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2013 Standards Conference SC18 Committee on Quality Standards Washington, DC June 27, 2013
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2013 Standards Conference SC18 Committee on Quality Standards Washington, DC June 27, 2013 API Monogram Program Status Report W. Don Whittaker Manager Monogram Program/APIQR [email protected] Aaron Duke Certification & Audit Program Development Monogram Program/APIQR [email protected]
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API Monogram Program Status Report. 2013 Standards Conference SC18 Committee on Quality Standards Washington, DC June 27, 2013. Aaron Duke Certification & Audit Program Development Monogram Program/APIQR [email protected]. W. Don Whittaker Manager Monogram Program/APIQR [email protected]. - PowerPoint PPT Presentation
Transcript of 2013 Standards Conference SC18 Committee on Quality Standards Washington, DC June 27, 2013
2013 Standards ConferenceSC18 Committee on Quality Standards
Washington, DCJune 27, 2013
API Monogram ProgramStatus Report
W. Don WhittakerManagerMonogram Program/[email protected]
Aaron DukeCertification & Audit Program DevelopmentMonogram Program/[email protected]
API Monogram/APIQRProgram Status Report
1. Monogram Program Statistics2. Fraud and Misuse3. Q1 & Q2 Updates4. Audit Program5. License Format Changes6. API Conference & Expo – Beijing – 20137. myCerts Update
2004
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YTD0
1000
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50004218
1645
API Monogram Licensees APIQR Certified Companies
API Monogram/APIQR Clients
6-13
4738 Active Clients
4218 Licensed Companies. 1645 Companies Certified with APIQR. 1125 Companies With Both.
6-13
API Monogram Licensed Companies
Top Countries:1. China – 14682. USA – 6193. India – 2264. S. Korea – 1435. Italy – 1056. Canada – 907. UAE – 758. Indonesia – 749. UK – 7010. Japan – 5411. Germany – 5412. Mexico – 4413. Singapore – 4314. Malaysia – 4115. Russia – 40 3713 Licensees. 78 Countries.
Asia PacificNorth AmericaEuropeSouth AsiaSE AsiaMiddle EastSouth AmericaAfricaAustralasiaCentral Asia
6-13
API Monogram Licenses
Top Countries:1. China – 22872. USA – 9173. India – 4314. Italy – 2275. S. Korea – 2096. UAE –1847. Canada – 1408. Indonesia – 1369. Germany – 10810. UK – 10411. Singapore – 9612. Japan – 9213. Mexico – 7414. Malaysia – 6715. France – 65 6130 Licenses.
Asia PacificNorth AmericaEuropeSouth AsiaMiddle EastSE AsiaSouth AmericaAfricaAustralasiaCentral Asia
6-13
Top Specifications
API-5CT
API-6A
API-6D
API-7-1
API-5L
API-7K
API-16A
API-16C
API-5DP
API-4F
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Top Licensed Products
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API-6D Ball Valves 666 API-5L PSL 1 Line Pipe 542 API-5CT Threader 534 API-7-1 Threading 512 API-6A Flanges 510 API-6D Gate Valves 506 API-6D Check Valves 501 API-6A Valves 460 API-5L PSL 2 Line Pipe 452 API-6A Tees and Crosses 430
APIQR ISO 9001 Certified Companies
1192 Companies. 66 Countries.
North AmericaAsia PacificEuropeSE AsiaMiddle EastSouth AsiaSouth AmericaAfricaAustralasiaCentral Asia
6-13
Top Countries:1. China 3182. USA 3133. Canada 614. India 545. Indonesia 386. Singapore 317. UAE 308. Russia 289. S. Korea 2710. Mexico 25
APIQR API Spec Q1 Certified Companies
1214 Companies. 68 Countries.
North AmericaAsia PacificEuropeSE AsiaMiddle EastSouth AsiaSouth AmericaAfricaAustralasiaCentral Asia
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Top Countries:1. China 3292. USA 3033. Canada 584. India 555. Singapore 416. Indonesia 397. S. Korea 308. UAE 309. Russian 2710. Mexico 24
API Monogram Applications
918 Applications at 638 Companies.
Asia PacificNorth AmericaEuropeSE AsiaMiddle EastSouth AsiaSouth AmericaAfricaAustralasiaCentral Asia
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Top Countries:1. China 4082. USA 1153. India 614. Indonesia 335. S. Korea 316. UAE 287. Canada 288. Singapore 189. Italy 1810. Romania 15
APIQR ISO 9001 Applications
340 Applications.
North AmericaAsia PacificEuropeSE AsiaMiddle EastSouth AmericaSouth AsiaAfricaAustralasiaCentral Asia
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Top Countries:1. China 1012. USA 883. Singapore 194. Canada 175. UAE 136. Russia 127. India 118. Indonesia 89. Malaysia 510. Italy 5
APIQR API Spec Q1 Applications
373 Applications.
Asia PacificNorth AmericaEuropeSE AsiaMiddle EastSouth AsiaSouth AmericaAfricaAustralasiaCentral Asia
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Top Countries:1. China 1122. USA 893. Singapore 254. Canada 155. Russia 136. UAE 137. India 128. Indonesia 89. S. Korea 610. Malaysia 5
Fraud and Complaints Overview
2009 2010 2011 2012 2013
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5
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15
20
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35
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Cases per year
• 27 cases received to date• 11 open / 16 closed• New trend towards
investigative audits as resolution rather than issuing simple notices to facilities
• 9 cases have been handed to auditors for investigation in 2013
2013 Fraud Cases
Product Complaints
18 total product complaints received in 2012/2013
14 Clients/End
Users
2 API Affiliates
2 Ex-employees
Product Complaints
Complaint outcomes
4 total were unsubstantiated
3 resulted in suspension
1 resulted in cancellation
3 resulted in scope changes/reduction
Product ComplaintsComplaint Details:
• 7F Roller Chain manufacturer• Chains that break after minimal
use• Complaining party was certain
facility performed nonconforming manufacturing practices
Investigation Result:
• Facility exposing products to corrosive liquids
• Facility performed analysis and issued warning to all clients
• Complaint dismissed
Product ComplaintsComplaint Details:
• Report from potential client as a result of a customer audit
• Concerns that facility did not have minimum capability to design, weld, and heat treat 16A products
Investigation Result:
• Total of 19 findings• Incomplete design packages• Missing acceptance criteria for
calibrated equipment• Production not performed under
controlled conditions• Some missing evidence of final
inspections• Immediate Suspension
Product ComplaintsComplaint Details:
• Report facility operated out of an office block
• Facility also lacked capability to design, fabricate, manufacture, assemble or test Derricks, Masts and Substructures
Investigation Result:
• Facility had a sub-site where they assemble, test, and Monogram
• Procedures did not explain or reference activities
• Facility forced to switch Monogram location to sub-site and switch main office to APIQR
Product ComplaintsComplaint Details:
• 5L manufacturer delivering corroded pipes with low impact strength, poor finish, and inaccurate mill test reports
Investigation Result:
• Facility had been subcontracting manufacturing
• Only possessed capability to process pipe
• 5L scope immediately reduced from manufacturer to processor
Q1 & Q2 Update
API Spec Q1, 9th Edition TransitionJune 1 through November 1, 2013
• Audits conducted to 8th Edition• Auditor and Staff training to new requirements
July 8, 2013•Send “Conformance Matrix” to all participant Organizations
December 1, 2013 through May 1, 2014•Audits conducted to 9th Edition•Findings raised against new requirements will be “Concerns”
• Applicants Only: Beginning on March 1, 2014, any finding raised against new requirements will be considered a full nonconformance
June 1, 2014•Conformance to Spec Q1, 9th Edition mandatory •“Conformance Matrix” due
API Spec Q2 – Program ImplementationMarch 2013
• Beta Assessments completed
July 29th – August 2nd 2013•Mock audit planned – Halliburton, Bakersfield•Full test of audit process, planning and reporting
Fall 2013•Accepting applications for certification•Train and qualify auditors and staff
First Quarter 2014•Audits to API Spec Q2
Audit Program Status Report
45%
37%
16%1%
MonogramDualRegistrationOther
1286 Audits Performed
Audits by Program: Monogram Only – 583 Dual – 480 Registration – 207 Other – 19
Audits by Country: China – 455 (35%) USA – 247 (19%) India – 68 (5%) Canada – 50 (4%)
2013 To DateTotal Certification Program Audits
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API Monogram Audits
Initial Renewal Re-Audit Other0
50100150200250300350400
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Dual (API Monogram / APIQR) Audits
Initial Surveillance Recertifica-tion
Re-Audit Other0
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150
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286
7016 8
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APIQR Registration Audits
Initial Surveillance Recertifica-tion
Re-Audit0
102030405060708090
100 89
22
89
7
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First 6 Months Previous 12 Month Period (June-June)0
250500750
1000125015001750200022502500275030003250
20092010201120122013
2009 – 2013Historical Comparisons
Reg Surv-Recerts
Dual Surveillance-Recerts
Monogram Renewals
0 100 200 300 400 500 600 700 800 900
Complete Scheduled To Schedule
2013 Audits Due – Status
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Active API Monogram/APIQR Auditors
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2013
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151 Active Auditors• 146 QMS-Monogram• 16 Auditors in training• 15 EMS-OHSAS• 11 API-U• 15 Perforator Witness
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Local Auditors in 31 Countries.
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Audit Program - Auditors
16 Auditors-in-training / 10 more started process• Focusing on USA
Auditor Training-Qualification Sessions• Houston-Longview & Carrollton• Training sessions with mock audits
Auditor Training-Qualification Plans• API Spec Q2 & API Spec Q1 – training• API Spec Q2 – qualify auditors for fall 2013• Still working on 5CRA and 20A plans• 10 auditor observations complete – 20 more scheduled for 2013
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Audit Program - Audits
Product Spec Questions• In place for 34 product specs – all up-to-date• 12 more to be in place by mid-August
Periodic Audits – Goals Established for 2013• 44 scheduled or completed in 2013• Goal – perform 100 in 2013
Testing of revised audit report
Using SC5 draft audit tools – positive feedback to date
Adding operational resource in Houston office
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API Monogram ProgramProposed Changes to License Format
• Product listings getting longer and more complex• More grades, groups, PSLs, FSLs, quality levels, etc.• Cannot effectively be displayed on a 1 page License document• Looking at a 2 page format for the License
• Page 1 general license and scope information• Page 2 specific product scope with applicable details• Example follows
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QuestionsComments
OTHER OPTIONS• 1 page Monogram License document (see page 1 of example)• Only show generic scope with reference to API Composite List• Details included on API Composite List• 8 ½ x 14 format?
Any comments or concerns?
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www.apibeijing2013.org
Upstream TrackConference Schedule – September 11th, 12th and 13th, 2013
Health, Safety & EnvironmentalCharlie Williams–Center for Offshore Safety
Standards & RegulationsAaron Swanson–Baker Hughes–[email protected]
Roland Goodman–API–[email protected]
Quality & ReliabilityZhang Hanliang–Petro China–[email protected]
Rennie Van Wyck–Intertek–[email protected]
Drilling & Production – 2 SessionsJim Raney–Anadarko–[email protected]
George Gillespie–Weatherford–[email protected] Lechinger–Stress Engineering–[email protected]
Upstream Track
myCertsmyCerts.api.org
Laura LevandoskiSr. Associate –Project ManagerGlobal Industry [email protected]
myCerts• What is myCerts?• myCerts-2013 Release• Testing
myCerts Today• myCerts.api.org• myCerts is our secure web site• Resolve audit findings
myCerts - 2013• Applications will only be accepted on-line• Electronic legal agreements • Contacts will be managed by the clients• Include product details • Audit resolution• New composite list
Migration Plan• Pilot - Fall 2013• Application process• Continuous review of business process• Full Launch – Late 2013• Migrate all clients • Only migrating email address
System Requirements• All common browsers will work
– Internet Explorer Version 8 or higher– Firefox Version 3.5 or higher– Chrome– Safari
• No additional plug-ins
Volunteers - Testing• July 2013 – client testing• Email API if interested – [email protected]• Expectations:
– 2-3 hours – Complete application and review audit response process– Document comments with screen shots and notes– Screen share with API
HelpdeskHelpdesk Information• myCerts -2013 will have a new helpdesk• Email: [email protected]• Email suggestions and issues
Questions?
Thank you……….
W. Don WhittakerManagerMonogram Program/[email protected]
Aaron DukeCertification & Audit Program DevelopmentMonogram Program/[email protected]
Laura LevandoskiSr. Associate –Project ManagerGlobal Industry [email protected]
