03 & 04 Duties of SWI and Quality
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Transcript of 03 & 04 Duties of SWI and Quality
Duties & Responsibilities
Honesty
Integrity
Knowledgeable
Good communicator
Physically fit.
Personal AttributesPersonal Attributes
Supervise
Planning
Organisation
Auditing
Duties & ResponsibilitiesDuties & Responsibilities
DUTIES OF SENIOR WELDING INSPECTOR
What are the Duties of the Senior Welding What are the Duties of the Senior Welding Inspector?Inspector?
The senior welding inspector will be required to:-The senior welding inspector will be required to:-• manage and control.manage and control.• provide guidance and advice on subjects of a provide guidance and advice on subjects of a
technical nature.technical nature.• show leadership skills in addition to technical skills show leadership skills in addition to technical skills
and experience.and experience.
Technical skills required for the Senior Technical skills required for the Senior Welding Inspector?Welding Inspector?
1. Knowledge of technology.1. Knowledge of technology.2. Knowledge of normative documents.2. Knowledge of normative documents.3. Knowledge of planning.3. Knowledge of planning.4. Knowledge of organisation.4. Knowledge of organisation.5. Knowledge of auditing.5. Knowledge of auditing.
DUTIES OF SENIOR WELDING INSPECTOR
1. Knowledge of technology.1. Knowledge of technology.Similar to that required for a welding inspector. Similar to that required for a welding inspector.
Additional knowledge would include;Additional knowledge would include;• Commonly used NDT techniques.Commonly used NDT techniques.• Radiographic interpretation.Radiographic interpretation.• QA/QC knowledge.QA/QC knowledge.• Basic metallurgy of commonly welded materials.Basic metallurgy of commonly welded materials.• Assessment of fracture surfaces.Assessment of fracture surfaces.
DUTIES OF SENIOR WELDING INSPECTOR
2. Knowledge of normative documents.2. Knowledge of normative documents. Specified normative documents should be Specified normative documents should be
available at the work place. The SWI would be available at the work place. The SWI would be expected to read, understand and apply them expected to read, understand and apply them with the necessary level of precision and direction.with the necessary level of precision and direction.
The SWI should be aware of common standards The SWI should be aware of common standards applied in the welding industry.applied in the welding industry.
DUTIES OF SENIOR WELDING INSPECTOR
3. Knowledge of planning.3. Knowledge of planning.• Planning will be required for all phases of a project, Planning will be required for all phases of a project,
from start to completion.from start to completion.• Planning for inspection would usually relate to the Planning for inspection would usually relate to the
following areas as a minimum;following areas as a minimum;• Pre - contractPre - contract• In - contractIn - contract• Post - contract Post - contract
DUTIES OF SENIOR WELDING INSPECTOR
4. Knowledge of organisation.4. Knowledge of organisation. Organisational skills are necessary to ensure that the Organisational skills are necessary to ensure that the
inspection requirements of any plan can be met on inspection requirements of any plan can be met on time using the correct personnel for the job. time using the correct personnel for the job.
This may include assessment of;This may include assessment of;• Availability of inspectors.Availability of inspectors.• Competence of inspectors.Competence of inspectors.• Supervision / monitoring of inspectors.Supervision / monitoring of inspectors.
DUTIES OF SENIOR WELDING INSPECTOR
5. Knowledge of auditing.5. Knowledge of auditing.• Auditing may take place at any stageAuditing may take place at any stage in a project or contract.in a project or contract.• It is basically checking againstIt is basically checking against documented criteria.documented criteria. There are three areas of audit;There are three areas of audit;• Pre - productionPre - production• In - productionIn - production• Post - productionPost - production
DUTIES OF SENIOR WELDING INSPECTOR
Personality Professional Responsible Impartial Tolerant Factual Decisive Diplomatic Communicator
Technical Knowledgeable Qualification Experience Problem solver Advisory
SupervisionSupervision
What is a supervisor?• Supervisor – a person who supervises
another person(s),task, etc; manager, a superitendant,an on looker, a reviser, senior inspector,etc
To understand and what is a supervisor, put yourself those questions:
• What expected of me?• Where do I fit in?• What are my responsibilities?
SupervisionSupervision
What is expected of me?• Be knowledgeable of your job• Be a leader• Set a good example• Do your best and expect other to do the
same• Be a team player• Be fair but firm, earn respect
Duties & ResponsibilitiesDuties & Responsibilities
Where do I fit in?
SupervisionSupervision
Manager
Welding supervisor
NDT
Welding supervisor Inspection
Welding supervisor production
Welding foremen Welding inspector NDT Technician
Welders Welders Welders
What are my responsibilities?• Quality control• Welding• Training• Inspection & training• Safety• Report
SupervisionSupervision
QUALITY CONTROL
• Know the requirements!• Check the materials• Schedule NDE,be first to know results• Calibrated equipment used where required• Maintain current records
SupervisionSupervision
WELDING• Know the requirements!• Know the WPS’S• Know joint fit up and tolerence,clean!• Know the electrode types, heat treatments & any
special storage requirements• Know welder qualification and skill levels• Ability to communicate WPS requirements to welders• Ability to carried out demonstration if needed• Overall check on welders performance and any repair
or defect trends
SupervisionSupervision
TRAINING It is the supervisors to aid in recruitment and
qualifying welders when required for the job. He must help welders to improve their skills and productivity. He does this by:
• Maintain his own proficiency in the various welding process
• Visually inspecting each welders work and progress• Encouraging welders to achieve higher standards of
quality and production• Participating actively in safety awareness and
training
SupervisionSupervision
INSPECTION & TESTING
• Ensure work meets standards and codes• Ensures all testing & NDT is correct and
properly done• All works is completed & signed off when
required• Outstanding repairs are completely in at
timely manner
SupervisionSupervision
SAFETY
• Set the example (always wear safety equipment/P.P.E)
• Participate actively in safety meeting• Highlight any unsafe practices to senior
management• RAP (reconised,avoid & prevent)• Daily safety contact (solve issues with
workforce)
SupervisionSupervision
REPORTS
• Record drawings (numbers,revisions,etc)• Check if NDT is completed and all report
sign and accepted• No safety issues are outstanding• Produce a weekly progress and overall
quality report for management meeting
SupervisionSupervision
Resources can be:All planning requires answers to the “five planning questions”• What?• Where?• When?• Who?• How?
Planning & organisationPlanning & organisation
It is your responsibility to organize and allocate resources to task
Those resources can be:1) PEOPLE• Knowledgeable• Experience• Training• Task and safety• Number
Planning & organisationPlanning & organisation
Resources can be:2) MATERIALS• Permanent /contract• Expendable• Drawings• Specifications• Procedures
Planning & organisationPlanning & organisation
Resources can be:3) EQUIPMENT• Major equipment:Crane,generator,welding
plant, air compressor ,etc• Tools: welding leads, air
hose,grinders,grinding ,etc• Supplies : welding consumables,gas,etc• PPE : Hardness, grinding shields, ear
plugs,glasses,etc
Planning & organisationPlanning & organisation
4) Documentation Specifications: revisions amendments etc. Manufacturing: job instructions, mill certs etc Modifications – concessions Quality manual Procedures: assembly, welding, repair welding, NDT etc Welder qualification: approval and history etc Inspectors: approvals and history etc Calibration certificates All reports
Planning & organisationPlanning & organisation
How much inspection is required? Total man hours required Number of personnel required Estimation of job times Analysis of job sequences Preparation requirements & time Travel and down time (mobilisation/demob) Leave time for personnel Ability of staff
Planning & organisationPlanning & organisation
The amount of planning required depends upon the company size
Why? To force people to think things through To optimise team/individual performance To provide documentation for traceability To convert solved problems into recorded knowledge To co-ordinate actions between departments To improve efficiency, Quality and cost effectiveness
Planning & organisationPlanning & organisation
1. Jobs are planned and issued in correct sequence, reducing unnecessary work
2. Men and equipment are supplied at the right time with the correct materials
3. The correct quality standards are achieved for the minimum cost
4. Completed goods are despatched as promised5. Adequate stock levels are maintained6. Greater job satisfaction/security
Advantages of planning
Planning & organisationPlanning & organisation
Auditing Auditing stagestage
Pre - productionPre - production
In - productionIn - production
Post - Post - productionproduction
Actions requiredActions required
Assess qualifications / ability of staff.Assess qualifications / ability of staff.Planned work scheduling.Planned work scheduling. Assess whether specifications are beingAssess whether specifications are beingworked to.worked to.
Assess overall standard of welding and Assess overall standard of welding and inspection.inspection.
AUDITING.AUDITING.
Definitions:systematic,independent and documented process for obtaining evidence it objectively to determine the extent to which criteria are fulfilled
AuditingAuditing
Audit
a system
a compliance
Is quite shallow; examines the system to confirm that if follows the quality manual and procedures are in place
It goes in- depth; examines the compliance with procedures and quality manual
Definitions Audit program: set of one or more audits planned Audit criteria: set of policies, procedures or requirements used as a reference Audit evidence: records, statements of fact which relate to audit criteria Audit findings: results of the evaluation of the collected audit evidence against audit criteria Audit conclusion: outcome of an audit provided by the audit team, after considerations of the audit findings
AuditingAuditing
Assessment of:
Staff
Equipment
Q.A / Q.C and Inspection
Documents
Safety
AuditingAuditing
Internal audits First Party Audits Conducted for the companies internal purposesExternal AuditsSecond Party Audits Conducted by parties having an interest in the company, such as customers or by other persons working on their behalfThird-Party Audits Conducted by external independent organizations, which provide certification of conformity
AuditingAuditing
Traceability
Definition: Ability to trace the history, application or location of that which is under consideration
Traceability Traceability can relate can relate
to:to:
The origin The origin of materials of materials
and partsand parts
The The processinprocessing historyg history
The The distribution distribution and location and location
of the product of the product after deliveryafter delivery
Traceability - HOW?hard stampingpainting/etchinglabelling
WHEN? Immediately after the operation!
Conformity
RequiremeRequirementnt
ConformityConformity
fulfilmentfulfilment
NonconformiNonconformityty
non-non-fulfilmentfulfilment
Corrective Corrective actionaction
NonconformitNonconformity reporty report
RepairRepair ScrapScrap ConcessioConcessionn
ReleaseRelease
SDRSDR
Conformity evaluation
Test determination of one or characteristics according to a procedure can be non-destructive or destructive
ConformitConformity y
evaluatioevaluationn
Inspection evaluation by observation and judgement can be accompanied by measurement, testing or gauging
Inspection - terminologydetectable change in the
material
signal from a discontinuity typical to the testing method used
DiscontinuitDiscontinuityy
IndicationIndication
DetectioDetectionn
Acceptance Acceptance levellevel
EvaluationEvaluation
prescribed limit below which a component is accepted
RecordablRecordable e
indicationindication
DEFECTDEFECT
Quality Control & Quality Assurance
is a subjective thing……
..what is quality to you might not be quality to me……
‘Quality’
QualityQuality
Quality = degree to which a set of inherent characteristics fulfills explicit and implicit requirements
Quality - definitionsQuality - definitions
Quality
Management
Policy
system
Coordinated activities to direct control an organization
Overall intentions and directions of an organization related to quality as formally expressed by top management
A system to direct and control an organization with regard to quality
Quality management activitiesQuality management activities
Quality
Assurance
Control
Part of quality management focused on providing confidence that quality requirements will be fulfilled
Part of quality management focused on fulfilling quality requirements
Why we need QA?
• prevent defective work
• ensure programme commitment are achieved
• provide feedback to the management
Quality assurance documentsQuality assurance documents
Quality assurance documents
specification
Code of practice
Document stating requirements (related to activities or products)
Quality manual
Quality plan
procedure
Document specifying the quality management system of an organization
Document specifying which procedures and resources shall be applied by whom and when to a specific project
Specified way to carry out an activity
Set of rules for manufacturing a specific product or activity
- Is a check list specifies which procedures and associated resources shall be applied, by whom and when to a specific project,product,process or contract
- Is a list with the main operation following manufacturing sequences
- Stop/hold point with specific requirements (e.g. document check,NDT witnessed by customer representative, independent body supervision, procedure used, acceptance standards,etc)
- Type and number of document issued (NDT report,WPAR,welder qualification , dimensional check list,etc)
- Name and signature of welding coordinator in charge with each operation ( if required)
- Date of completion for each step
Quality planQuality plan
Quality planProcess Process
descriptiodescription activityn activity
ResponsiblResponsible persone person
Process Process reference reference documentdocument
ApprovaApproval l
/remark/remarkssHH
H - Hold point: work shall stop until H - Hold point: work shall stop until representative are present to representative are present to monitor/observe activitymonitor/observe activity
WW
W - Witness point: notifiable point; should W - Witness point: notifiable point; should representative fail to attend, work may representative fail to attend, work may proceedproceed
RR
R - Document reviewR - Document review
AA
A - Document approvalA - Document approval
MM
M - Monitor/periodic control of activityM - Monitor/periodic control of activity
Welding map
CC55
Information's to be Information's to be supplied:supplied:
LL11
LL22
LL33
LL44
LL55
CC11
CC22
CC33
CC44
CC66
NN11NN22 NN33
NN44
SS11SS22
•weld type and weld type and positionposition•WPS and PQR WPS and PQR numbernumber•type and extent of type and extent of NDENDE
•welder’s stamp welder’s stamp numbernumber•type of PWHTtype of PWHT
Quality pack
a.k.a. doc pack, history a.k.a. doc pack, history docketdocket
Quality pack Quality pack contentcontent
Documents supplied Documents supplied before before
commencement of commencement of manufacturemanufacture
Documents Documents supplied on supplied on
completion of completion of constructionconstruction
Quality pack content
•certificate of conformance with different codes/standards•design calculations (optional)•manufacturing drawings•WPS with supporting WPQR (copies)•welder qualifications•qualification of NDT personnelNDT procedures•PWHT oven calibration record (optional)
•material test certificates (list!)•welding production tests (if required)•PWHT record (if required)•NDT test reports: dimensional, pressure test and coating thickness are included•quality plan and weld map•as-built drawings•non-conformity reports (SDR)•operating/mounting instructions
Documents supplied Documents supplied before manufacturebefore manufacture
Documents supplied Documents supplied after manufactureafter manufacture
QA applies to all areas which have
an affect on quality
QC deals with the actual measurement
of quality performance
“has the work been performed correctly?”
“is the work/action been performed correctly?”
QA – Vs - QCQA – Vs - QC
QA is mainly about documentation
And must see the whole picture
Inspection is mainly about physical reality,
monitoring and measuring, a QC tool
“quality assurance is not inspection”
“comparing the results against documented criteria”
QA – Vs - InspectionQA – Vs - Inspection
Quality Assurance: All those planned and systematic actions necessary to provide adequate confidence that a product or service will satisfy given requirements for quality or that quality requirements will be fulfilled
Quality Control: The operational techniques and activities that are used to fulfil the requirements for quality
Inspection: Activities such as measuring, examining, testing, gauging one or more characteristics of a product or service and comparing these with specified requirements to determine conformity. Inspection is a tool used for quality control
Testing: Determination of one or more characteristics according to a procedure
Definitions Relating to QualityDefinitions Relating to Quality
top management
quality management
quality planning quality assurance quality control
Inspection
Concepts Relating to Quality ManagementConcepts Relating to Quality Management
Grade
QualityDegree to which a set of inherent characteristics
fulfils requirements
Customer satisfactionCustomers requirements
have been fulfilled
Requirements
Concepts Relating to Quality ManagementConcepts Relating to Quality Management
You are required to visit a site on which your welding inspectors have been involved
The work concerns the inspection of a welded fabrication to a specific application standard and is now ready for final approval
What question do you ask?
What documents do you review and what inspections do you require before submitting an inspection report to the authorities concerned?
CSWIP 3.2 Mandatory Question CSWIP 3.2 Mandatory Question
CSWIP 3.2 Mandatory Question CSWIP 3.2 Mandatory Question
Prior to your visit on site it is important to spend time planning and organizing the visit, in order that all the vital details are not overlooked.Knowledge of the product with regards to the specification and codes and standards from which it has been fabricated and the service life and service conditions of the product are beneficial in assessing the fitness of the product for service.A list of the inspection team will ensure that those involved with the fabrication and inspection of the product are at hand to answer any question.
The following documents should be reviewed as a minimum prior to the final approval of the product.
CSWIP 3.2 Mandatory Question CSWIP 3.2 Mandatory Question
1. Review the quality plan and inspection check lists ensuring all stages have been completed and signed.
2. Review the client specification as to ensure weld and materials suitability.
3. Check material/mill certs, ensuring all heat numbers have been transferred where applicable.
4. Review procedure and qualification test certs for bending, rolling and all other cold forming operations.
5. Review all welding procedure specifications, repair welding procedure.
6. Review all NDT procedures7. Review all NDT personal, checking qualifications against clients
requirements.8. Review PWHT records, check calibration certs of equipment
used where applicable.
CSWIP 3.2 Mandatory Question CSWIP 3.2 Mandatory Question
9. Check the technical data sheets of all welding consumables used, storage conditions and heat treatments where applicable.10. Check welder approval certs, check all welding operations carried out by qualified welders only.11. Check that all production tests on parent material and welds have been carried out, where applicable.12. Check and review all NDT reports.13. Review all technical drawings, showing materials and weld maps tractability.14. Dimension checks.15. Check all painting/coating procedures.16. Check all painting/coating reports.17. If applicable, check the final as-build drawings, locating all material used in the fabrication, cross-referencing the weld identification numbers to the NDT reports.
Weld Procedures& Welder
Quals
Missing Documents
Material Traceability &
Mill Certs
Pressure
testing
Coatings
Inspection Reports,
Distortion &
Dimensions
Inspection personnel,
Any QuestionsAny Questions
??