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 Print
A Division of Cameron Publications Limited
Dartmouth, NS
3
CISC
Steel Fabrication
Quality Systems Guideline
Published by the
CANADIAN INSTITUTE OF STEEL CONSTRUCTION
300 201 Consumers Rd
Willowdale (Toronto), Ontario
M2J 4G8
4
TABLE OF CONTENTS
Preface
1. Scope and Aims of Manual
2. Normative Reference
3. Terms and Defnitions
4. Quality System Requirements
1.1 GeneralRequirements
1.2 WorkProcedures
1.3 ControlofDocuments
1.4 ControlofQualityRecords
5. Management Responsibility
1.1 ManagementCommitment
1.2 Organization
1.3 ResponsibilityandAuthority
6. Resource Management
1.1 WeldingPersonnel
7. Process Management
1.1 QCPlanning
1.2 ContractReview
1.3 Purchasing
1.4 Receiving
1.5 MaterialVerifcation
1.6 ControlofWorkmanship
1.7 ProductVerifcation
1.8 CustomerSuppliedProducts
7.9 Storage,Loading,andShipping
7.10 ControlofMeasuringandInspectionEquipment

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8. Measurement, Analysis, and Improvement
1.1 ControlofNonconformity
1.2 CorrectiveAction
1.3 PreventiveAction
8.4 AnalysisofData
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PREFACE
TheCanadianInstituteofSteelConstruction(CISC)isthe
nationalindustryassociationrepresentingthestructuralsteel,
openwebsteeljoist,andsteelplatefabricatingindustriesin
Canada.TheCISCfunctionsasanot-for-proftorganization
promotingtheeffcientandeconomicuseoffabricatedsteelin
construction.
TheCISChaspreparedthisGuidelineinrecognitionofthe
interestinmeetingthequalityrequirementsofitscustomers.
ItisdesignedtoassistCISCFabricatorsindevelopinga
QualitySystemthatwillprovideassurancethatproducts
willconformtocontractualandregulatoryrequirements.
Thisguidelineaddressesthespecialprocessesandspecifc
requirementsofthesteelfabricationindustry.
TheGuidelineisbasedonthebeliefthatqualityawareness
isanintegralpartofallproductionprocesses.Bypromoting
a"prideinworkmanship"attitudeintheemployees,product
qualitywillbemaintainedinthemosteconomicalmanner.
Theguidelinehasbeenpreparedwithreferencetothefollowing
publications:
(a) CSAS16
(b) CSAW59
(c) CSAW47.1
(d) CISCCodeofStandardPractice
(e) ISO9001:2000
(f) ISO9001:1994
Fabricatorsmaychoosetohavetheirqualityassurance
programauditedandregisteredbyaCISCapproved,accredited
qualitysystemsregistrationorganization.
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1. SCOPE AND AIMS OF MANUAL
TheQualitySystemsManual,tobedevelopedbythe
Fabricator,shalldefnethescopeofapplicationwithrespectto
departmentsorsystemsincluded,andproductionlocationif
morethanonelocationiscovered.
2. NORMATIVE REFERENCE
Referencetothefollowingdocuments,whenmadeinthis
guideline,refertothemostcurrentpublishededition.
(a) CSAS16
(b) CSAW59
(c) CSAW47.1
(d) CISCCodeofStandardPractice
3. TERMS AND DEFINITIONS
Thefollowingtermsanddefnitionsapplytothisguidelineor
arecommonlyusedintheindustry.Thefabricatormaychoose
toincludeindustryspecifc,orcompanyspecifctermsand
defnitionsinthissection.
Corrective Action
Anactiontakentoeliminatethecauseofadetected
nonconformity orotherundesirablesituation.
Defect
The non-fulfllment of a requirement that is recognized and corrected
while in current process. For example, a misplaced cleat detected
at the ft checking stage may be directed back to the ftting 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 defne and/or
establish quality requirements.
Nonconformity
Thenon-fulfllmentofarequirement.
Objective Evidence
Datasupportingtheexistenceorverityofsomething
Preventive Action
Actiontoeliminatethecauseofapotentialnonconformityor
otherundesirablepotentialsituation.
Quality Assurance
Qualityassurancemeanstoestablishmeasurestoprevent
problemsandtodemonstratethatsuchmeasuresaretaken
andareeffective,providingconfdencethatthequality
requirementswillbefulflled.
Quality Control
Qualitycontrolencompassesactivitiesaimedatdetermining
whetherresultsobtainedthroughanactivityconformtostated
objectivesforthisactivity.Theresultsaremeasuredandthen
comparedwithapre-establishedobjectiveforthisactivity.
Quality Management System
Asystemtoestablishthepolicyandobjectivesrequiredto
directandcontrolanorganizationwithrespecttoqualityand
toachievethoseobjectives.
Quality Objective
Anaimorgoalrelatedtoimprovementinthequalitysystem.
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Quality Policy
Overallintentionsanddirectionofanorganizationrelatedto
qualityasformallyexpressedbyseniorlevelmanagement.
Record
Arecordissomethingstatingresultsachievedorproviding
evidenceofactivitiesperformed.
Root Cause
The initial and main reason why an event occurs. In corrective
action, the removable factor leading to the elimination of future
nonconformity
4. QUALITY SYSTEM REQUIREMENTS
4.1 General Requirements
TheFabricatorshalldevelopaQualitySystemManualthat
documentstheprocessesnecessarytoprovideassurance
thatfnishedproductsconformtocustomerrequirementsin
accordancewiththerequirementsofthisguideline.
4.2 Work Procedures
TheQualitySystemManualshallbesupportedwithapplicable
workproceduresandsampledocuments.
4.3 Control of Documents
4.3.1 General
TheFabricatorshallestablishandmaintainproceduresfor
approval,issue,andmaintenanceofthedocumentsanddata
requiredfortheoperationoftheQualitySystem.Required
documentationshallinclude,butmaynotbelimitedto,the
following:
(a) Contractdrawings,specifcations,andamendments.
(b) Detailanderectiondrawings.
(c) WeldingdocumentationasrequiredbyCSAW47.1.
(d) Purchaseorders.
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4.3.2 Erection diagrams and shop details
4.3.2.1
The Fabricator or his assigned representative shall prepare shop
details and erection diagrams from Certifed 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.
4.3.2.2
Revisionstodetaildrawings/datashallbedealtwithinthe
samemannerastheoriginals,orasagreeduponwiththe
Customer.
4.3.2.3
Currentissuesofappropriatedocumentationshallbeavailable
atallpointsofuse.Provisionmustbemadetoensurethat
obsoletedrawings/dataareremovedfromallpointsofuse.
4.3.2.4
Ashopdrawingcontrolsystemshallbemaintained.
4.3.3
TheFabricatorshallcontrolthedocumentationrequiredfor
procuredandsubcontracteditems.
4.3.4
TheFabricatorshallensurethatallrequireddocumentationis
reviewedforadequacypriortorelease.
4.3.5
TheFabricatorshalldefnetheretentionperiodfor
documentation,includingconsiderationforrequirementsof
specifccontractsandgoverninglegislation.
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4.4 Control of Quality Records
4.4.1
TheFabricatorshallestablishandmaintainasystemforthe
identifcation,collection,andstorageoftherecordsdetermined
todemonstrateconformancetotherequirementsandeffective
operationoftheQualitySystem.Requiredrecordsshall
include,butmaynotbelimitedto,thefollowing:
(a) Contractdrawings,specifcations,andamendments,
(b) Milltestreports,
(c) Purchaseorders,
(d) Applicableinspectionandtestrecords,
(e) Calibrationrecordsformeasuringandinspection
equipment,
(f) Shippingandreceivingreports,
(g) Non-conformity,correctiveaction,andpreventiveaction
reports.

4.4.2
Allrecordsrequiredbythecontractspecifcationsshallbe
availableforreviewbythecustomerorhisrepresentative.
4.4.3
TheFabricatorshallcontroltherecordsrequiredforprocured
andsubcontracteditems.
4.4.4
Thefabricatorshalldefneretentionperiodsforrecords,
includingconsiderationforrequirementsofspecifccontracts
andgoverninglegislation.

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5. MANAGEMENT RESPONSIBILITY
5.1 Management Commitment
Managementisresponsibleforensuringthat:
(a) Adocumentedstatementisinplacethatdescribes
theFabricator'sQualityPolicywithrespectto
commitmentandqualityobjectives,
(b) Allemployeesaremadefullyawareoftheirauthority
androleintheQualitySystemasdescribedinsection
5.3.1,
(c) AQualitySystemthatconformstotherequirementsof
thisguidelineisimplemented,
(d) Aseniorlevelmanagementrepresentativeisappointed
toensurethattherequirementsoftheQualitySystem
aremaintainedandreported,
(e) Aqualitysystemauditiscarriedoutatamaximum
intervalofoneyear,
(f) TheQualitySystemisreviewedataseniormanagement
levelatamaximumintervalofoneyear,ormore
frequently,toensureitscontinuingsuitabilityand
effectiveness,
(g) Adequateresourcesareprovidedtocarryoutthe
QualitySystemincludingperformanceandverifcation
ofwork.
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5.2 Organization
5.2.1
TheFabricatorshalldefneanorganizationalstructure,which
includesthefollowingfunctionsasapplicable:
QUALITYASSURANCE
ENGINEERING
PRODUCTION
MANAGEMENT DRAFTING
PURCHASING

SALES/ESTIMATING
PROJECTMANAGEMENT
5.2.2
Thischartrepresentsatypicalorganizationalstructure.
Departmentsmayvaryfromcompanytocompany,andmore
thanonefunctionmaybeheldbyoneperson.Anyofthe
functionsnotedmaybesubcontracted.
5.3 Responsibility and Authority
5.3.1
Eachemployeeisresponsibleforthequalityofhisorher
ownworkandcarriesanequallyimportantshareinthe
effectivenessofthequalityassuranceprocess.
5.3.1.1
Allemployeesareresponsibletoensurethatthework
performedbythemconformstoastandardofworkmanship
requiredbythecompanyinaccordancewiththeapplicable
contractrequirements.
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5.3.2
Managementisresponsibleforensuringthatresponsibilityand
authorityisdefnedforcarryingoutthefollowing:
(a) ensuringthatallproductqualityverifcationsare
carriedoutonacontinuousbasis,
(b) dealingwithnon-conformitiesandensuringthatthe
specifeddispositionsarecarriedoutonacontinuing
basis,
(c) communicatingwiththecustomersappointed
inspectionrepresentative(s),
(d) workiscarriedoutinaccordancewiththeapplicable
codesandstandards;
(e) allweldingisinaccordancewiththelatestrequirements
ofCSAStandardsW47.1andW59,
(f) non-conformitiesofatechnicalnaturearedealtwithin
accordancewiththeapplicablecodesandstandards,
(g) ensuringthatallproductionpersonnelunderstandthe
contractrequirementspertinenttotheirassignment,
(h) providingsuffcientnoticeandmakingproper
arrangementsforrequiredinspection,
(i) ensuringthatallcontractrequirements,including
revisions,areconveyedtotherelevantdepartments
andincorporatedintothedetaildrawingsandother
fabricationdata,
(j) purchasingallitemsinaccordancewiththecontract
requirements,includingrevisions,andforobtainingthe
requireddocumentation.
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6. RESOURCE MANAGEMENT
ExceptasstatedinSection6.1,theFabricatorshallidentifythe
personnelandthecorrespondinglevelofeducation,training,
skills,andexperiencerequiredinordertoensurethatwork
affectingproductqualityiscarriedoutintherequiredmanner.
6.1 Welding Personnel
Welders,weldingoperators,tackwelders,weldingsupervisors,
andweldingengineersshallbequalifedtotherequirementsof
thelatestissueofCSAstandardW47.1.
7. PROCESS MANAGEMENT
7.1 QC Planning
TheFabricatorshalldeterminetheprocedures,documentation,
recordsandresourcesrequiredtoensurethattheirproduct
meetsthecustomerrequirements.
7.2 Contract Review
7.2.1
TheFabricatorshallhaveasysteminplacetoensurethat
contractrequirementsarereviewedandincorporatedintothe
work.
7.2.2
TheFabricatorshallensurethatthenecessaryexpertise,
personnel,equipment,andplantresourcesareavailableto
meetthecontractrequirements.
7.2.3
TheFabricatorshallensurethatalladditionsandrevisionsto
contractrequirementsaredulycommunicatedtothenecessary
personnel,andincorporatedintothework.
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7.3 Purchasing
7.3.1
Purchaseordersshallclearlydescribethegoodsandservices
beingordered.Thedescriptionsshallincludethefollowing
informationasapplicabletotheproductbeingpurchased:
(a) Quantity
(b) UnitofMeasure
(c) ProductName
(d) ManufacturersDescription
(e) SizeandLength
(f) MaterialSpecifcation
(g) SpecialProperties(e.g.ImpactCategory)
(h) Finish
(i) InspectionInstructions
(j) SpecialPackagingorShippingInstructions
(k) Applicablestandards
(l) Scopeofwork
(m) Attachmentstothepurchaseorder
(n) Tolerances
7.3.2
Forsubcontractedwork,theFabricatorisresponsibletoensure
thatthefnalproductmeetsthecustomerrequirements.
7.3.3
Specifcations,drawings,processrequirements,inspection
instructionsandotherrelevanttechnicaldatashallaccompany
thepurchaseorderifapplicable.
7.3.4
Purchaseordersshallclearlyspecifythewrittendocumentation
thatshallbeprovidedtoverifyconformancewithpurchase
orders.
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7.4 Receiving
7.4.1
Incomingmaterialsshallbematchedagainstreceivingslips
andpurchaseorders.
7.4.2
Nonconformitiesthatareidentifedatthereceivingstage
shallbedealtwithinaccordancewithSection8.1,Controlof
Nonconformity.
7.4.3
Materialshallnotbeusedorprocesseduntilithasbeen
inspectedandapprovedforuse.
7.5 Material Verifcation
7.5.1
TheFabricatorshallbeabletoverifythematerialspecifcation
ofallitemsinstock,andincorporatedintothework.
7.5.2
Whereindividualpieces,lots,andbatchesarerestocked,the
identifcationsystemshallbemaintained.
7.6 Control of Workmanship
7.6.1
Allemployeesshallbemadeawareoftheirresponsibilities
underSection5.3.1ofthisGuidelineastheyapplyto
workmanship.
7.6.2
Workmanshipandtolerancesshallconformtotheapplicable
clausesinthelatesteditionsofCSAStandardsS16,W59,and
totheCISCCodeofStandardPractice.
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7.6.3
Fabricatorsperformingweldingshallbecertifedbythe
CanadianWeldingBureauinaccordancewiththerequirements
ofCSAStandardW47.1.
7.6.4
TheFabricatorshallensurethatmanufacturingoperations
arecarriedoutundercontrolledshopconditions.Controlled
shopconditionsshallincludeallconditionsthataffectproduct
qualityandtheachievementofcustomerrequirements.
7.6.5
Alltoolsandequipmentusedshallbesuitabletoperformthe
workandshallbeinproperworkingorder.
7.7 Product Verifcation
TheFabricatorshallverifyconformancetothecontract
requirements.
7.7.1
TheFabricatorshalldefneinspectionpointsandinspection
recordrequirementstoverifyconformancetothecontract
requirements,includingthefollowing:
(a) Examinationofmaterialforsize,conformanceto
dimensionaltolerances,andsurfaceconditionordefects,
(b) Examinationofassembliesforoveralldimensions,and
locationandorientationofholesanddetailcomponents,

(c) Verifcationthatweldingiscarriedoutinaccordance
withthecompany'sweldingstandards.Thisincludes
visualexaminationofcompletedweldments,
(d) Examinationofsurfacepreparationandfnish.
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7.7.2
Anyadditionalinspectionrequirementsnotedinthecontract
documentsshallbeidentifedandimplemented.
7.7.3
TheFabricatorshallprovideaccesstoandcooperationwith
theCustomers'designatedrepresentativeforinspectionofthe
workasrequired.Unlessspecifcprovisionsareincludedinthe
contractdocuments,suchinspectionsshallbescheduledsoas
nottoimpedetheprogressofproduction.
7.7.4
TheFabricatorshallensurethatallverifcationhasbeen
performedinconformancewithcontractrequirementsandthis
Guideline.
7.7.5
Alltestrecordsspecifedabovearemaintainedinaccordance
withSection4.4.
7.8 Customer Supplied Products
7.8.1
Uponreceipt,theFabricatorshallexamineallitemsfor
compliancewiththecustomer-supplieddocumentationandto
detectnonconformities.
7.8.2
TheFabricatorshallpromptlyreporttothecustomer,anyitem
foundtobedamaged,incomplete,orotherwiseunsuitable.
7.8.3
Unlessotherwisespecifed,itistheresponsibilityofthe
customertoensurethatitemssuppliedbythecustomer
conformtothecontractrequirements.
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7.9 Storage, Loading, and Shipping
7.9.1
TheFabricatorshallmaintainprocedurestoensurethatall
itemsareproperlyprepared,handled,and/orpackagedfor
storageandshippingtopreventdamagetoproduct.
7.9.2
TheFabricatorshallensurethatitemsloadedcorrespondtothe
shippingbill.
7.9.3
TheFabricatorshallmaintainrecordsofallitemsthathave
beenshipped.
7.10 Control of Measuring and Inspection Equipment
7.10.1
TheFabricatorshallmaintainprocedurestodefnethe
frequencyandmethodsofchecking,testing,and/orcalibration
ofmeasuringandinspectionequipment.
7.10.2
TheFabricatorshallensurethattheequipmentissuitable
fortheworkandcapableofmeasuringwithintherequired
tolerances.
7.10.3
TheFabricatorshallensurethatnewequipment,stored
equipment,andrepairedequipmentarecheckedbeforeuse.
7.10.4
TheFabricatorshallensurethatcalibrationstatusiscontrolled
byphysicalmarking,orothermeans.
7.10.5
TheFabricatorshallensurethatcalibrationrecordsfor
measuringandinspectionequipmentaremaintained.
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8. MEASUREMENT, ANALYSIS, AND IMPROVEMENT
8.1 Control of Nonconformity
8.1.1
TheFabricatorshallestablishaproceduretodealwith
nonconformitiesinordertoensurethatonlyproductsthatmeet
thecontractrequirementsarereleased.
8.1.2
TheFabricatorshalldefnethe:
(a) Authorityfordispositionofnonconformities;
(b) Needfornonconformityreporting;
(c) Methodofidentifyingnonconformitiestoprevent
unintendeduse.
8.1.3
TheFabricatorshallensurethatallnonconformitiesare
dispositionedinoneofthefollowingsways:
(a) Inconsultationwiththecustomer,theitemmaybe
judgedtobeacceptableforitsintendeduse'asis'.
(b) Theitemmaybereworkedorrepairedbyan
acceptableprocedurethatconformstothecontract
requirements.Inthisinstance,itemsmustbere-
inspectedpriortorelease.
(c) Theitemmayberejectedand/orreturnedtostockfor
re-useasallowable,ortothesubcontractor/supplier
asapplicable.
(d) Theitemmaybescrapped.
8.1.4
Recordsoftheresultsanddispositionofnonconformitiesshall
bemaintainedinaccordancewiththerequirementsofSection
4.4.
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8.2 Corrective Action
8.2.1
TheFabricatorshallmaintainasystemforimplementationof
correctiveaction.Proceduresforcorrectiveactionshallinclude
directivesforinvestigationofthecause,recommendationsto
preventrecurrence,andfollowup.
8.2.2
TheFabricatorshalldeterminethelevelofcorrectiveactions
requiredconsideringthemagnitudeoftheproblemsandthe
associatedrisks.
8.3 Preventive Action
8.3.1
TheFabricatorshallmaintainasystemforimplementation
ofpreventiveaction,andestablishaproceduretodealwith
preventiveactioninitiatives.
8.3.2
TheFabricatorshalldeterminethelevelofpreventiveaction
requiredconsideringthemagnitudeoftheproblemsandthe
associatedrisks.
8.4 Analysis of Data
8.4.1
InaccordancewithSection7.7,thefabricatorshalldefne
inspectionpointsandinspectionrecordrequirementstoverify
conformancetothecontractrequirements.
8.4.2
TheFabricatorshalldefnecriticalinspectionpointsand
collectandanalyzerelevantdatapertainingtothosecritical
inspectionpointsemployingsuitableanddefnedstatistical
techniques.Thiswillbecompletedatsuitabledefned
intervals.
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8.4.3
TheFabricatorshallestablishimprovementobjectives,where
necessary,inaccordancewiththeanalyzeddataandother
defnedsourcesofdata.Othersourcesofdatamayinclude,but
arenotlimitedtoNonconformanceReports,CorrectiveActions
ataminimum.