STEEL

fabricaTion

quaLiTy

SySTEmS

guidELinE

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.