User Manual QMS - Quality Control

8/19/2019 User Manual QMS - Quality Control

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Process Manual – QMS

USER MANUAL

Quality Management System (QMS) – Part II

Quality Control

Prepared by:

Sadashi Salun!he

Customer

L & T, Heavy Engineering Division

Process Manual - QMS Page 1 of 58


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DOCUMENT CONTROL

DOCUMENT TITLE: User Manual – Quality "ontrol # Quality "ontrol

DOCUMENT PURPOSE $o guide QMS users through %aaN QMS Module&

ERSION: '&'

RELE!SE ST!TUS: ra*t

"ILE LOC!TION:

!UT#OR $S%: Sadashi Salun!he

REISION #ISTOR&

ERSION D!TE DESCRIPTION ' !CTIIT& !UT#OR $S%

'&' +nd May +'', ra*t Sadashi Salun!he



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Table of Contents

1. Introduction..............................................................................................................................4

2. Overview..................................................................................................................................4

3. Quality Control (QC)................................................................................................................6

3.1 Introduction..............................................................................................................................6

3.2 Receipt Inspection....................................................................................................................63.2.1 Maintain pproval....................................................................................................................................6

3.2.2 !rovisional pproval................................................................................................................................"

3.3 In !rocess Inspection..............................................................................................................1#

3.3.1 $est !lan ($!).........................................................................................................................................1#3.3.2 Inspection C%ec&list (IC')......................................................................................................................11

3.3.2.1 Copy $est plan taes into C%ec&list.............................................................................................11

3.3.2.2 !reparation o* +ertical C%ec& 'ist.................................................................................................12

3.3.2.3 Maintain !arts *or Inspection ,y !ro-ect........................................................................................143.3.2.4 Maintain /pdate IC'...................................................................................................................10

3.3.2.0 pprove IC'..................................................................................................................................2#

3.3.2.6 /pdate IC' tatus..........................................................................................................................2#

3.3.3 Maintain O**ers *or Inspection................................................................................................................213.3.4 nter $est Results....................................................................................................................................26

3.3.4.1 Maintain test results *or Inspection................................................................................................2"

3.3.4.2 Maintain test results *or Inspection etails.................................................................................2"

3.3.0 on estructive $est ($)...................................................................................................................3#

3.3.0.1 5enerate $ Reuest..................................................................................................................3#3.3.0.2 Maintain $ Reuest lines..........................................................................................................31

3.3.0.3 Maintain $ Reuest etails......................................................................................................34

3.3.0.4 nter $ $est Results..................................................................................................................373.3.0.0 Maintain $est Results *or $ 8 !O$.........................................................................................39

3.4 :inal Inspection......................................................................................................................42

3.0 $%ird !arty Inspection ($!I)..................................................................................................433.0.1 5enerate $%ird !arty Inspection !lan.....................................................................................................43

3.0.2 Maintain $%ird !arty Inspection encies ,y taes.............................................................................443.0.3 Maintain $%ird !arty Inspection Results................................................................................................46

4. Maintain ;ployee ut%ori


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1. Introduction

The Quality Management System hels in!ustries er"orm regular inse#tion ro#e!ures toattain the re$uire! $uality% QMS uses logisti#al "lo o" ro!u#ts to s#he!ule inse#tions% 'nevery #omany, ro!u#ts, in#lu!ing ra materials, en! ro!u#ts, an! ro!u#ts in (eteenmanu"a#turing stes, are regularly inse#te! to ma)e sure the ro#e!ure runs smoothly, torevie hat ent rong, or to !etermine hat #oul! go rong !uring ro!u#tion, !istri(ution,or in the time that ro!u#ts are in inventory%This !o#ument rovi!es !etaile! QMS ro#e!ure a!ote! (y L&T * HED to monitor an!imrove the $uality o" their ro!u#ts%

2. Overview

HED has #ustomi+e! the stan!ar! 'n"or ER QMS mo!ule to suite its Quality Controlre$uirements% 't-s a stan!alone mo!ule hi#h is not integrate! ith other .aaN mo!ules%'t mainly #overs three areas o" oeration%

• Re#eit 'nse#tion

• 'n ro#ess 'nse#tion

• /inal inse#tion

Re#eit 'nse#tion is ali#a(le "or ur#hase! arts li)e ra materials, #omonents, su(assem(lies et#% materials #annot (e use! issue! "or ro!u#tion unless it is #leare! (y

inse#tion% Hoever rovisional #learan#e 0aroval1 is ossi(le to allo material issue"or ro!u#tion%

'n ro#ess 'nse#tion is !one on the arts !uring manu"a#turing ro#ess% 2el!ingro#ess is e3tensively use! in manu"a#turing o" HED ro!u#ts% Hen#e QMS is largely"o#use! on el!ing ro#ess & its asso#iate! Quality Control ro#e!ures% On#e thero!u#t !esign is "ro+en & !raings are release!, Seams are i!enti"ie! to reare theTest lan% Master !ata li)e arameters 0Chara#teristi#s1, 'nse#tion Stages 0ase#ts1,!e"ault Tests are !e"ine! in .aaN% .ase! on Test lan 'nse#tion Che#)list is reare!%Stages are o""ere! in a re!e"ine! se$uen#e to ensure Quality #omlian#e at ea#h stageo" manu"a#turing% 'nse#tion metho! !een!s on the tye o" stage, e%g% NDT 0RT4UT1,Others & 'nse#tion% Test results are entere! against ea#h arameter & status is

u!ate! as Cleare! 4 Re5e#te!%

/inal 'nse#tion ensures the #omletion o" all Tests & 'nse#tion a#tivities "or the "inal!elivera(les (e"ore osting to /6% 0Stores Cre!iting1% L&T Test Certi"i#ate is reare! &!elivere! to #ustomer% 't #omrises !etails li)e 7li#a(le Stan!ar!s, 'nse#tion

7gen#ies involve!, et#%



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/olloings are the three ro#ess oners o" QMS in .aaN%

• 2el!ing Engineer * 2el!ing Engineering

• 'nse#tor * Quality Control 0QC1

• Suervisor * ro!u#tion Centre 0C1

Ea#h one o" them 0.aaN user1 has (een assigne! a se#i"i# role & authori+ation to

er"orm set o" a#tivities%

This !o#ument is su(!ivi!e! into to arts to "a#ilitate .aaN Users to un!erstan! theirrole se#i"i# a#tivities in .aaN%

81 2el!ing Engineering 9 art ':1 Quality Control 9 art ''

3. Quality Control (QC)

;% 'ntro!u#tion

The QMS e3e#ution art is largely !one (y Quality Control !eartment% QC users aregiven the role o" Inspector to er"orm transa#tions in .aaN% The transa#tions li)eMaintain 7roval, reare 'nse#tion Che#) List 0'CL1, 7rove 'CL, Enter TestResults, 6enerate NDT re$uest, et#% Re#eit 'nse#tion & 'n ro#ess 'nse#tion ishan!le! (y QC% The .aaN ro#e!ural ase#ts have (een e3laine! in !etails (elo%


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.1.1 !aintain "##roval

Re#eit 'nse#tion is !one "or ur#hase! items li)e ra materials, arts, #omonents,su( assem(lies, et#% it is ali#a(le "or the items only i" 'nse#tion "lag is Yes in 'temData & Sulier !ata along ith Maintain Approval ste is art o" Or!er tye% '" the item

is re#eive! 0'MR1 & 'nse#tion "lag is Yes, then re#eive! $uantity is )et on hol! "orinse#tion a#tivity% 't is (lo#)e! "or "urther transa#tion till it is #leare! (y inse#tion%'nse#tor #an use .aaN utility rint 4 Dislay sessions to )no the 'MRs 0re#eits1en!ing "or 'nse#tion% 7"ter hysi#al inse#tion is #omlete!, inse#tor #an maintaintest result as 7rove! 4 re5e#te! "or the $uantity inse#te!% /olloing .aan session isuse! to maintain 7roval "or re#eit 'nse#tion%Session Name * Maintain 7roval 0t!ur;8:8m===1



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On#e the 'MRs 0re#eit no1 are retrieve! "rom .aaN using utility sessions, sele#te! 'MRno is sear#he! in the a(ove session to enter 7rove! 4Re5e#te! Quantities%

Form No 1

Field $ata

Re#eit No 'MR no% aaiting "or inse#tion

a#)ing Sli No De"aults "rom the 'MR

Sulier De"aults "rom the 'MR

Or!er linesDe"aults "rom the 'MR, Or!er No, os No, 'tem Re#eive!,Delivere! Qty 0Re#eive! Qty1, Unit o" Measure

7rove! 7##ete! Qty * Enter O> Qty in the su( session invo)e! (y thesystem 0t!il#;8:?s===1%

.a#) Or!er System #al#ulates .a#) or!er Qty !een!ing on a##ete! Qty0Or!er Qty 9 Cumulative 7##ete! Qty1



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Form No. 2

Field $ata

Re5e#te! QtyDislays Re5e#te! Qty hi#h is entere! in the su( session0t!il#;8:?s===1%

Reason /orRe5e#tion

Dislays Reason "or re5e#tion hen reason #o!e is sele#te! in

the su( session * maintains aroval e3tension% This session isinvo)e! (y #li#)ing on @oom (utton%

'tem inventory aearing On Hold is #leare! a"ter the aroval is maintaine! in thesystem% 't is no availa(le "or "urther transa#tion su#h as 'n(oun! to arehouse, et#%

.1.2 Provisional "##roval

Sometimes item #annot (e arove! "or the ant o" test #erti"i#ate, Certi"i#ation "romT' agen#ies, et#% 'n su#h s#enarios item #an (e rovisionally #leare! "or the imme!iate

ro!u#tion re$uirement% The aroval status remains as rovisional #learan#e (PRV) tillsulier "ul"ills the state! re$uirements% Sulier ayment is not release! till it is "inally#leare! (FIN). The rovisional #learan#e is given (y using same session as use! "or Maintain aroval%Session Name * Maintain 7roval 0t!ur;8:8m===1



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Cli#) on @oom (utton on the right han! si!e, to oen the su( session 9 Maintain 7roval E3tension 0t!ur#8?


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A% 'n ro#ess 'nse#tion

Process Flow

%.1.1 Test Plan (TP)

2el!ing engineer i!enti"ies #riti#al seams "or the ro!u#t & #reates seam ise Test lanin .aaN% .ase! on the Quality 'Ds lin)e! to seams, system oulates all the stageslin)e! to $uality 'D in the Test lan% These stages aear in a re!e"ine! se$uen#e to"a#ilitate stage ise inse#tion o" Seam% Test lan is arove! (y #on#erne! authority &is "inally #oie! into Inspection Checlist (y QC 'nse#tor% !Please refer Part I - "el#ing $ngineering for further #etails of %est Plan&.



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'nse#tion Che#)list is reare! (y #li#)ing on the (utton 9 IC' PreparationThis oulates all the test lan stages into 'CL & user 'D is #ature! (y the system%0NoteB * Test lan status must (e 7rove! (es (e"ore this a#tion1

%.1.2.2 Pre#aration of +ertical C&ec' ist

'nse#tor i!enti"ies stages hi#h are not art o" Test lan (ut ne#essarily to (e art o"inse#tion% These stages are !e"ine! as !e"ault stages "or the entire ro5e#t% They #an(e seam se#i"i#, art se#i"i#, ali#a(le to (oth seam & arts, an! mis#ellaneoustyes% Seam & art se#i"i# stages are a!!e! "or the se#i"i# seam 4 art hereasmis#ellaneous tyes are a!!e! !ire#tly into 'CL% The verti#al #he#) list is rimarily use!to a!! stages other than seams & hi#h are #ommon "or all%

/olloing .aaN session is use! to maintain !e"ault stages (y ro5e#t%

.aaN session * Maintain De"ault Stages (y ro5e#t 0t#lnt=88:m===1



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Field $ata

ro5e#t Enter ro5e#t no% (y #li#)ing grou insert )ey "rom the tool (ar%

De"ault Stage @oom to stage master & sele#t the aroriate stage%

Tye

Miscellaneous

Seam onl)

Part onl)

Seam & art only

Sele#t the tye "rom !ro !on list

These stages ill (e a!!e! in the 'CL "or the ro5e#t i%e% onlyon#e "or the ro5e#t hen save! here%

These stages are a!!e! in 'CL "or seam only "or the ro5e#tun!er #onsi!eration henever seam is save! in Seams4 arts

(y ro5e#t%These stages ill (e a!!e! in the 'CL "or arts only "or thero5e#t un!er #onsi!eration henever art is save! in Seams4arts (y ro5e#t%

These stages ill (e a!!e! in the 'CL "or seam & art "or thero5e#t henever Seam4 art is save!%

%.1.2.3 !aintain Parts for Ins#ection by Pro,ect

art num(er is uni$ue "or a ro5e#t & is !ire#tly loa!e! "rom #ustomi+e! .OMmaintaine! "or the ro5e#t% art num(er has one to one relationshi ith item #o!e% artnum(er is same as osition num(er in #ustomi+e! .OM "or the "inal item o" the ro5e#tinstea! o" item num(er itsel"%Hoever 'nse#tor #an #reate ne arts "or the se#tions o" the en! ro!u#t to #arry outoverall inse#tion% These se#tions are !e"ine! as arts in the system% e%g% Shell assly,#hannel assly, et#/olloing .aaN session is use! to maintain arts "or 'nse#tion (y ro5e#t%

.aaN Session 9 Maintain arts "or 'nse#tion (y ro5e#t 0t#lnt=888m==81



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Field $ata

ro5e#t Enter ro5e#t no% (y #li#)ing insert )ey "rom the tool (ar%

art Enter the art no & !es#rition "or the se#tion o" assem(ly

'ns Quantity De"ault is = 0not relevant1

Field $ata

Quality 'D@oom & sele#t the Quality 'D% Stages & arameters lin)e! to this'D are oulate! in 'CL un!er the art #reate!

reare! .y Login i! is #ature! (y the system hen the re#or! is save!%

%.1.2.- !aintain /#date IC



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'nse#tor i!enti"ies stages hi#h nee! to (e a!!e! (e"ore or a"ter stages in 'CL that are#oie! "rom Test lan% These stages are a!!e! in 'CL o" all ali#a(le seams 4 arts "orthe ro5e#t% The se$uen#ing o" stages is #riti#al hile a!!ing ne stages in 'CL% Revisionno% is in#remente! (y one ea#h time the 'CL is mo!i"ie! & arove!% Te3t #an (e a!!e!"or the 'CL4stage%

/olloing .aan session is use! to maintain 4 u!ate 'CL%.aaN Session 9 Maintain 'CL Lines 0t#lnt=8:?m==81%

Form No.1

Field $ata

ro5e#t Enter ro5e#t no% (y #li#)ing insert )ey "rom the tool (ar%

art Enter the art no to u!ate the art 'CL

Seam Enter the Seam no to u!ate the Seam 'CL

T RevTest lan revision no% Ne Rev no is u!ate! henever T ismo!i"ie! & arove! (y 2el!ing Engineer%



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Field $ata

+n#er Inspection

*ffere# to N,%

Cleare#

Reor

Remae

,elete# ) N,%

2hen suervisor o""ers it "or inse#tion in this session , theinse#tion status #hanges to Un!er 'nse#tion-% This ill remainso until any o" the arameters un!er stage is Re5e#te!- orCleare!- in #ase o" non*NDT stage as er result in Test results%

2hen inse#tor runs the session 6enerate NDT re$uest-,'nse#tion status #hanges to O""ere! to NDT-% 't is !one only "or NDT tye Stages i%e% RT4UT & ha! inse#tion status Un!er'nse#tion-

2hen all arameters un!er stage are #leare! as er result inTest results, inse#tion status #hanges to Cleare!-%

2hen any o" the arameters un!er stage is re5e#te!, inse#tionstatus #hanges to Reor)-% Suervisor has to re o""er stage inEnter Test Result- & then status #hanges to Un!er 'nse#tion-

2hen any o" the arameter un!er stage is rema)e-, as erresult in Test results, the inse#tion status #hanges to Rema)e-"or all the stages un!er that seam% This means that a ne seamhas to (e entere!%

2hen NDT erson !eletes a re#or! in the re$uest, the status(e#omes Delete! (y NDT-% 't ill again #hange to O""ere! toNDT- hen re$uest is regenerate! (y the suervisor

'ns% Center @oom & sele#t la#e "rom master list o" 'nse#tion #enters

O)This a#tion (utton is use! "or registering thea!!ition4mo!i"i#ation o" stage in 'nse#tion #he#) list%

Can#el 't is use! to $uit the session ithout saving any re#or!%

Rese$% StagesRe se$uen#ing o" the stages is to (e !one hen the 'CL is"ro+en% Re se$uen#ing is not ossi(le i" any stage o" seam orart is o""ere! "or inse#tion

7 Seam4 art This (utton is use! "or aroving the seam or art in!ivi!ually%

7rove all This (utton is use! "or aroving all seams4 arts

Field $ataU!ate Rev No This a#tion (utton is use! "or u!ating the revision num(er

ro5e#t E3tn This (utton is use! "or maintaining the te3t "or the revision



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Field $ata

U!ate status

This otion sets inse#tion status o" un o""ere! stage ith loestse$uen#e num(er to Rea!y to O""er-% 7lso it (lan)s the re#or!shi#h have !isaeare! "rom 'CL !ue to mo!i"i#ation4 #hange inTest lan% User authori+e! to reare & arove 'CL #anoerate this user otion%



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!/ll are #ispla) fiel#s onl)0 up#ate# ) the s)stem on actions #one ) the users.&

Form No.2

Field $ata

'ns% O""er

This "iel! in!i#ates hether the art or seam is o""ere! toinse#tion or not% On#e a stage is o""ere! to inse#tion,su(se$uent #hanges to the relate! art or seam are nota##ete!%

Field $ata

ShoThis value is entere! (y the suervisor hen a stage o" art orseam is o""ere! "or inse#tion%

Lo#ationThis value is entere! (y the suervisor hen a stage o" art orseam is o""ere! "or inse#tion%

'ns% E3tent'nse#tion e3tent !etermines hether this stage inse#tion

nee!s to (e er"orme! "ully or artially%

'ns% QtyQty !e"aulte! "rom the "iel! .OM $uantity entere! in Maintainarts "or inse#tion (y ro5e#ts%

O""er Qty Total o""ere! $uantity

Cleare! Qty Quantity #leare! & entere! (y 'nse#tor in test results%



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!/ll are #ispla) fiel#s onl)0 up#ate# ) the s)stem on actions #one ) the users.&

Form No.

Field $ata

L & T Result De"aults the test results entere! (y the 'nse#tor 0#leare!1

DateDate on hi#h inse#tion result entere! (y 'nse#tor or NDTerson%

Time Time registere! (y the system hen results are entere!%

/inal result'" all agen#ies #lear the stage, the "inal result is #leare!% '" Thir!arty inse#tion is not re$uire!, this result is #leare!imme!iately a"ter internal inse#tion is #leare!%

Date Date on hi#h "inal results entre!%

Te3t 'n!i#ates )es " te3t is resent

%.1.2. "##rove IC

'nse#tion Che#)list List is arove! (y QC authori+e! erson only% This a#tivity ensures'CL enlist all stages essentially to (e #overe! un!er inse#tion% 7ny mo!i"i#ation !one in'CL nee!s aroval (e"ore it is ma!e availa(le "or inse#tion% 7rover has otions toarove 'CL in!ivi!ually "or seam 4 art or all 'CLs "or the ro5e#t (y single #li#) o"(utton% The !ate & time o" aroval is registere! & !islaye! against ea#h stage%System also #atures the arovers- user 'D & !islays on the s#reen%



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/olloing .aaN session is use! to arove 'CL%

.aaN session 9 maintain 'CL lines 9 0t#lnt=8:?m==81

%.1.2.% /#date IC tatus

'nse#tor u!ates the 'CL status to ma)e stages availa(le "or inse#tion% This a#tion#hanges the status o" un o""ere! stage ith loest se$uen#e num(er to Rea!y to O""er-%

7ll !elete! stages are also remove! "rom 'CL% User authori+e! to reare & arove 'CL#an er"orm this a#tivity%

%.1.3 !aintain Offers for Ins#ection

'nse#tion a#tivity is triggere! (y the inse#tion o""er ma!e (y ro!u#tion Center 0C1% 7ll the stages are o""ere! "or inse#tion in a #hronologi#al or!er% 't means no su##ee!ingstage #an (e o""ere! "or inse#tion unless re#e!ing stage is #leare!%

Stage ith status Rea#) to *ffer #an (e o""ere! "or inse#tion% 't is man!atory to entersho, lo#ation & el!ers "or the stages o" non NDT tye% The status #hanges to Un!er'nse#tion- imme!iately a"ter the stage is o""ere! "or inse#tion% Thus stage (e#omesavaila(le "or QC inse#tor to er"orm re$uire! arameter #he#)s & enter test results inthe system% '" the stage tye is NDT, 'nse#tor generates NDT re$uest ith re$uire!!etails & o""er to NDT% Stages ith (lan) status are not visi(le to Suervisor%

'n #ase o" re5e#tion, the status is #hange! to either Reor or Remae% 7##or!ingly Cnee!s to ta)e #orre#tive a#tion on the seam or art (e"ore reoffering the stage "orinse#tion% 'teration No% is u!ate! ea#h time re o""er is ma!e% Suervisor #an enterhis4her remar)s i" any%/olloing .aaN session is use! to maintain o""er "or inse#tion%

.aaN session 9 Maintain O""er "or inse#tion 0t#lnt=8:?m==;1



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Form - Common

Field $ata

ro5e#t ro5e#t No%

Stage

Stage may aear ith !i""erent statuses "or !i""erent seams%e%g% Rea!y to o""er, un!er inse#tion 4 #leare!, Reor)% Stageith status Rea!y to o""er or reor) #an (e o""ere! "orinse#tion%

art art No in the a(sen#e o" seam

SeamSeam no% to hi#h this stage (elongs% One stage #an (e art o"many 'CL in the same ro5e#t%

Se$ Se$uen#e No% !e"aulte! "rom the e3tension to stage master

'trn'teration No% initial value is set to =% The no% is in#remente! (yone ea#h time re o""er is ma!e (y C%

'nse#tion Status Stage ith status Rea!y to O""er #an (e o""ere! "or 'nse#tion%

rov 4/inalSystem u!ates this "iel! as Pro i" T' is involve!% .y !e"ault itis )et (lan) till the time "inal inse#tion results are entere!% 't is#hange! to /inal a"ter results are entere! in the system%

O""er es in!i#ates o""er is ma!e%



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Field $ata

Sour#e Seam

This "iel! #an (e use! hen no% o" seams are inse#te! in onego & results to (e entere! are same% 'n su#h #ase !ata isentere! "or single singe seam #alle! Sour#e Seam & #oie! toothers%

L&T ResultsResults entere! (y internal inse#tion 0QC1% '" T' is involve! ininse#tion, stage #annot (e #leare! unless (oth results aremaintaine! in the system%

Sho 't-s the la#e here inse#tion nee!s to (e #arrie! out%

Lo#ation Lo#ation in the sho here inse#tion nee!s to #arrie! out%

Suervisor Suervisor user i! is #ature! ho has o""ere! the stage

Date & Time Date & time on hi#h the o""er is ma!e

O""er Sele#t the stage & #li#) on *ffer (utton on RHS to o""er thestage "or inse#tion%

Test DataSuervisor #an a##ess the Test Data to re o""er stage & enterhis4her remar)s%

Coy Test DataTest !ata su#h re$uire! value, measure! value, #he#)e! value,arameter results #an (e #oie! "rom one seam to other%

Non 'CL stagesNe Stages #an (e a!!e! & o""ere! to 'nse#tion (ySuervisor%

Form 3 Part offer



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Field $ata

art art No i" the stage (elongs to the art 0erti#al #he#) list1

SeamSeam no% to hi#h this stage (elongs% One stage #an (e art o"many 'CL in the same ro5e#t%

Se$ Se$uen#e No% !e"aulte! "rom the e3tension to stage master

'ns QtyQty !e"aulte! "rom the "iel! .OM $uantity entere! in Maintainarts "or inse#tion (y ro5e#ts%

Current o""er Qty Total o""ere! $uantity 0not ali#a(le in the e3isting ro#ess1

Cleare! Qty Quantity #leare! & entere! (y 'nse#tor in test results% 0notali#a(le in the e3isting ro#ess1

Total O""er Qty Total #umulative o""ere! Qty 0not ali#a(le in the e3isting ro#ess1

Form - "el#ers



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Field $ata

2el!er 't is man!atory to inut el!ers "or the seam inse#tion%2el!ers #an (e entere! (y using session Maintain "el#ing

Processes ) pro4ect5seam5el#er !tclnt6127m666&%

Inspection Status



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Ho inse#tion status o" stage #hanges (y user a#tions is given (elo%



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%.1.- 0nter Test esults

Test results are entere! "or the stages ith status Un!er 'nse#tion 4 O""ere! to NDT-%'nse#tor is authori+e! to enter results "or 'nse#tion stages hereas NDT test results


"ction"ction

yIns#ection tatus

"fter action

.y !e"ault stage ith loer most se$uen#e*R 7"ter earlier se$uen#e stage is #leare!(y L&T 'nse#tion

Ready to offer

Stage is o""ere! "or 'nse#tion% C Under Inspection

Results not a##ete! (y L&T 'ns% QC Rework

Stage is re o""ere! "or 'nse#tion a"terre#ti"i#ation%

C Under Inspection

Results a##ete! (y L&T 'nse#tion (ut 7aiting T' inse#tion

QC Under Inspection

Results 7##ete! (y L&T & T' QC Cleared.

NDT Stages

7"ter earlier stage is #leare! (y L&T Ready to offer Stage is o""ere! "or 'nse#tion% C Under Inspection

NDT Re$uest is generate!% QC Offered to NDT

Result entere! (y NDT0Seam not "ully#leare! 1%

NDT Rework

Re*generate o" NDT re$uest C Offered to NDT

Results Entere! 07ll sots Cleare!1% NDT Cleared.


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are entere! (y NDT erson only% arameters are #he#)e! against the a##etan#e#riteria & the results are entere! a##or!ingly%

• Cleare!

• Re5e#te! !Reor 5 Remae&

'" all the arameters are #leare!, stage status in 'CL #hanges to FCleare!--% 'n #ase o"any re5e#te! arameter, the stage status #hanges to Reor)G% Suervisor has to ta)e#orre#tive a#tion (ase! on inse#tion remar)s & Re o""er the stage "or inse#tion%System #atures 'nse#tion !ate, time & inse#tor user i! hen the re#or! is save!%/olloing .aaN session is use! to enter test results%

.aaN session * Enter Test Results 0t#lnt=8:?m==


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Field $ata

ro5e#t ro5e#t No

Stage Sele#t the Stage "or inse#tion%

Seam 7ll the seams are !islaye! having this stage art o" theirinse#tion #he#) list%

Se$% No% Stage se$uen#e no%

Re$% No% NDT re$uest no% i" the stage is NDT tye

'trn'teration No% initial value is set to =% The no% is in#remente! (yone ea#h time re o""er is ma!e (y C%

Sour#e Seam

This "iel! #an (e use! hen no% o" seams are inse#te! in onego & results to (e entere! are same% 'n su#h #ase !ata is

entere! "or single singe seam #alle! Sour#e Seam & #oie! toothers%

'nse#tion Status 't in!i#ates inse#tion status o" the stage against various seams .!please refer section 7..2.7 for further #etails&

rov 4/inalSystem u!ates this "iel! as Pro i" T' is involve!% .y !e"ault itis )et (lan) till the time "inal inse#tion results are entere!% 't is#hange! to /inal a"ter results are entere! in the system%

Sho 't-s the la#e here inse#tion nee!s to (e #arrie! out%

Lo#ation Lo#ation in the sho here inse#tion nee!s to #arrie! out%

Suervisor Suervisor user i! is #ature! ho has o""ere! the stage

O""er Date 'nse#tion o""er !ate

O""er Time 'nse#tion o""er time

Test !ata

This otion is use! to enter the test results%Sele#t the re#or! & #li#) on %est ,ata (utton, "olloing sessionsill invo)e !een!ing uon the tye o" stage, seam4art#om(ination%'" the sele#te! re#or! is i" art or seam is sele#te! & stage tyeis NDT system +ooms to session Maintain test results for N,%!tclnt1127s666&.'" art is sele#te! & stage tye is non NDT system +ooms tosession Maintain test results for parts !tclnt1122s666&.

'" seam is sele#te! & stage is non NDT system +ooms tosession Maintain test results for Inspection !tclnt1126s661&

Coy Test Data Test !ata #an (e #oie! "rom sour#e seam% alues, results, et#

/orm no%: & ? are !islay "orms, shos $uantity & el!er !etails%'" the seam is sele#te! & stage is non NDT tye, "olloing session invo)es a"ter ressingthe Test Data (utton%



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Maintain test results "or 'nse#tion 0t#lnt88:=s==81

%.1.-.1 !aintain test results for Ins#ection

This session #an (e #alle! only (y 'nse#tor or Suervisor an! hen the stage is non*NDT "or a seam% Suervisor #an re o""er a seam "or inse#tion "rom here a ne iterationnum(er is generate!% 2hen re o""ering is ma!e, o""er !ate & time is #ature!% %estinstruments & Remars #an (e entere! at hea!er level%

%.1.-.2 !aintain test results for Ins#ection $etails

7"ter #li#)ing on the (utton 8,etails in the a(ove session system ill oen the "olloings#reen% This session is use! to maintain the arameter results o" non*NDT stages o" aseam% The re$uire! value & measure! value is "ille! in (y the suervisor hereas the#he#)e! value is to (e "ille! (y the inse#tor% Results only "or the last iteration num(er#an (e "ille! u as only these are visi(le here%

The result here #an (e maintaine! (y inse#tor only% '" all the arameters o" a seam are#leare! then "iel! L & T Result- is set to FCleare!G in ta(le 'CL line% '" any o" thearameter is ma!e as Rema)e- then "a#ility to ma)e results o" all the arameters as



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2el!ing ro#ess is #ategori+e! as a se#ial ro#ess & nee!s stringent ro#ess #ontrolto ensure $uality outut & #omlian#e ith ali#a(le stan!ar!s% This is vali!ate! (yinse#tion & test on the el!e! seam% NDT is one o" the se#ial tests% e%g% Ra!iograhyTest 0RT1, Ultrasoni# Test 0UT1% NDT is #arrie! out (y searate NDT #ell hi#h is art o"Quality Control%

'" the stage tye NDT is o""ere! "or inse#tion (y suervisor, Q# 'nse#tor has to raise aNDT re$uest in .aaN (y rovi!ing re$uire! !etails to NDT #ell% Only authori+e! erson0NDT erson1 is alloe! to ro#ess the NDT re$uest in .aaN%lease "in! (elo the !etails o" NDT ro#e!ure%

%.1..1 5enerate 4$T e6uest

2hen NDT stage is o""ere! "or inse#tion (y C, NDT re$uest is raise! (y 'nse#tor%

System generates re$uest only "or the NDT stages Un!er inse#tion-% 7ll "urtherro#essing #an (e tra#)e! (y NDT re$uest no% The re$uest no% aears on the 'CL lines,NDT re$uest hea!er & lines & stage status #hanges to O ffere# to N,%./olloing .aaN session is use! "or generating NDT re$uest "or all ali#a(learts4seams having NDT stages Un!er 'nse#tion-%

.aaN Session 9 6enerate NDT Re$uest 0t#lnt=::?m==81



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Field $ata

ro5e#t ro5e#t No%

art Range o" arts (elonging to the ro5e#t

Se$% Stage Se$uen#e no i" one seam 4art is sele#te!

Series "orNDT re$uest

@oom & sele#t the aroriate series "or the re$uest no%

rint Cli#) Print to generate re$uest no%

%.1..2 !aintain 4$T e6uest lines

2hen the re$uest is ma!e "or NDT, relate! !ata is entere! (y the re$uesting erson%The !ata li)e sot length, seam length, seam tye, et#% Sot is a art o" total seam hi#his inse#te! in one go% Length !etermines the no% o" sots generate! (y the system%

Sot no% i!enti"ies a arti#ular lo#ation on the seam un!er #onsi!eration%

e%g% Sot length *?==mm, seam length is 8


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8 8*: 8*: : :*? :*? ? ?*; ?*; ; ;*< ;*< <


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Field $ata

Status

/tten#e#

Pen#ing

,elete#

Status o" the NDT re$uest% .y !e"ault it is set to Not atten!e!hen ne re$uest is generate!% Only NDT erson #an #hangethe status to 7tten!e!, en!ing or Delete!%

't in!i#ates the NDT has (een !one

Re$uest is ut un!er en!ing status i" NDT erson is una(le toer"orm the test "or the reasons (eyon! the s#oe o" NDT asell as sho%

'" reason "or ostoning o" the test is ith sho then the re#or!is !elete! (y NDT erson ith remar)s "or !eletion% Suervisorhas to ta)e #orre#tive a#tions & regenerate the re$uest% 'n this#ase no ne iteration no is generate! as test is yet to (e !one%

Suervisor User i! o" the suervisor ho has regenerate! the NDT re$uest%

'ns E3t% E3tent o" inse#tion in er#entage, generally 8== I

No% O" SotsEnter th sot length in mm hi#h !etermines the no% o" sotsgenerate! "or the NDT% 't also !een!s on the seam length%

Seam Length Length o" the seam un!er #onsi!eration 0in mm1

Tye Seam tye 9 Straight 4 Cir#ular

Ra!iation Thi#)ness o" the ra!iation%

Con"m 'n!i#ates #on"irmation !ate (es 5No

Otion SetNDT Test Results

This otion is availa(le only ith NDT erson% HE4She #an enter test result (y #li#)ing on this otion%

NDT SotsThis otion is use! to e!it the sot in"ormation li)e sot no%,!es#rition ,length, et#

Re$% DetailsRe$uester uses this otion to u!ate the re$uest !etails% 't has(een !is#usse! in the ne3t se#tion%

rint Results To rint test results entere! (y NDT erson

%.1..3 !aintain 4$T e6uest $etails



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Re$uester rovi!es NDT !etails "or the seam un!er #onsi!eration% Some o" the !etailsare u!ate! (y the system i" they are maintaine! in other .aaN sessions%e%g% Materials, thi#)ness, ali#a(le stan!ar!s

/olloing .aaN Session is invo)e! through session Maintain NDT Re$uest Lines%

Maintain NDT Re$uest * Details 0t#lnt=8A:s8=81



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Form No.1

Field $ata

Sur"a#e Con!itionCon!ition o" the seam 4 art sur"a#e is entere! here (ysuervisor 4inse#tor through ou master

art

art num(er is a uni$ue "or a ro5e#t an! is !ire#tly loa!e! "rom#ustomi+e! .OM maintaine! "or the ro5e#t% art num(er hasone to one relationshi ith item #o!e% Hoever art num(er issame as osition num(er in #ustomi+e! .OM "or the "inal item

o" the ro5e#t instea! o" item num(er itsel" Material This is the material o" a art atta#he! to a seam%

Thi#)ness Thi#)ness o" material se#i"ie! (e"ore%

Field $ata

7ro3% !ia 7ro3imate !iameter o" the se#imen

Seam4 art Length 7ro3imate length o" the se#imen

2el!er-s Remar) 2el!er-s remar) i" any

Sho 'ssuing sho num(er in hi#h the art4 seam e3ists%

Lo#ation Lo#ation o" the sho at hi#h art4 seam e3ists%

Suervisor User 'D o" suervisor%

Con" Date The !ate o" the #on"irmation o" NDT re$uest%

Con" Time The time o" #on"irmation o" NDT re$uest%

Del Date The !ate o" !eletion o" NDT re$uest%

Del Time The time o" !eletion NDT re$uest%

Regen Dt System !ate hen the re$uest is generate!%

Regen Tm System time hen re$uest is generate!%

O""% Dt The NDT o""er Date

O"" Tm The NDT o""er Time



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Form No.2

Field $ata

Seam Thi#)nessThi#)ness o" the seam 0!e"aults "rom the !ata entere! insession maintain seam (y ro5e#t1

Total Th) ith Rein" Total thi#)ness

Joint TyeDe"aults "rom the !ata entere! in session maintain seam (yro5e#t%

'nse#tion E3tent 'nse#tion e3tent !etermines hether this stage inse#tion nee!to (e er"orme! "ully or artially

7li#a(le Se#De"aults "rom the !ata entere! in session maintain a##etan#estan!ar! (y stage o" the ro5e#t% 't #an (e e!ite!%

7##etan#eStan!ar!

De"aults "rom the !ata entere! in session maintain a##etan#estan!ar! (y stage o" the ro5e#t% 't #an (e e!ite!%

2el!ing Remar)s 2el!ing remar)s i" any%

Manu"a#turing #o!e Manu"a#turing #o!e i" any

7gen#yThir! arty 'nse#tion agen#y that has to (e atta#he! to therange o" stages maintaine!%

Consuma(le Mt

Tye

Consuma(le material tye%

Heat4 late NoB Heat 4late num(er "or i!enti"i#ation%

Re$uest status't in!i#ates the status o" the re$uest ma!e (y the inse#tor tothe NDT

Material #ategory Category o" the material% 't is entere! through master%

Remar) "or !eletion Remar) "or !eletion i" any%



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%.1..- 0nter 4$T Test esults

NDT test results are entere! (y sots hi#h !e#i!e inse#tion result "or the stage%Unli)e non NDT stage 0inse#tion stage1, NDT inse#tion results in#lu!e various other!etails ertaining to tye o" NDT is use! i%e% RT4UT% The !etails li)e, re#or!a(lein!i#ations, arameter, RT4UT te#hni$ue, sear#h unit, et#% Only NDT erson isauthori+e! to enter the NDT test results in the system%/olloing test results #an (e entere! "or the sots a##or!ing to the tye o" NDT 0RT4UT1%

•

Cleare!• Rema)e

• Re5e#te!

• Re shoot

• Che#) Sur"a#e

'" one o" the sots are mar)e! other than #leare!, suervisor has to ta)e #orre#tivea#tion & regenerate the NDT re$uest ith ne iteration no% Every time re$uest isregenerate!, status o" inse#tion #hanges to *ffer to N,% & re$uest status #hanges toNot /tten#e# % 2hen all sots are mar)e! #leare!, the status "or stage is #hange to#leare!%

/olloing su( session #an (e invo)e! to enter the NDT test results (y #li#)ing on N,%test result otion in the session Maintain NDT Re$uest Lines 0 t#lnt=8A:m===1

*R .y #li#)ing on %est ,ata otion in the session Enter test results 0t#lnt=8:?m==


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Form - Common

Field $ata

'ns ComleteThis "lag #an (e set to No i" inse#tion o" all the sots o" theseam is not #omlete! ithin a shi"t% This results in #reation o"ne samle no% "or the seam%

Test 'nstrument @oom & sele#t the Test instrument use! "or inse#tion

Duration /rom Enter the start !ate o" inse#tion

Duration To Enter the en! !ate o" inse#tion

Remar) Enter the remar)s i" any%

Cleare! Qty Enter the $uantity #leare!%

7llo#ation Enter the allo#ation o" Hours (y Jo(, sho, RT4UT or su(*#on

Otion setarameters

Cli#) on Parameters otion to enter re$uire! NDT arameters%

Details Cli#) on Details to enter the test results (y sot%0lease re"er ?%?%


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%.1.. !aintain Test esults for 4$T 7 POT

The su( session Maintain %est Results for N,% 3SP*% !tclnt1121s666& is invo)e! (y ressing ,etails otion in the session !is#usse! a(ove% This session is use! to enterRe#or!a(le in!i#ations & inse#tion results "or the sots% UT arameters #an (e entere!"or ea#h sot, e%g% ro(e angle, length, !eth, et#%

'n #ase o" Thir! arty 'nse#tion, results are entere! "or the agen#ies involve!% Seam#an (e "inally #leare! a"ter entering internal 0L&T1 & e3ternal 0T'1 inse#tion results "orall the sots o" seam un!er inse#tion%



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Form -Results

Field $ataResult

Cleare#

Remae

Re4ecte#

Re shoot

Chec surface

Sele#t inse#tion result "rom the list% The result entere! "or sots!etermines the status o" stage%

Sot is #leare! (y NDT% '" all the sots are #leare! along ithT' results, stage status #hanges to #leare!%

'" result o" any single sot is to Remae, entire seam is re5e#te!& stage status #hanges to Re4ecte# in 'CL%

The sot is re5e#te! (y NDT, suervisor nee!s to ta)e #orre#tivea#tion & regenerate the NDT re$uest% Every time re$uest isregenerate!, status o" inse#tion #hanges to *ffer to N,% &re$uest status #hanges to Not /tten#e# %

NDT erson re shoots the sots ith result Re shoot% There isno ne re$uest is generate! (y the suervisor, instea! iterationno% is in#remente! (y one, e%g 'tr% No% 8, :%%%%

Suervisor nee!s to ta)e #orre#tive a#tion & regenerate theNDT re$uest%

UT length Length in mm

Re#or!a(le'n!i#ations

@oom & sele#t the aroriate re#or!a(le in!i#ations% Notali#a(le "or UT

'nse#tionRemar)s

Enter UT !etails o" in!i#ations, ali#a(le "or UT%

Re5e#t Set re5e#t "lag to ES i" sot is re5e#te!%



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The other to "orms are Data & T'% The !etails o" in!i#ations & reason #o!e areentere! in D7T7 "orm hereas T' results are entere! in T' "orm%'



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K% /inal 'nse#tion

/inal 'nse#tion ensures the #omletion o" all Tests & 'nse#tion a#tivities "or the "inal!elivera(les (e"ore osting to /6% 0Stores Cre!iting1%

QC reares the L&T Test Certi"i#ate in .aaN ith !etails li)e ro5e#t No, Customer ONo, 'nse#tion 7gen#ies, 7li#a(le Stan!ar!s, Signing 7uthorities, et#%

/olloing (aaN sesseion is use! to enter & rint L&T Test Certi"i#ate

.aaN Session 9 Maintain L&T Test Certi"i#ate 0ltlt#=8=8m===1



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% Thir! arty 'nse#tion 0T'1

Sometimes inse#tion is re$uire! to (e !one (y e3ternal inse#tion agen#ies to "ul"illman!atory re$uirement or !eman! (y #ustomer% E3ternal 7gen#ies #on!u#t varioustyes o" #he#)s & #erti"y the ro!u#t #on"orman#e to the state! re$uirements% Thir! arty 'nse#tion ro#e!ure has (een mae! in L&T QMS mo!ule% User may use"olloing sessions to maintain !ata relate! to T'% Results o" T' a""e#t the "inal#learan#e o" the stage% Unless T' is #leare!, stage #annot (e #leare! even i" internal0L&T1 inse#tion is #leare!%

/cti9it) Flo Chart

8.1.1 5enerate T&ird Party Ins#ection Plan

This session is use! to generate T' "or the entire ro5e#t% 'nse#tion agen#ies arei!enti"ie! & inse#tion #he#) tye is maintaine! in the system% e%g% '.R, 7.S, et#%'nse#tion Che#) Tyes are revie, itness, monitoring, veri"i#ation, et#%



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Field $ata

ro5e#t No% ro5e#t No%

Stage Sele#t the stage4s to generate T'

7gen#y 8%%? @oom & sele#t 'nse#tion 7gen#ies i!enti"ie!

Che#) tyeSele#t #he#) tye alie! "or the agen#y% This !etermines therole o" inse#tion agen#y in "inal inse#tion%

rint Cli#) on rint (utton to generate T'%

8.1.2 !aintain T&ird Party Ins#ection "*encies by ta*es

This session is use! to maintain or e!it 'nse#tion 7gen#ies an! their #he#) tyesatta#he! to their various stages o" the ro5e#t% 't #an (e u!ate! (y sele#ting a re#or! &#li#)ing on se#ial to oen session Maintain chec t)pe of Inspection /gencies

U!ate 'CL (utton on this session lin)s T' ith stan!ar! inse#tion & u!ates the samein 'CL "or the stages sele#te!%



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Field $ata

ro5e#t No% ro5e#t No%

art art no% 0not ali#a(le1

Seam "rom To Sele#t range o" seams "or the ro5e#t

Stage't !islays stage un!er the seam sele#te!% Ea#h stage #an (esele#te! in!ivi!ually to maintain 'nse#tion 7gen#y & Che#)tye%

U!ate 'CL Line Cli#) on this (utton to u!ate T' !ata in 'CL "or the rese#tivestages%



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/olloing sessions #an (e a##esse! (y #li#)ing on the se#ial menu% 'nse#tion 7gen#ies & Che#) tyes are maintaine! "or the stages sele#te! in earlier sessin%

8.1.3 !aintain T&ird Party Ins#ection esults

2hen Stage is su(5e#t to (oth tye o" inse#tion, i%e% 'nternal 0L&T1 & T', internalinse#tion results are entere! "irst in the system% the status #hanges to rovisionallyCleare# % T' results are entere! in the system ith the !etails o" inse#tion & status isu!ate! Cleare# un!er "inal results o" 'CL lines%

/olloing session is use! to Maintain Thir! arty 'nse#tion Results

Sele#t the re#or! & #li#) on +oom to maintain thir! arty inse#tion !etails%



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Sele#t the re#or! & #li#) on +oom to maintain thir! arty inse#tion !etails%

T' inse#tion !etails are maintaine! in the session (elo%



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%8%8 Maintain NDT ersonal Master

This session is use! to maintain NDT ersons & their !etails % Only ersons maintaine!here #an (e maintaine! as NDT erson es in emloyee authori+ation



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1


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Sele#t "olloing tye o" stages & save the re#or!% '" no arameter is maintaine! "orstage, insert minimum : arameters "rom the list%

i1 'nse#tion tye 9 : nos% 0Sele#t the stage ith se$% no% 8= & :=1ii1 Others tye *? nos%iii1 RT or UT 9 ? nos%

A1 Maintain a##etan#e stan!ar!s & se#i"i#ation "or the sele#te! stages%Session * Maintain 7##etan#e St! (y Stage o" the ro5e#t 0t#lnt=8;m===1

K1 De"ine Seams "or the ro5e#t% Create Seam #o!e as Pyour ro5e#t #o!e4==8Session 9 Maintain Seam (y ro5e#t 0t#lnt=888m===1De"ine minimum ? seams "or your ro5e#t & lin) them to your Quality 'D%

1 Revie the test lan "or the seams%Session 9 Maintain Test lan 9 0t#lnt=8:?m===1O(serve stages aear in the test lan% 07ll the stages lin)e! to Quality 'D !o notoulate in Test lan1%

7!! any one ne stage in the test lan o" ea#h seam%O(serve the #hanges ta)ing la#e in some o" the "iel!s%

1 7rove the Test lan%Session 9 Maintain Test lan 0t#lnt=8:?m===1

8=1 7!! any one ne stage in the test lan o" ea#h seam & o(serve the #hanges ta)ing

la#e in some o" the "iel!s% 7rove the test lan & u!ate the revision no%

881 Coy test lan stages into 'CL% O(serve stages that are #oie! into 'CL%Session 9 Maintain Test lan 0t#lnt=8:?m===1

8:1 7!! ne stages in 'CL (e"ore or a"ter the stages e3ist in 'CL%Session 9 Maintain 'CL Lines 0t#lnt=8:?m==81

8?1 reare erti#al Che#)list (y a!!ing !e"ault stages "or the ro5e#t% 7!! minimum < !e"ault stages & sele#t stage tye as 8miscellaneous. O(serve the #hange in 'CL a"ter #reating !e"ault stages%

Session 9 Maintain De"ault stages (y ro5e#t 0t#lnt=88:m===1

8;1 De"ine ne arts o" the ro5e#t 0en! ro!u#t1 "or overall inse#tion%Session 9 Maintain arts "or 'nse#tion (y ro5e#t 0t#lnt=888m==81

8


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8A1 7rove 'CLs reare! "or all the seams & arts%Session 9 Maintain 'CL Lines 0t#lnt=8:?m==81

8K1 7!! ne stages in one o" the stage & o(serve #hange in 'CL% 7rove 'CL & u!aterevision no% & status% O(serve #hange in status "or the stage ith loest se$uen#e no%

81 O""er stage "or inse#tion a"ter "illing all re$uire! !etails & o(serve the #hange instatus% Session 9 Maintain o""ers "or 'nse#tion 0t#lnt=8:?m==;1Session 9 Maintain 2el!ing ro#ess (y ro5e#t4seam4el!er 0t#lnt=8:;m===1

81 Enter test results "or the stage un!er inse#tion- & o(serve #hanges in 'CL%Session * Enter Test Results 0t#lnt=8:?m==


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