1.NEED FOR MATERIAL QUALITY STANDARDS
TWAD Board is the pioneering organisation endowed with the domain knowledge and expertise in drinking water and sewerage sector. TWAD Board formulate and implement Water Supply and Sewerage Projects in Tamil Nadu on turnkey basis which entail to procure materials by the contractors. There is an inherent need to test the quality materials at site to ensure conformance to the respective standards published by Bureau of Indian Standards (BIS). The important decision on the probable quality of the completed facility is to be made during the implementation phase itself. The quality of materials in every sphere of execution is tested with all attendant objectives to promote project sustainability envisioning “Zero Defects”.
The conformance to the standards is the crux of Quality control for which testing and evaluation is vital in view of the following:
- The quality assurance at site becomes increasingly important than ever before in view of the myriads of product choices for procurement.
- Conformity assessment of the materials received at site with the relevant Bureau of Indian Standards prior to its usage.
- The need to obviate substandard products is paramount, due to the allied defects or failures or impaired facility functions.
- The measurement of quality is the prize of nonconformance, which otherwise may leave the objectives in peril.
The cost of quality can be categorized into the following areas:
Conformance (cost of quality) which pay for quality during the project to avoid issues and Non-Conformance (costs of non-quality) which include Money spent for issues arising after the project. Per se, it become imperative to measure and verify the materials prior to its usage at site to embrace Conformance eliminating chances of nonconformance. Hence, the services of Quality control labs for parametric testing of the material samples received at field becomes all the more necessary for quality assurance by conformity assessment.
2. GENESIS OF QUALITY CONTROL LABS AND CREDENTIALS:
The setting up of Quality Control Lab dates back to 1999 at Coimbatore and 2001 at Madurai, both under the auspices of World Bank funded project. More importantly, after taking cue from the experience gained over the years, it has been proposed to expand the horizon of Quality control labs, in tune with times. Accordingly, 2 more Laboratories one each at Trichy and Tindivanam has been created during 2014, expediently utilising the NRDWP support Activities fund and TWAD Board General funds.
TWAD Board has hitherto established 4 Quality Control Laboratories comprising one for each Region at Coimbatore (1999), Madurai (2001), Trichy (2014), and Tindivanam (2014) respectively. At this juncture, it is a pride privillege to proclaim that the Quality Control Labs at Coimbatore and Madurai are already crowned with ISO 9001 certification. All the above 4 laboratories complemented by the territorial QATA unit in all the Circle offices is functioning under the technical control of Deputy Chief Engineer(SQMS) at TWAD Head Office, Chennai which is appropriately monitored directly by the Managing Director, TWAD Board, Chennai.
3.TESTING FACILITIES AT A GLANCE & TEST TARIFF:
The parametric testing of materials is a noble beginning to open up the pristine gateway to quality control. The cumulative analysis of various attributes in the Labs will ensure conformity assessment to satisfy the set standards. Perhaps, this will facilitate the field Engineers to accept such material with a quality tag.
The laboratories are fully equipped with necessary machineries, equipments and instrumentation for conducting the parametric tests as per the procedures postulated in the relevant Bureau of Indian Standards. The Quality control manual that delineate Standard Operating procedures in conformity with the provisos in relevant BIS is the criteria guiding the laboratory test practices for the various parametric rests conducted with due precision in our laboratory. All the measuring instrumentation/devices are properly calibrated from time to time, from NABL accredited agencies, The broad spectrum of test facilities adorning the Laboratories include the following:
- Construction materials like cement, steel rods, sand, coarse aggregates (HBG stone) including bricks and concrete cubes, Filter media, Hollow blocks, Paver blocks, PVC Pipes, HDPE pipes, GI pipes, DI pipes and Stoneware pipes.
- Mix design of concrete for the M30 grade now being used in TWAD Board for the various Water retaining Structures.
- Cable testing facility.
More importantly, the Concrete Mix design unit is now in place at Madurai, Trichy and Tindivanam, apart from newly added at Madurai Lab is a big boon to the Quality Control process. The modernisation and improvements of the laboratory is being constantly nurtured under the auspices of NRWP Support Activities, which indeed is catalysing TWAD Board to move forward in our mission towards “Zero Defects”. The current test tariff as approved by TWAD Board is shown in the Link.
4.TWAD BOARD MATERIAL QUALITY CONTROL INFORMATION SYSTEM
TWAD Board strives to make change a routine part of organisational strategy, to adapt to newer environment, to take advantage of emerging opportunities. TWAD Board is constantly encouraging to define the vision to reach the mission. Of course, we aim to maintain a common understanding of the requirements and monitoring work that need to be done to accomplish the larger objectives. The largesse of NRDWP Support Activities readily came in handy, to modernize the lab monitoring system, with a harmonised digital platform. Hopefully, it provides the eagerness to improve the overall performance architecture that the system demands.
Whenever materials supplied by the contractors are received at site, it is sampled with authentication of the field engineers appropos to the sampling frequency and procedures. The sample collected will be sent to lab in the prescribed format along with Demand Draft in lieu of the testing charges. All of the existent operational/structural/facility shortcomings and practices that needed to be changed immediately in the existing set up has been taken care of now. Accordingly, the upgraded digital platform launched herein comprise the following new additions, to catalyse the requisite change
The web based material quality control information system envisage uninterrupted access into the following facilities on an an user friendly platform:
- Delay in queue avoided, with quick access for data entry and to the information product
- Online filing of filled format for registration of samples by the users from their head quarters.
- Confirmation of sample registration at laboratory end
- Sample traceability tag
- Receipt of test charges and instant validation
- Consolidated Labwise Status of sample acceptance, testing (passed/rejected) and certification at a glance
- Online portability of test reports.
- Instantaneous Client access to online test reports
- Tracing the sample acceptance or rejection with reasons
- Tracking status or test reports referencing scheme/Sample No./ Division / Sub Division
- Monthwise tally of revenue earned by each lab
- Expenditure incurred under AMC
- Collated data of failed samples/resamples/replacement samples Divisionwise or schemewise
- Display of test facilities and testing tariff
- Display of Sampling procedures for ready reckoning of users
- Identifying the field Engineer who authorised sample for testing
- Interactive query platform for clarifying doubts with the System Administrator or Laboratory Unit
After completion of testing process, copies of test certificates are posted online for instant verification and collation of such test results for their field requirements. The computerised data entries for receipt, traceability by assigning lab sample number, posting test observations, calculating and generating test results, besides, formatting test certificates and its quick transmittal to the field with a quality tag, readily meet their requirements in consonance with the onsite target. The unique information product is delivered on a transparent scale with ease of portability. The quality Control services rendered to the client is sure to bring in the much needed transparency, accountability and functional efficacy in the process and system as well.
