Audit Report Entry

Audit Report Entry for Egyptian Styrene and Poly Styrene Production Company - E. Styrenes

Audit Type:

Strength Point:

Audit Objectives:

Area for Improvement:

Observation:

Minor NCR:

NC-01: Unauthorized Use of Certification Body Logos
During inspection of finished product packaging, certification body logos (BV & SGS) were observed printed on product bags. 
while requiements in GCB use of logo policy (QMS-PL03 ) require to not use the logo in final products or services.
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NC-02: Supplier Evaluation Not Implemented
Interviews with the procurement function and review of supplier records showed that some suppliers are not evaluated.
while ISO 9001:2015 Clause #8.4.1 require The organization shall determine and apply criteria for evaluation, selection, monitoring of performance, and re-evaluation of external providers.
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NC-03: Calibration Status Not Demonstrated
Upon request, calibration certificates were not available for: 
- Internal calibration devices used by the Engineering Inspection Department.
- Environmental monitoring instruments.
- Measuring devices installed in the environmental monitoring vehicle.
while ISO 9001:2015 C# 7.1.5.2.a  required the organization equipment shall calibrated or verified, or both, at specified intervals, or prior to use, against measurement standards traceable to international or national measurement standards; when no such standards exist, the basis used for calibration or verification shall be retained as documented information.
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NC-04: Expired Fire Extinguishers
Inspection of the administrative building revealed fire extinguishers bearing inspection labels with expired dates at the time of the audit.
while ISO 45001:2018 – Clause 8.1 REQUIRE THAT The organization shall implement operational controls to eliminate hazards and reduce OH&S risks.
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NC-05: Improper Hazardous Waste Classification and Control
During inspection of waste storage areas:
-Hazardous waste containers were not clearly identified or classified.
-No MSDS documentation was available for hazardous waste.
-Fluorescent lamps were observed disposed of inside general waste drums
ISO 14001:2015 – Clause 8.1
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NC-06: Significant Energy Uses (SEUs) Not Implemented propably 
Review of energy management documentation and interviews with the energy team confirmed that Significant Energy Uses (SEUs) criteria were not propably identified.
ISO 50001:2018 clause 6.3.
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NC-07: Lack of Safety Signage and Traffic Segregation
Site inspection of the packaging unit revealed:
Absence of safety and environmental signage.
No floor markings or defined routes separating forklift movement from pedestrian traffic.
while ISO 45001:2018 – Clause 8.1 REQUIRE THAT The organization shall implement operational controls to eliminate hazards and reduce OH&S risks.

Major NCR:

Man Days:

Team Leader Recommandations:

Audit Findings

Clause No.	Requirements/Departement	Evidence	Result	Delete
	HSE	The organization has identified its internal and external issues verified through procedure EST-HSE-001 mention all issues, It also identified all interested parties with respect to their requirements and expectations verified through HSE-063 Rev 1, The scope is identified with respect of boundaries, needs and expectations of workers and interested parties verified through HSE Manual
	HSE	A strong commitment and leadership from top management to HSE has been confirmed through interview with top management and the HSE policy is well maintained, documented and communicated in the whole company verified through EST-En-ms-W101, Workers participations and consultation has been confirmed through a tool box talk HSE-058 Rev 0 dated 12/7/2025 as evidence of workers participations and a training evaluation form AD-02 Rev 1 dated 20/9/2025 as an evidence of worker consultation.
	HSE	The organization has planned action to address its risks and opportunities and has identified all its hazards verified through hazards identification check list form HSE-EST-WI-053, It also documented a list of legal requirements maintain it as documented information HSE-EST-WI-003 Rev 1, and comply with legal requirements by civil defense approval dated 23/7/2025 Also checked HSE objectives and the plan attached to achieve it verified through EST-HSE-049 Rev 0 dated 2025
	HSE	The organization has determined necessary resources and competency required to HSEMS verified through certified 80 workers for fire fighting and 20 workers to first aid as annual basis check and evidence by workers certificates, Also apply necessary awareness for workers by providing trainings to staff at different departments in different training objects verified through training plan dated 2025 and training attendance HSE-071 Rev 0 dated 20/9/2025, The organization also retain communication forms for internal and external verified through a letter from HSE dep. To service dep. Contain request for grass removal dated 29/9/205 evidence as internal communication and a letter from HSE dep. To governmental civil defense request staff training dated 3/8/2025 evidence for external communication.
	HSE	The organization has established, maintained and implemented operational controls used to eliminate the hazards and reducing the risks in both safety and environment verified through the hazards list, ways to eliminate, the risk assessments and check the influence of applied control via RA- HSE-020- Rev 1, also work permit (hot work serial 5158) dated 12/7/2025 signed from involved departments and has HSE instructions for working at heights HSE-EST-WI-026, instructions for confines space HSE-EST-WI-035 and for environmental instruction for hazardous materials handlings HSE-EST-WI-019, And for management of changes M.O.Cs verified through the procedure EST-ENG-01 and hazop procedure EST-ENG-02, Outsource contracting for annual environmental measurements hired Enviro Alex to perform the measurements dated 9/2025, Contracted with eltawoneya company who has environmental approval to transport hazardous wastes dated 30/1/2025 evidence for approval and safe disposal has been confirmed dated 19/11/2023 and for liquid hazardous waste there’s agreement between the company and petro trade for transportation dated 18/8/2024, The organization complies with emergency preparedness and response as they established, maintained, implemented safety and environmental drills verified through an emergency drill for styrene tank B on site visit, also retained drill form HSE-029 fire drill dated 22/9/2025 Tank 800-01B as safety drill and oil leakage drill HSE-029 Demi water Area 900 from soda tank dated 23/10/2025 as environmental drill.
	HSE	The organization has retained documents for monitoring, measurements and performance evaluation verified through mid annual safety KPI HSE-014 Rev0, Environmental KPI mid annual HSE-014 Rev 0, Tracing has done from W.P to blanco used in lifting process and checked the calibration certificate E/EST/25-01 dated 23/2/2025, Also checked evaluation of compliance with laws and regulation verified through HSE-EST-WI-002/003/004, Managemnt review has been carried out successfully done on monthly basis checked and verified through main HSE committee meetings to apply decisions and review the performance and apply of HSE controls dated 4/11/2025.
	HSE	10.1/10.2 HSE The organization has retained documents for incidents checked by reviewing incidents record for 2025/2024 which have no incidents, Also reviewing nonconformities and their attached corrective actions verified by near miss report HSE-008 Rev 1 dated 12/11/2025 for probability of falling lamb and corrective action taken on same form HSE-008 Rev 1 dated 13/11/2025 by taking necessary actions, The organization takes necessary actions and decisions for continues improvement verified by testing new qualified candidates to hire in HSE to complete its O.C and also decision for improve fire detection system in main warehouse to become automatic fire detection and fighting system, verified through main HSE committee dated 4/11/2025. C
	Warehouse	- A sample of finished product lot No. 106548, grade GPPS-251, was traced to the finished product warehouse and verified as recorded on Goods Addition Note No. 306/225 dated 15/12/2025. The lot number and product grade are clearly identified and registered in the warehouse records. - Movement of finished product is monitored through a Daily Product Movement Balance Report, where finished goods stock is checked and daily issues are recorded to ensure that quantities delivered meet contractual requirements. A specific delivery No. 264/2025 was traced, supported by Proforma Invoice PF311. Finished product lots are further controlled and traced using an Excel sheet and a lot location map (PP-07, dated December 2025), showing the physical location of each lot in the warehouse. - Interviews were conducted with warehouse personnel: Mr. Ahmed Mohamed Khader, Mr. Belal Mohamed Awad and Mr. Karim Shaaban, who are responsible for warehouse operations. They demonstrated awareness of their roles and responsibilities, as well as the procedures for receiving, storing and issuing finished product, including lot identification and traceability. - The receipt of a raw material shipment was verified through the Raw Material Receiving Report No. S-(001-SM-KOL-01) / 2025, which records the delivery details, quantities received and initial checks performed at the time of unloading from the port to the storage system. - Bulk raw materials are received from the port and transferred to the plant storage tanks through dedicated transfer lines and pumps, in accordance with the documented operating procedures. During the audit, the process for feeding raw material from the jetty to the storage tanks was reviewed, including records of transfer operations. The storage tanks are equipped with circulation systems and cooling facilities; the raw material is periodically circulated inside the tanks and cooled in order to maintain the product within the specified temperature range and to preserve its quality. Temperature indications and trends are monitored from the control room, and records showed that the specified temperature limits are being controlled and maintained. - Spare parts warehouses are managed through an Access database “Inventory Management System”, which is used to record item codes, descriptions, quantities, locations and movements of spare parts. The system supports control of stock levels and traceability of issues and receipts. - Interviews were conducted with Mr. Ahmed Abdel Hakim, Warehouse Manager, and Mr. Ahmed Abdel Rahman, warehouse representative. They demonstrated awareness of their roles and responsibilities, as well as the main procedures and systems used for controlling raw material, finished product and spare parts warehouses (including identification, traceability and stock control).
	Laboratory	- Samples from a styrene monomer shipment received from vessel “NCC SHAMS” on 19/01/2024 were tested in the laboratory in accordance with the standard ASTM D5135. Test results were found to be within the specified limits, and the shipment was accepted and transferred to the storage system based on the compliant results. - For finished product lot No. 106548 (grade GPPS-251), laboratory test records were reviewed. The lot was subjected to the required mechanical tests as well as all other specified quality tests in the QC laboratory. All results were within the defined acceptance criteria, and the lot was accepted prior to release to the finished product warehouse. - Water samples are tested daily at 10:00 a.m., and the results are recorded in the COMPLETE ANALYSIS REPORT. The reports reviewed confirmed that routine analyses are carried out as scheduled and that water quality parameters are monitored against defined specifications.
	Engineering inspection	- During the audit of the Engineering Inspection Department, a vibration measurement activity on rotating equipment was traced. It was noted that the vibration measuring instrument Model CSI 2130 used for this task did not have a valid calibration certificate, and no evidence of recent calibration/verification could be provided. In addition, a metal thickness measuring device, Model 38DL, was found in use for thickness measurements without valid calibration evidence or an up-to-date calibration/verification record. - A breakdown notification was traced for a steam gate valve No. 800 SHHA-602 reported with a mechanical failure (valve body/steam leak). The maintenance process was followed, including technical inspection of the defective valve, issuing the required spare parts from the warehouse, replacement of the valve and subsequent functional testing to verify proper operation after repair. Relevant work order and spare parts issue records were available and consistent.
	Competence	-The organization determined necessary competences of personnel working under its control, each job has a detailed description. Two samples were been tested. -The organization is taking actions to assure competence of candidates’ personnel through a recruitment process that includes personal and technical assessment interviews. Samples of retained documents of candidates’ acceptance evaluation process are gathered.
	Planning of production	-the organization main operation of producing polystyrene is planned such that final product can be verified and validated thru mechanical, thermal and optical lab tests.
	Release of products	- The organization is carrying out sample testing of the final products before delivery to assure it will satisfy customer requirements.
	EnMs Team	- check Energy Review criteria for selection for SEUs , the criteria is not probably implmented , and selection for Electric consumpution as EnPI is not effectively as it is already controlled , and methodology not address the criteria for changing or updating the Energy baseline and selecting another SEUs. - discussion with QA manager , the need for energy consumption is due to busniess needs for reducing the production cost , but there is no EnPIs related or relation between consumption and energy cost.
	EnMs / Utility Department	- Meet with Dr.Hytham QA manager , and Eng. Ahmed El tanany Electric manager , Energy team Eng.Taher Guda , Eng.Abd el rahman , Eng. Ahmed Megahd Current energy baseline related to electricity and natural gas . and check current objective for 2026 document EST-EN_MS_P-1 objectove procedure and related to Energy risk procedure En-MS-P01 and objective form EST-EN-MS-F10 rev.0 , the objective 1 related to reduce consumption by 10% for Natual gas for boiler in utility by boiler modification by subcontractor , and reduce Natural gas consumption by 10% by changing Oligmar properties. - Plans are established by EPROM utility Engineer and considered payback. - KPI for objectives have been established for electricity & NGAS
	IT Department	check IT topolgy and backup policy applied , USB prohabited , network segrgations for controlling IT risks due to Attacks or accidentally erase data

Audit Team

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Auditees

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