Republic of the Philippines Department of Education HIGH ...

Unit of Competency: CONTRIBUTE TO QUALITY SYSTEM

Module No.: 1

Module Title: CONTRIBUTING TO QUALITY SYSTEM

Republic of the Philippines

Department of Education

HIGH SCHOOLS

8

ACKNOWLEDGMENT

Copyright Department of Education 2008

First Published JUNE 2008

This work was produced with funding provided by the Department of Education.

The Department of Education (DepED), Central Office through Technical Vocational Task Force wishes to extend its gratitude and appreciation to all the Module Writers for sharing their time and expertise in the Refinement and Enrichment of Competency-Based Learning Materials for Strengthening Technical Vocational Education Program (STVEP) held at Marikina Hotel, Marikina City on April 20-25, 2009.

MODULE WRITERS:

WELDING

JIMMY P. OCAMPO

Rizal Experimental Station and Pilot School of Cottage Industries (RESPSCI) Maybunga, Pasig City NCR

JIMMY P. DOMINGO

San Pedro Relocation Center NHS San Pedro, Laguna Region IV-A

JEFFREY G. MORENOS

Assemblywoman Felicita G. Bernardino Memorial Trade School Lias, Marilao, Bulacan Region III

BENJIE R. SAN JUAN

Community VHS (Calapan City NHS) Calapan City, Oriental Mindoro Region IV-B

SCIENCE

EDNA M. PASAMONTE

B.S. Aquino National High School Concepcion, Tarlac Region III

MATH

FRANCISCO M. JAVIER

Muntinlupa Business High School Espeleta St., Buli, Muntinlupa City NCR

ENGLISH

MA. NONELA B. CASTILLO

Rizal Experimental Station and Pilot School of Cottage Industries (RESPSCI)

Maybunga, Pasig City NCR

FACILITATOR :

VICTORIO N. MEDRANO

Principal IV San Pedro Relocation Center NHS San Pedro, Laguna Region IV-A

EDITOR:

MRS. CAROLINA F. CHAVEZ

Principal II Muntinlupa Business High School Muntinlupa City NCR

ENCODER :

MA. RIZA B. ZAMORA

DepED – Budget Division, Meralco Ave., Pasig City

This work was produced with funding provided by the Department of Education.

TABLE OF CONTENTS

Page

How to Use this Module ................................................................................................ i Introduction ................................................................................................................... ii Technical Terms ........................................................................................................... iii Learning Outcome 1 ............................................................................... 1

Learning Experiences/Activities .................................................................2

Information Sheet 1.1 ............................................................................. 3-5

Self-Check 1.1 ............................................................................................. 6

Learning Outcome 2 .............................................................................................. 7

Learning Experiences/Activities ........................................................................ 8

Information Sheet 2.1 ................................................................................. 9-11

Self check 2.1… ................................................................................... 12

Learning outcomes 3 .......................................................................................... 13 ● Learning Experiences/Activities ............................................................... 14

Information sheet 3.1… ....................................................................... 15-16

Self check 3.1… ................................................................................... 17

Answer Keys ......................................................................................................... 18

Date: LO 1. INSPECT WORK DONE Page #

Version No.: Module Title: CONTRIBUTING TO QUALITY SYSTEM i

HOW TO USE THIS MODULE

Welcome to the Module “Contributing to Quality System”. This module

contains training materials and activities for you to complete.

The unit of competency “Contribute to Quality System” contains the

knowledge, skills and attitudes required for Shielded Metal Arc Welding (SMAW) required to obtain the National Certificate (NC) level I.

You are required to go through a series of learning activities in order to

complete each of the learning outcomes of the module. In each learning outcome there are Information Sheets, Job Sheets, Operation Sheets and Activity Sheets. Do these activities on your own and answer the Self-Check at the end of each learning activity.

If you have questions, do not hesitate to ask your teacher for assistance.

Recognition of Prior Learning (RPL)

You may already have some basic knowledge and skills covered in this module.

If you can demonstrate competence to your teacher in a particular skill, talk to

your teacher so you do not have to undergo the same module again. If you have a qualification or Certificate of Competency from previous trainings show it to him/her. If the skills you acquired are consistent with and relevant to this module, they become part of the evidence. You can present these for RPL. If you are not sure about your competence skills, discuss this with your teacher.

After completing this module, ask your teacher to assess your competence.

Result of your assessment will be recorded in your competency profile. All the learning activities are designed for you to complete at your own pace.

In this module, you will find the activities for you to complete and relevant

information sheets for each learning outcome. Each learning outcome may have more than one learning activity.

This module is prepared to help you achieve the required competency, in

receiving and relaying information. This will be the source of information that will enable you to acquire the knowledge and skills in Shielded Metal Arc Welding (SMAW) independently at your own pace with minimum supervision from your teacher.



Program/Course Shielded Metal Arc Welding (SMAW) NC-1

Unit of Competency Contribute to Quality System


INTRODUCTION:

This module contains information and suggested learning activities on Contribution to Quality Sytem.

This module consists of three (3) learning outcomes. Each learning outcome

contains learning activities supported by instruction sheets. Before you perform the activity, read the information sheets and answer the self-check provided to as certain your competence, your teacher will assess what you have acquired when the knowledge necessary to perform the skill portion of the what particular learning outcome.

Upon completing this module, report to your competence teacher for

assessment to check your achievement of knowledge and skills requirements of this module. If you pass the assessment, you will be given a certificate of completion.

SUMMARY OF LEARNING OUTCOMES:

Upon completion of the module the students should be able to:

LO1 Inspect work done;

LO2 Apply Quality Standards to work;

LO3 Protect Company Property and Customer Interest.

ASSESSMENT CRITERIA:

Refer to assessment criteria of learning outcomes 1-4 of this module.

PREREQUISITE:



TECHNICAL TERMS

Code is a body of Laws, as a nation, or a city, arranged systematically for easy

reference.

Standard is something that is established for use as a rule or basis of

comparison

Specification describe as detailed description of the parts of a whole statement

or enumeration of particulars, to actual or required size, quality,

performance, term, etc.

ISO International Organization for Standardization

ISO 900 a tool to provide a foundation for quality improvement and quality

management

WPS Welding Procedure Specification, a guide for welders and inspectors to

verify the welding procedures

Pre-qualification Test a test conducted in the shops for the purpose of

determining the procedures.

Quality Control a unit or department to organize and are responsible for the

quality of products or outputs.

Program/Course: SHIELDED METAL ARC WELDING

Unit of Competency: CONTRIBUTE TO QUALITY SYSTEM


Learning Outcome 1:

Inspect Work Done

Assessment Criteria:

1. Appropriate inspection of work done are conducted. 2. Ensure that the company quality system and procedure are

maintained/followed 3. Job Specifications/Work order and quality standard are identified. 4. Faults/Defects are identified and rectified according to company

procedure.

REFERENCES:

Welding Technology

Second Edition

Gower A. Kennedy

Welding Inspection Technology

Education Department

American Welding Society, Inc

Welding Principles and Application

Larry Jeffus and Harold V. Johnson


Version No.: Module Title: CONTRIBUTING TO QUALITY SYSTEM 1

LEARNING EXPERIENCES/ACTIVITIES

Learning Outcome 1: Inspect Work Done

Learning Activities Special Instructions

1) Read the attached information

sheet 1 inspect work done

2) Answer the self-check No.1.1

3) Compare your answer on answer

key

4) If you failed to meet the 80%

requirement passing standard,

go over again the information

sheet

Answer the Self-check without

looking at the information sheet

Assignment sheet will be issued as advanced requirement prior to learning the next information sheet


Version No.: CONTRIBUTING TO QUALITY SYSTEM 2

Date: LO 2. APPLY QUALITY STANDARDS TO WORK Page #


Information Sheet # 1.1

INSPECT WORK DONE

The inspection of work relative to the welding is one of the requirements for production. The various inspections are company’s concern in order to meet the work standards as viewed in products and safety. Welding inspection personnel may have specific skills and expertise for the tasks. To enumerate the various inspection categories are as follows: Weld Visual Inspection, Material Inspection, Dimensional Inspection and Non Destructive Testing (NDT) Inspection. These inspectors discharge their duties in a separate functions and no one could be placed at any capacity or assignment to do due to the qualifications of a person.

Quality Systems and Procedures

Work Instructions

The work instructions are taken from jobs/projects to be made in the work

place. These are the package of instructions allocated in the various shops of the company. These are sets of work instruction for production and another set for quality control department. The specific duties and responsibilities of each department to implement the program of works and activities and that are formed in the contracts and agreement between the fabrication and the client.

Documents pertaining to contracts, work orders and specifications were

discussed and approved by both the Fabrication Company and the client. The two parties assume their specific responsibilities in time of preparations and implementation of the project. Some of the four reasons why do we keep records intact and accessible anytime:

▪ Records serve as basis for future reference of information.

▪ Records and reports can be the basis for turn-over works in case of leave

of absence or shifting.

▪ Records will be the protection should question arise later.

▪ Records as pre-qualification test for welders, materials, procedures,

processes and NDT for future referral/review by both parties.

Welders and workers will have to respond positively on the cases of quality record keeping and reporting as to maintain the standard operations in the workplace.



Safe Work Procedures

It is the mandate that anyone in the company must observe and follow the work safety. Safety practices must be observed in order to meet the standard production operation in the shop.

Welding Quality Standard/ISO

ISO 9003 – A Model for Quality Assurance in Final Inspection and Test

To ensure the quality, reliability and strength of weldment, an inspection

program of the company is strictly observed and followed. The fabrication details is reflected in the plan for the procedure has been developed based on appropriate codes and standards. The Welding Procedure Specifications (WPS) which considered the bible of welders is always made available. At any time, and is placed in areas that are accessible to information. The products that are subjected to inspection must be included in the quality program of the production so that it will be easier to monitor and evaluate the flow of operation. There are critical weld joints that must pass through intensive post-weld inspection after welding. These category of weld joints fall under fabricated structures such as Boilers, Reactors, Heat Exchanger and High Pressure Vessels. Since these products calls for critical services, the weldments must pass the inspection requirements and utmost must be approved and certified for acceptability of the weld profile requirements.

Welding Codes and Standards/ISO

The selection of codes and standard to be used maybe based upon several

factors, including the following:

Many government agencies (local, state, federal) require that a specification code or standard should be followed.

The manufacturers consider cost and reliability; that is, a stricter standard is applied to the weld made, the cost of the weld necessarily increases.

The code and standard used is considered standard and the industry has been use for sometime.

The fitness of the service weld requirement as established through testing.

The perfect welds are not required. The difference between what is

acceptable and fit for service, such perfection what is known as tolerance. Agencies that issue codes and standard and each give the specific tolerance.

o American Bureau of Shipping o American Petroleum Institute o American Society of Mechanical Engineers (ASME) o American Society for Testing Materials (ASTM) o American Welding Society (AWS)



o British Welding Institute (BWI) o United State Government (USG)

Here are some of the noted American Welding Code Standards:

AWS D.1.1 – Structural Welding Code ASME IX – Pressurized Vessels Welding Code APII 1104 – Standard for Welding Pipeline and Related Facilities

Communication Process

Production managers, supervisors and quality inspectors are the

communicators of workers. Simple, concise and clear instructions will have to promote better understanding on the part of the workers. This is possible through the issuance of Office Memorandum, letter of instructions, work procedures, observation and inspection reports as a routine communication process.



SELF CHECK # 1.1

LO1 INSPECT WORK DONE

Direction: Encircle the letter of the correct answer.

1. The Welding Procedure Specification is considered?

A. Welding procedure for welder during welding B. Document of pre-qualification test C. Welding instructional guide D. None of the above

2. What statement does not belong to quality control?

A. Welding Specification and Standard B. Welding Inspection C. Welding Process D. Materials Coding and Specifications

3. How do you judge weldment that pass the quality requirements?

A. weld by experience welder B. good appearance weld but w/o welding procedure C. weld with approved welding procedure specification D. all of the above

4. Something that is established for use as a rule of comparison in

measuring or judging capacity quantity extent, value, quality, etc.

A. specification B. code C. standard D. agreement

5. ASME means

A. American Society of Mechanical Engineering B. American Society of Mechanical Engineers C. American Society of Manufacturing Engineering D. American Society of Mining and Energy



Course Program : SHIELDED METAL ARC WELDING (SMAW) NC1 Unit of Competency : CONTRIBUTE TO QUALITY SYSTEM Module Title : Contributing to Quality System

Learning Outcome 2

Apply Quality Standard to Work


1. Observation and visitation to industry are conducted to maintain quality standard practices.

2. Appropriate quality standards applied through out the production

process.

3. All work activities are coordinated through out the workplace to ensure

efficient work outcomes.

References:

Welding Inspection Technology Education department American Welding Society, Inc.

International Organization for Standardization (ISO) Training Manual

Welding Technology Second Edition Gower A. Kennedy

Welding Principles and Application Larry Jeffus Harold Johnson




Learning Outcome 2: Apply Quality Standards to Work



sheet 2.1 apply quality standards

to work.

2) Answer the self-check No.2.1 to

test your knowledge on apply

quality standard to work.


key




sheet





Information Sheet 2.1

LO2: Apply Quality Standards to Work

Once a code and standard in welding has been established and selected, the quality control department will have to decide the methods for the pre- qualifications procedures and processes applied to welding production.

Some of the pre-qualification testing that has to be done. These are pre-

qualifications of welders, procedures, materials, welding positions and welding processes. These activities will have to be recorded and documented for the formulation of future welding procedure specifications (WPS).

Certifying Companies/Agencies

ISO 9001 is an International Standard for Quality Management Systems

(QMS) issued by the International Organizations for Standardization. ISO is an internationally recognized series of quality system standard that provides quality management guidance, and identify generic quality system elements necessary to achieve quality assurance.

Has been widely used in commercial transactions whereby suppliers

and buyers agree on very clear guidelines for achieving consistent product quality and customer satisfaction.

Seventy-four (74) countries adapted these International Standards.

Used as framework for continuous improvement.

ISO Certifying Companies here in the country use standards, norm,

regulations that are prescribed and recognized by the International Institutions as they evaluate firm or a school for that matter, that demonstrated utmost level of excellence and had completely satisfied all requirements necessary in the performance of its duties. People’s perception of passing ISO standards means you have threaded the eye of the needle.

There are ISO certifying companies operate all over the country, the

following are:

Societe Generale de Surveillance Philippines Inc. (SGS) Det Norske Veritas (DNV) Anglo-Japanese American Registrar (AJA) United Kingdom Accreditation Scheme (UKAS)

Some of the aspects that the ISO Certifying Companies are concern are in

the Management System such as:



Operations (Work Procedures material Specification etc.) Human resources (Qualification and Testing Requirements) Customer Service (Marketing and Product Promotions) Facilities (Standard Requirements of Building and Equipments) Environmental Policies (Physical and Human Safety)

Other Areas of Concerns

ISO Agencies in the Philippines

Bureau of Products and Standards (National Accrediting Body) Certification no. series PNS 1000/ISO 9000

Workplace Visitation/Observation

Company visitation and observation tour in the welding production is at routine works that the group of persons is doing periodically. The company may invite guest and customer for job promotions and for future investment.

Another form of visitation and observations are team of inspectors. The

purpose of the visit is to assess the general update of the standard inspection operations in the workplace. These officials, includes owners, Government representatives, productions and in-house inspectors.

Three general categories into which the inspectors work function can be

grouped into:

Overseer Specialist Combination of Overseer and Specialist

Record Maintenance

Keeping of records and documents in the welding production is essential.

There’s no such production of welds without a system of recordings because it’s hard for the company to attract acceptance from the customers. The complete recording and updating for processes in the workplace must always be a part in favor for the client approval.

Most codes used by the manufacturer’s requires a binding agreement

between the contractors and the client. The welding qualification testing document must be intact and accessible any time for future reference as the works progresses in the shop.

Communication Process

Workers in the workplace must learn the communication requirements

adopted by the company. There are basic informations and messages commonly applied from one office to another, familiarity with the verbal and written instructions coming from co-workers and from the authorities.



The Management will provide desirable places in posting informations and communications for conveying workers to comply of any task(s) relative to productions, procedures and processes. Safety signs must be posted in places accessible to read to avoid injuries and accidents..

Date: LO 3. PROTECTION OF COMPANY’S PROPERTY AND CUSTOMER’S INTEREST Page #


Self Check 2.1

LO2: Apply Quality Standard to Work

Direction: Encircle the letter of the correct answer

1. Which certifying company operates only in the Philippines?

A. Societe General de Surveillance (SGS B. Anglo-Japanese American Registrar (AJA) C. United Kingdom Accreditation (UKA) D. Bureau of Products and Standards (BPS)

2. What department or section responsible in monitoring and checking quality of products/welds?

A. production department B. quality control department C. planning department D. drawing department

3. A pre-qualification testing for welding as a requirements that focuses in

the following statement except one

A. Welders qualification test B. Material qualification test C. Welding procedure test D. Welding inspection test

4. An appropriate reason for keeping the records and documents intact and

accessible anytime is for

A. For recording only B. For future reference and review C. To be checked the work D. For office needs

5. Why safety signs and symbols must be posted in a readable corners?

A. everyone can read B. everyone can follow directions C. for safety D. for structure display

Course Program : SHIELDED METAL ARC WELDING (SMAW) NC1 Unit of Competency : CONTRIBUTE TO QUALITY SYSTEM Module Title : Contributing to Quality System



Learning Outcome 3

Protection of Company’s Property and Customers Interest


1. Possible damage to company’s property is avoided by adhering to

company’s Quality Procedure.

2. Quality of work is reviewed to ensure that the customer requirements and company standard are met.

References:

Welding Inspection Technology Education department American Welding Society, Inc.

International Organization for Standardization (ISO) Training Manual

Welding Technology Second Edition Gower A. Kennedy

Welding Principles and Application Larry Jeffus Harold Johnson




Learning Outcome 3: Protect Company’s Property and Customer’s Interest



sheet 3.1 protections of

company’s property and

customer’s interest.

2) Answer the self-check No.3.1 to

test your knowledge on

protections of company’s

property and customer’s

interest.


key




sheet





Information Sheet 3.1

Learning Outcome 3 Protection of Company’s Property and Customer Interest

The company operates in the manner that the basic policies and regulations

has been formed by the Policy Making Body of the Organization. The company aims to deliver the maximum quality service in terms of product, output with customer’s satisfaction. Therefore the management will have to initiate reforms after reviewing the existing status of the operations. The assessment results will be the basis for improvement.

Company System, Processes and Quality Requirements

The Company manuals and procedure manuals are the documents that provide all information regarding the company operations. These documents include the abstract presentation of the sites, buildings, facilities, products, and quality procedures.

The quality standard manuals and the inspection record manuals are of

separate documents that are kept in the quality control department. All information and guidelines pertaining to the quality is in the manuals. The inspection record manuals are specific instructions for all inspections activities. These include material records, inspection records, processes involved and the various sample forms of inspection reports. These inspection reports of all finished products are registered in the manual of inspection for purposes reference in the review of the production procedures.

Processes and Quality Requirements are both tailored based in the contract

between the client and the manufacturers. Each of the sectors has to perform the specific function. These task(s) are focused to implement and monitor the production and quality requirements.

Quality Assurance Principles

Quality assurance is a statement that also referred to the process of products

that is quality assured. This will be possible in producing products that passed through a qualified or certified process and in compliance with he standard requirements. The common practices of the production sector and the quality control group well done assessment if all activities performed are in compliance with the standard.

If we are going to focus on production of welding, we are assured of quality

if we realize the importance of welding inspectors. They don’t just look in the finished weld, but looking back on how the weld is done; Section 4 of AWS QC I standard in Qualification and Certification of Welding inspectors. From the many responsibilities of welders and welding inspectors, it is proper to discuss that both of them having separate jobs to do. Welders do follow the welding production requirements and to note:



Receive specific instruction from welding foreman/foremen regarding the scope of work.

Follow the welding Procedures and sequence by referring to (WPS) Perform Welding Production and with compliance. Apply safety assurance in the workplace.

Handling of Materials

The company/industry is assigning personnel responsible specifically for

materials, tools, and equipment. The skills of these workers to do the specific functions are credible and appropriate because of basis for accepting them to the position are their qualification.

In the welding production, materials are stocked and filed in the stockyard

in a very spacious area or location and that at the same time an office for material control and maintenance. All of the materials and processes are based on standard operations of receiving delivery and in the issuance of materials to the production in-charge personnel and to quality inspector. There are numerous ways and methods for controlling materials in the stockyard, and this performed by personnel in-charge.

In many industries, one of the more important aspects of fabrication is

identification and traceability of materials. Some inspectors maybe required to assist in the material control program as part of their regular duties. It is therefore that the individual must be capable of properly identifying material and that information related to documentation.

Materials for welded fabrication and often ordered with the stipulation that

they meet a particular specification. To demonstrate this compliance, the supplier can furnish documentation which describes all important characteristic of the materials. This documentation in metals sometimes referred to as “MTR” which is an abbreviation in material (or MILL) Test Report. This document is a statement by the manufacturer that the particular item exhibit specific chemical and mechanical properties.

Handling of Tools and Equipments

Issued tools and equipments in the shop needs proper control and

maintenance. Regular or periodic inspections must be done in order not to hamper the production outputs on the daily basis. Tools that are not fit for use must be reported and marked defective for immediate replacement. Malfunctioning machines and equipment must be repaired urgently to avoid production output loses.



Self Check 3.1

LO3: Protect the Company’s and Customer’s Interest

Direction: Encircle the letter of the correct answer.

1. A document that provides information of company operations which includes the abstract presentation of the sites, buildings, facilities, products and quality procedures.

A. inspection manual B. standard manual C. company manual D. record manual

2. Processes and quality requirements are both tailored in the agreement

between the.

A. manufacturer and client B. company and workers C. inspector and production D. all of the above

3. Workers and welders while performing their duties in the production area

are prone to hazards. The protective device for them is

A. safety glass B. gas mask C. welding gloves D. goggles

4. One of the four (4) reasons why do we keep records intact anytime

A. Records for pre-qualification test of welders. Procedures and non-

destructive test for future referral B. For products file C. Record purposes of quality control unit D. All of the above

5. The department or section in the manufacturer that is in-charge for the

implementation of the program of works/activities for production

A. Quality Control Department B. Production Department C. Promotional Department D. All of the above



Self Check # 1.1

1. A 2. C 3. C 4. C 5. B

Self Check # 2.1

1. D 2. B 3. B 4. D 5. B

Self Check # 3.1

1. C 2. A 3. A 4. A 5. B

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