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Initial Audits - Prepare for NIICAP

Uncategorized Mar 10, 2020

The first step in NACE NIICAP Accreditation is exploring a company's existing processes and culture for opportunities to smoothly improve and align with the NIICAP requirements. It is always a priority to change as few things as possible during the Accreditation process.

A QA Program audit permits you to review the effectiveness of your Quality Management systems and processes, and whether or not they are delivering the reliability and availability you want.

The QA Audit approach is to collect information on your current Quality processes, and from the Quality information systems used at your operation, and analyze them for process improvement opportunities or growth.

Interviews would be conducted with senior managers in Operations, Finance, Maintenance, and the Chief Executive to gain an appreciation of how the current processes perform. Interviews are also conducted with supervisory personnel in Operations to understand day-to-day interactions and performance of planning, materials management, and QA/QC activities.

Information on failure history, corrective work, materials usage, and man-hours for each major project over the last five years by type is also gathered if available. These are used in a Pareto chart and graphed to identify cost or time issues.

The entire listing of planned activities is also reviewed to check the coverage and mix of preventive and predictive processes. This allows comparisons with best industry practices.

A report is provided explaining the range of investigations performed, analyses conducted and the resulting recommendations. The report also indicates the results of the best practices benchmarking.

The QA Audit is specifically aimed at the following purposes:

  1. Review of the project management processes and practices at the operation
  2. Benchmark Quality at the operation against best practice maintenance
  3. Identify opportunities to refine the existing QA/QC processes
  4. Identify opportunities for efficiency improvements within current practices
  5. Identify opportunities to make better use of constrained resources, particularly manpower.

 

Plotting your Maintenance Capability

 

The Quality Audit Process

An objective Quality audit is completed by using a targeted questionnaire covering the key factors needed for world-class maintenance developed specifically for rating an operation. The questionnaire allows you to compare the current effectiveness of Quality processes performed in your operation with best practices used by successful similar organizations across the world.

The aspects and issues specifically relevant to Quality Management were addressed by the use of recognized planning, materials management, project management, and Quality Control best practice guides and standards.

A common audit objective is to use the audit questionnaire so as to answer the key areas of Quality Management system performance listed below.

  • Organisation Culture and Employee Empowerment
  • Tactical Delivery: Work and
    Contractor Management Processes
  • Training Management Strategy
  • Reliability Improvement
  • Materials Management
  • Performance Measurement
  • Quality Process Improvement
  • Budgeting and Cost Control Processes
  • Planning and Scheduling Processes
  • Information Technology Management

Often there are many opportunities to improve the performance of an industrial coatings operation. The challenge is to ensure a focus on making the most significant improvements first, and being selective about the areas for improvement to focus on.

Trying to make too many improvements simultaneously frequently means that little is achieved at all.

To find the right ways that successfully improve your Quality and Reliability performance permanently requires an investigation into your business systems and the maintenance work processes in use, including the paradigms and beliefs held in your company.

Getting the absolute maximum benefits for your business is helped with a well structured and targeted Quality Audit.

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