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SBU-Quality Services

Approach to Inspection
& Reporting
By
M. Bhoopathy

Approach to Inspection

Approach to Inspection

Approach to Inspection
The Process: Receipt of Inspection Notification from Client/Supplier/RIC
Preparation:
Establishing Contact with Supplier
Verification of Authenticity of the Inspection Notification
Awareness of the Material / Equipment to be inspected including
functional requirements
Verification of technical inputs available with office/ Supplier
Contract Code
Chargeability
Formats to be used
Verification of earlier Inspection Documents, if any
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Approach to Inspection
At Suppliers Location:
Contact the concerned personnel
Verification of applicable (approved) documents like MR, PO,
Drawings, ITP, Specifications, Procedures, Data Sheets, WPS, PQR,
WPQR and/or any others
Verification of Vendors Internal Inspection Reports such as
dimensional reports, NDT reports, Certified Material Test Reports
(CMTR), Pressure Test reports as per ITP
Availability of calibrated instruments/equipments with Supplier
Verify if the calibration certificates of the instruments / equipments
are traceable to National / International standards

Approach to Inspection
Sampling :
Sampling plan as per ITP/Customer Approved Document or
Applicable standard
Normally sampling is 100% or Random
Percentage of random sampling is to be specified in the approved
document. If not, the same should be clarified from Customer.
In case the Customer is not available/reachable, enquire with the
Supplier on what he intends to offer. Carryout inspection of the
offered materials and record in the report. Seek final decision of
from Customer
Identify the samples witnessed with Sr. No. / Identification No.

Approach to Inspection
Explanation of Hold, Witness, Review, Verification:
HOLD (H):
Hold points are defined as critical steps in manufacturing and
testing whereby SELLER is obligated to advise the
BUYER/BUYERS REPRESENTATIVE in advance of the operation
so that it can be witnessed.
The SELLER cannot proceed with work past the hold point without
witness by the BUYERS REPRESENTATIVE, except by prior
written authorization of the waiver.

Approach to Inspection
Explanation of Hold, Witness, Review, Verification:
WITNESS (W):
Witness points are defined as critical steps in manufacturing and
testing whereby SELLER is obligated to advise the
BUYER/BUYERS REPRESENTATIVE in advance of the operation
so that it can be witnessed.
The SELLER may proceed with work past the witness point if the
BUYERS REPRESENTATIVE can not attend. Seller will keep
record of the inspection activity for review of Buyers
representative.

Approach to Inspection
Explanation of Hold, Witness, Review, Verification :
During the next visit, any similar activity may be witnessed and
reported.
REVIEW (R):
Inspection by review of documentation
Suppliers advance notification is not required.
VERIFICATION (V):
Not a standard term, though finds use with many Customers
Care should be taken while interpreting the term
It can include physical verification of the job, like a joint, a dimension
before signing off the document.
Should be defined clearly before using the term V
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Approach to Inspection
Inspection-Visual & Aesthetics:

Checking completeness with respect to BOM / Drawing / Part List/


P&ID
Cleanliness of the equipment / assembly / system
Weld Cleaning
Verification of bought-outs for Make, Model with respect to
Customer approved documentation

Approach to Inspection
Inspection-Visual & Aesthetics:
Matching of components, wherever possible, if the components are
assembled at Project Site
Match marking (Should be mentioned in the Inspection Report, if not
match marked)
Flatness, buckling, dents, scratch marks, temporary tacks & cleats,
finish
Preparation for shipment (if in scope of inspection)

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Approach to Inspection
Dimensional Inspection:
Check:
Appropriate measuring instruments (accuracy,
least count etc)
Completeness
Orientation
Elevation
Verticality
Straightness
Alignment
Water level
Base frame dimensions
Fitment dimensions

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Approach to Inspection
Dimensional Inspection:
Check:
Keys & key-ways (with slip gauges)
End connections
Threads (with gauges)
Counter flanges
Flatness
Twist
Distortion
Staggering of nozzles / holes
Flange type & serration

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Approach to Inspection

Non-Destructive Testing (NDT):


To be Witnessed for HOLD or WITNESS
To be reviewed for REVIEW
EXCEPTION: Normally Radiographs are reviewed for conformation
to specification. In such case, it should be recorded in the report
as Films Reviewed , Radiographs Reviewed while signing off
the RT report
Verify the calibration requirements of the equipment before
witnessing NDT
Verify approved makes/validity of consumables

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Approach to Inspection
Pressure Test (Hydrostatic / Pneumatic):
Preferably to be carried out with an approved procedure
Minimum two pressure gauges should be used (difference in
reading between two gauges should be 2% of test pressure
maximum)
Range selection of the Gauge (1.5 to 4 times the test pressure)
Dial Size (minimum 2 required by some Customers)
Gauges should be calibrated
Calibration certificates should be traceable to National OR
International standards
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Approach to Inspection
Pressure Test (Hydrostatic / Pneumatic):
Location of Gauges on the job (one at the bottom and the other at
the top location)
Location of vent
Water analysis is available (for Stainless steel equipments)
Safety: Hydrostatic test location should be away from normal
work place, proper scaffolding should be available (if required)
Temperature Rise during test

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Approach to Inspection

Pressure Test (Hydrostatic / Pneumatic):


Circumference of vessel before, during and after hydrostatic test
Pressurizing; Should be done gradually. The Supplier should
carry out hydrostatic test internally before offering to Inspector
Hold Period: As per the approved procedure or standard
Visual Inspection: All area should be visually seen after the Hold
period. Inspector to take help of light to increase visibility.
Observe pressure drop, if any.

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Approach to Inspection
Painting:
Surface Preparation: Roughness and finish
Painting system
Monitor Climatic conditions: Humidity, temperature, cleanliness
(painting booth)
Verify storage facilities of paints
Verify Manufacturers batch No. of the paint (base and hardener)
and their expiry dates
Verify the interval between two coats of paint

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Approach to Inspection
Painting:
Inspect:
Paint shade
Dry Film Thickness (DFT)-Minimum and Maximum Value
Wet Film Thickness (WFT) if required
Scratch test
Adhesion test

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Approach to Inspection
Documentation:
Final Documentation / Inspection Record Book / Manufacturing record
Book / Manufacturers Data Record / Final Disposition Record
Documentation should be reviewed by Supplier for correctness before
submitting for Inspectors review
Check testing, if required, should be done for all the specified
elements of the standard, including the TRACE elements
Verify Material Certification required
Documentation should be reviewed with respect to a specification
(refer spec.)
Supplier to ensure any specific format requirements of Customer
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Approach to Inspection
Documentation:
Documents should be prepared by Supplier as per approved ITP or
procedure
Documents should be compiled by Supplier with respect to an Index
All the sections of the final documentation should be traceable to
Main Index. The individual sections should have sub-index
All the sections of the final documentation should be traceable to
Main Index. The individual sections should have sub-index
All the pages of the Final Documentation should be progressively
numbered
Documentation should be complete, legible
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Approach to Inspection
Material Certification (BS EN 10204):

Types of Material Certification requirements:


(Based on Criticality of Service)

Type 2.1
Type 2.2
Type 3.1
Type 3.2

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BS EN 10204-Type of documents
Non-specific
inspection
documents
Type 2.2

Type 2.1
Name:
Declaration
of
compliance with the order
Content:
statement
of
compliance with the order
(doesnt
include
test
results!)
Who validate
manufacturer

it

the

Name: Test report


Content:
statement
of
compliance with the order
(include test results!)
Who validate
manufacturer

it

the

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BS EN 10204-Type of documents
Specific
inspection
documents
Type 3.1
Name: Inspection certificate 3.1

Type 3.2
Name: Inspection certificate 3.2

Content:
statement
of Content: statement of compliance
compliance with the order
with the order (include specific
(include specific test results!)
test results!)
Who
validate
it
the Who validate it - the manufacturer
manufacturer
inspection
inspection
(independent
of
(independent of manufacturing
manufacturing department!) +
department!)
purchasers/official
designated
authorised inspector
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Approach to Inspection
Conduct of Inspector:
Surveyor represents the Organization. Hence, conduct of the
Surveyor reflects the Organization's culture and value
Surveyor should be impartial, unbiased, honest and should
conduct himself with high dignity in any situation
Surveyor should not indulge in any sorts of unwarranted
argument with Suppliers personnel
Surveyor should not disclose information of one supplier/client to
other supplier/client

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Report writing

Reporting

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Report Writing

Remember
You are the one actually seeing the Equipment/item

Where as
The Customer is visualizing the Equipment/item through your
report

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Report Writing

Inspection Report

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Report Writing
What Do Customers look for in Inspection Report?

Simple

Legible

Complete

Decisive

Conclusive

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Report Writing

Simple Report
For Eg:
Visual-Satisfactory.
or
Visual: Undercuts noticed on CS1 between 90-180,
to be rectified. Other areas visually found ok.
Simple report does not mean insufficient information

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Report Writing

Legible Report

Use black pen 0.5 tip

Write in block letters

Use soft version maximum possible

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Report Writing
Completeness
Verify that all requirements are ensured as per P.O, Drawings,
Technical Specification, ITP as applicable.
Sequence the report, preferably as per the ITP Sl no/contents.
Mention all the documents referred including revision numbers.
Ensure that all the information are ticked/filled as applicable.
Qty - inspected/accepted/rejected/hold are exactly filled in
Reference to the previous reports and content, where applicable

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Report Writing
Decisive
Ensure that you are decisive in each stage
For eg: RT films reviewed and found acceptable.
or
Slag to a length of 19 mm observed in LS4 segment AB
against 12 mm as per code. Not acceptable.
If the requirements are clear, do not expect client to
clarify.
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Report Writing

Conclusive

Client may not have time to go through complete


report

Conclusion of your report is very important

If you seek customer clarification, elaborate and be


specific on what customer need to do. (seek
clarification only if you do not have the acceptance
norm)

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Report Writing

Expediting Report

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Report Writing

What do customer look for in your expediting report?


What is the expected delivery
What is the back up for your assessment
What are the constraints
What should I (customer) do
What should supplier/others do

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Report Writing
Make a Comprehensive Report
Your report should cover

Availability of P.O
Acknowledgement of P.O
Status of Engineering activities
No of drawings & size
under preparation
under approval
commitment for submission

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Report Writing

Status of QAPs

Whether prepared

Submitted for approval

Commitment for submission

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Report Writing
Status of Materials

Consolidated list of materials/BOQ

Whether ordered

Verify proof of ordering

Verify delivery schedule as per sub p.o.

Check with sub supplier in case of critical materials

Whether received at shop

When expected

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Report Writing
Status of Bought Outs

Whether ordered

Verify sub P.O.

Check with sub supplier

If necessary make a visit/recommend visit

Commitment for delivery

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Report Writing
Status of Manufacturing
Verify bar chart/mfg schedule
Verify availability of resources
Men
Machinery
Materials
Verify present load and shop commitments
Project the expected delivery based on your overall
observations

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Report Writing
Highlight where there are possibilities of slippages
Could be

Design
Resources
Client
Summarize action points
Identify responsibilities
Get the time frame
Highlight
What
Who
When
How
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Report Writing

Follow Up

Keep track of action points


Keep client informed of developments (over phone,
mail etc if there is no immediate visit)

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Report Writing

Some Tips
Take notes of your findings
Sequence your findings
Verify all Points are addressed

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Report Writing

A Simple way is Self Audit


or
A re look at your report before signing

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Report Writing

Your report is the ultimate one which converts our


service into revenue
Each of our inspection visits are to be charged
correctly
Ensure that all columns are filled correctly QS No,
Report No, Date etc
Remember billing personnel are non technical and all
your entries are to be accurate.

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Report Writing

Doubts! Please Do Not Hesitate To Ask

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Thank you

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