Group Five Civil Engineering

OPERATIONAL SYSTEM PROCEDURE

PRODUCTION AND SERVICE PROVISION

Document No.
OPP-001
Revision No.
00
Page No.
Page 1 of 10

OPERATIONAL SYSTEM PROCEDURE FOR

PRODUCTION AND SERVICE PROVISION
OPP-001

Name
Designation

Originated By
Evanee Jackson
Quality Manager

Review By
Jan du Toit
SHEQ Manager

Approved By
Andrew McJannet
Managing Director

Signature

Date
Copyright Group Five 2010. All Rights Reserved - This documentation is considered the intellectual property of Group
Five. Unauthorised reproduction or distribution of this documentation or any portion of it may result in severe civil and
criminal penalties, and violators will be prosecuted to the maximum extent possible under law.

Group Five Civil Engineering

OPERATIONAL SYSTEM PROCEDURE
PRODUCTION AND SERVICE PROVISION

Document No.
OPP-001
Revision No.
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Page No.
Page 2 of 10

Table of Contents
1
2
3
4
5
6
7
8

Purpose......................................................................................................................................... 3
Scope............................................................................................................................................ 3
References.................................................................................................................................... 3
Definitions, Acronyms and Abbreviations.......................................................................................3
Responsibilities.............................................................................................................................. 4
Procedure...................................................................................................................................... 4
Records....................................................................................................................................... 10
Attachments................................................................................................................................. 10

Group Five Civil Engineering

OPERATIONAL SYSTEM PROCEDURE
PRODUCTION AND SERVICE PROVISION

Document No.
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1.

Purpose
To provide an outlay for written instructions and procedures to be compiled to ensure production
processes and services are carried out under controlled conditions. This procedure provides
guidelines for reasonable and responsible management of a product during its progress from
inception to its ultimate use and beyond.

Scope
Planning for process control, process capability, supplies, handling, material control, traceability
and identification, equipment control and maintenance, process control management,
documentation, process change control, control of verification status and control of nonconforming products.

References
ISO 9001:2008
OHSAS 18001:2007
ISO 14001:2004
MS-001
MSP-005

Quality Management Systems Requirements

Occupational Health and Safety Specifications
Environmental Management Systems Requirements
Management System Manual
Control of Non-Conformances, Corrective and Preventative
Action

Definitions, Acronyms and Abbreviations

Manufacturing
Includes any form of processing of substances, articles and materials, to derive a product for
sale.
Product
In the context of this standard means all manufactured goods and elements of a construction
project, from the raw materials to the completed arrangement.
Recycling
Reclaiming or reusing substances where appropriate and applicable.
Material Safety Data Sheet (MSDS)
A material safety data sheet contains data regarding the properties of a particular substance.
It is intended to provide workers and emergency personnel with procedures for handling or
working with that substance in a safe manner, and includes information such as physical data
(melting point, boiling point, flash point, etc.), toxicity, health effects, first aid, reactivity, storage,
disposal, protective equipment, and spill-handling procedures.
MSDS provide information on chemicals, chemical compounds, and chemical mixtures.
This includes instructions for the safe use and potential hazards associated with a particular
material or product.

Group Five Civil Engineering

OPERATIONAL SYSTEM PROCEDURE
PRODUCTION AND SERVICE PROVISION

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Transport Emergency Cards (TREMCARDS)

Transport emergency cards must be carried in the cab of any vehicle carrying dangerous goods
in quantities exceeding the exempt quantities.
The purpose is to instruct the driver in the event of an incident.
They may also assist emergency response workers, as they carry information which is specific
to the particular goods being carried.
There must be a card for each dangerous goods item in the load.

Responsibilities
In respect of this procedure:
Action

Responsibility

Preparation
Review
Approval
Implementation

QA Manager
Management Representative
Managing Director
Personnel as shown in this procedure

In respect to implementation:
The person appointed as the person legally responsible to ensure compliance with relevant
legislation must ensure that a process is established to ensure that basic procedures are
implemented and maintained.

Procedure
As a product moves along its commercial life, or a construction project develops it becomes
remote from its manufacturer or developer.
The risks associated with that product becomes more difficult to manage.
Planned and coordinated pre-emptive care mitigates this problem.

Consider ongoing attention at every interface of the product, procurement, processing and
handling
Ensure the site team understands their part within the chain to ensure that no harm, injury
or damage occurs to person or product.
Address the principles of; the right to know, the need to know and the duty to inform, by
providing comprehensive up to date information that is easily understood.

6.1 Implementation
This will be implemented and maintained via management system procedures, work
instructions, SHEQ Plans, method statements and quality control plans.
These procedures describe the criteria for determining satisfactory work completion or
conformance with specified requirements.
Implementation of these procedures will

Aid in minimising errors and maximising yields.

Group Five Civil Engineering

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PRODUCTION AND SERVICE PROVISION

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Allows the team to assess environmental impacts at each stage in the product
lifecycle
Address elements which will minimize negative impacts and maximize positive
impacts
Investigate the use natural resources in order to promote sustainable development
Identify applicable laws, regulations, permit conditions or national standards.
As a minimum ensure compliance at each stage of the product lifecycle

6.2 Product Provision

Monitoring and control of processes takes place as described in the Project Quality Plan,
Method Statements and in site specific Quality Control Plans. Verification will be by
release records, internal audits and in actual product and service provision.
Control of non-conforming product, corrective and preventive action implemented is
addressed in Control of Non Conformances, Corrective and Preventive Action MSP 005.
Product quality is addressed through each stage of production from purchase of raw
material to final delivery (handover).
Process capability will be verified as being in accordance with specified requirements
through final inspection and testing and analysis of data as reflected in Quality Control
Plans.
Machinery and Equipment management, utilisation and availability are addressed on site
using Preventive Maintenance Programmes and other relevant control documents.
Control of monitoring and measuring devices is exercised through Control of Monitoring
and Measuring Equipment OPP 004 and is applicable for all equipment used in critical
inspection, measuring and testing.
The skills, capabilities and knowledge of all personnel operating processes that have an
affect on product quality will be addressed through the Human Resources training
programmes.
All documents and records will be managed and controlled as per Control of Documents
and Data MSP 001, Control of Records MSP 002 and Control of Documents and Records
OPP 003.
Contracts are monitored during the progress of works through site meetings and marking up
of programmes to monitor progress.
Special processes or methods to be employed on site are described in Method Statements,
for acceptance by the Client.
The method statements are distributed to the applicable construction personnel and provide
vital information on method, workmanship and resources to be utilized. The absence of
such instruction could have an adverse affect on Quality.
Method Statements are prepared by experienced company personnel.

Group Five Civil Engineering

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PRODUCTION AND SERVICE PROVISION

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6.3 Service Provision

To satisfy this element we will endeavour to hand over all work on time and will attend to
items arising, during any contractual stipulated maintenance period, promptly and effectively.
We recognise that customer satisfaction is an integral aspect of our Management System.
The customer perception of the company image, culture and performance is important. It is
acknowledged that improved performance promotes customer satisfaction and leads to
increased market share.

6.4 Product Identification and Traceability

Identification of products or items will be as follows:
Off the shelf items must be identified by labels or casting numbers (bolts and nuts etc.)
Manufactured items will be hard stamped or painted with the drawing or item number.
Reinforcing steel will be identified by labeling (in bundles), referring to bending schedules
and mill certificates.
Concrete structures will be identified to drawings pre and post concrete inspection
records.
All hazardous materials delivered to site must have the relevant Material Safety Data
Sheets.
Traceability of items and materials will be as follows:
Visually inspect the incoming raw material for quantity, workmanship, damage and
corrosion protection as relevant.
Traceability will be by delivery note or material certificate and thereafter will not be available
except as records.
Manufactured items will be traceable by item numbers and material certificates as indicated
in Method Statements and Quality Control Plans.
Reinforcing will only be traceable to a batch number at place of cutting and bending,
thereafter traceability will not be available but only referenced to material certificates or
supplier Certificate of conformance (Mill certificates).
Finished construction items will be traceable to inspection records as to geographical
location as indicated on the construction drawings.
Status
Stickers or calibration records will determine the inspection and test status of monitoring
and measuring equipment.
The inspection status of reinforcing steel will be determined by means of tagging and will
also be referenced to the bending schedules.

Group Five Civil Engineering

OPERATIONAL SYSTEM PROCEDURE
PRODUCTION AND SERVICE PROVISION

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Revision No.
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The inspection and test status of structures will be traceable to concrete inspection and
test records. The concrete materials test status will be demonstrated on the grading
analysis and cube strength data sheets. No visual indication on completed items will be
available.
Brick inspection and test status will be traceable to crushing strength data sheets supplied
by the subcontractor. No visual indication on bricks will be available.
Inspection and test status on structural steel items (Hard stamping or painting) will only be
traceable to inspection release and galvanise release records. No visual indication will be
seen on completed items.
Inspection and test status will be determined through labels, stickers, batch numbers and
conformance certificates.
Inspection status of completed structures will be determined through data packs (including
handover status).

6.5 Customer Property

Customer property will be identified in the project quality plan.
On receipt of supplied materials, the Site Agent or his nominee must ensure that all
materials delivered are as per delivery note or schedule.
The Site Agent or his nominee must visually inspect the material for quantity,
workmanship, damage and corrosion protection.
If found acceptable, sign the delivery note to indicate that the materials and
documentation is acceptable.
If found unacceptable, or without documentation, Quarantine the items and notify the
Client in writing, why the material or documentation is unacceptable.
All reasonable precautions must be taken by the site to safe-guard Customer property
against damage and/or theft.
If customer property has been stolen or damaged, it is the sites responsibility to notify the
Client in writing and maintain the applicable records.

6.6 Preservation
Handling
All galvanised, specially coated articles and pipes will be off loaded by using web slings.
Alternatively, wooden planks will be placed between the wire slings and the pipe or
galvanised article surface to avoid damage to the surface.
Handling of reinforcing steel and associated materials are generally not very sensitive to
damage, however, care is still necessary in handling to prevent damage.

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PRODUCTION AND SERVICE PROVISION

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Revision No.
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Storage
All items will be stored in designated areas in such a manner as to facilitate ready access,
receipt inspection or maintenance without excessive handling.
Items stacked or stored will be arranged so that racks, cribbing or containers are bearing
the full mass without distorting of the items.
Hazardous chemicals, paints, solvents and other flammable materials will be stored
separate and in a well-ventilated area.
All items or their containers will be clearly marked to ensure easy identification and to
avoid the unnecessary breaking open of containers. The shelf life of specialised items
must also be visible.
Packaging
Special care must be taken to prevent damage to packaging i.e. sacked cement drums
of oil or items specially packed with instructions for its preservation.
Delivery
The supplier is to ensure protection of product quality during transit.
The delivery note must be checked against the relevant requisition and buying order on
site. If materials arrive without a delivery note, they must be stored in a quarantine area
until the documentation is available.
Ensure all hazardous materials delivered to site have the relevant Material Safety Data
Sheets available.
Completed works must be protected and preserved until handover (delivery) to the
customer.
Where the supplier transports potentially hazardous materials all required information
must be obtained. Material Safety Data Sheets must be given to the Safety Officer on site.
It is the responsibility of the driver of the vehicle to keep a TREMCARD in the cab of the
vehicle during transportation.

6.7 Infrastructure
Group Five Civil Engineering provides the necessary infrastructure to enable achievement
of product conformity to requirements via:
The availability of offices both on site and at Head Office that is adequate for our
managerial and administration requirements. Site based prefabrication units serve as
office units, ablution blocks, canteen facilities and use of containers as site stores.
The offsite work is contracted out to approved suppliers whose premises and facilities
are assessed for suitability prior to order placement.

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PRODUCTION AND SERVICE PROVISION

Document No.
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Revision No.
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Company transport is available to SA sites and contracted transportation for site workers
on cross border contracts.
Communication equipment ranges from cell phones, satellite links, and facsimile
machines to computer e-mail systems.
Work Environment
Management will ensure that the work environment has a positive influence on motivation,
satisfaction and performance of all employees and other people, in order to enhance the
performance of the organisation.
The creation of a suitable work environment, as a combination of human and physical
factors, will include consideration of the following:

Creative work methods and opportunities for greater involvement to realise the
potential of people in the Business Unit.
Health and safety rules, plans and risk assessments.
Ergonomics.
Site Establishment and layout procedures with consideration to the local
community and social interaction.
Adequate facilities as per statutory requirements and/or national buildings
regulations.
Hazard identification and risk assessments inclusive of heat, humidity, light,
airflow, hygiene, cleanliness, noise, vibration, pollution, occupational health and/or
tropical diseases.

Standard Hazard Identification and Risk Assessment formats will be used prior and during
any project.
Critical task analysis will be identified from the Method statements compiled by the
Contracts Manager or Site Agents/Engineer.
The analysis must be forwarded for review and approval by the Safety Officer on site.
Training and induction courses will be conducted per contractual requirements.
The work environment, i.e. Head Office and Construction sites, is managed with
compliance to the applicable Health and Safety legislations.
SHE personnel are allocated according to the specific legislation and generally reside in
the vicinity of the actual Site/Contract to satisfy customer/contractual requirements.
SHE staff report directly to specific Contracts Manager/Site Agent on the day to day site
related SHE issues, but in a functional and consultative basis to the Head Office Safety
Manager.

Records
Documentation will be described in various Procedures, Work Instructions and Quality Control
Plans.

Group Five Civil Engineering

OPERATIONAL SYSTEM PROCEDURE
PRODUCTION AND SERVICE PROVISION

Attachments
Nil

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