Example of Procedure for Inspection & Testing

Uncategorized 4 Minutes

1.0 PURPOSE

The purpose of this procedure is:

  • To verify that product requirements have been met.
  • To describes the requirements for in-process and final inspection and testing.
  • To define in detail the various steps to be initiated for the inspection and testing of raw materials and finished products for achieving process control and optimum quality Control.

2.0 SCOPE

This procedure is applicable to all the following systems and standards

  • ISO 29001: 2020/ API Spec Q1, 9th edition
  • API Spec ….
  • API Spec …..
  • API Spec …..
  • API Spec …..
  • API Spec ….

Applies to all processes which has an influence on product quality

3.0 RESPONSIBILITY

  1. QA/QC Engineer
  2. Operations Engineer
  3. Machine Shop Manager
  4. All concerned process owners

4.0 INPUT

  • Requirements for in-process and final inspection and testing
  • Production & Quality plan
  • Inspection & Test plan

5.0 RESOURCES

All MMEs, Trained Manpower, Computers, Printer & net connection, XXX Procedures/QIPs/ Work instructions

6.0 PROCEDURE

XXX maintains a documented procedure for inspection and testing to verify that product had met the requirements.

6.1 IN-PROCESS INSPECTION AND TESTING

  1. Production & Quality Plans or written instructions/route sheet identify all ‘hold’ points during the production process where inspection, testing and identification is required. This is accomplished through inspection and testing, process monitoring or sampling to a specified sampling plan.
  2. Acceptance of the above, are identified by signing the document by the concerned inspection authority. (QA/QC Engineer)
  3. No material is moved to the next process station until the above verification is completed unless under a ‘positive recall’ method.
  4. Non-conforming ‘in-process’ material are identified as above and the material is quarantined awaiting disposition, in accordance with this quality procedure.
  5. In case of site operation the in process inspection may be managed by an Inspection Release Note or other release note or inspection clearance acceptable to the customer.

6.2 FINAL INSPECTION AND TESTING

  1. All product manufactured by XXX have a final inspection and testing to validate the conformance of the product to the manufacturing specification requirement and customer specification in accordance with the product quality plans.
  2. Personnel other than those who performed or directly supervised the production of the product is (i.e. QA/QC Engineer) to perform the final acceptance inspection at planned stages of the product realization process.

6.3 HARNESS SURVEY

6.3.1 REQUIREMENTS FOR HARDNESS SURVEY

  • The hardness inspector derives instructions from QA/QC department to conduct hardness inspection.
  • Hardness testing is done as per procedure.

6.3.2 INSPECTION AND WITNESSING

  • The QA/QC Engineer is responsible to identify and mark up punch location of the equipment.
  • QA/QC Engineer obtains current version RRIR sheet from QA/QC Engineer and/or Production In charge.
  • QA/QC Engineer is required to witness all punches, record them into   RRIR sheet after conversion by using Brinell Hardness Chart and endorse them with his signature and date.
  • There should not be any form/register for recording hardness readings.
  • The reading recorded along the punch is not taken into consideration.
  • RRIR sheets, once endorsed by QA/QC Engineer are filed back in the job folder.
  • Readings are subject to final approval from QA/QC Manager/Operations Manager.

6.3.3 EQUIPMENT

  • Hardness Testing is conducted using XXX hardness tester and a hammer of more than Kg 1 is used.
  • Equipment should be cleaned prior to and after its use
  • Periodic Inspection of the equipment is done by QA/QC dept. to ensure validity of the results obtained.
  • Equipment is stored in the gauge room, at a secure place
  • Hardness pins (carbide pin) is reordered by writing a material requisition to the stores in charge.

6.3.4 HEALTH, SAFETY AND ENVIRONMENT

  • Refer to XXX HSE manual.

6.3.5 PERSONNEL

  • Only qualified personnel are given the responsibility of hardness test.
  • Personnel qualification is done by QA/QC Engineer by training and examination.
  • Requalification of personnel is due every 365 days of the last qualification.
  • Records are maintained.

6.3.6 NON-CONFORMANCES

  • Initial and final hardness reading recorded is checked for compliance with Hydril/GE acceptable ranges.           
  • In case of deviations, Nonconformance report is raised, and communicated to all concerned including customer.
  • Equipment is marked/tagged red and moved to NC area with in machine shop until rework.

6.4 INSPECTION RECORDS

Inspection records are maintained to reflect the status of the product at all stages which include:-

  1. Records of Incoming Material (Material Receiving Inspection Report & Store Receipt Voucher)
  2. Records of In-process Inspection (Production & Quality Plan and Release Notes)
  3. Records of Final Inspection (Work Shop Report, Dimensional Report, Hardness Test Report, Pressure Test Reports, Liquid Penetrant Report) and when on Project/site operations this is replaced by “Completion Report”

Inspection records are treated as quality records and are retained as per the L2 – 04 Control of Records.

7.0 OUTPUT

  • All inspection & Test reports, MTCs,
  • Completed Production & quality plan and ITPs

8.0 KEY PERFORMANCE

No rejections

9.0 ASSOCIATED DOCUMENTS & RECORDS

DESCRIPTIONFORMAT NUMBERRESPONSIBILITY
ML of Independent Inspection PersonnelXXX / QA / D03QA/QC Engineer
ML of NDT Certified PersonnelXXX / QA / D04QA/QC Engineer
Production & Quality PlanXXX / QA / 01QA/QC Engineer
Dimensional ReportXXX / QA / 02QA/QC Engineer
Hardness Test ReportXXX / QA / 03QA/QC Engineer
Pressure  Test ReportXXX / QA / 04QA/QC Engineer
Liquid Penetrant Examination (PT) ReportXXX / QA / 05QA/QC Engineer
Magnetic Particle Examination (MT) ReportXXX / QA / 06QA/QC Engineer
Ultrasonic Wall Thickness ReportXXX / QA / 07QA/QC Engineer
Daily Blasting And Painting ReportXXX / QA / 08QA/QC Engineer
Radiography Examination ReportXXX / QA / 09QA/QC Engineer
Heat Treatment Instruction and ReportXXX / QA / 11QA/QC Engineer
API Gauge Engagement RecordXXX / QA / 17QA/QC Engineer
Certificate of ConformanceXXX / QA / 23QA/QC Engineer
Visual Inspection ReportXXX / QA / 32QA/QC Engineer
Goods Receiving & Inspection ReportXXX / QA / 33QA/QC Engineer
Material Verification FormXXX / QA / 38QA/QC Engineer
Process Validation RecordXXX / QA / 39QA/QC Engineer
Equipment or Product Specification RecordXXX / QA / 40QA/QC Engineer
Work Shop ReportXXX / QA / 41QA/QC Engineer
Nonconformance Product ReportXXX / QA / 42QA/QC Engineer

Published by Pretesh Biswas

Pretesh Biswas has wealth of qualifications and experience in providing results-oriented solutions for your system development, training or auditing needs. He has helped dozens of organizations in implementing effective management systems to a number of standards. He provide a unique blend of specialized knowledge, experience, tools and interactive skills to help you develop systems that not only get certified, but also contribute to the bottom line. He has taught literally hundreds of students over the past 5 years. He has experience in training at hundreds of organizations in several industry sectors. His training is unique in that which can be customized as to your management system and activities and deliver them at your facility. This greatly accelerates the learning curve and application of the knowledge acquired. He is now ex-Certification body lead auditor now working as consultancy auditor. He has performed hundreds of audits in several industry sectors. As consultancy auditor, he not just report findings, but provide value-added service in recommending appropriate solutions. Experience Consultancy: He has helped over 100 clients in a wide variety of industries achieve ISO 9001,14001,27001,20000, OHSAS 18001 and TS 16949 certification. Industries include automotive, metal stamping and screw machine, fabrication, machining, assembly, Forging electrostatic and chrome plating, heat-treating, coatings, glass, plastic and rubber products, electrical and electronic equipment, assemblies & components, batteries, computer hardware and software, printing, placement and Security help, warehousing and distribution, repair facilities, consumer credit counseling agencies, banks, call centers, etc. Training: He has delivered public and on-site quality management training to over 1000 students. Courses include ISO/TS -RAB approved Lead Auditor, Internal Auditing, Implementation, Documentation, as well as customized ISO/TS courses, PPAP, FMEA, APQP and Control Plans. Auditing: He has conducted over 100 third party registration and surveillance audits and dozens of gap, internal and pre-assessment audits to ISO/QS/TS Standards, in the manufacturing and service sectors. Other services: He has provided business planning, restructuring, asset management, systems and process streamlining services to a variety of manufacturing and service clients such as printing, plastics, automotive, transportation and custom brokerage, warehousing and distribution, electrical and electronics, trading, equipment leasing, etc. Education & professional certification: Pretesh Biswas has held IRCA certified Lead Auditor for ISO 9001,14001 and 27001. He holds a Bachelor of Engineering degree in Mechanical Engineering and is a MBA in Systems and Marketing. Prior to becoming a business consultant 6 years ago, he has worked in several portfolios such as Marketing, operations, production, Quality and customer care. He is also certified in Six Sigma Black belt .

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