BRSM
Systems: QMS ISO 9001 (2008) & EMS ISO 14001 (2004)
Assessment Report/Checklist
Form 009
CLIENT‐ORGANIZATION (NAME): Kordestan Cement Co.
PHYSICAL LOCATION(s): 5th km Bijar Road, Bijar, Kordestan, Iran
Phase II Audit Date(s): Phase II :2, 3 & 4 July 2015
Phase I Audit Date(s): Phase I : 15 Jun 2015
NAICS (or NACE) CODE 23.51
NAICS : North America Industry Classification System (if you operate within the EC you may use NACE)
ISO 9001 EXCLUSIONS: 7.3
Assessment objectives: Attesting requirements of EMS and QMS systems
have been met in client’s management system
ASSESSMENT TEAM INFORMATION
Assessment Team Leader, ATL Faezeh Ashoorzadeh
Assessor 2 Vahid Salahi
Assessor 3 Bijan Rajabi
Assessor 4 Shabnam Hosnyousef
Assessor 5 Roya Boostani TE
Assessor 6
Note: Adjusting the language within this form to the type of activity and nature of the organization is acceptable.
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We pursuit to assure that client‐organization adheres to the protection of communities and consumers. This is to
1 follow the intent to the substitution of the word “identify” to the word “determine” as part of the importance to
the processes being capable of achieving desired outputs (including consumer’s well‐being).
Production of Cement including Type I (class 325, 425), Type II Portland , Portland Pozolani
2 Scope of activities
and special Portland Pozolani
BRSM requires that the organization’s legal obligations and regulatory
3 Legal status
are met as part of granting certification.
4 Quality Management System (QMS)
the organization has identified its processes and strated implementing
more than 3 years.
Raw material:Mineral purchased, plants and minerals in the mining of
raw materials facilities and spaces
Products during the process:Crusher, raw mill, kilnker feed and raw
material silos, grate cooler
General Final product:The output cement mills (cement production), loading
Requirements – cement, clinker loading
4.1 What is the the organization Has identified the processes and interactions in
implementation / management systems programs FR11, the criteria for operation and
transition date? control has been defined as Indication /indices
outsourced activities have been included such as Calibration where the
lab must possess ISO 17025 certificate
the organization monitors/measures and analyses its processes through
Monitoring and measuring procedures input items PR22 / 17/02
Monitoring and measurement of product during processing procedure
PR22 / 18/02
Monitoring and measurement of the final product procedure PR22 / 19/02
explicit policy and Quality objectives shows that organizing is moving
Documentation toward its policy ,strategic plans and management strategic system
4.2 Requirements an explicit (and controlled) QM: MN11/01/04
(includes records) documents has been reviewed and reported in BRSM Form 002 report
QM include the scope of the EMS/QMS: Kurdistan Cement Company, the
largest industrial Unit in Kurdistan province of Iran is located in north‐
western of Bijar . at the moment Kurdistan Cement works With a
4.2.2 Quality Manual capacity of 3,200 tons of clinker per day
Products 1‐ cement type I class 325 , 2‐ cement type I class 425, 3‐
cement type II, 4‐Normal pozzolanic cement, 4‐sepcial pozzolanic
cement. Clause 7.3 is excluded
FORM‐009_V4_en Issued: July 9, 2003 Revised: March 2013 Page 2 of 15
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PR11/01/03 , PR11/01/02 document and record control procedure,
Documents Control PR11/01/03 and records control PR11/02/02
procedures, are electronically available to all units.
4.2. Control of
Documents
Main list and distribution of documents (Master List) code Li11 / 01, the
list of external documentation with code Li11 / 02 was observed,
obsolete documents are stamped on paper or omitted from the
electronic system
PR11/01/03 record control procedure is effective , records are legible,
4.2. Control of Records identifiable, retrievable, and the place for storage and the mean to
4 – Are records… protection and retrieval / Recovery has been considered electronically ,
restoration time for physical files is 10 years and then dispose the paper,
Identification and assessment of risks to safety and environmental aspects
Procedures is developed and ialmplement.
Safety Team has been determined and trained
Identification and risk assessment procedures PR12 / 01/02
Is there a
The audit observations are mentioned in this report.
procedure for
In HSE unit risk assessment is done in accordance with identification and
identifying
assessment risk and environmental aspect PR1201. The assessment
environmental
4.3 evaluation method is combination of Villiam Fine وJSA models.
aspects relevant to
the activities, RPN
processes,
RPN>150: extreme, Not acceptable, Corrective action is needed to issue
products, and the act as soon as possible and to reduce the risk control should be
services of the increased.
organization, et all
100<RPN<=150: High, acceptable, Prompt Appropriate action must be
considering risk?
taken
RPN=<100<50: Medium, acceptable, Situations must be under control
through Control actions
RPN=<50: Low, acceptable, The risk must be monitored and controlled
the organization has identified regulatory requirements such as those
ascribed by organization for environment protection of Iran
regarding the exhaust regulations related to cement manufacturers
Legal
These requirements are up to date.
4.3.2 Requirements and
there is a documented procedure for identification, determining
Others
responsibility, updating and communicating legal and other
requirements: Internal and external communications procedure PR
11/09/01
there is explicit – documented procedure(s) for communicating
information relevant to the EMS to staff
4.4.3 Communication Internal and external communications procedure PR 11/09/01
Staff were aware of environmental consequences associated to their jobs,
they are informed via paper letters or in verbal
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There is an explicit document addressing meeting the EMS policy,
procedures, objectives, targets and others relevant to significant
aspects, Operations control procedure PR12 / 03/02
The procedure addresses following factors:
Reviewing of purchases and contracts,
Control of product and plant / facility design,
Contracting and purchases,
Operational Evaluation of contractors,
4.4.6
Control Storage, handling, packaging, filling, delivery, transport and preservation,
Services,
Maintenance and calibration of devices, equipments and others,
Preventive and corrective maintenance,
Clearing of premises activities and discharge of effluents,
Handling of residual effluents or solids, inclusively storage, handling and
transport, and
Relating to other processes and activities
the organization has through documented procedure identified the
potential for emergencies deriving, minimum, from significant
environmental aspects. According to procedure LI12/06 the emergency
situations are defined Fire,Effluent residual from fire fighting, Spill,
Extreme meteorological conditions, Gaseous emissions / atmospheric
Emergency1 discharges, Loss of energy, mater, cooling, then the plan is established
4.4.7 Preparedness and then the emergency preparedness mock program is conducted according
Response to form FR12/06 the team members are; factory manager as commander
in his absence senior engineer, to run the plan arrangements is done with
local authorities such as fire station,
The evaluation of last emergency preparedness drill was recorded in
form FR12/23 this drill was about collection of waste in 3 month before
this external assessment
4.5 Checking
measurement and monitoring is run over important characteristics
relevant to the significant environmental aspects
the results of controls is recorded to monitor the overall performance
EFQM is implementing in organization, so for measurement indicator is
defined and monitored through balanced Scorecard.
Environmental For example clinker heat energy consumption with the goal of 805 (kcal
4.5.1 Monitoring and per kg clinker) and the implementation of 812,
Measurement Average of customer satisfaction was considered 93% and practical
result was 95%.
The evaluation of the 93 departments from the perspective of energy
consumptions was observed. For crushing 0.94, 18.39 mill products,
bakery 31.47, a 43.1 line cement, cement line of 40.45, 41.74 cement
mill, loading rate of 0.89 KWH / T\
1
Consider that in certain global regions other terms apply (e.g. contingency, accident)
FORM‐009_V4_en Issued: July 9, 2003 Revised: March 2013 Page 4 of 15
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To commit to policy the organization controls the output of all
environmental aspects
the environment aspects legal entities are identified in this case in the
form of legal identification code LI12 / 02 record for legal identification
(the Department of Environment of the country) have been identified,
as well as to make sure to update this reference form the latest edition
references to the number FR12 / 04 is completed in the organization
according to which a person responsible for contact centers 6‐month
intervals legislator in order to ensure that the change the rules of the
Contact may, in person, by telephone, or by reference to the website of
the client. After registration and ensure the rules are updated in
accordance with the risks and identify aspects of the organization of
part of the regulatory requirements applicable to the identification and
registration.
On safety aspects with regard to the aspects identified in the cooking
department as follows:
‐ oil leakage ‐ Water, electricity, paper, fuel, medicines, raw materials,
Evaluation and
4.5.2
Compliance
detergents and chemicals ‐ The production of waste oil
‐ Waste concrete and brick ‐ Gas production NOx, CO, CO2 ‐ Scattering
waste For all aspects of the identified legal requirements have been
recorded as follows: ‐ Law on Waste Management ‐ Act to Prevent
Pollution ‐ Environmental Protection Act ‐ Executive Regulations
Waste Management
In accordance with the law of air pollution prevention and
environmental laws Since the last edition, the cement industry has
been required to install continuous momentary monitoring systems,
therefore Kurdistan Cement Company has installed the monitoring
system that the monitoring moment on All outlets have been installed
and the Organization Department of the Environment the province
monitors real‐time organization outputs. Since the installation in
Kurdistan Cement Company only an infraction on 10/12/92 that the
amount of CO2 had been exceeded, in this case by changing the filter
bag, it was resolved and no irregularities have been happened since
then.
FORM‐009_V4_en Issued: July 9, 2003 Revised: March 2013 Page 5 of 15
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Assessment team observed knowledge of staff of policy and customer
requirements as a mean to determine effectiveness in the development
and implementation of the EMS/QMS, audit team determined
effectiveness in the development and implementation of objectives as a
Management mean to improve the EMS/QMS, including resources. Management
5
Commitment procedure and strategic management committee producers
Objectives Registration form and of executive management systems
programs FR11,
statutory / regulatory requirements are Communicated to staff regularly
according to Internal and external communications procedure PR
11/09/01
policy is appropriate to the nature of the activities and purpose of the
organization, the policy implies to commit to customer requirements
5.3 Quality Policy
and continuous improvement as well as environment requirements, the
objectives is reviewed annually, staff has understood the policy.
Objectives has been developed in terms of improvement projects
according to the EFQM Excellence Model, which are measurable and
within time frame
As an example :a multi‐chamber silo construction project planning,
Planning Quality purchase and installation of elevator rubber mill, the construction of a
5.4
Objectives new cement mill line roller observed in the objectives registration form
and of executive management systems forms FR11/24/00
Environmental objectives to reduce fossil energy consumption through
replacement ventilation grate cooler, replace the flow outlet ducts for
fixing the amount of dust with action plans was observed(FR11/25/01)
Organization chart( CH01/02) was observed,
Job description (FR/16/03) for production operator and commercial
expert has been observed. Staff profile Quality Manager and
Management representative was checked
Responsibility, Training evaluation records for Trading with industrial waste, balance
5.5 Authority and training techniques, optimizing the mine fire courses was observed
Communication (FR20/01 ).training plan FR20/04 was observed . Effectiveness evaluation
of training courses is not complete, such as troubleshooting of electric
motors
Effectiveness evaluation of training courses is not complete, such as
troubleshooting of electric motors
FORM‐009_V4_en Issued: July 9, 2003 Revised: March 2013 Page 6 of 15
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Mr. Eliasvand from the organization’s management team was assigned as MR
Management
5.5.2
Representative
to establish, implement, and maintain the EMS QMS and to report the
performance of the QMS and promote awareness
Management review meeting was held in 93/7/28 accordance with
Management management review procedure (PR11 / 05/02). the records was
5.6
Review observed
Results of audit, Customer feedback, Status of process performance and
product performance, Status of corrective actions, Status of preventive
5.6.2 Review Inputs actions, Follow‐up action from previous reviews, Changes that affect the
QMS/EMS and Recommendations for improvement had been considered
in agenda
management review considered Improving the QMS (through its
processes Identification and provision of resources
5.6.3 Review Output Important outcomes of the meeting are :
Increase distribution of cement in the region (85% of the total domestic
supply) Led research in the field of export to Iraq
6 Resource Management
Competence is based on Education, Training, Skills, and Experience
6.2.1 General
Training evaluation records for Trading with industrial waste, balance
training techniques, optimizing the mine fire courses was observed
Competence, (FR20/01(.training plan FR20/04 was observed. Effectiveness evaluation
PR20 /
01/03
6.2.2 Awareness and of training courses is not complete, such as troubleshooting of electric AR
Training motors
6.2 Human Resources
physical location, workplace and utilities are adequate to processes
All maintenance activities are performed by software APS‐TIMAR 2006
Preventive maintenance program for device control table of the crusher
6.3 Infrastructure (370101 code includes inspection and adjustment, testing, cleaning was
observed.
Records overhaul program for drive system that includes 78 Items was
observed
FORM‐009_V4_en Issued: July 9, 2003 Revised: March 2013 Page 7 of 15
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The PPE and required work environment tools are provided for staff , the
6.4 Work Environment overall environment of company is according to labor and social welfare
requirements
7 Product Realization
7.2 Customer‐Related Processes
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by reviewing product‐related requirements from client, before
Review of committing to accept the order, the organization ensures that can meet
Requirements the product requirements, check any requirements differing from
7.2.2
Related to the routine products , through the process if any requirement is changed
Product this is communicated in written to managers/supervisors and then
verbally to operational staff
means for the organization communicating with the customer are as
follows: Telephone calls, emails and letters, in such communications
Customer
7.2.3
Communication
information regarding Product information is transferred and Customer
responses, opinions, and/or comments is registered and conveyed to
operational staff
Design and
7.3
Development
Excluded
7.4 Purchasing
PR13 / 02/02
code FR13 / 01/00 was observed
Verification of
7.4.3 Records of periodic evaluation of suppliers in the form of code FR13 / AR
Purchases
03/00 with a score of 82% for Data Sazan Gharb, salamat andishan with
a score of 90%, , the Mining contractor (Mr. Saifi) with a score of 86 %,
was observed these are assessed based on criterion for selection,
evaluation and re evaluation available
7.5 Production and Service Provision
FORM‐009_V4_en Issued: July 9, 2003 Revised: March 2013 Page 9 of 15
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Production plan is defined annually then then divided into intervals of a
month Daily Report of grinding (code FR 17/03/00 dated 12.20.93), the
daily report of the crusher with code FR17 / 09/00 dated 12/20/93 and
produce monthly reports with code FR17 / 14/00 to March 93 was
observed.
Information describing product characteristics is available as tables in
Lab.
Quality control Laboratory:
In chemistry and physics units, required tests are done on semi‐finished
products and finished products clinker cement type I and II .the
specifications of the control schemes have been developed in
accordance with the standard ISIRI389.
Quality control of semi‐finished products or clinker:
Liter weight of free lime:
According to the liter weight test WI22 / 18, hour‐liter clinker weight
Control of were measured and recorded in the form of a laboratory report, the
7.5.1 Production and control kiln room operator is informed by telephone.
Service Provision If the weight of produced clinker is less than 1,100g/L is considered as
nonconforming product. Appropriate action will be taken against non‐
conforming items in accordance with control of nonconforming product
procedures.
Based on measured free lime instructions WI 22/51, every 2 hours (12
times in 24 hours) clinker output is sampled and after testing and
calculation based on the calculation of free lime TB22 / 03and results
filed in report form.
Control of cement production:
:Cement Softness
Based on samples taken per hour, Softness of cement measured and
calculated according to the national standard 390 No and calculated
according to Blaine table (TB22 / 04)
And roughness of cement, measured according to the Iranian National
Standard No. 390
FORM‐009_V4_en Issued: July 9, 2003 Revised: March 2013 Page 10 of 15
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Measured free lime:
Hourly samples of produced cement is kept in the container, after 24
hours of 24‐hour average sample provided by the physics experimenter
and free lime average of these samples, were Measured according to the
measure of free lime (WI22 / 27) and the calculation of free lime (TB22 /
03) then the report recorded in the form of office physics laboratory .
Control of loading cement:
Following test is done on samples taken from loading cement silos
Setting time of cement
In physic laboratory, Initial Setting Time & Final setting Time is measured
based on national standard (NO.392) and is recorded in physic
laboratory forms.
Blaine of cement (ASTM C204)
Blaine of the cement is calculated based on national standard (NO.392)
and Blaine Table (TB22/04) is recorded in physic laboratory forms. The
Control of sample was passed through 45µ Mesh.
7.5.1 Production and Measuring of cement expansion
Service Provision Every other day final cement and once in a week the average of Cement
produced is sampled and check out based on national standard
(NO.390), the expansion is measured after exiting from Autoclave ,
sample shown was 0.81 expanded, was in range
Measuring of mechanical strength cements
Every day final cement and 2 times a week average of Cement produced
based on national standard (NO.393), working instruction of external
mixture machine is examined, and records are completed
Sample observed, the produced sample in June 17 2015, the results
were 113 for a 2 day sample and 488.5 for a 28 day sample.
Chemical analyze of cement:
Every other day the sample average of final cement is examined by
supervisor of chemistry laboratory based on national standard
(NO1692), working instruction of external mixture machine
And recorded is registered in FR22/40, by Photometer device. Observed
sample: Magnesium 6%, SO3 was between 3 and 3.5% and weigh
reduction of oxygen was 2.7% with 0.73 % residue in acid.
Validation of The temperature of the furnace is monitored and registered as a process
Processes for that output, cannot verify subsequently, FR17/05/00
7.5.2
Production and Calibrated thermometers are used to register the temperatures
Service Provision And experienced staff monitor the operation of the furnace
traceability and identification procedure PR22/21
a sample was taken from the product loaded to trucks and traced back to
Identification and
7.5.3
Traceability
the raw material, the progression - control established and implemented
relevant to monitoring and measurement status has been recorded
according to the procedure
FORM‐009_V4_en Issued: July 9, 2003 Revised: March 2013 Page 11 of 15
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Normally there is no property of client and there was none at the day of
assessment, but if so the property will be labeled to prevent from being
7.5.4 Customer Property
lost and is usually kept in particular area considered in warehouse to
prevent it from being damaged
All the important safety and environmental protection aspect were
observes in warehouses.
It also records the entry and exit of the filter bags were observed. Last
Preservation of exit of filter, number350 was on 11/21/93 which is done in annual repairs
7.5.5
Product The emission of environmental pollutants into the air is Monitored by the
Department of Environment online and Any nonconforming items in the
chimney outlet, which is caused by damage to filters is reported to be
eliminated as soon as possible
All laboratory equipment in accordance with the identification and
coding procedure of laboratory equipment (code PR22 / 01), identify and
the tag is attached on them
In addition, the list of equipment is developed (code 22.1.) those
laboratories equipment that need to be calibrated have been identified.
Control of The chief of laboratory attach tags on verified equipment .It should be
7.6 Monitoring and noted that the internal calibration performed on laboratory by relevant
Measuring Devices personnel, is accepted only if approved by the technical or laboratory
director.
equipment that are calibrated outside the organization :
Calibration is done by A national authorities (Institute of Standards and
Industrial Research of Iran) or approved centers or by international
bodies.
8 Measurement, Analysis and Improvement
8.2 Monitoring and Measuring
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PR11 /
06/00
effectiveness of the EMS/QMS to input to management review
8.4 Analysis of Data
all processes were measured and analyzed except for some processes AR
such as warehouses and purchase
8.5 Improvement
FORM‐009_V4_en Issued: July 9, 2003 Revised: March 2013 Page 14 of 15
By exception we indicate the specific Strengths and weakness of the organization in light of the management system of the management system, as we
perceive and seen through processes in reference to requirements of the criteria being ascribed as these apply and relate to the assessment plan and
planning of the assessment. This aspect relates to AVA™ as it does to the protection of consumers in the client-organization’s role within their respective
supply – chain.
Disclaimers: (1) herein, we reiterate that any suggestion or opinion that the assessment team expresses does not construe to be a contractual
requirement. (2) The degree of certainty in conclusions increases by the competence of the assessment team as well as the attestation within the
assessment protocol, values, mission and vision under which we operate for the protection of consumers, still remains a certain level of uncertainty.
Strength Weakness
Number of staff in training department
Application of paper‐less administration processes
Updating system related records
action Request Type I Form-008 – as we indicate and that each of the RA addresses the basic four (4) questions
as seen in Form-008:
action Request Type II Form-008 – as we indicate and that each of the AR addresses the basic four (4) questions
as seen in Form-008:
1- Effectiveness evaluation of training courses is not complete, such as troubleshooting of electric motors
3-Records of reviewing environmental aspects of contractors are not complete. Such records in mining area Jun 2014
END of REPORT
FORM-009 – MS Reporting,
FORM-014 – Opening Meeting Checklist
FORM-008 – RA / AR, as requires
FORM-017 – Closing Meeting Checklist
FORM-018 – OBS, as requires
FORM-005 – Participants of opening & closing meetings
FORM-010 – As requires, recommendation for CoR
FORM-004 – Assessment Plan
FORM-026 – Assessment documents check-sheet,
FORM-007 – Planning onto -004, as process determined
for guidance purpose