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Discussion on Quality Issues in POWERGRID

Discussion on Quality Issues in POWERGRID. Jaipur : 20 th May 2009. What is Quality?. Hard to describe, you know if it is there,Matter of feeling Hence, Every individual defines Quality in his own way. Some of the common definitions of Quality are as follows:   Fitness to use Reliability

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Discussion on Quality Issues in POWERGRID

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  1. Discussion on Quality IssuesinPOWERGRID Jaipur : 20th May 2009

  2. What is Quality? Hard to describe, you know if it is there,Matter of feeling Hence,Every individual defines Quality in his own way. Some of the common definitions of Quality are as follows:   Fitness to use Reliability Serviceability Aesthetics Luxurious, Rich, Expensive Affordability Conformance to Standards Durability Value for money

  3. Why Quality ( in POWERGRID ) High availability of installed system Minimum O&M cost i.e. least spare inventory Confidence building and satisfaction of stakeholders Timely completion of Projects with specified requirement

  4. DESIGN & ENGINEERING

  5. Potential 'QUALITY'failuredue to • -Inappropriate / Inadequate design ( equipment / component ) • -Inappropriate material ( component ) • -Improper workmanship / assembly ( equipment / component ) • -Inadequate validation in testing ( equipment / component ) • -Improper packaging & storing • -Inappropriate handling & transportation • -Defective erection / installation • -Wrong operation • -Inadequate maintenance

  6. Quality in Project Cycle Chain Pre-Manufacturing Stage Pre-award Stage Vendor / Sub-vendor Selection MQP/FQP Finalisation Tech. Specs. Post Bid Tie-up Analysis and Quality Inputs Technological development / standards provision Feedback Received Receipt at Site Installation Testing & Commissioning Manufacturing Stage FQA Stage Operational Stage Final Inspection In-Process Raw Material

  7. Confidence building and Transparency Defining various approval processes in WPPP and making it available on web-site Defining requirement of MQPs and Inspection Levels at the time of award itself Web based Inspection Call Management System On-line issuance of CIP and MICC Compendium of approved vendors at web-site for reference of all concerned

  8. Categorisation of Equipment Four Categories depending on their attributes to the system availability Critical ( TX, Insulator, Tower, Conductor etc ) Important ( Eartwire, BPI, cables, C&R panel etc ) Supportive ( Tower Accessories, B/N, MS rod, Lighting Pole ) Standard ( Switches, receptacles, a/c, lamps etc ) Points considered for Categorisation Manufacturing Complexity Consequential impact of failure Replacement time Value and Population

  9. Level of Inspection Why ? Appropriate Attention / Vigilance Optimum utilisation of resources Increased Business activity / Vendors / Geographical spread Inspection for Value addition & not a formality Various Levels Inspection Level –I ( Inspection by Manufacturer himself ) Inspection Level – II (Inspection by Contractor; POWERGRID’s involvement optional ) Inspection Level – III – (Inspection by POWERGRID optional for stage; essential for Final) Inspection Level – IV – (Inspection by POWERGRID , essential) All Inspections to be registered for accountabiltiy

  10. POWERGRID’s Quality Set-up CorporateQA & I Corporate Quality Assurance Field Quality Assurance at each Project Site Regional Inspection Offices

  11. Quality Structure Roles and responsibilities of Corporate QA Pre-award QA activities Corporated level systems certifications MQP / FQP finalisation / re-validations Quality surveillance / Audits / Process Inspection Vendor/Sub-vendor assessment and approval Vendor development Deviation dispositions Developmental Initiatives including systems and procedure for QA&I Failure analysis Review and Updation of ICMS / Compendium

  12. Quality Structure Roles and responsibilities of Inspection Offices Inspect the material as per TS / BOQ / Drawing / Standards / Plant Standards / MQP Issue CIP / MICC as per contractual requirement including signing of reports wherever witnessed Report the failure and / or deficiencies observed during inspections Quality surveillance / Audits / Process Inspection / Vendor/Sub-vendor assessment and approval as and when directed To follow the guidelines / procedure / instruction issued by CQA and communicate feedback Nine Inspection Offices ( at Gurgaon, Kolkata, Mumbai, Nagpur, Baroda, Hyderabad, Banglore, Chennai and Bhopal )

  13. Quality Structure Responsibility of FQA To follow the guidelines / procedure / instruction issued by CQA and communicate feedback, if any To assure quality of storage , erection and commissioning as per the guidelines To ensure compliance of FQP, wherever applicable QA & I activities of Regional awarded packages.

  14. Web based Insp Management System Advantages Designed and Implemented in-house and hence possibility no-sweat and timely refinement Complete record of Inspection activities available on Internet. Reduction in Communication expenses Viz FAX, STDs etc. Reduction in travel. Improved Control over Inspection Activities. Improved utilisation of Manpower. Increased Vendor satisfaction. On Line monitoring of Inspection Activities. Discipline in Inspection Process Transparent Information for all concerned

  15. New Quality Initiatives Combination of inspections calls under same / separate Contracts. Shifting of Product to Process inspection of main manufacturer / critical component manufacturer Opening of Quality Improvement Register at manufacturer works for continuous monitoring of quality improvements Emphasis on development of in-house facilities by manufacturer. Issuance of CIPs by FQA / Region for Inspection Level-I items

  16. Excess Inspection produces “JUNK” which is avoidable and not environmentally good

  17. Old and New Perceptions About Quality OLD Perception Should be Strictly Supervised Inspector is Responsible Defects to be Within Limits Screen Bad Ones from Reaching Customer Quality and Cost are Linked-Compromise has to be made NEW Perception Should be Built-in, Supervision adds to Cost Operator is Responsible Zero-Defect. Prevent Production of Bad Ones. Quality Thrives on Competition, Enlarges market & Reduces Cost

  18. Shifting from Product to Process Inspection Tests on Sample have “owner's” as well as “seller's” risk “Lot” is considered generally as the “Offered Lot” instead of “lots” having same processes Processes are generally not defined in Standards Check of processes as a part of approval / Revival of approval of MQP Product Inspection Screens Bad Ones from Reaching Customer and Process Inspection Prevents Production of Bad Ones. Quality raw material / component and compliance to process parameters automatically assures quality product Strict Process Inspection may lead to reduced sampling and / or tests resulting in reduced product inspection

  19. What is Process-inspection? process-inspection is a system for preventing production of bad ones ( whereas, product-inspection is a system of screening bad ones -already manufactured ) It helps in mapping different processes and their interconnections Identification of areas of improvements based on internal/external failure observations and their analysis Enhancement of process capability Scope of design/process validation Way forward for continuous improvement for in-built quality of the product leading to zero defect

  20. CIP & MICC * These are certificates * CIP ( Customer Inspection Point ) -certificate is issued once the material is accepted technically -It is signed by POWERGRID Inspection Engineer & Manufacturer / Contractor *CIP have Five (5) Categories - Cat-A ( Unconditional acceptance ) - Cat-B ( Conditional acceptance ) - Cat-C ( Hold ) - Cat-D ( Rejected ) - Cat-E ( Material not ready ) * MICC ( Material Inspection Clearance Certificate ) -is issued by POWERGRID Inspection Engineer for billable items only

  21. Validation by Inspection On every (each ) Equipment : -Limited Quantity requirement -High Value ( cost ) -Tailor manufacturing process On Sampling: -Huge quantity requirement -Small value ( cost ) -Mass manufacturing process

  22. For sampling inspection Why: -All can not be subjected to test -Resource consuming Go for : representative sample form the lot Risk involved: -Purchaser's risk : sample passed though lot having few defectives -Supplier's risk : sample failed though lot having few defectives

  23. FAILURE IS A FACT -In-built probability of failure exists in a sample -Standard permits Repeat test ( Re-test ) -Double sampling theory accepts failure of samples to certain extent -This is primarily accepting error due to variation in test set-up, test environment, instrument , measurement , Operator etc. Product standardised → Re-engineering for efficiency → (Initial) Failure → Corrective action → Product standardised

  24. WPPP clauses Cl. C.2.9.5.1 Report on receipt of defective material Cl. C.2.9.5 Item cleared for erection should have Cat-A CIP

  25. Few Site Issues Request from Contractor for issuance of Duplicate ( Xerox authenticated ) CIP / MICC Request for advance / CCPs should come from RHQ BBU to be issued for lot/set/lump sum items at the earliest for facilitating issue of MICC of component along with CIP Timely issue of Change Order / Amendment ( positive or negative ) will help reduce rework on excess quantity CIP ( in some cases ) In case of preponement of supply / inspection beyond L2 network, special request to GM (QA&I) with approval of concerned ED of Region/field. Change Order / Amendment of Quantity shall also indicate delivery schedule.

  26. Inspection of RE Projects

  27. Inspection of RE Projects-At Works

  28. Tier-1: Turnkey Contractor Complete Area by Turnkey Contractor

  29. Tier-1: Project Implementing Authority Complete Area by Project Implementing Authority

  30. Tier-1: Third Party Inspection Authority Other Items for inspection 10% by Third Party Inspection Authority DT Conductor Energy Meters Poles Insulators

  31. Tier-2: REC Other Items for inspection At least one inspection by REC DT Conductor Energy Meters Poles Insulators

  32. Tier-3: MOP Other Items for inspection Review of test records on sampling basis DT Conductor Energy Meters Poles Insulators

  33. Inspection of RE Projects-At Site

  34. Tier-1: Project Implementing Authority Tier-1: Third Party Inspection Tier-1: Turnkey Contractor 50% Villages 100% Villages 10% of 50% BPL 100% BPL Connections At Least 5 BPL in each village covered and 100% New Sub-Stations 100% New Sub-Stations 100% Sub-Station Extn. 50% Sub-Station Extn. (Min. 1)

  35. Tier 2: REC 10% Random Villages 25% of 10% BPL Connections + at least 5 in each village covered 25% Random New S/S (min.1) 5% Random S/S Extn. (min.1)

  36. Tier 3: MOP 1% Random Villages 0.5% BPL connections + at least 5 BPL connections At least 1 new Sub-Station At least 1 Sub-Station Extn.

  37. Assessment of PSC poles • Turnkey contractor proposal for new vendor • Proposal is priliminiary reviewed by CQA & forwarded to site incharge for assessment works • 16 point assessment areas • Report submission by site thro’ concerned area incharge of DMS to CQA • Approval case is initiated • Approval conveyed to turnkey contractor, site and DMS, CC after internal approvals • Thereafter inspection is carried out by DMS site as per SMQP,Drawings & technical specs • CIP is issued by concerned and authrised site representatives and MICC is issued by nearest/concerned IO

  38. QUALITY IS A JOURNEY AND NOT A DESTINATION

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