What are the most common quality issues during Plant Engineering audits and reviews?

1. Improper Implementation of QMS/PQP 2. Improper Quality records 3. lacking of Quality personal 4. Reporting issues 5. Quality deliverables issues 6. unapproved design issue.

1. Inadequate Inspection readiness evaluation. 2. Resistance to adopt changes. 3. Improper linkage between identified root cause and proposed CAPA. 4. Not serious about concern identified by internally.

1. Non-compliance with regulations and standards. 2. Poor documentation and record-keeping. 3. Lack of preventive maintenance. 4. Inadequate corrective and preventive actions. 5. Inefficient process controls.

1.Determining the conformity or non-conformity of the elements of the quality system with the specified requirements. 2.Verification of objective evidence of processes Provide evidence to reduce and eliminate any problem areas. 3.Ensuring that the products are suitable for use. Are they safe for consumers? Are the regulations followed? 4.Identifying whether the quality policies of organizations adequately meet the quality standards or not? 5.Take corrective action for deficiencies. 6.Identify opportunities for improvement.

Common quality issues in Plant Engineering audits and reviews involve equipment maintenance lapses, non-compliance with standards, inefficient processes, poor documentation, inadequate training, supply chain problems, safety hazards, energy/resource inefficiencies, quality control issues, and technological obsolescence. Addressing these problems is essential for operational optimization, compliance, efficiency, and maintaining quality standards.

Scope creep is well known to happen in all industries, especially construction. Keeping documentations and records of past work, can prevent this for negative impact the business. I often take pictures everyday of work that has been done as insurance. Furthermore when deadlines are made and main objectives are achieved, sometimes the client or main contractor may ask you to do supplementary scopes. This is reactive works and a different approach is needed to handle the objective. Watch for ambiguous works and ambitious people, as often this leads to not for fillings the objective. Only take work on, if your confident that the objective can be reasonably archived.

Some of the most commonly encountered issues are: 1. Lack of Documentation control and maintenance. 2. Loosen up of adherence in following up with Maintenance and Calibration schedule for equipment. 3. Lack of accountability and communication.

Design & Documentation: Missing or unclear info in drawings/specs ❌ Non-compliance with safety and regulatory codes ⛔ Inadequate procedures and manuals Equipment & Materials: Choosing the wrong equipment for the job ️ Using substandard materials Poor installation and commissioning ️ Lack of preventive maintenance Process & Operations: Inefficient or non-optimized processes Deviations from established procedures ⚠️ Untrained or inadequately trained personnel Poor communication and coordination

Common issues: 1. Number of times rework 2. Repeated NCRs 3. Misinterpretation of drawings 4. Fabrication errors 5. Damages and defects unnoticed 6. Punch list items not closed as required 7. CARs not in alignment with requirement 8. Incorrect strength test pressure and duration 9. Wrong gasket/bolts/paint/insulation/preservation methods/internal cleanliness/material type/support arrangement/labeling 10. Missing documents in MC Dossier. 11. Contamination of materials 12. Errors in design 13. Prime contractor did not enforce ITP on the vendors 14. Flaws in criticality rating procedure 15. Key Technical requirements missing from the spec 16. Item missed from Responsibility matrix resulting in incomplete task, e.g. missing valve

Mise en œuvre inappropriée du QMS/PQP 2. Enregistrements de qualité inappropriés 3. manque de qualité personnelle 4. Signaler des problèmes 5. Problèmes de qualité des livrables 6. problème de conception non approuvé.

Records and reports should be based on actual results. It should not be manipulated as required by the code or the specifications.

Required documentation shall be initiated as per the projects specifications & utilizing standards with clear reference. The documentation shall show the history of the work performed with proper detail of the process.

All the concerned parties should meet once a week or in a day face-to-face to discuss multiple but simultaneous tasks. Which are connected to each other.

Weekly, Biweekly or Monthly meetings shall be conducted for discussing the issues and finding solutions with all the relevant parties present. Self-Preparation should be made before attending meetings with all the relevant authorities. A constructive meetings will have the solutions at the end.

Due to cost cuting while hire the competent persons Lack of encouragement in the organization Some of the superior taking whole credit of team work.

In my opinion, Poor Communication is one of the major reasons for flaws in Plant Audits and reviews. When the policies, procedures and reports are not adequately communicated across the organization, the organizational message will not be delivered effectively. There should be a proper and robust communication system in the organization to implement the organizational Quality goals effectively and to make sure proper audits and reviews are performed.