National Certification Division NCD/FAT/07

Title: Audit Report Format Page 1 of 8

S-Mark Initial Certification Audit Report

1. Identification of the CB
Rwanda Standards Board (RSB)
KK 15 Rd, 49
P.O BOX 7099, Kigali, Rwanda
Tel: (+250) 788303492
Toll Free:3250
Email: info@rsb.gov.rw
Website: www.rsb.gov.rw
2. Identification of the Client
2.1. Name and address of the organization
PLASMACO (Plastique Materiaux des Constructions) LTD
Tel: (+250) 788303276
Kigali City, Gasabo District, Ndera Sector, Kigali Special Economic Zone
2.2. Organization representative
Dr. Ir. Alexis NSENGUMUREMYI
Chief Executive Officer (CEO)
Tel: (+250) 788303276

2.3. Site location

Kigali City, Gasabo District, Ndera Sector
Kigali Special Economic Zone
2.4. Number of staff
Currently, the company employees ten (10) permanent employees and four (4) casual
workers, six (6) are males and four (4) are females.

2.5. Processes/Services
Manufacturing of High-Density Polyethylene (HDPE) pipes with brand name of
PLASMACO.

2.6. Significant changes since the last audit (if any)

Not applicable for the Initial Certification Audit.

3 Type of audit: S-Mark Initial Certification Audit

4 Audit dates:
13th July, 2022
5 Audit Criteria:
 RS ISO 4427-1:2019 Plastics piping systems for water supply and for drainage and
sewerages under pressure— Polyethylene (PE) — Part 1: General
 RS ISO 4427-2:2019 Plastics piping systems for water supply and for drainage and
sewerages under pressure— Polyethylene (PE) — Part 2: Pipes
 Plasmaco Ltd.’s documentation

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Interpretation Documents:

 RS 354:2018 Occupational health and safety for non-food industrial workers — Facility
requirements
 Law No 70/2019 of 10/01/2020 governing metrology in Rwanda.

6 Audit Objectives:
The objective of the audit was to evaluate the compliance of the mentioned products against
applicable standards and S-Mark Certification requirements. Outcome from the Audit and
laboratory test results are the basis for Certification of the above-mentioned products.

7 Audit Scope:
The audit covered the whole manufacturing processes of HDPE PN 6, PN 10, PN 12.5,PN16,
PN 20 and PN25 with diameter of 20mm, 25mm, 32mm, 40mm, 50mm, 63mm, 75mm, 90mm,
110mm, 125mm, 140mm and 160mm from the reception of raw materials, manufacturing,
quality control, marking and storage, some aspects of health and safety for workers as well as
maintenance and calibration of equipment.

8 Any deviation from the audit plan and their reasons: Not identified
9 Unresolved issues/diverging opinions observed (if identified): Not identified
10 Audit Team
- Jean Marie Vianney Ndayiragije (Audit Team Leader)
- Aimée Marie Chantal ABITONDA (TA)
- Eric KABANDA (Observer)

11 Audit Findings
11.1 Area audited: Top Management Responsibility

11.1.1 Positives/ Conformance

 PLASMACO (Plastique Materiaux des Constructions) Ltd is a sister company of
EGC (Entreprise General des Constructions) Ltd. The company started its
operations in June 2022 and is legally registered in RDB with certificate issued on
31st March 2022 with commercial registration number 120162688.
 The brand name PLASMACO is registered in RDB with application number
RW/T/2022/75 dated 22nd February 2022 in the name of EGC Ltd.
 The company is committed to produce quality products evidenced by the fact that
they applied for S-Mark certification of their products. Moreover, the sister
company (EGC Ltd) is certified against RS ISO 9001:2015(Quality Management
System), RS ISO 14001:2015 (Environmental Management System) and RS ISO
45001:2018 (Health and Safety Management System)

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 The employees are given contracts with job descriptions as stipulated in article 8.1
of sampled contract of Machine Operator signed on 24th June 2022
 The production and quality control Manager is experienced in pipes manufacturing
evidenced by his working experience in different pipes industries in Rwanda,
Kenya and India.
 Training programs for employees is established and on job trainings are provided
for staff e.g.: trainings conducted including the production machine operation,
standards requirements and health and safety of workers.
 Collective accident Insurance from Radiant with policy number
RY001ACC2001279 (Medical and pension) and Industrial risks insurance from
Prime Insurance with policy number 330/00095787-SG with Insured number
SG/00181867 are provided for all PLASMACO Ltd.’s employees.

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11.1.2 Areas for further improvement/observations

 The organization chart is not documented (The company is still referring to its
sister’s company’s organization structure.
 Training records were not kept.
 The company provides the generic job responsibilities.
11.1.3 Non-conformities
 Not identified
11.2 Area audited: Manufacturing and quality control
PLASMACO LTD manufactures High Density Polyethylene (HDPE) pipes of PN 10, PN
12.5, PN 16, PN 20 and PN 25 with nominal diameter 25mm, 32mm, 40mm, 50mm,
63mm, 75mm, 90mm and 110mm.
The main raw materials are pure black virgin HDPE-PE 100 with grade P6006 and food
grade masterbatches (blue and white are mixed). All of these raw materials are mainly
imported from Saudi Arabia (SABIC).

Manufacturing process of HDPE pipes:

- Weighing and mixing: using an electronic balance, a sack of 25kg of the pure black virgin
HDPE-PE 100 is measured and mixed with 2.5% of masterbatches (blue and white are mixed)
- Pre-drying Stage: using a hoop dryer, the mixture of raw materials is dried at 80 0C with warm
air to remove the moisture.
- Mold mounting: depending on the production planned size of pipes, a mold with its respective
PN (Nominal Pressure) and outside diameter is mounted on the extruder machine and the
mold can be changed according.
- Feeding Process: HDPE PE100 granules are automatically loaded in a plastic tank then
automatically sucked into the machine standby hooper then fed in the main extruder machine
- Heating barrel zones Process: The mixture of HDPE PE100 granules and 2.5% of
masterbatch are heated at 2300C until melting using a set of thermo heaters which are
interconnected to die head mold with thermocouples.
- Sizing process: the melted mixture passes through different Dye zones to keep the size of
pipes and the temperature is kept at 2300C
- Lining Process: using a lining machine for marking the identification stripe is connected to the
main machine (Extruder machine).
- Cooling process: using two (2) water pumps with industrial specialized water chillers, the
produced pipes pass through a vacuum sizing water tank of 8m and 2 spraying sizing water
tanks of 6m for cooling and maintaining the outside diameter.
- Marking of finished product: by using a continuous LASER (Light Amplification by Stimulated
Emission of Radiation) printing machine, PRASMACO HDPE pipe are marked as follows: for
example, HDPE pipe PN 25 of 40mm: PLASMACO LTD HDPE PIPE PE 100 DN 40MM PN25
SDR 7.4 AS PER ISO 4427/2 MADE IN RWANDA 004MTR BATCH NO PE 02C
PRODUCTION DATE 20220713
- Finished pipes pass through traction with two tracks driven by motors to pull the pipe in a
continuous and stable state

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- Cutting Process: Final produced HDPE pipes are cut (depending on the length needed) using
cutting machine which is driven by pneumatic system.
- After cutting the pipe with appropriate length, the final product is coiled/rolled using winder
machines.

11.2.1 Positives/ Conformance

- The company has the copies of relevant products standards and the requirements of the
standard are followed during production of HDPE PRASMACO pipes.
- Certificates of analysis are supplied with raw materials and are checked if all tested parameters
passed as criteria for selection of raw materials evidenced by the certificate analysis number:
804654207 of 31st March 2022 with lot number: 22720264 and 22728139.
- The company produces black colored pipes with clear blue stripes and smooth finishing inside
and outside when physically observed.
- The average monthly production capacity is 300 tones.
- When the manufactured pipes are visually inspected and touched by hands, they are smooth,
clean and free from scoring, cavities and other surface defects.
- The company conducts quality control of finished products. Audit team witnessed the
laboratory testing for tensile strength, hydrostatic pressure, heat reversion, dimensions, and
physical check tests and the records are kept evidenced by the laboratory test results kept on
23rd June 2022 which shows that the PLASMACO pipes passed for all tested parameters.
- The daily production records for both raw materials and finished products are kept and
documented evidenced by the records taken on 23rd June 2022
- Finished pipes are coiled into coils of different internal diameters following the law of 18dn. Big
sizes are not coiled.
11.2.2 Areas for further improvement/observations
- PLASMACO Ltd is not able to test the heavy metal content (Lead content, Mercury content,
Cadmium Content and Arsenic Content)
- No manufacturing flow diagram
11.2.3 Non-conformities
Not identified
11.3 Area Audited: Marking and Labelling
11.3.1 Positives/Conformance
- The manufactured HDPE pipes are marked with the following information as required by the
standard:
 Name of Manufacturer (PLASMACO Ltd)
 Material: HDPE pipe PE 100
 Outside Diameter DN
 Nominal Pressure PN
 SDR
 Standard used
 Production country
 Meterage
 Batch number

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 Production date

11.3.2 Areas for further improvement/observations

Not identified

11.3.3 Non-Conformities
- Not identified

11.4 Area audited: Storage and store management

11.4.1 Positives/ Conformance
- The company has sufficient storage areas for both raw materials and finished products (big
space outside and within the factory)
- Finished products are well arranged in a well cleaned and ventilated warehouses with enough
light.
- The raw materials are stored within different warehouse with enough pallets
11.4.2 Areas for further improvement/observations
Not identified
11.4.3 Non-conformities
Not identified
11.5 Area audited: Design and Facilities
11.6 Positives/ Conformance
- The factory is accessible to the main road.
- Clean offices with MDF tables, ergonomic seating chairs were in place.
- The company has an automated manufacturing machine (extruder machine) used in production
of HDPE pipes from 20mm to 160mm of diameter with different mold in the stock
- The company’s infrastructures are adequately lighted, well ventilated with enough space for the
manufacturing of HDPE pipes.
- The company has the laboratory with necessary tools/ equipment for quality testing. The
following equipment are in the laboratory:
 Tensile Strength testing machine of 25KN Capacity.
 Hydrostatic Pressure machine with three stations that can work simultaneously
when testing three different samples at 20 0C and a HDT Software hydrostatic
buster test
 Micrometer for testing wall thickness
 Vernier caliper and PI tape used to measure the outside diameter and ovality of
the pipe.
 Hot and cool water tank
11.6.1 Areas for further improvement/observations
Not identified
11.6.2 Non-conformities
Not identified
11.7 Area audited: Health and safety
11.7.1 Positives/ Conformance

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- The working environment is clean and ventilated with uniform lighting

- Seating facilities are provided for employees
- Toilets and washrooms are provided for staff.
- First aid kit is in place and is equipped with necessary tools such as bandages, gloves, sterile
plaster, cleaning wipes, etc.
- Employees were trained on how to use First aid kit and the records are kept
- Employees are provided with personal protective equipment (working clothes)
- Fire precautions (fire extinguishers) are in place and serviced.
- Water and lunch are provided for workers.
- There is no harmful noise produced during operations
- The manufacturing area has safe entry and exit
11.7.2 Areas for further improvement/observations
- Changing rooms for both males and females are not in place.
- Warning signs, color coding and emergency assembly point are not in place.
- Staff were not wearing industrial shoes
11.7.3 Non-conformities
- Not identified
11.8 Area audited: Maintenance and Calibration
11.8.1 Positives/ Conformance
- Maintenance plan is in place (weekly plan) evidenced by the plan prepared on 19 th May 2022
and maintenance records are kept.
- The company applied for calibration of their equipment (vernier caliper, PI TAPE, weighing
scale, woven, hydrostatic pressure test machine, tensile test machine and micrometer) on 5 th
July 2022. This is evidenced by the application done with number MCP004048.
11.8.2 Areas for further improvement/observations
- Not identified
11.8.3 Non-conformities
- Not identified
12. Verification of effectiveness of taken corrective action regarding previously identified non
conformities, if applicable.
- Not applicable since it is initial certification audit
13. A statement on the conformity and effectiveness of the production controls to meet:
- the applicable statutory and regulatory requirements: The company is legally
operating and is registered in RDB with code 120162688 and RRA for tax payment
and is operating with the registered scope of operation. PLASMCO Ltd provides
accident and industrial insurance for staff in RSSB.
- the applicable standard requirements: During the audit, the identified positive
findings and areas of improvement were discussed with the company’s management.
Samples of audited product were randomly collected from factory and submitted to
RSB Laboratories for testing dimensions (Outside diameter and wall thickness),
Hydrostatic strength test and chemical composition (Lead content, Cadmium content,
Mercury content and Arsenic Content).

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14. The audited client is effectively controlling the use of the Certification documents
(Licensing Contract, License, Certificate of Conformity, Scheme of Supervision and
Control) and S-Mark (if applicable)
- Not applicable
15. Recommendation from the audit team.
The audit team would like to recommend the management of Plasmaco Ltd to address the
highlighted areas of improvement to ensure the full compliance with S-Mark certification
requirements.

In addition, the samples of PLASMACO HDPE pipes (PN 10 DN 110MM, PN 16 DN 90MM, PN

20 DN 50MM, PN 25 DN 50MM) were taken to RSB laboratories for testing dimensions,
Hydrostatic pressure test and chemical composition (Lead content, Cadmium content, Mercury
content and Arsenic Content). The test results Indicated that all the samples of PLASMACO pipes
passed for all tested parameters.

16. Conclusion on the appropriateness of the certification scope

The audit scope defined as manufacturing of HDPE pipes was found appropriate as it was
matching with the company’s process.

17. Confirmation that audits objectives have been fulfilled.

The audit objective was fulfilled since there were no nonconformities raised and Samples of
audited product were collected from the factory and submitted to RSB Laboratories for testing
dimensions, hydrostatic Strength test and chemical composition and the samples passed for all
tested parameters.

Disclaimer: “This audit was based on random samples and not every aspect of the system was
necessarily covered. Audit results reflect the situation found by the audit team at the time of the audit.
Therefore, nonconformities that have not been identified in this report may exist. The
recommendations from the audit will be subject to an independent review, before any final decision is
made concerning the granting or maintenance of certification”.
Annex A: Audit Plan
Annex B: Agenda of opening meeting
Annex C: Attendance list of opening and closing meeting
Annex D: Minutes of closing meeting
Annex F: CAR forms, if any
Annex G. Test Reports

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