Daewoo Engineering and Construction Company Limited as Project QA/QC Manager (June 2014 to till date)
Company Profile: Korean based EPC Company, having core business in design, procurement, manufacturing, installation & commissioning of Combined Cycle, Thermal and Tidal Power Projects, LNG Storage tanks, Nuclear & Oil and Gas Projects and newly entered into Renewable Energy sector.
- Ensuring implementation and maintenance of Quality Management Systems (QMS) at project site with a team of QC personnel in various disciplines (civil, structural, UG/AG plant piping, Mechanical equipment’s, E&I etc.).
- Implementing the existing Project Management System to achieve company policies, objectives, targets and standards, auditing subcontractors and reviewing their quality systems as per plan.
- Coordinating with Corporate QA/QC Manager to ensure availability of competent Quality Control personnel at site, evaluating training needs to enhance knowledge and meet requirements of the Continues improvement Program.
- Ensuring compliance with the assigned project scope & requirements, identifying quality problems, identifying non-conformances and initiating & recommending corrective measures.
- Reviewing project specific WPS/PQR and WPQR and developing and implementing requisite Project Quality Assurance Plan and procedures.
- Ensuring in handling procurement quality requirements in line with QMS of the company by conduction internal audits, technical bid evaluation of vendor, involving in all phases of design review of vendors with company engineering team, verification and release of BOM raised by engineering and review of procurement inspection assessment package for assurance of customer satisfaction.
- Acquiring client approvals for Project Quality Assurance Plan, ITPs and Technical Work Instructions as per contract scope, specifications and company quality control system requirements.
- Monitoring and updating client on NCR & CAR log, analyzing root cause analysis for deviation and ensuring timely closure of NCRs and CARs.
- Identifying and maintaining adherence to quality requirements throughout the phase of contract performance including compliance with applicable codes and standards as defined in ARAMCO Schedule-Q.
- Ensuring deployment of approved practices, procedures, inspection & test plans and audit program including proper utilization throughout the project construction phase.
- Compiling witness and inspection hold points as per approved ITP to maintain construction targets and completing & maintaining project documents with traceability through scheduled internal audit.
- Conducting internal meetings with QCIs & Construction Superintendents for feedback compliances and solutions, coordinating with clients and identifying appropriate resolutions for queries & grievances.
- Interfacing with clients for construction and QC issues, coordinating with third party inspection agencies and liaising with client QC representatives for seamless operations.
- Maintaining minimum weld joint repair rate for the projects, ensuring zero NDT backlog to monitor welders’ performance including maintenance of updated welders qualifications through vigilant supervision.
- Acting as a focal point for handling ISO external & client audits, conducting internal audits and preparing & submitting quality report to Corporate QA/QC Manager on inspection progress and concerns at project site.
- Achieving and maintaining monthly project quality index (PQI) as a part of measuring & monitoring customer satisfaction, reviewing and ensuring compliance with quality records during project execution.
- Setting guidelines, monitoring the piping test packages flow with zero backlogs in quality domain and ensuring preparation and timely submission of final project QA/QC dossiers to the client.
Mohammad Al-Mojil Group (MMG), KSA as Site QA/QC Manager (Jan 2007 – May 2014)
Company Profile: MMG’s core business includes construction of projects in Oil & Gas and Petrochemical industry. MMG is mainly involved in onshore and offshore construction, having 5 basic units (Civil, Structural, Mechanical, Electrical and Instrumentation and Maintenance & Turnaround Work Units). MMG undertakes Oil and Gas Projects, utility projects and Power Plants.
- Ensuring implementation and maintenance of Quality Management Systems (QMS) at project site with a team of QC personnel in various disciplines (civil, structural, underground/above ground plant piping, etc.).
- Implementing the existing Project Management System to achieve company policies, objectives, targets and standards, auditing subcontractors and reviewing their quality systems as per plan.
- Coordinating with the QA/QC Manager to ensure availability of competent Quality Control personnel at site, evaluating training needs to enhance knowledge and meet requirements of the Continues improvement Program.
- Ensuring compliance with the assigned project scope & requirements, identifying quality problems, identifying non-conformances and initiating & recommending corrective measures.
- Reviewing project specific WPS/PQR and WPQR and developing and implementing requisite Project Quality Assurance Plan and procedures.
- Acquiring client approvals for Project Quality Assurance Plan, ITPs and Technical Work Instructions as per contract scope, specifications and company quality control system requirements.
- Monitoring and updating client on NCR & CAR log, analyzing root cause analysis for deviation and ensuring timely closure of NCRs and CARs.
- Identifying and maintaining adherence to quality requirements throughout the phase of contract performance including compliance with applicable codes and standards as defined in ARAMCO Schedule-Q.
- Ensuring deployment of approved practices, procedures, inspection & test plans and audit program including proper utilization throughout the project construction phase.
- Compiling witness and inspection hold points as per approved ITP to maintain construction targets and completing & maintaining project documents with traceability through scheduled internal audit.
- Conducting internal meetings with QCIs & Construction Superintendents for feedback compliances and solutions, coordinating with clients and identifying appropriate resolutions for queries & grievances.
- Interfacing with clients for production and QC issues, coordinating with third party inspection agencies and liaising with client QC representatives for seamless operations.
- Maintaining minimum weld joint repair rate for the projects, ensuring zero NDT backlog to monitor welders’ performance including maintenance of updated welders qualifications through vigilant supervision.
- Acting as a focal point for handling ISO external & client audits, conducting internal audits and preparing & submitting quality report to Corporate QA/QC Manager on inspection progress and concerns at project site.
- Achieving and maintaining monthly project quality index (PQI) as a part of measuring & monitoring customer satisfaction, reviewing and ensuring compliance with quality records during project execution.
- Setting guidelines, monitoring the piping test packages flow with zero backlogs in quality domain and ensuring preparation and timely submission of final project QA/QC dossiers to the client.
Alstom Projects India Ltd. as Project QA/QC Manager (Aug 2004 – Jan 2007)
Company Profile: EPC Company, having core business is construction of Power Projects and pioneers in design, procurement, manufacturing, installation & commissioning of Gas Power Plants, Thermal & Hydro Power Plants worldwide. Having own manufacturing facilities of Pressure Vessels, Gas & Steam Turbines, Pumps, Motors and Electrical & Instrumentation Panels, etc.
- Ensured implementation of Quality Management Systems (QMS) at project site including maintenance during procurement stage & field quality control and monitoring with assigned QMS requirements.
- Ensured quality control & assurance with various national/international codes and statutory regulations for Pressure Vessels, Heat Exchangers, Storage Vessels, Power/Process Piping, etc. in the power sector.
- Evaluated sub-contractors / vendors for suitability of quality products.
- Verified QA/QC procedures of sub-contractors, reviewed and acquired approval of the suppliers’ quality plan.
- Verified sub-contractor’s ITPs, WPS/PQR & WPQR, acquired approval and provided suggestions for correction.
- Interfaced with clients, conducted inspections as per approved ITPs and identified cost effective solutions.
- Maintained minimum weld joint repair rate for the projects.
- Maintained updated welders’ qualifications and managed internal and client NCRs.
- Identified potential non-conformance and deployed preventive measures to avoid major NCRs.
- Coordinated inspection with third party inspections agencies and reviewed inspection documents.
- Coordinated inspection with client for Hold/witness stages as per approved ITP.
- Prepared inspection and testing plans for project during contract stage.
- Identified and prepared inspection requirements and test plants at bidding stages.
- Inspected equipment’s like boiler steam drums, Harps, HRSG casing and internal/external piping.
- Inspected bought-outs items like control, safety valves, boiler feed pumps, ID, FD fans, etc.
- Ensured compliance with project procedures for final documentation by sub-contractors.
- Visited sub-contractors to ensure adherence to project requirements as per assigned specifications.
- Participated in construction progress meetings and monitored performance of vendors / sub-contractors.
- Provided technical support in the preparation of field quality plan, field change requests and change orders.
- Coordinated internal & external audit schedules, conducted internal audits and closed audit NCRs.
- Interfaced with client and contractors for punch items clearing status and quality issues.
- Reviewed and acquired approval of third party NDT Company profile and personnel.
- Assigned roles for different discipline Inspectors and supported engineering for preparing weld mapping.
- Audited subcontractor’s flow of drawings, welding history sheets and rejection rates of welders.
- Set guidelines and monitored piping test packages flow with zero backlogs in quality domain.
- Monitored preparation of final QA/QC dossiers and timely submission to the client.
Thermal Systems Pvt. Ltd., Hyderabad (Aug 1992 – Aug 2004)
Progressed from QA/QC Inspector to QA/QC Manager
Company Profile: An EPC company, having core business in construction of Waste Heat Recovery Boilers and pioneers in design, procurement, manufacturing, installation & commissioning of Process Plants like Zinc, Copper Smelters, Carbon Black, Sulphuric Acid, Coke Oven Steel Plants, etc. TSPL is also engaged in design, procurement and manufacturing of pressure vessels for Power Boilers, Refineries, Oil & Gas and Chemical Plants.
- Ensured implementation of Quality Management System (QMS) in projects & fabrication shops including monitoring, auditing and review of quality as per company QMS requirements.
- Monitored effectiveness of all sub-contractors process, controls and quality performance.
- Supervised, implemented and controlled contract quality and technical requirements.
- Resolved quality problems and prepared & maintained subcontract quality records.
- Prepared inspection and testing plans for boilers, pressure vessels, heat exchangers, piping, etc.
- Developed, implemented and monitored all contract specific procedures and work instructions.
- Conducted stage wise inspection as per the defined acceptance criteria and QAP.
- Performed materials receiving inspection and review of Mill test Certificates.
- Handled physical inspection of pipes, fittings, flanges & valves as per purchase order.
- Ensured inspection of mechanical and chemical properties as per code & specification requirement.
- Monitored welding processes (SMAW, GMAW, GTAW and SAW) and maintained NCR’s log book.
- Analyzed defects, identified root causes and implemented corrective & preventive measures for improvement.
- Coordinated inspection with client and third party inspection agencies, statuary body-IBR/EIL.
- Interfaced with Authorized Inspection Agency – LR insurance Inc. and LLOYDS Notified Body for PED jobs.
- Developed a succession plan and provided quarterly feedback and updates to the senior management.
- Monitored pre-heat, inter-pass temperature and PWHT in compliance with requisite WPS/PQR.
- Selected welded joints for RT, PT, MT and UT at pre-fabrication shop and construction site.
- Interpreted RT films and reviewed NDE reports as per applicable codes.
- Monitored weekly & monthly performance rejection rate of welder as per NDE report.
- Certified the Welder/Welding Operator’s performance qualification.
- Verified final QC dossier of all equipments and reviewed & approved WPSs.
- Reviewed PWHT Chart and generated hardness report for higher thickness C.S and Alloy steels.
- Generated Positive Material Identification report for Alloy and S.S.
- Reviewed Technical Specification for procuring raw material & welding consumable.
- Reviewed and released test packages and witnessed hydro, pneumatic and service tests.
- Prepared Manufacturing Data Report (MDR) of ASME vessels.
- Prepared weekly & monthly quality reports, maintained quality records and submitted QC dossier to the client.
Trainings / Workshops Attended
- PMP Training (Project Management Professional)
- Workshop on ASME Boiler and Pressure Vessel Code, Hartford Steam Boilers International GmbH
- Course on Design, Fabrication & Inspection of Boilers, Bharat Heavy Plates & Vessels Ltd., Vizag, India
- Bachelor in Mechanical Engineering
