MANUFACTURER'S DATA RECORD [ M.D.R.] · PDF fileMANUFACTURER'S DATA RECORD [ M.D ... AWS...

Rokonma-RKM (DongGuan) Co., Ltd.

Project:

Project No.

Contract Numbers:

Order Numbers: WO74832

RKM Sales Order Numbers: 281, 282

CONV. No:

Report No: RKM / MDR / FRAME / 01 / Del: 1

MANUFACTURER'S DATA RECORD [ M.D.R.]

SUPPLY OF CONVEYOR FRAMES FOR:

Rokonma-RKM (DongGuan) Co., Ltd.Client: Contract No: 45019551 (SL1) 45019552 (SL2)

Project: PO No: WO74832 (SL1) WO74833 (SL2)

Project No. RKM Sales Order No: 281 (SL1) 282 (SL2)

VOLUME SECTION SUB SECT.A

A-1A-2A-3A-4

BB-1B-2B-3B-4B-5B-6

C

DD-1D-2

EE-1E-2

FF-1

G

II-1I-2

JJ-1J-2

PP-1

QQ-1

R

Certificates of Compliance

Welding Procedure Records

FRAME MDR INDEX

ITEM DESCRIPTION

Consumable Certificates Register

Material Certificates - Test Reports - Material Traceability RecordsRolled Steel Angle - Material Certificates

Frame Process Flow Chart

Frame Inspection Frequency

Circular Hollow Section - Material Cretificates

Inspection & Test Plans

Frame Inspection and Test PlanFrame Inspection Levels

Material Traceability Register

Steel Plates and Flats - Material CertificatesRectangular Hollow Section - Material Certificates

Assembly and Dimensional Check FormFinal QA Check

Non-Conformances and ConcessionsNon-Conformance Report Register

As-Built DrawingsDrawing Register

Welding Procedure Specification (WPS)

Welder Qualification Record

Customer/Third Party Inspection FormPackaging and Delivery Form

Weld Traceability & Non-Destructive Testing Records.

MPI Test Report

Welder and Welding Operator RecordsWelder Qualification Register

Procedure Qualification Record

TQ Register

Miscellaneous Certificates and Forms

Dimensional Records

Surface Treatment Procedures and Records

DOCUMENT NO :

RKM \ QP \ 4.10 \ ITP\ BKT \ C.01

Rokonma-RKM (DongGuan) Co., Ltd.Date: REVISION

17-Apr-13 No. 04

Equal Angles Misc.Items/components Flat Bars

REJECT QC: 1 REJECT QC: 1 REJECT QC : 1

CUTTING SHEARING

STAMPING /

QC: 2 QC: 2 BENDING etc.

BENDING

and REWORK REWORK

DRILLING

( FOR SAG -

ETC MODELS) TACK

WELDING

REWORK QC: 3

FULL

WELDING

REWORK QC: 4

PAINTING HOT -DIP

GALVANISED.

REWORK QC: 5

FINISHED

PRODUCT

REWORK QC: 6

STORAGE

A-1 Frame Process Flow Chart

Doc No: RKM / MDR / I .T . P / A .01

Rokonma-RKM (DongGuan) Co., Ltd. Page No : 01 of 01 Rev: 04

Inspection Location: RKM-Rokonma, China.

Client: * H = Hold point; W = Witness point

Project: * R = Review Point; M = Monitor point

* S = Self Inspection.

CONTROL CATEGORIES: H = Inspection Hold Point (Work must not proceed to the next step until this activity is completed and a signature obtained from the column placing the HOLD; i.e.. QA or Client);

W = Witness Point (Notify to permit witness, work can proceed if witness does not attend at agreed time); S = Surveillance Point (Monitor operations); R = Review Documentation (Sign or Stamp to record review).

CONTROL POINT

1 Submission/Approval of Documentation

1.1 Inspection & Test Plan and MDR Index. Review contract requirementsITP's

MDR Index

H H/R

1.2Weld Procedure Specifications (WPS) & Weld

Procedure Qualification Records (WPQR)

Review Qualifications & register

& update as required

(AS1554.1.SP) AWS

D1.1/AWS D1.1M:2010

equivalent to ISO5817 : 1992

Quality level.

WPS, PQR, Register & Test

reports

H H/R Records held in job file

1.3Welder Qualifications

Submit Welder Qualifications & Register.

Review Qualifications & register

& update as required

(AS1554.1.SP) AWS

D1.1/AWS D1.1M:2010

WQT, Welder Register &

Test reports

H H/R Maintained in RKM

employee files

2 Materials

2.1

Inspect materials including welding consumables for

damage or contamination and verify that they are

correct in accordance with Purchase Order, Delivery

Docket and Material Certificates.

Purchase orders to request

material certificates. Inspect &

verify delivery dockets.

As per approved drawings

Purchase Order

Material Certificates

Delivery Docket

H / R S Records held in job file

2.2Store material and welding consumables to eliminate

damage and contamination.

Store materials in designated

areas.

S S Records held in job file

3 Pre Processing & Assembly

3.1Material allocation, preparation, cutting, drilling,

pressing and Identification Marking

Drafting office to produce cutting

list, factory drawings &

identification tags

As per approved drawingsCutting List

Drawing / Item Mark


3.2

Assembly of components prior to welding.

Fit-up & alignment Cutting & bending lists actioned

& signed off.

Approved drawings

Qualified WPS

(AS1554.1.SP) BS EN 288 Part

3 : 1992

Drawings


4 Welding

4.1

Welding to be performed by qualified welder in

accordance with approved Welding Procedure

Specification.

Check & Sign off factory drawing(AS1554.1.SP) AWS

D1.1/AWS D1.1M:2010

WPS, PQR, WQT Welder

Register & Test Reports

R/S S Records held in job file

4.2

Welding visual Inspection, Check:

Root pass/weld size/profile & finished welds

Closing weld size/profile & finishCheck & Sign off factory drawing

(AS1554.1.SP) AWS

D1.1/AWS D1.1M:2010

H S Records held in job file

4.3Weld repairs (if any) remove defect (e.g. sharp edges)

in accordance with qualified procedure.

Check & Sign off factory drawing.

Notify client rep.

(AS1554.1.SP) AWS

D1.1/AWS D1.1M:2010


5 Inspection & Testing

5.1100% Final visual inspection of all welds and check for

distortion, sharp edges & holes de-burred.Check & Sign off factory drawing

Approved drawings

(AS1554.1.SP) AWS

D1.1/AWS D1.1M:2010

ITP


5.2 Dimensional check after welding 'As Built' Check & Sign off factory drawing(AS1554.1.SP) AWS

D1.1/AWS D1.1M:2010

As Built Drawings Check

Sheets

H S As built drawings provide in

MDR6 Surface Treatment

6.1 Protective Coatings Galvanising procedure S S

6.2 Final Inspection of Surface Treatment Verify test report H/R S/R

7 Final Inspection & Dispatch

7.1

Final inspection to ensure internals are clean, all

necessary inspection & testing has been conducted

with all necessary contract requirements completed.Verify delivery dockets

Inspection Release, Delivery

Docket

H S

7.2 Protect and secure components for transport Visual inspection Delivery DocketH S

8 Finalise Documentation

8.1 Sign off Inspection & Test Plan ITP H/R H/R Provided with MDR

8.2 Complete MDR MDR R R Client Approval of

Completed MDR

Provided with MDR

REMARKS /

CLIENT APPROVALRKM Signature CLIENT Signature

Subcontractor ITP Surface Treatment ReportProvided with MDR

A-2 Frame Inspection Test Plan

Customer Contract No:

RKM Order No:

VERIFYING

DOCUMENTATION

ACT.

No.ACTIVITY ROKONMA PROTOCOL

PROCEDURE or

SPECIFICATION

REFERENCE

ACCEPTANCE CRITERIA

Rokonma-RKM (DongGuan) Co., Ltd. Doc. No: RKM / MDR / I .L / A .01

Page No : 01 of 01 Rev: 03

Client: Customer Contract No: Inspection Location:

Project: RKM Order No: Rokonma (DongGuan) Co., Ltd.

China.

Item : CONVEYOR FRAMES

3 - 5% of total qty / delivery




Meets RKM Specification or

as per Client's Specifications.

8

9

10

Note* Type of Inspection;Inspection

Prepared:Factory Manager APPROVED BY CLIENT : Date : 17-04-2013 Levels & Acceptance Criteria are

…………………………….. CLIENT SIGNATURE: Latest Revision: 03 subjected to changes upon mutual

agreement between both parties.

5 Packaging 100% of total qty / order Advise: Client- "Ready to Dispatch"

3 Finished product Meets RKM Specification or as

per Client's Specification Records Held in Job File

4 Surface Finish & Galvanising to Specification Meets RKM Specification or as


1 Incoming Materials Meets RKM Specification Records Held in Job File

2 In-Process Meets RKM Specification or as


Remarks.

A-3 Frame inspection Levels

No. Type of Inspection Inspection Level Acceptance Criteria

DOCUMENT NO :

Rokonma-RKM (DongGuan) Co., Ltd. RKM \ QP \ 4.10 \ ITP\ BKT \ C.01

REVISION

No. 05

QC check points: From Incoming till Finished Products.

QC NO TEST / INSPECTION FREQUENCY

1.Documentation from supplier

- Delivery order

2. Dimensional check

- Length 3- 5 % of total

- Width & Thickness quantity per delivery

QC 1

1.Documentation from supplier

- Delivery order 3- 5 % of total

2: Quantity & Packaging. quantity per delivery

QC 2 1.Dimensional check

- Length 3- 5 % of total

- Width & Thickness quantity per model

QC 3 FLAT BARS :- - Slot height & width 3- 5 % of total

STAMPING, SLOT - Width & Thickness quantity per model

FABRICATION etc.

QC 4 "TACK" WELDING 1.Components / parts 3- 5 % of total

and 2.Frame- dimensional check quantity per model

FULL WELDING 3. Weld characteristics

QC 5 1. Surface ~ De-slagged & clean

2. Appearance:- Free from 3- 5 % of total

injurious defects etc quantity per model

3. Thickness, Colour & Finish

1. Surface ~ De-burred & clean

2. Appearance:- Free from 3- 5 % of total

injurious defects etc. quantity per model

3. Thickness.

QC 6 1. Model 3- 5 % of total

2. Specifications quantity per model

GRIND ETC

PAINTING

GALVANISING

FINISHED PRODUCT

FLAT BAR,

PIPE, RHS

CUT, BEND, DRILL,

Date:

17-Apr-13

RHS

PAINTS

ANGLES, PLATE

A-4 Frame Inspection Frequency

ITEMS INSPECTED

PLATE

ANGLES

FLAT BAR

PIPE

Doc. No:RKM / MDR / I.Q.C./A.01 Page No : 01 of 01 Rev: 01

Client: Contract No: 45019551(SL1) / 45019552(SL2)

Project: PO No: WO74832(SL1) / WO74833(SL2)

B-1 Rolled Steel Angle - Material Certificates

Conveyor Frame - Rolled Steel Angle 125 x 125 x 8 - Material Certificate

Conveyor Frame - Rolled Steel Angle 140 x 140 x 10 - Material Certificate


RKM Sales Order No: 281(SL1) / 282(SL2)




B-2 Plate and Flats - Material Certificates

Conveyor Frame - 6mm Plate and Flats - Material Certificate









B-3 Rectangular Hollow Section - Material Certificates

Conveyor Frame - RHS 100 x 50 x 4 - Material Certificate






B-4 Circular Hollow Section - Material Certificates

Conveyor Frame - CHS Ø88.9 x 5.5mm - Material Certificate




B-5 Material Traceability Register

Client: Contract No: 45019551 (SL1) 45019552 (SL2)



Unique ID

No.Material Grade Material Description

Thickness

(mm)Heat No.

Batch/ Serial

No.Material Certificate No. Manufacturer

Test Report

No. (if

applicable)

Sampling

DateRemarks

1 Q345B Steel Angle 125 x 125 x 8 8 13/03/2013

2 Q345B Steel Angle 140 x 140 x 10 10 13/03/2013

3 Q235B 6mm Steel Plate 6 22/07/2013

4 Q235B 8mm Steel Plate 8 15/08/2013

5 Q345B 10mm Steel Plate 10 01/04/2013

6 Q235B 12mm Steel Plate 12 16/06/2013

7 SPHC Steel RHS 100 x 50 x 4 4 14/01/2013

8 13F7503 Steel CHS Ø88.9 x 5.5 5.5 05/09/2013

9

10

11

12

13

14

15

16

17

18

19

20

21

22


B-6 Consumable Certificate Register




Product Description Manufacturer/Supplier Classification Size Batch / Lot Number Certificate Number

Welding wire AWS A5.15 ER70S-6 Ф1.2MM


C - Certificates of Compliance




We hereby certify that the goods provided against the above purchase order have been carried out under

our supervision and, that to the best of our knowledge and belief, fabricated and tested satisfactory in

accordance with the contract requirements, and to the applicable codes, standards and specifications

noted below and complies in all and every respect with these requirements.

Code: AS1554.1:2011 SP Frame Welding

AS4680 Hot Dip Galvanising

Additional Requirements:

For Supplier:

Position:

Name:

Place:

Signature:

SUB-CONTRACTOR

Doc No: RKM / MDR / W.P.S / A .01



Client:

Project:

FRAME WELDING PROCEDURE SPECIFICATION

Inspection Location:Rokonma,China

Contract No: 45019551(SL1) / 45019552(SL2)

PO No: WO74832(SL1) / WO74833(SL2)


D-1 Welding Procedure Specification (WPS)




Client:

Project:


Inspection Location: Rokonma,China

Contract No: 45019551(SL1) / 45019552(SL2)

PO No: WO74832(SL1) / WO74833(SL2)

D-2 Procedure Qualification Record


E-1 Welder Qualification Register




WELDER NAME WELDER ID WPS NoCODE

QUALIFIEDDATE QUALIFIED REPORT No PROCESS QUALIFIED POSITION QUALIFIED

THICKNESS

RANGE

RE-VALIDATION

DATE

RE-VALIDATION

REPORTOTHER QUALIFICATIONS

Ye DG-WPS-01 AWSD1.1 Sep.22,2012 120705005 GMAW-Semiautomatic 2F 6.5mm 2 years

Fu DG-WPS-01 AWSD1.1 Sep.22,2012 120705002 GMAW-Semiautomatic 2F 8.5mm 2 years

Xue DG-WPS-01 AWSD1.1 Sep.22,2012 120705001 GMAW-Semiautomatic 2F 8.5mm 2 years

Yang DG-WPS-01 AWSD1.1 Sep.22,2012 120705003 GMAW-Semiautomatic 2F 8.5mm 2 years

Huang DG-WPS-01 AWSD1.1 Sep.22,2012 120705004 GMAW-Semiautomatic 2F 8.5mm 2 years




Client:

Project:



Contract No: 45019551(SL1) / 45019552(SL2)

PO No: WO74832(SL1) / WO74833(SL2)

E-2 Welder Qualification Record




Client:


F-1 MPI Test ReportInspection Location: Rokonma,China


Contract No: 45019551(SL1) / 45019552(SL2)




Client:

Project:


Contract No: 45019551(SL1) / 45019552(SL2)

F-1 MPI Test Report

PO No: WO74832(SL1) / WO74833(SL2)


Doc. No: RKM / MDR / Q.A.F / A .01


Client: MODEL/BW/TYPE : SVIL1800C615NS-RKM1840

Project:

Report No: 01 of 01

Batch NO :10 of 10

Conv. No: SL1 & SL2 BOOM

FRAME TYPE.

Carry Trough: Jackdown Tag No. DWG1840

Carry Transition

Carry Retractable

Carry other Inspected By:

Return Vee

Return Flat

Return Other

FRAME :DIMENSIONAL CHECK AGAINST RKM DRAWING.

Transom size :mm

End Brackets size :mm

End Brackets Gusset size :mm

Centre Brackets size :mm

Feet size :mm

Troughing Angle :⁰

Rolling Height :mm

Bolt Centres Longitudinal :mm

Bolt Centres Tranverse :mm

Mounting Feet Slots :mm

Distance between the mounting flats. :mm

Across the flats of slot :mm

FRAME CHECKS.

CHECK REQUIREMENT

Manufacturer - Record name.

Full Dimensional Check wrt Drawing Drawing specification & tolerances /

Weld Check / Inspection Full penetration,continuous and smooth /

Corrosion Prevention Hot dipped Galvanised /

General Appearance Free of Imperfections & Injurious defects etc /

Others:- /

Name: ………………………………….

Signed : …………………………….. Date: ………………………

966

Flat: 6 & Slot: 22.5

40 x 6

250 x 6

150

2210

65 x 6

REMARKS:

SATISFACTORYYES / NO (tick box)

17 x 30


I-1 Assembly & Dimensional Check Form

Contract No: 45019551(SL1) / 45019552(SL2)

RKM Sales Order No.: 281(SL1) / 282(SL2)

-216

✔

Ø88.9x5.5 CHS

NA

15


Inspected by : QC Dept ./ Approved by

{O.Q.C} REV: 01 Report No: 01 of 01

Batch No : 10 of 10

Client: Contract No: 45019551(SL1) / 45019552(SL2) All dimensions on Drawing are to be checked & ticked off. Appearance :- Free of any defects, tick box

Project: PO No: WO74832(SL1) / WO74833(SL2) Total Qty. - this delivery: 20

RKM Sales Order No: 281(SL1) / 282(SL2) Tag No. DWG1840 Total Qty. / order / conveyor number: 20/281/282/WO74832 (SL1)/WO74833 (SL2)

Doc. No: RKM / MDR / O.Q.C / A.01

Page No : 01 of 10


J-1 Non-Conformance Report Register




OriginatorIssued

toIssued Closed

NCR

No.Date Raised Description

Date


J-2 TQ Register




Date

Yes NoIssued (to

Client)

Received (from

Client)Actioned

Date

TQ Prepared by Subcontractor

Title No. Description

Variation to Scope of

Work


P-1 Drawing Register




All items fabricated on the drawings listed on this register have been built as per the supplied drawings with no alterations.

Drawing No Rev

RKM1840-SVIL1800C615NS 3

RKM1842-SRSIL 1800D430NS 3

RKM1844-SRSIL1800D445NS 3

RKM1845-STIIL 1800D345NS 5

RKM1847-SRSIIL 1800D345NS 3

RKM1848-STIL 1800D445NS 5

RKM1849-STTSIL 1800D43045NS 6

RKM1850-STTSIL 1800D41530NS 6

RKM1851-STTSIL 180040520NS 6

RKM1852-SRIL 1800C600NLS 3

RKM1854-SVIL 1800C615NS 3

RKM1855-SVIL 1800C610NS 3

RKM7856-SRIL 1800C600NS 3

RKM1857-SRIL 1800C600NS 3

RKM1858-SRIL 1800C600NRLS 3

RKM1880-SRSIL 1800D445NS 2

RKM1881-SRSIIL 1800D345NS 2

RKM1882-WG-1 1

RKM1883-ESG178X30 1

Comments

Rokonma-RKM (DongGuan) Co., Ltd. Doc. No: RKM / MDR / P-List / A .01





DELIVERY No:

Crate No.: 1 of

QTY. TAG No. Conveyor No. Delivery Advise Note

Inspected by : QC Dept./Approved by:

………………………. / …………………….

Q-1 Packaging and Delivery Form

Deliver To:

Above & below information to be min. 20mm letter size on 2 opposite sides of box

Dimensions: 0000 mm x 0000mm x 0000mm

Any labels & tags to be visible & legible for 12 months

Weight (kg):

Description

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