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QUALITY SYSTEM MANUAL
Pr2 Production
Purpose
In this procedure is described how BETONIQ produces their products. BETONIQ is a company that controls all aspects of Design, Production, Construction and Real Estate Management. The BETONIQ products are complete buildings with static structures made out of Precast Concrete. “Complete” in a sense that all components are fabricated and assembled by BETONIQ firms. Purchase of materials for the BETONIQ production only exist of raw materials, building materials (like cement, rebar, bricks, heating and electricity equipment) and machines (like trucks, cranes, tools and factory equipment). To produce the projects, BETONIQ uses several departments and production units, each with specific disciplines.
Production starts when a project-order is signed. To be able to make a project-offer a certain urban design that is based on the several BETONIQ Building Concepts has to be in place with specifications regarding materials and timetable, and also a Project-Feasibility as the basis for the offer. So production will always start with this information present.
Procedure
- Building Permit Phase
The first step of production is to gather and optimize all information, and to get the building permit for the project. This is a task of the Project Manager that uses the Project Sheet Checklist to check is all information is complete and accurate. Parallel to this phase, construction work like cleaning and fencing the terrain can be executed. Every week there is a Project Preparation Meeting to check the progress off the Permit Phase. Once all information is optimized and available, including the building permit, the Project Manager applies for a construction start at the Senior Project Manager. The first Project Preparation Meeting will be logged as Startup Meeting. Once this request is granted the Senior Project Manager puts a "construction started" remark on the Project Sheet and in the Projects List. Once construction is approved, two processes start running parallel:
- 2. Production Preparation, and
- 9. On Site Infrastructure and Foundation work.
If no building permit can or will be purchased, and the Senior Project Manager doesn't see any possibilities to get one, production continues in 15.
Responsible: Project Manager
- Production Preparation
Together with the Project Manager, the Production Supervisor, Production Planner and Production Surveyor do a Project Preparation Meeting where every week the Preparation of the production is discussed in a sense that the factory capacity must be enabled to absorb the production of the precast concrete elements for the project for machines, personnel and raw materials. The same applies for the production of additional products like windows and kitchens. The Project Preparation Meeting continue until the Delivery of the project (step 14). It is the responsibility of the Project Manager to increase or moderate the frequency of the Project Preparation Meetings when it makes sense to do so. This step (step 2 Production Preparation) continues in 3 when the first precast element for the project is produced.
Responsible: Project Manager
- Production
The Production Supervisor schedules production planning as he maintains the overview of all requirements and processes. This is done in the BETONIQ Products Monitoring Program, releasing the elements for production. Once the first element for the project starts getting produced, the regular production process is started. All regarding production units get informed to be producing parts of the element during a certain part of the day. Before any casting of products takes place a thorough Quality Control check is made of the moulds and all constituent parts by the QA/QC Production Engineers before any placement of concrete is permitted. Production must be realized taking in account the Employee Safety Program. Once the element is finished to be transported to the Storage facility, the procedure continues in step 4.
Responsible: Production Supervisor
- Pre-storage Quality Control
Just before the element gets transported to the storage facility a very thorough Quality Control will be executed by the QA/QC Production Manager and the QA/QC Production Engineers. This to be sure that the quality of the element and all its reinforcement, fittings and measurements is absolutely correct. If an element doesn't get approved, the Production Supervisor will be informed and asked to also do a visual inspection and confront the regarding workers with their mistakes. Possible correction measures will be discussed but if that is not possible, the element will be discarded. The inspection results will in either case be registered in the BETONIQ Products Monitoring Program. If the element is disapproved the procedure continues in 3, if it is approved the procedure continues in step 5.
Responsible: Production Supervisor
- Storage
When the element is approved, it can be transported to the element storage area, also taking in account regulations of the Employee Safety Program. The storage location is determined by the Stockyard Supervisor and who transported the element and whereto will be registered by the Stockyard Supervisor in the BETONIQ Products Monitoring Program. Part of the Employee Safety Program is that the entire factory and storage facility will be filmed constantly. This is also important for Quality Control because besides monitoring dangerous situations also damaging of elements can be recorded so improvement measures can be done. The procedure continues in step 6.
Responsible: Stockyard Supervisor
- Finishing stored products
After the elements are stored in the factory stockyard the Production Supervisor and Painters finish the elements. These activities will also be registered by the Stockyard Supervisor in the BETONIQ Products Monitoring Program. The procedure continues in step 7.
Responsible: Stockyard Supervisor
- Product Quality Control
Just before the element gets transported to the Construction Site another very thorough Quality Control will be executed by the QA/QC Production Manager and the QA/QC Production Engineers. This to be sure that the finishing quality of the element and repairs are applied correctly. If an element doesn't get approved, the Production Supervisor will be informed and asked to also do a visual inspection and confront the regarding workers with their mistakes. Possible correction measures will be discussed but if that is not possible, the element will be discarded. The inspection results will in either case be registered in the BETONIQ Products Monitoring Program. If the element is disapproved the procedure continues in step 3 or 6 (depending of the choice of the Production Supervisor), if it is approved the procedure continues in step 8.
Responsible: QA/QC Production Manager
- Product Transport
When the element is approved for assembly, it can be transported to the construction site, again also taking in account regulations of the Employee Safety Program. The exact transport time is determined by the External Transport Supervisor and who transports the element will be registered by the External Transport Supervisor in the BETONIQ Products Monitoring Program. The QA/QC Production Manager will check the element during and direct after Assembly and deviations will be registered by the QA/QC Production Manager in the BETONIQ Products Monitoring Program. This is also important for Quality Control because besides monitoring dangerous situations also damaging of elements can be recorded so improvement measures can be done. The procedure continues in step 10.
Responsible: External Transport Supervisor
- On Site Infrastructure and Foundation work
Once the building permit is issued the regular construction process starts with the Project Manager scheduling the activities on the construction site in the Project Schedule. All regarding construction units get informed to start construction work like putting fencing around the terrain, cleaning of the terrain, making preparations and applying infrastructure, measurements for foundations and constructing foundations. At executing these on site infrastructure and foundation work, the Employee Safety Program must be taken into account. Once the precast concrete element are assembled (see step 8), the procedure continues in step 10.
Responsible: Project Manager
- Assembly
In the construction process On Site Infrastructure and Foundation work and Assembly work can be executed parallel to each other. Especially when there are more buildings in a project several steps of the Pr2 Production Procedure will be executed parallel. Nevertheless, each part of the building will have to go all steps of this Procedure. When external persons (like government, clients, buyers or tenants) want to visit the site, they have to comply with the rules of the BETONIQ Security Program. In the Assembly step, the Erection Supervisor and Erection Foremen, control the work of the Erection Operatives, the On Site Crane Drivers and the Grouter & Finishers that assemble the buildings using the precast concrete elements. Once parts (like a complete storey) or an entire building is assembled, the procedure continues in step 11.
Responsible: Erection Supervisor
- Pre finishing Quality Control
Inspections will be carried out when elements are delivered to site and unloaded to ascertain that there has been no damaged sustained during transport. This will be recorded on the accompanying transport delivery notes and will be executed by the QA/QC Production Manager and the QA/QC Project Assistants. This to be sure that the quality of the assembled element is correct. If assembly doesn't get approved, the Project Manager will be informed and asked to also do a visual inspection and confront the regarding workers with their mistakes. Possible correction measures will be discussed but if that is not possible, (the part of) the building will have to be de-assembled. The inspection results will in either case be registered in the BETONIQ Products Monitoring Program. If the assembly work is disapproved construction work halts and the procedure continues in 3, if it is approved the procedure continues in step 12.
Responsible: QA/QC Production Manager
- On Site Fitting and Finishing
In the on site fitting and finishing step, The MEP, Painting and Carpentry units apply all necessary fitting and finishing. Also fitting and finishing infrastructure is part of this step. Once parts (like a complete storey) or an entire building or (parts of) infrastructure is fitted and finished, the procedure continues in step 13.
Responsible: QA/QC Production Manager
- Final Quality Control
Just before the delivery (of part) of the project, a Quality Control survey will be executed by the QA/QC Production Manager and the QA/QC Project Assistants.This to be sure that the on site fitting and finishing quality is ok. If (the part of) the project doesn't get approved, the Production Supervisor will be informed and asked to also do a visual inspection and confront the regarding workers with their mistakes. Possible correction measures will be discussed. The inspection results will in either case be registered in the BETONIQ Products Monitoring Program. If (the part of) the project is disapproved the procedure continues in step 12, if it is approved the procedure continues in step 14.
Responsible: QA/QC Production Manager
- Project Delivery
Once the final Quality Control is executed, the project delivery can be organized by the Project Manager. The Project Manager invites the clients (or a representative) to deliver the project using the Delivery Statement and Checklist. The procedure continues in step 15.
Responsible: Project Manager
- Production Evaluation
Here the Pr2 Production procedure ends and continues in item 12 of Pr1 Acquisition, Development and Sales where the project gets evaluated.
Permanent activities: Quality, Safety and Security.
While executing all steps of the Pr2 Production procedure, all appointments of the Quality System and Risk Management System, Employee Safety Program and the BETONIQ Security Program apply.
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