quality guideline for w47.1
DESCRIPTION
Application for W47.1TRANSCRIPT
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STEEL
fabricaTion
quaLiTy
SySTEmS
guidELinE
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Copyright 2002
by
Canadian Institute of Steel Construction
All rights reserved. This book or any part therof must not be reproduced in any form without written permission of the
publisher.
First Printing October 2002
PRINTED IN CANADA
by
MacNab PrintA Division of Cameron Publications Limited
Dartmouth, NS
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CISCSteel Fabrication
Quality Systems Guideline
Published by the
CANADIAN INSTITUTE OF STEEL CONSTRUCTION300 – 201 Consumers Rd
Willowdale (Toronto), OntarioM2J 4G8
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TABLE OF CONTENTS
Preface
1. Scope and Aims of Manual
2. Normative Reference
3. Terms and Definitions
4. Quality System Requirements1.1 GeneralRequirements 1.2 WorkProcedures 1.3 ControlofDocuments 1.4 ControlofQualityRecords
5. Management Responsibility1.1 ManagementCommitment1.2 Organization1.3 ResponsibilityandAuthority
6. Resource Management1.1 WeldingPersonnel
7. Process Management1.1 QCPlanning1.2 ContractReview1.3 Purchasing1.4 Receiving1.5 MaterialVerification1.6 ControlofWorkmanship1.7 ProductVerification1.8 CustomerSuppliedProducts7.9 Storage,Loading,andShipping7.10 ControlofMeasuringandInspectionEquipment
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8. Measurement, Analysis, and Improvement 1.1 ControlofNonconformity1.2 CorrectiveAction1.3 PreventiveAction8.4 AnalysisofData
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PREFACE
TheCanadianInstituteofSteelConstruction(CISC)isthenationalindustryassociationrepresentingthestructuralsteel,openwebsteeljoist,andsteelplatefabricatingindustriesinCanada.TheCISCfunctionsasanot-for-profitorganizationpromotingtheefficientandeconomicuseoffabricatedsteelinconstruction.
TheCISChaspreparedthisGuidelineinrecognitionoftheinterestinmeetingthequalityrequirementsofitscustomers.ItisdesignedtoassistCISCFabricatorsindevelopingaQualitySystemthatwillprovideassurancethatproductswillconformtocontractualandregulatoryrequirements.Thisguidelineaddressesthespecialprocessesandspecificrequirementsofthesteelfabricationindustry.
TheGuidelineisbasedonthebeliefthatqualityawarenessisanintegralpartofallproductionprocesses.Bypromotinga"prideinworkmanship"attitudeintheemployees,productqualitywillbemaintainedinthemosteconomicalmanner.
Theguidelinehasbeenpreparedwithreferencetothefollowingpublications:(a) CSAS16(b) CSAW59(c) CSAW47.1(d) CISCCodeofStandardPractice(e) ISO9001:2000(f) ISO9001:1994
FabricatorsmaychoosetohavetheirqualityassuranceprogramauditedandregisteredbyaCISCapproved,accreditedqualitysystemsregistrationorganization.
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1. SCOPE AND AIMS OF MANUAL
TheQualitySystemsManual,tobedevelopedbytheFabricator,shalldefinethescopeofapplicationwithrespecttodepartmentsorsystemsincluded,andproductionlocationifmorethanonelocationiscovered.
2. NORMATIVE REFERENCE
Referencetothefollowingdocuments,whenmadeinthisguideline,refertothemostcurrentpublishededition.(a) CSAS16(b) CSAW59(c) CSAW47.1(d) CISCCodeofStandardPractice
3. TERMS AND DEFINITIONS
Thefollowingtermsanddefinitionsapplytothisguidelineorarecommonlyusedintheindustry.Thefabricatormaychoosetoincludeindustryspecific,orcompanyspecifictermsanddefinitionsinthissection.
Corrective ActionAnactiontakentoeliminatethecauseofadetectednonconformity orotherundesirablesituation.
DefectThe non-fulfillment of a requirement that is recognized and corrected while in current process. For example, a misplaced cleat detected at the fit checking stage may be directed back to the fitting station for proper relocation may be considered a defect and not a non-conformity.
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Document Information and its supporting medium used to define and/or establish quality requirements.
NonconformityThenon-fulfillmentofarequirement.
Objective EvidenceDatasupportingtheexistenceorverityofsomething
Preventive ActionActiontoeliminatethecauseofapotentialnonconformityorotherundesirablepotentialsituation.
Quality AssuranceQualityassurancemeanstoestablishmeasurestopreventproblemsandtodemonstratethatsuchmeasuresaretakenandareeffective,providingconfidencethatthequalityrequirementswillbefulfilled.
Quality ControlQualitycontrolencompassesactivitiesaimedatdeterminingwhetherresultsobtainedthroughanactivityconformtostatedobjectivesforthisactivity.Theresultsaremeasuredandthencomparedwithapre-establishedobjectiveforthisactivity.
Quality Management SystemAsystemtoestablishthepolicyandobjectivesrequiredtodirectandcontrolanorganizationwithrespecttoqualityandtoachievethoseobjectives.
Quality ObjectiveAnaimorgoalrelatedtoimprovementinthequalitysystem.
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Quality PolicyOverallintentionsanddirectionofanorganizationrelatedtoqualityasformallyexpressedbyseniorlevelmanagement.
Record Arecordissomethingstatingresultsachievedorprovidingevidenceofactivitiesperformed.
Root CauseThe initial and main reason why an event occurs. In corrective action, the removable factor leading to the elimination of future nonconformity
4. QUALITY SYSTEM REQUIREMENTS4.1 General RequirementsTheFabricatorshalldevelopaQualitySystemManualthatdocumentstheprocessesnecessarytoprovideassurancethatfinishedproductsconformtocustomerrequirementsinaccordancewiththerequirementsofthisguideline.
4.2 Work ProceduresTheQualitySystemManualshallbesupportedwithapplicableworkproceduresandsampledocuments.
4.3 Control of Documents 4.3.1 General TheFabricatorshallestablishandmaintainproceduresforapproval,issue,andmaintenanceofthedocumentsanddatarequiredfortheoperationoftheQualitySystem.Requireddocumentationshallinclude,butmaynotbelimitedto,thefollowing:(a) Contractdrawings,specifications,andamendments.(b) Detailanderectiondrawings.(c) WeldingdocumentationasrequiredbyCSAW47.1.(d) Purchaseorders.
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4.3.2 Erection diagrams and shop details 4.3.2.1The Fabricator or his assigned representative shall prepare shop details and erection diagrams from Certified for Construction contract documents. Preparation, use, and approval of these documents shall conform to Section 5 of the CISC Code of Standard Practice, and Provincial and Territorial Engineering Association guidelines, where applicable.
4.3.2.2Revisionstodetaildrawings/datashallbedealtwithinthesamemannerastheoriginals,orasagreeduponwiththeCustomer.
4.3.2.3Currentissuesofappropriatedocumentationshallbeavailableatallpointsofuse.Provisionmustbemadetoensurethatobsoletedrawings/dataareremovedfromallpointsofuse.
4.3.2.4Ashopdrawingcontrolsystemshallbemaintained.
4.3.3 TheFabricatorshallcontrolthedocumentationrequiredforprocuredandsubcontracteditems.
4.3.4TheFabricatorshallensurethatallrequireddocumentationisreviewedforadequacypriortorelease.
4.3.5TheFabricatorshalldefinetheretentionperiodfordocumentation,includingconsiderationforrequirementsofspecificcontractsandgoverninglegislation.
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4.4 Control of Quality Records 4.4.1TheFabricatorshallestablishandmaintainasystemfortheidentification,collection,andstorageoftherecordsdeterminedtodemonstrateconformancetotherequirementsandeffectiveoperationoftheQualitySystem.Requiredrecordsshallinclude,butmaynotbelimitedto,thefollowing:
(a) Contractdrawings,specifications,andamendments,(b) Milltestreports,(c) Purchaseorders,(d) Applicableinspectionandtestrecords,(e) Calibrationrecordsformeasuringandinspection
equipment,(f) Shippingandreceivingreports,(g) Non-conformity,correctiveaction,andpreventiveaction
reports.4.4.2Allrecordsrequiredbythecontractspecificationsshallbeavailableforreviewbythecustomerorhisrepresentative.
4.4.3TheFabricatorshallcontroltherecordsrequiredforprocuredandsubcontracteditems.
4.4.4Thefabricatorshalldefineretentionperiodsforrecords,includingconsiderationforrequirementsofspecificcontractsandgoverninglegislation.
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5. MANAGEMENT RESPONSIBILITY5.1 Management CommitmentManagementisresponsibleforensuringthat:
(a) AdocumentedstatementisinplacethatdescribestheFabricator'sQualityPolicywithrespecttocommitmentandqualityobjectives,
(b) AllemployeesaremadefullyawareoftheirauthorityandroleintheQualitySystemasdescribedinsection5.3.1,
(c) AQualitySystemthatconformstotherequirementsofthisguidelineisimplemented,
(d) AseniorlevelmanagementrepresentativeisappointedtoensurethattherequirementsoftheQualitySystemaremaintainedandreported,
(e) Aqualitysystemauditiscarriedoutatamaximumintervalofoneyear,
(f) TheQualitySystemisreviewedataseniormanagementlevelatamaximumintervalofoneyear,ormorefrequently,toensureit’scontinuingsuitabilityandeffectiveness,
(g) AdequateresourcesareprovidedtocarryouttheQualitySystemincludingperformanceandverificationofwork.
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5.2 Organization5.2.1 TheFabricatorshalldefineanorganizationalstructure,whichincludesthefollowingfunctionsasapplicable:
QUALITYASSURANCE
ENGINEERING
PRODUCTION
MANAGEMENT DRAFTING
PURCHASING SALES/ESTIMATING
PROJECTMANAGEMENT
5.2.2Thischartrepresentsatypicalorganizationalstructure.Departmentsmayvaryfromcompanytocompany,andmorethanonefunctionmaybeheldbyoneperson.Anyofthefunctionsnotedmaybesubcontracted.
5.3 Responsibility and Authority5.3.1 Eachemployeeisresponsibleforthequalityofhisorherownworkandcarriesanequallyimportantshareintheeffectivenessofthequalityassuranceprocess.
5.3.1.1Allemployeesareresponsibletoensurethattheworkperformedbythemconformstoastandardofworkmanshiprequiredbythecompanyinaccordancewiththeapplicablecontractrequirements.
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5.3.2Managementisresponsibleforensuringthatresponsibilityandauthorityisdefinedforcarryingoutthefollowing:
(a) ensuringthatallproductqualityverificationsarecarriedoutonacontinuousbasis,
(b) dealingwithnon-conformitiesandensuringthatthespecifieddispositionsarecarriedoutonacontinuingbasis,
(c) communicatingwiththecustomer’sappointedinspectionrepresentative(s),
(d) workiscarriedoutinaccordancewiththeapplicablecodesandstandards;
(e) allweldingisinaccordancewiththelatestrequirementsofCSAStandardsW47.1andW59,
(f) non-conformitiesofatechnicalnaturearedealtwithinaccordancewiththeapplicablecodesandstandards,
(g) ensuringthatallproductionpersonnelunderstandthecontractrequirementspertinenttotheirassignment,
(h) providingsufficientnoticeandmakingproperarrangementsforrequiredinspection,
(i) ensuringthatallcontractrequirements,includingrevisions,areconveyedtotherelevantdepartmentsandincorporatedintothedetaildrawingsandotherfabricationdata,
(j) purchasingallitemsinaccordancewiththecontractrequirements,includingrevisions,andforobtainingtherequireddocumentation.
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6. RESOURCE MANAGEMENTExceptasstatedinSection6.1,theFabricatorshallidentifythepersonnelandthecorrespondinglevelofeducation,training,skills,andexperiencerequiredinordertoensurethatworkaffectingproductqualityiscarriedoutintherequiredmanner.
6.1 Welding PersonnelWelders,weldingoperators,tackwelders,weldingsupervisors,andweldingengineersshallbequalifiedtotherequirementsofthelatestissueofCSAstandardW47.1.
7. PROCESS MANAGEMENT7.1 QC PlanningTheFabricatorshalldeterminetheprocedures,documentation,recordsandresourcesrequiredtoensurethattheirproductmeetsthecustomerrequirements.
7.2 Contract Review7.2.1TheFabricatorshallhaveasysteminplacetoensurethatcontractrequirementsarereviewedandincorporatedintothework.
7.2.2TheFabricatorshallensurethatthenecessaryexpertise,personnel,equipment,andplantresourcesareavailabletomeetthecontractrequirements.
7.2.3TheFabricatorshallensurethatalladditionsandrevisionstocontractrequirementsaredulycommunicatedtothenecessarypersonnel,andincorporatedintothework.
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7.3 Purchasing7.3.1Purchaseordersshallclearlydescribethegoodsandservicesbeingordered.Thedescriptionsshallincludethefollowinginformationasapplicabletotheproductbeingpurchased:
(a) Quantity(b) UnitofMeasure(c) ProductName(d) ManufacturersDescription(e) SizeandLength(f) MaterialSpecification(g) SpecialProperties(e.g.ImpactCategory)(h) Finish(i) InspectionInstructions(j) SpecialPackagingorShippingInstructions(k) Applicablestandards(l) Scopeofwork(m) Attachmentstothepurchaseorder(n) Tolerances
7.3.2 Forsubcontractedwork,theFabricatorisresponsibletoensurethatthefinalproductmeetsthecustomerrequirements.
7.3.3 Specifications,drawings,processrequirements,inspectioninstructionsandotherrelevanttechnicaldatashallaccompanythepurchaseorderifapplicable.
7.3.4Purchaseordersshallclearlyspecifythewrittendocumentationthatshallbeprovidedtoverifyconformancewithpurchaseorders.
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7.4 Receiving7.4.1Incomingmaterialsshallbematchedagainstreceivingslipsandpurchaseorders.
7.4.2NonconformitiesthatareidentifiedatthereceivingstageshallbedealtwithinaccordancewithSection8.1,ControlofNonconformity.
7.4.3Materialshallnotbeusedorprocesseduntilithasbeeninspectedandapprovedforuse.
7.5 Material Verification 7.5.1TheFabricatorshallbeabletoverifythematerialspecificationofallitemsinstock,andincorporatedintothework.
7.5.2Whereindividualpieces,lots,andbatchesarerestocked,theidentificationsystemshallbemaintained.
7.6 Control of Workmanship7.6.1AllemployeesshallbemadeawareoftheirresponsibilitiesunderSection5.3.1ofthisGuidelineastheyapplytoworkmanship.
7.6.2WorkmanshipandtolerancesshallconformtotheapplicableclausesinthelatesteditionsofCSAStandardsS16,W59,andtotheCISCCodeofStandardPractice.
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7.6.3FabricatorsperformingweldingshallbecertifiedbytheCanadianWeldingBureauinaccordancewiththerequirementsofCSAStandardW47.1.
7.6.4TheFabricatorshallensurethatmanufacturingoperationsarecarriedoutundercontrolledshopconditions.Controlledshopconditionsshallincludeallconditionsthataffectproductqualityandtheachievementofcustomerrequirements.
7.6.5 Alltoolsandequipmentusedshallbesuitabletoperformtheworkandshallbeinproperworkingorder.
7.7 Product VerificationTheFabricatorshallverifyconformancetothecontractrequirements.
7.7.1TheFabricatorshalldefineinspectionpointsandinspectionrecordrequirementstoverifyconformancetothecontractrequirements,includingthefollowing:
(a) Examinationofmaterialforsize,conformancetodimensionaltolerances,andsurfaceconditionordefects,
(b) Examinationofassembliesforoveralldimensions,andlocationandorientationofholesanddetailcomponents,
(c) Verificationthatweldingiscarriedoutinaccordance
withthecompany'sweldingstandards.Thisincludesvisualexaminationofcompletedweldments,
(d) Examinationofsurfacepreparationandfinish.
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7.7.2Anyadditionalinspectionrequirementsnotedinthecontractdocumentsshallbeidentifiedandimplemented.
7.7.3TheFabricatorshallprovideaccesstoandcooperationwiththeCustomers'designatedrepresentativeforinspectionoftheworkasrequired.Unlessspecificprovisionsareincludedinthecontractdocuments,suchinspectionsshallbescheduledsoasnottoimpedetheprogressofproduction.
7.7.4TheFabricatorshallensurethatallverificationhasbeenperformedinconformancewithcontractrequirementsandthisGuideline.
7.7.5AlltestrecordsspecifiedabovearemaintainedinaccordancewithSection4.4.
7.8 Customer Supplied Products7.8.1 Uponreceipt,theFabricatorshallexamineallitemsforcompliancewiththecustomer-supplieddocumentationandtodetectnonconformities.
7.8.2 TheFabricatorshallpromptlyreporttothecustomer,anyitemfoundtobedamaged,incomplete,orotherwiseunsuitable.
7.8.3Unlessotherwisespecified,itistheresponsibilityofthecustomertoensurethatitemssuppliedbythecustomerconformtothecontractrequirements.
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7.9 Storage, Loading, and Shipping7.9.1 TheFabricatorshallmaintainprocedurestoensurethatallitemsareproperlyprepared,handled,and/orpackagedforstorageandshippingtopreventdamagetoproduct.
7.9.2 TheFabricatorshallensurethatitemsloadedcorrespondtotheshippingbill.
7.9.3 TheFabricatorshallmaintainrecordsofallitemsthathavebeenshipped.
7.10 Control of Measuring and Inspection Equipment7.10.1 TheFabricatorshallmaintainprocedurestodefinethefrequencyandmethodsofchecking,testing,and/orcalibrationofmeasuringandinspectionequipment.
7.10.2TheFabricatorshallensurethattheequipmentissuitablefortheworkandcapableofmeasuringwithintherequiredtolerances.
7.10.3 TheFabricatorshallensurethatnewequipment,storedequipment,andrepairedequipmentarecheckedbeforeuse.
7.10.4 TheFabricatorshallensurethatcalibrationstatusiscontrolledbyphysicalmarking,orothermeans.
7.10.5 TheFabricatorshallensurethatcalibrationrecordsformeasuringandinspectionequipmentaremaintained.
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8. MEASUREMENT, ANALYSIS, AND IMPROVEMENT8.1 Control of Nonconformity8.1.1TheFabricatorshallestablishaproceduretodealwithnonconformitiesinordertoensurethatonlyproductsthatmeetthecontractrequirementsarereleased.
8.1.2TheFabricatorshalldefinethe:
(a) Authorityfordispositionofnonconformities;(b) Needfornonconformityreporting;(c) Methodofidentifyingnonconformitiestoprevent
unintendeduse.
8.1.3TheFabricatorshallensurethatallnonconformitiesaredispositionedinoneofthefollowingsways:
(a) Inconsultationwiththecustomer,theitemmaybejudgedtobeacceptableforitsintendeduse'asis'.
(b) Theitemmaybereworkedorrepairedbyanacceptableprocedurethatconformstothecontractrequirements.Inthisinstance,itemsmustbere-inspectedpriortorelease.
(c) Theitemmayberejectedand/orreturnedtostockforre-useasallowable,ortothesubcontractor/supplierasapplicable.
(d) Theitemmaybescrapped.
8.1.4RecordsoftheresultsanddispositionofnonconformitiesshallbemaintainedinaccordancewiththerequirementsofSection4.4.
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8.2 Corrective Action8.2.1TheFabricatorshallmaintainasystemforimplementationofcorrectiveaction.Proceduresforcorrectiveactionshallincludedirectivesforinvestigationofthecause,recommendationstopreventrecurrence,andfollowup.
8.2.2TheFabricatorshalldeterminethelevelofcorrectiveactionsrequiredconsideringthemagnitudeoftheproblemsandtheassociatedrisks.
8.3 Preventive Action 8.3.1TheFabricatorshallmaintainasystemforimplementationofpreventiveaction,andestablishaproceduretodealwithpreventiveactioninitiatives.
8.3.2TheFabricatorshalldeterminethelevelofpreventiveactionrequiredconsideringthemagnitudeoftheproblemsandtheassociatedrisks.
8.4 Analysis of Data 8.4.1 InaccordancewithSection7.7,thefabricatorshalldefineinspectionpointsandinspectionrecordrequirementstoverifyconformancetothecontractrequirements.
8.4.2TheFabricatorshalldefinecriticalinspectionpointsandcollectandanalyzerelevantdatapertainingtothosecriticalinspectionpointsemployingsuitableanddefinedstatisticaltechniques.Thiswillbecompletedatsuitabledefinedintervals.
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8.4.3TheFabricatorshallestablishimprovementobjectives,wherenecessary,inaccordancewiththeanalyzeddataandotherdefinedsourcesofdata.Othersourcesofdatamayinclude,butarenotlimitedtoNonconformanceReports,CorrectiveActionsataminimum.