
MFR
Type
Model
Item No. :
Quantity
Inspection Checklist
Inspection Items
AV.
N/A
AV.
Inspection Items
Monogram Certificate
Visual Inspection
Calibration Certificate
Identification Check
Manufacture Certificate
N/A
Dimensional Check
MIRC
Conclusion
Drawings
Acceptable
Calculation Sheets
Not Acceptable
M.S.D.S.
NCR No.
Submission Date
Closing Date
Note
Inspection By
: Material Inspection
Neme
Neme
Date
Date
Signature
Signature
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