Bumaas Engineering Solutions & Technologies Pvt Ltd

Quality Control

Ø     Purpose

Ø  Scope

Ø  References

Ø  Management Responsibility

Ø  Direction and Leadership

Ø  Management Representative

Ø  Resources

Ø  Personnel

Ø  Buildings, Workspace and Associated Utilities

Ø  Detailing

Ø  Customer Approval of Shop Drawings

Ø  Purchasing

Ø  Purchasing Data

Ø  Selection of Subcontractors and Suppliers

Ø  Verification of Purchased Product, Materials and Services

Ø  Customer Verification of Fabricated Product

Ø  Control of Customer-Supplied Material

Ø  Material Identification

Ø  Receiving Inspection

Ø  Release or Dispositioning of Material Conforming –

Ø  Material Storage

Ø  Fabrication Process Control

Ø  Welding

Ø  Inspection and Testing

Ø  Inspection Program

Ø  Material Receipt Inspection

 

 

 

 

Ø  In-Process Inspection

Ø  Final Inspection

Ø  Inspection Records

Ø  Calibration of Inspection, Measuring Equipment

Ø  Control of Nonconformance

Ø  Corrective Action

Ø  Handling, Storage and Delivery of Product and Materials

Ø  Internal Audit

  

 Purpose

 

                             The purpose of this manual is to outline the criteria within Global Engineers for shop construction of pressure vessels, heat exchangers and parts there of.

 

Scope

                             It allows customers and outside functions a means to understand Global Engineer’s Quality Management System, when such a system is required in full or in a segmented approach as required by the customer and project.

 

References

                               Global Engineers has made every effort to have the applicable reference documents, standards, codes, or other applicable documents readily accessible to the individuals who need them. Global Engineers has also made every effort to assure that these references are both current and meet the requirements of customer contracts.

 

Management Responsibility

 

                              Global Engineer’s executive management is responsible for developing a commitment to quality, directing the corporation to achieve that quality, providing personnel and resources as applicable, and overseeing the Quality Management System in an effort to comply with its quality directives. Commitment (Policy) Global Engineers has established and implemented a company policy with respect to quality. Policy Statement – Global Engineers policy is to produce steel components in an effort to achieve customer contracts with the fewest possible errors, and to maintain a commitment to the satisfaction of customer requirements. This policy statement is disseminated to personnel affecting quality by displaying it throughout the facility. The target is to ensure that personnel are aware of the company’s commitment to quality.

 

Direction and Leadership

 

                                 Recognizes that effective leadership begins at the top with the executive management. Their commitment to the highest quality standards is made evident to the people who report directly to them. These people in turn carry on that leadership to the people reporting to them and so on all the way to the personnel on the shop floor. This commitment to quality applies equally to all personnel regardless of the position they hold within the company. To demonstrate the effectiveness of the program, executive management evaluates the established goals as outlined in the quality policy.

 

                                  

                           These goals will be evaluated according to a predetermined schedule, which will determine the current level versus the desired outcome. Based on the goal or the data utilized by executive management, the demonstrated plan can take any form, such as a trend chart, computer printouts, pictorial diagrams, or any means which executive management determines is best applicable. The quality management system is reviewed annually by executive management to ensure its continuing adequacy and effectiveness. Changes or additions to the system are made in accordance with a perceived opportunity for improvement in attaining customer satisfaction. Records of management reviews are maintained in a Quality Management System Review Log, and include such information as: audit results, customer feedback, and information from previous management review (outputs) which include product conformity reports and improvement of product quality and resources needed.

 

Management Representative

 

                                 The Quality Manager of Global Engineers is responsible for ensuring that procedures are established, implemented and maintained for the quality management system. The Quality Manager submits a written, annual report to executive management on the performance of the quality management system and any need for change or improvement. The report is reviewed by executive management who determine whether or not it is in the company’s best interest to act on the CEO’s recommendations for improvement. All improvements are implemented to reduce the occurrence of non-conformities.

 

Resources

 

                        Executive management provides the resources necessary to achieve conformity to contract specifications. Such resources include personnel, work space equipped with appropriate utilities, and equipment. Product evaluations and internal audits are conducted to ensure that resources remain adequate for the production of quality product.

 

Personnel

 

                         Minimum qualifications exist for all personnel, including the Quality Assurance and Quality Control personnel. The personnel responsible for the performance of work affecting quality, and their interrelationship with other employees within the corporation are defined and documented using organization charts. Personnel can be assigned to more than one function, provided they are qualified to perform each job. Annual performance reviews are conducted by department supervisors to ensure that the qualifications of the personnel performing specific duties are concurrent with changing job requirements. On-the-job training is employed for those individuals whose job functions are enhanced to ensure that all employees have a thorough understanding of and ability to perform their specific job requirements.

Buildings, Workspace and Associated Utilities

 

                         Global Engineers has adequate workspace within their buildings to provide the amount of space necessary to produce quality product. There is ample space provided for administration, as well as shop functions such as fitting, bolting, welding, painting etc. Areas suitable for the storage and shipping of materials are also provided.

 

Detailing

 

Customer Approval of Shop Drawings

 

                            Shop drawings released for fabrication are first approved by the customer. All drawings contain the written signature of the customer or authorized representative approving the drawings before the drawing is logged into the Shop and Erection Drawing Log Book and released for fabrication. This is applicable whether the drawing is done in-house or by a subcontractor. If the customer elects to waive approval of the drawings, a request to the customer will be made to document this waiver in writing.

 

Purchasing

 

                            Global Engineers implements a system to ensure that purchased products, subcontractors, materials and services conform to project requirements. Purchase orders, records of the qualification of subcontractors and suppliers, and records of the periodic evaluation of suppliers are maintained within the Purchasing Department.

 

Purchasing Data

 

                        Global Engineers clearly describes subcontracted work and the purchased products, materials and services ordered in purchasing documents. Purchasing documents may contain the following information, as applicable: Type of service, material, class, grade and other unique identification  Project specifications, drawings, process requirements and inspection instructions that may apply. Delivery instructions and date  Certificate of Compliance / Conformance, mill rest reports and/or NDT reports as required. Compliance  as appropriate Special instructions or any other information pertinent to the product ordered.

 

Selection of Subcontractors and Suppliers

 

                      Subcontractors and suppliers are evaluated annually by conducting an audit or through documented past experience of providing similar products or services . The Project/Purchasing Manager selects subcontractors and suppliers on the basis of their ability to meet subcontract requirements, the Global Engineers quality management system, the requirements of the Standard, project requirements and any specific inspection requirements.

 

Verification of Purchased Product, Materials and Services

 

                       The Purchasing/Project Manager ensures inspection of all incoming product and material to ensure that it conforms to the purchase order, as well as to project requirements. When required by the project, test reports, certificates of compliance and other evidence of quality control are kept on file in the Purchasing Department.

 

Customer Verification of Fabricated Product

 

                         The customer sometimes requests the right to verify the conformance of the final product to the project requirements at the corporation. This is typically documented in the contract drawn up before the actual project work begins. This verification can include anything from hands-on involvement, observation or audit. Global Engineers cooperates with the customer fully in this regard

 

Control of Customer-Supplied Material

 

                      If materials are supplied by the customer, the Project Manager is responsible for ensuring that the material is stored and maintained properly so as to avoid loss, damage or misuse of the material. All customer-supplied material is inspected to ensure that the material is appropriate for the intended project and meets the quality requirements. Any material nonconformance or loss, damage or misuse of the material is recorded and reported to the customer.

 

Material Identification

 

                              Global Engineers implements a system for identification of material. This system also provides a method for material traceability when invoked by contract. At a minimum, material identification is maintained until the first fabrication operation when our project numbering system takes over. Purchasing documents for materials furnished to ASTM specifications include the information required in the “Order Information” section of the ASTM Standard .GLOBAL ENGINEERS retains test reports, manufacturers’ test reports, and certificates of conformance for base materials, bolts, welding consumables and coatings for one year past project completion. All materials used in the production process are identified with a GLOBAL ENGINEERS project number. Our system provides the ability to associate a report provided by our supplier with our order using project numbers. Our system also describes a method to provide full, specific traceability when required by contract. The purchasing manager is responsible to invoke the appropriate level of control for each order and each contract.

 

Receiving Inspection

 

                        Upon receipt of purchased material, the inspector will: Compare the material and documentation to the purchase order, ensuring that it is the proper material and that all required documentation is present. Compare the certifications to the purchase order and applicable specifications. The receiving inspector will place a check mark beside each specification requirement on the certification as it is verified.

 

Release or Dispositioning of Material Conforming –

 

                          When a lot of material is found to be totally conforming, the Inspector will sign and date the receiving report, tag or segregate material, then send P.O. and accompanying documentation to QM for filing. Nonconforming - When a lot of material is found to be nonconforming it will be identified, segregated and dispositioned.

 

Material Storage

 

                          Upon release of material from Receiving Inspection, all material will be identified and stored. The lot or batch number will be traceable to all material or parts. Lots of material will not be mixed in individual bins, boxes, or containers. Material will be stored in the environment required by the customer or specification

 

Fabrication Process Control

 

                           Global Engineers has established and implemented documented procedures necessary to produce a finished product with a quality level that meets the requirements of the codes and specifications. This includes any “special procedures” that might be performed during the production process. At a minimum, effective implementation of the following procedures is required.

 

Welding

 

                            When code welding is required, an evaluation of existing welding procedures will be performed by the Quality Manager or Project Manager to determine which procedure(s) will be applicable to the project. If it is determined that an additional procedure is required, it shall be developed and qualified in accordance with the applicable code/customer specification

 

Inspection and Testing

 

                            Global Engineers implements a program for inspection and testing of material and services to ensure that the product quality meets the project requirements. The Quality Control Inspector is responsible for inspections at various intervals during the production process, depending on the complexity of the project. When required, these inspections may be subcontracted to an outside agency. The level and frequency of inspections will be as directed by the contract documents, but may be increased at any time if it is determined that the required level of quality is not being met. The inspection program includes incoming materials, in-process and final inspection of all product furnished to a project. Records of such inspections are compiled and maintained in the Quality Manager’s office

 

Inspection Program