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Quality System Manual
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Phone 325-643-2277 Fax 325-643-2221
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P. O. Box 2217
Brownwood, Texas 76804
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Document No. QSM – 208
Section i Page 1 of 1
Revision 5
Date Issued: 4/4/2012
Quality System Manual

TABLE OF CONTENTS REV DATE
Section i Table of Contents 5 4/4/2012
Section ii Management Approvals of QSM 5 11/1/2011
Section 0 Quality Policy and Manual Control 5 3/29/2012
Section 1 Scope, Definitions, and Objectives 5 1/23/2012
Section 2 Management Organization and Responsibilities 4 3/29/2012
Section 3 RFQ, Contract, and Specification Review 3 11/1/2011
Section 4 Supplier/Contractor Quality Verification 3 3/27/2012
Section 5 Inspection and Test Plan 4 11/1/2011
Section 6 Receiving Inspection 4 11/1/2011
Section 7 In-Process Inspection 4 11/1/2011
Section 8 Final Inspection 4 11/1/2011
Section 9 Inspection Status 4 11/1/2011
Section 10 Identification and Traceability 4 11/1/2011
Section 11 Special Processes 4 11/1/2011
Section 12 Preservation, Packaging and Shipping 4 11/1/2011
Section 13 NCR, Corrective and Preventive Action 4 11/1/2011
Section 14 Document Control 4 11/1/2011
Section 15 Drawing Review, Control and Issuance 6 3/26/2012
Section 16 Quality Program Procedures 4 11/1/2011
Section 17 Quality Program Review and Manual Revision 4 11/1/2011
Section 18 Quality Records and Documentation 4 11/1/2011
Section 19 Quality Audit 2 3/28/2012
Section 20 Training and Qualification of Personnel 2 11/1/2011
Section 21 Measuring and Test Equipment Calibration 2 11/1/2011
Section 22 Measurements of Quality 1 11/1/2011
Exhibits Documents used for verification of activities 2 11/1/2011

© 2008 Barr Fabrication, LLC. Contains proprietary information. Not to be copied or released without authorization.

Document No. QSM – 208
Section 0 Page 1 of 2
Revision 5
Date Issued: 3/29/2012
Quality System Manual

QUALITY POLICY AND MANUAL CONTROL

Quality Policy Statement
It is the policy of Barr Fabrication, L.L.C. to satisfy the expectations and needs of its
Customers, by providing products of the highest quality of manufacture which fully
meet their requirements, delivered on time and at the agreed price.

Barr Fabrication, L.L.C. is committed to providing our customers with consistently
high quality products/services by implementing a Quality System which recognizes
that everyone is responsible for the quality of their work, which must be consistent
in quality and produced in a cost effective and efficient manner. The aim of each
and every employee is to satisfy our performance standard of producing at the first
attempt defect free work which conforms to requirements every time, or have them
officially changed.

To achieve our company goal of “defect free work”, we have established the
following items to be monitored as a measurement of our on-going commitment to
achieve set goals and continuously improve our products and service to our clients.
 Maintain weld repair rate less than 5% measured monthly
 Maintain dimensional errors less than 250 per month
 Limit Customer complaints to less than 50 annually

© 2008 Barr Fabrication, LLC. Contains proprietary information. Not to be copied or released without authorization.

Document No. QSM – 208
Section 0 Page 2 of 2
Revision 5
Date Issued: 3/29/2012
Quality System Manual

Manual Control
The Quality System Manual is a Company wide document. The requirements stated
in this manual describe the official management position and directives which
establish the Quality System and Quality Assurance Program by which the
company’s quality objectives are achieved.

This Manual is issued and controlled by Barr Fabrication, L.L.C. (BF) Quality
Assurance Department. Copies are issued on a controlled and uncontrolled basis.
A Copy Number inserted in the appropriate space on the title page identifies a
controlled copy of this document. A watermark stating “Uncontrolled Copy” shall be
placed on every page to identify a document that is not subject to updates and/or
revisions.

Controlled copies, and subsequent updates, are issued to assigned Controlled
Manual Holders via a transmittal and acknowledgement sheet accompanied by any
new or revised document(s). The manual holder is responsible for updating their
assigned manual by removing obsolete or superseded pages, if applicable, and for
signing and returning the transmittal and acknowledgement sheet.

© 2008 Barr Fabrication, LLC. Contains proprietary information. Not to be copied or released without authorization.

This Quality Assurance Program describe herein. and effective correction of non-conforming items  Provide our customers with consistently high quality in all products  Assurance of the quality of materials and workmanship from suppliers  Continuously improving the quality of our products and processes © 2008 Barr Fabrication. issue of raw material. packaging. and actions necessary to prevent their re-occurrence. procedures and activities performed to assure conformance with all applicable requirements. early detection. stocking. LLC. LLC. QSM – 208 Section 1 Page 1 of 2 Revision 5 Date Issued: 1/23/2012 Quality System Manual SCOPE. The requirements outlined by this Quality System Manual shall apply throughout the entire process of manufacture or repair. OBJECTIVES. company management responsibilities. . shall apply to materials. identification. processing. and the identification. Document No. inspection and assembly. Contains proprietary information. These controls and procedures provide for early detection of nonconforming items. Objectives of the Quality Program  Compliance with all client requirements as specified  Prevention. the timely corrective action of identified discrepancies. and shipping of completed items. including procurement. products and services used in the manufacture and repair of products/parts by Barr Fabrication. fabrication. Not to be copied or released without authorization. . AND DEFINITIONS Scope This Quality System Manual establishes the company’s Quality Policy and describes the Quality Assurance Program.

C. and the mission of the company’s leadership to the development and effective implementation of the quality system. The written and signed policy by the senior executive of this organization is evidence of the commitment to quality. . monthly reports are provided to management as part of our continuing quality improvement process. Document No. that specifically addresses prescribed requirements of standard or specification defining item Critical To Quality. Quality Control by inspection is one of the elements of the Quality Assurance Program and is the responsibility of the Quality Assurance Department. to define our company goal of zero defects. and company requirements related to the quality of products and services provided by the company. corrective actions and improvements to the Quality System and Quality Assurance Program. QSM – 208 Section 1 Page 2 of 2 Revision 5 Date Issued: 1/23/2012 Quality System Manual Definitions Defect free The term used by Barr Fabrication. Not to be copied or released without authorization. © 2008 Barr Fabrication. Quality System Manual A written description in manual format. evaluating performance to requirements. Contains proprietary information. of all elements of the quality system by which contract requirements are satisfied and company objectives regarding quality are met.L. Quality Policy A directive to all employees to comply with all requirements and to make customer satisfaction a priority in all work performed. . regulatory. All welding activities are tracked by inches of weld deposited and inches of repairs made. performing inspections. methods and other features of the Quality System. monitoring processes. L. initiating or causing to be initiated. LLC. Quality Assurance A department with the responsibility and authority for administering a Quality Management System which includes conducting evaluations. Quality Assurance Program The combination of all written descriptions. actions. Quality System The network of processes specifically designed to identify and ensure compliance with all customers. activities.

Minimum qualifications for key positions shall be established by the executive to whom the position is to report. . QSM – 208 Section 2 Page 1 of 9 Revision 4 Date Issued: 3/29/2012 Quality System Manual MANAGEMENT ORGANIZATION AND RESPONSIBILITIES 1.2 This section of the Manual summarizes the authorities and responsibilities for those who perform activities described in various sections of the manual. Scope Applies to all personnel who perform or are responsible for activities described in this Quality System Manual and the Quality Assurance Program established and maintained by Barr Fabrication. Detailed and specific Quality System elements are provided in other sections of this Manual.1 General 3. 3. Purpose To define the responsibilities and authority for quality related activities for those managing and performing the work.L. L. 2.1.1. HR shall maintain personnel files for each © 2008 Barr Fabrication. 3. and their relationship within the organizational structure. . Document No.3 Each activity shown in the Functional Organizational Chart shall be performed by competent personnel who have the knowledge. Not to be copied or released without authorization. and verifying conformance to quality requirements. LLC. Contains proprietary information.C. 3. experience.1.1 Management personnel are responsible for identifying and providing adequate resources for the performance and verification of the work affecting quality. The organizational relationships of key positions describe herein are depicted in the Functional Organizational Chart contained in this section. and qualifications to fulfill the responsibilities for the position to which they are assigned. The qualifications of each position will be defined in job descriptions which have been included in the company Standard Operating Procedures Manual (SPM) for record purposes only. . Responsibilities 3.

.2 Special projects and/or proto types are entered into the processing system and are processed according to the established policies. .C. production activities. and the review and approval of the Quality System Manual.2 Company Management 3.1 The Functional Organization Chart identifies the members of the Senior Management (SMT) of Barr Fabrication. 3. The President.2 Department Managers are responsible for ensuring the management.1 On occasion. is responsible for the development of the Quality System. operations. and together. Contains proprietary information. by utilization of the SMT. Document No. © 2008 Barr Fabrication. The President. procedures and requirements of the Quality System described in this Manual. LLC.3 Project Management 3. QSM – 208 Section 2 Page 2 of 9 Revision 4 Date Issued: 3/29/2012 Quality System Manual incumbent assigned to key positions in sufficient detail to provide objective evidence of meeting the established minimum qualification requirements for the position assigned.2. a Project Manager may be assigned by the Executive Vice President to manage all activities associated with a special and/or unique project to ensure continuity of production flow and success of the project.3.3 The Project Manager is responsible for coordinating various functions required to fulfill the scope of the special project. oversees all company activities including marketing. establishes the company Quality Policy. procurement and material traceability. The Project Manager shall report directly to the Executive Vice President for all activities relating to the project. 3. administrative and support functions are performed in accordance with the applicable requirements of the Quality Policy and this Quality System Manual including the referenced mandatory procedures which support the Quality Assurance Program. L. and all administrative activities required to support company operations. 3. 3.3.2. quality management. in conjunction with this Senior Management Team. . 3. Quality Assurance Program.L. Personnel performing those functions shall have indirect responsibility to the Project Manager for the performance of those duties until project completion. Not to be copied or released without authorization.3.

3.3 Plant supervisory personnel. welding. Operations.L. Review meetings of this nature are of paramount importance for first time customers. and/or with new and unfamiliar specifications or CTQs. L.4 Marketing 3.5.5 Operations Management 3. packaging. 3. report to the Manager. oversees all sales activities including the following:  Obtaining all customer requirements or specifications pertaining to the order. training. Document No. are responsible for verifying satisfactory completion of manufacturing operations performed in their area of © 2008 Barr Fabrication. and safety. Operations is responsible for directing all plant manufacturing and support functions. Supervisory personnel.C.5. LLC. The review of contract requirements is required by the Quality Assurance Program as described in Section 3 of this manual as soon as practical after receipt of an Request for Quote. QSM – 208 Section 2 Page 3 of 9 Revision 4 Date Issued: 3/29/2012 Quality System Manual 3. Supervisory or Lead personnel are responsible for directing and supervising the work and assuring that the workers are provided sufficient instruction to perform the assigned work safety. understand the scope and requirements of the project. using a defined order entry and change order process.2 The Manger. Not to be copied or released without authorization. who may include Supervisors.5.2 Contract and Specification review is initiated as a function of marketing coordination activities. or their designees.1 The Executive Vice President. Team Leaders or Lead persons. Operations reports to the Executive Vice President and manages all manufacturing activities at the Plant Level. 3. shipping. . The Manager. Contains proprietary information. including material storage.4. This process is to ensure that all personnel involved from the customer and Barr Fabrication. .1 The Executive Vice President also oversees all plant and production operations.  Documenting and communicating all order requirements including subsequent change orders. .4. 3.  Coordinating marketing activities with operations personnel to fully utilize the available resources. products.

including supervision of plant Quality Assurance final Inspection personnel. Not to be copied or released without authorization. the Manager. Plant workers are ultimately responsible for the quality of their own work. inspection results. .5. Contains proprietary information.  Working with suppliers and client to resolve quality issues and establish systems/procedures to prevent reoccurrence of non- conforming items/activities. subcontractors or developed in-house (Shop Drawings) for correctness. QSM – 208 Section 2 Page 4 of 9 Revision 4 Date Issued: 3/29/2012 Quality System Manual responsibility and for the quality of work produced under their supervision.4 Plant workers. 3. LLC.  Reviewing all drawings received from clients. welders. who may include operators. report to plant supervisory or lead personnel and are responsible for performing and verifying their work in accordance with all applicable requirements. including the formulation of policies and procedures by which the elements of the Quality System are addressed. fabrication details and required quality requirements. Quality Assurance reports to the Executive Vice President independently of production. and helpers.  Reporting on the status and improvement of the Quality Assurance Program to Senior Management Personnel. © 2008 Barr Fabrication. 3. Document No.2 The Manager. or quality resolution decisions are not subordinated to production concerns. assemblers. packers. Quality Assurance has the overall responsibility and authority for directing and managing the Quality Assurance Program.1 The Manager.  Maintaining the Quality Assurance Program in compliance with this manual. This reporting structure ensures Quality Assurance requirements.  Making final decisions and resolutions in matters regarding quality when Quality Policy direction is required. 3.3 In addition to the day-to-day oversight and administration of the quality program at the plant level. .6.6 Quality Management 3.6. These responsibilities include:  Ensuring compliance with the company Quality Policy  Developing.6. issuing and controlling the Quality System Manual. fitters. . 3.

However. processes or the Quality System. 3. Our customers provide engineering design drawings that are used as-is or to produce detailed shop drawings. LLC. Each is delegated the responsibility and authority to identify and document non- conformances and quality system problems. © 2008 Barr Fabrication. is under the supervision of the Drafting Supervisor who reports directly to the Manager. 3. The drafting function.1 Barr Fabrication.  Prevent further processing.7. Contains proprietary information. Shop drawings will provide sufficient details and instructions to comply with applicable industry standards. L.  Verify the implementation of solutions or corrective action required to resolve non-conformances. L. 3. Operations.C.2 Drafting personnel prepare shop drawings and bills of material and shop instructions as may be required. Document No.C. wither contract or performed in-house. processes and the Quality System. does provide “sketches” for preliminary proto type components for our clients’ information and production drawing development.6.  Initiate and/or recommend solutions to problems through designated channels. Not to be copied or released without authorization. Operations and are responsible for performing specified in- process Quality Control inspection activities. Barr Fabrication. .L. QSM – 208 Section 2 Page 5 of 9 Revision 4 Date Issued: 3/29/2012 Quality System Manual Quality Assurance shall have the authority and the organizational freedom to:  Initiate action to prevent the occurrence of any non- conformances relating to products.L. .L. does not perform in-house design or develop design drawings and specifications for products it manufactures. .7. delivery or assembly of non- conforming items until the deficiency or unsatisfactory condition has been resolved.C. a qualified professional engineer (or engineering company) is contracted to develop the design and appropriate drawings.  Identify and document any deficiencies relating to products. codes. is responsible for the design of a particular product.4 Production Quality Control Inspectors report to the Manager. when Barr Fabrication.7 Drafting Department 3. L.

The Manager.9. parts. .8.4 Customer furnished drawings are reviewed by the DRT for adequacy of detail.9 Purchasing and Material Services 3. shall be performed in compliance with approved procedures in accordance with AWS D1. 3.8. Quality Assurance. AWS D1. Document No. Operations reviews and approves all purchase orders as described in written procurement procedures. This function is responsible for overseeing activities regarding the procurement of raw materials. This function is responsible for the initiation. Contains proprietary information. .1 Purchasing activities are the responsibility of the Material Services Manager who reports to the Manager. 3.7. fabrication concerns and client specified items Critical to Quality (CTQ).1. © 2008 Barr Fabrication.2 Material Services is comprised of various functions which include.3 Shop detail drawings are reviewed for adequacy of detail and code compliance by a Drawing Review Team (DRT).2 The Welding Administration function is the responsibility of the Manager.8 Welding Program Administration 3. Welder Qualification Records (WQR) and documenting compliance with the plant Welding Program. 3. components.1 Production welding performed by Barr Fabrication.2. . Operations. Operations. AWS D1. estimating. QSM – 208 Section 2 Page 6 of 9 Revision 4 Date Issued: 3/29/2012 Quality System Manual client requirements.C. development and control of Weld Procedure Specifications (WPS). and Quality Program requirements described in this Quality System Manual. Procedure Qualification Records (PQR). purchasing. which includes Quality Assurance. 3. Any changes resulting from these reviews shall be processed through a change order. Not to be copied or released without authorization.5 or ASME SEC IX as applicable. sub-assembles and subcontracted services to meet specified project requirements and schedules. 3. materials control and inventory control.9.7. 3.L. L. prior to the release of the drawings to the Shop Floor. LLC. and the Client.

communicate the requirements.C. . QSM – 208 Section 2 Page 7 of 9 Revision 4 Date Issued: 3/29/2012 Quality System Manual 3.10. including the maintenance of accurate records of materials transactions. 3. Document No. individual certification is required to perform special processes.3 Material Services personnel shall provide input and feedback to the Manager. and to assure compliance in their area of responsibility. 3.10. . 3. Contains proprietary information.9.4 The Materials Services Manager is responsible for establishing and maintaining the Materials Traceability and Inventory Control programs.10. Process descriptions may be in the form of written procedures. one (1) department shall be assigned “ownership” of the overall process and coordinate the development of interdepartmental procedures to ensure continuity of workflow. 3. LLC.10 Shared Responsibilities 3.10. individual workers in production and other processes may require training to perform the assigned work. demonstrated performance and competency of the worker.1 Management and Supervisory personnel of the departments which affect quality are responsible for the development. which includes instructions for performing specified self-checking to verify quality. . L. and for meeting Barr Fabrication.4 To achieve compliance with the Quality Policy. Not to be copied or released without authorization. In some cases. ‘s quality objectivities and Quality Policy.9. 3. documented training.3 In those cases where the duties and responsibilities span departments. Quality Assurance as to supplier performance and ability to meet quality requirements as specified in the appropriate purchasing documents to assure the ongoing acceptable quality of procured materials and/or services. updating and implementation of written descriptions/procedures for activities performed by their departments to assure compliance with the requirements of this Manual.2 Department management for each of these areas is to define the process used to accomplish the activities assigned.L. or other appropriate documented evidence. Managers and Supervisors have the responsibility to implement the Quality Program. Quality Assurance and Quality Control personnel have the duty and responsibility to perform inspections and record results where © 2008 Barr Fabrication.

QSM – 208 Section 2 Page 8 of 9 Revision 4 Date Issued: 3/29/2012 Quality System Manual called for.10. as describe in this Manual and other procedures. © 2008 Barr Fabrication. . Continuous improvement occurs through the Corrective Action System. Document No. to monitor processes. . All processes and resulting documents. to assure all requirements of the Quality Program are met. 3. which affect quality. LLC. fall within the scope of the Quality Program.5 Quality is not limited to workmanship in manufacturing. Not to be copied or released without authorization. the Quality Policy and this Quality System Manual. . Contains proprietary information.

C. Contains proprietary information. L. .L. . Not to be copied or released without authorization. Document No. © 2008 Barr Fabrication. . LLC. QSM – 208 Section 2 Page 9 of 9 Revision 4 Date Issued: 3/29/2012 Quality System Manual Functional Organizational Chart Barr Fabrication.

CONTRACT AND SPECIFIATION REVIEW ED 1.2. LL 2. 3. L. Purpose To assure that a planned and coordinated review of Requests for Quote (RFQ).1.1. or supply.2.3 Barr Fabrication. Material Services.1 The requirements are adequately defined and C documented. .1 General O TR 3. parts. client furnished drawings and/or bills of material. . or other standard forms and written © 2008 Barr Fabrication. all applicable documents shall be reviewed to O ensure that: 3. 3. Contains proprietary information. Document No.2 Any omissions or differences between the contract requirements and those in the tender are resolved.C. Contracts and contracting Specifications is performed at the earliest practical date to ensure all parties. 3.2. .L. LLC.1. to manufacture.L. 3.1.L. L. Scope Applies to all orders of products. checklists. 3. Barr Fabrication.2 Standard Specifications. has the capability to meet the contract requirements.2 Senior Management Team N 3.2. and Quality Assurance.C.C. Production. or acceptance of a contract/order. Responsibilities 3. and proto types contracted to Barr Fabrication. components. Not to be copied or released without authorization. L.1 Before submission of a tender. produce.2.1 Quotation review and Order Processing functions are performed by marketing personnel in coordination with the Senior Management Team (SMT). QSM – 208 Section 3 Page 1 of 2 Revision 3 Date Issued: 11/1/2011 Quality System Manual RFQ. including the client. understand the scope and complexity of the proposed project. where no written statement of requirements is available for a request received by verbal or other means. shall N ensure that the project requirements are agreed upon by those parties concerned prior to acceptance of the U contract.

and O other controlled documents shall be processed and controlled as described in Section 15 of this Manual. including any changes made during the review process. regarding their needs for appropriate information and specifications to fulfill contract requirements U pertaining to their area of responsibility.2. are documented and incorporated into the appropriate shop work instructions.3 Marketing personnel. 3.2. specifications. .3.2. the order is entered and the requirements. define.6 Changes in contract requirements shall be reviewed. and communicate the client’s expectations and Barr Fabrication. LLC.4 A formal Contract and Document Review meeting shall be organized by Marketing personnel to include involvement or LL input from the customer or his representative for special projects with complex or unfamiliar products or requirements. shall obtain and/or initiate the required ED documentation/drawings prior to releasing the contracted work for production. ‘s understanding of the scope of the contracted work. N documented and processed following a written Change Order process. 3.2. Appropriate personnel from those departments expected to execute the contract shall participate in the review meetings to ensure the information needed to process their part of the work O is complete and clearly understood. Resulting changes in drawings. . Contains proprietary information. L.1 Each of these departments is responsible for providing input and assistance to Marketing and/or Project Management in N case of special projects. Material Services. Operations C 3. 3. Not to be copied or released without authorization. Upon acceptance and finalizing the specifications. . 3.L. 3.3 Quality Assurance. or the assigned Project Manager if applicable. © 2008 Barr Fabrication. Document No. QSM – 208 Section 3 Page 2 of 2 Revision 3 Date Issued: 11/1/2011 Quality System Manual requirements will be used to clarify.5 Contract review notes and decisions shall be documented and TR maintained.C.

1. .3. 3.L. qualified.C. LLC.3 Suppliers may be qualified on the basis of the following or other defined and documented methods as determined by Quality Assurance and/or Purchasing such as: 3.1 a review of the Quality system manual describing the supplier’s Quality program 3.1.3. QSM – 208 Section 4 Page 1 of 2 Revision 3 Date Issued: 3/27/2012 Quality System Manual SUPPLIER/CONTRACTOR QUALITY VERIFICATION 1. re-evaluated and monitored.1.L. the process by which suppliers utilized by Barr Fabrication. Contains proprietary information. are evaluated. 3. L. .1 Suppliers and Subcontractors shall be evaluated and qualified to supply products to Barr Fabrication.1.1 General 3. Responsibilities 3. Document No. Purpose To assure that products/materials are procured from or subcontracted to approved suppliers selected from the Approved Suppliers List.L. 3.2 an audit of their Quality processes 3.3.L. .C. Scope Applies to all purchased items and materials or services used in the production of products manufactured by Barr Fabrication.2 Suppliers and Subcontractors shall be evaluated and selected based upon their ability to consistently meet Purchase Order and CTQ requirements.1.3 a review of inspection and test plans © 2008 Barr Fabrication. L. and Quality Assurance activities described herein are performed by qualified Barr Fabrication. Material Control. in accordance with the requirements of this Manual and SOP-QA-2. All related Purchasing. Not to be copied or released without authorization. L.C. 2. personnel. L.C.1.

. 3.1.1.1.3. Quality Assurance Shall maintain a list of approved and qualified suppliers. Quality Assurance and Production personnel are responsible for reviewing requests for approval of new suppliers and determine the appropriate approval method.5 an on-going record of acceptable quality performance 3.2 Material Services. This review will be the joint responsibility of Purchasing and Quality Assurance 3. LLC. Quality Assurance shall be responsible for assuring that purchased items and materials and subcontracted services are inspected in accordance with procedures for incoming inspection 3.4 The initial and continuing qualification process will include reviewing records of supplier performance on an ongoing basis and evaluating the supplier’s capability to meet specified requirements.5 Suppliers’ and subcontractors’ verification of the quality of their products or services shall be surveyed or audited when determined necessary to assure conformance to requirements 3.4 The Manager. . Contains proprietary information.5 The Manager. QSM – 208 Section 4 Page 2 of 2 Revision 3 Date Issued: 3/27/2012 Quality System Manual 3. © 2008 Barr Fabrication. materials or services to be provided and the effect of the product on fabrication operations and/or the final product.4 a product evaluation audit to qualify the supplier or his product 3.3. . Not to be copied or released without authorization. based upon the items.1. .3 Purchasing shall be responsible for assuring that purchase orders are issued to approved suppliers. 3. Document No.

and items that may be subcontracted from time to time to be used in the manufacture and/or repair of those products. materials. Specified fabrication and inspection criteria shall be referenced and/or specified in the appropriate Shop Traveler (ST) for the item and/or product being manufactured and/or repaired. .Management N 3. Material U Services. © 2008 Barr Fabrication.1. Quality Assurance and when applicable. Production planning functions including scheduling activities. documented and performed as necessary to ensure conformance to specified acceptance criteria and requirements as annotated in appropriate contract documents. C 3.1. LLC and to all process. customer representatives to ensure that appropriate customer requirements are identified and included in the ST developed for each project. shall be performed in coordination with Manufacturing. QSM – 208 Section 5 Page 1 of 3 Revision 4 Date Issued: 11/1/2011 Quality System Manual INSPECTION AND TEST PLAN 1. inspection. Applicable portions of this Quality System TR Manual may be applied to subcontracted activities as necessary. Not to be copied or released without authorization. Purpose ED To assure that all work including fabrication. LLC personnel to perform the N duties specified for their appropriate departments and documenting these actions as necessary to ensure compliance with this section of the Quality O System Manual. Contains proprietary information. LL 2. 3. Document No. LLC. testing activities are planned.1. Responsibilities It is the responsibility of all Barr Fabrication. Scope This procedure applies to all products and/or parts manufactured and/or O repaired by Barr Fabrication. packaging and shipping. punch- out. from receipt of raw material through fabrication.

if required. in coordination with Manufacturing. fabrication. 3. packaging and shipping. This includes specifying appropriate quality program standards to be applied to all suppliers/subcontractors as approved by Quality Assurance. Not to be copied or released without authorization.2.3.2. 3.1. is responsible for the development and maintenance of Shop N Travelers for each product or item manufactured by Barr Fabrication. Material Services 3.1. as defined in their approved Quality Manuals TR and applicable Sections of this Quality System Manual.2.  Hold Points shall address applicable CTQ from receipt of material N through identification. Mandatory hold points which require witnessing or verification of selected Characteristics of an item or process. . QSM – 208 Section 5 Page 2 of 3 Revision 4 Date Issued: 11/1/2011 Quality System Manual 3. is responsible for selection of suppliers/subcontractors and the procurement of raw materials.  Where subcontractor’s services will be employed.C. © 2008 Barr Fabrication. 3.2.  Measurement or test records to be maintained.3. sub-assemblies. L. LLC.3.L. parts. The Shop Travelers shall indicate.3.2.2. Quality Assurance. Quality Assurance 3. Document No. Note: All suppliers and subcontractors are responsible for O inspection and verification at their facilities of the materials. and subcontracted ED services in accordance with applicable requirements as annotated in specified contract documents. items or services they provide. Contains proprietary information. U  Characteristics to be inspected. Receiving personnel are responsible for the inspection and LL verification of all purchased materials.  Quality program standards to be applied to subcontracted items and. identify or reference:  Each inspection hold point and its relative location in the fabrication C Cycle. beyond which the work shall not proceed. items and/or subcontracted services in accordance with Section 6 of this manual which includes the documentation of nonconforming items. examined or tested at each hold point and acceptance criteria to be used. components. O 3. Purchasing in conjunction with Quality Assurance.

or their designees.4. in coordination with Quality Assurance. Contains proprietary information. Quality Assurance is responsible for performing reviews of Supplier/subcontractor submitted Quality Programs.3. Production workers are responsible for verifying their work in accordance with all applicable requirements. LLC. Quality Assurance is responsible for performing Final Inspection activities in accordance with criteria as specified in applicable ED procurement documents. including performing In-Process Inspections of their own work. source inspection or receiving inspection. Production supervisory personnel. are N responsible for verifying completion of all In-Process Inspection and Test activities performed by Production Inspectors in their respective areas and completing the appropriate Shop Traveler. . O for the development of work instructions (as required). Surveillance Activities as may be required.4.3. 3. QSM – 208 Section 5 Page 3 of 3 Revision 4 Date Issued: 11/1/2011 Quality System Manual  Method of verification of subcontractor services by subcontractor inspection. Manufacturing 3. hold points establishment.4. O C N U © 2008 Barr Fabrication. 3. and punch-out. 3.3.2. Operations is responsible. and approving the Supplier/subcontractor for inclusion in Barr Fabrication’s Approved LL Suppliers List. Document No. TR 3. 3.1. and appropriate Shop Travelers which will specify the appropriate fabrication sequencing. Not to be copied or released without authorization.4.3.4.

Document No. N 3. and/or customer requirements.1.1. Responsibilities O TR 3. All incoming items and materials shall be visually inspected and verified Purchase Order or supply order requirements. Scope Applies to all incoming materials and items for use in the manufacture/repair of products by Barr Fabrication.2. Incoming items and materials shall be held until all inspections are C completed or the necessary inspection and test reports are received and verified. General 3. QSM – 208 Section 6 Page 1 of 3 Revision 4 Date Issued: 11/1/2011 Quality System Manual RECEIVING INSPECTION 1. 3. documented and dispositioned in accordance with applicable sections of this U manual. 3. LLC.1. © 2008 Barr Fabrication. When applicable.4.3. LL 2. LLC.1.1. N 3.1. . Purpose ED To ensure that incoming materials and items are inspected to verify Purchase Order requirements and to identify these items as required by the applicable Inspection and Test Plan. Nonconforming items or materials shall be identified. Contains proprietary information. Not to be copied or released without authorization. the objective evidence provided by suppliers and subcontractors shall be reviewed as a means of determining that O adequate quality verifications were performed.

Record any discrepancies found during the receiving N inspection activity on a Receiving Inspection Report.1.2. N 3.1.2.1. The receiving process shall include: ED 3.1. LLC.1.6. 3.3 Quality Assurance 3.2. Not to be copied or released without authorization. Visually inspect all incoming items and materials against the shipping notice and Purchase Order or supply order requirements.2.1.2.2. Compare shipping documents and materials certificates to Purchase Order to supply order requirements to assure compliance with the specified material specifications. Assure items and materials are identified in accordance with the applicable Inspection and Test Plan.1. © 2008 Barr Fabrication. Contains proprietary information. Verify that Material Test Reports or Certificates of Compliance are received. 3.2.3.3.5. Count items to verify quantities and visually check for any damage to shipment.2.2. O 3.4. TR 3.2. LL 3. if applicable. QSM – 208 Section 6 Page 2 of 3 Revision 4 Date Issued: 11/1/2011 Quality System Manual 3. Material Services / Materials Control / Receiving 3.1. U 3.7.1. Initial and date the shipping notice documents indicating acceptance and perform the appropriate inventory entry if C applicable. if required by the Purchase OOrder. .1. Quality Assurance personnel shall verify that all incoming items and materials are identified as required by the appropriate purchase order and take custody of the received MTRs/CofCs. Document No.

3. LLC.4 The Materials Expeditor shall be responsible for the appropriate documentation when moving material into and out of production areas to facilitate the maintenance of the Materials Traceability Program. LL 3.O.4 Materials Expeditor 3. Document No.2. 3.4.4. Contains proprietary information. Heat number. .2 The Materials Expeditor shall verify that all raw materials are ED identified correctly with the appropriate P.4. and Project number if required.1 The Materials Expeditor shall off load materials received in conjunction with receiving inspection activities. QSM – 208 Section 6 Page 3 of 3 Revision 4 Date Issued: 11/1/2011 Quality System Manual 3.4.3 The Materials Expeditor will ensure that the each part or lot of material is marked with the information noted in 3. number. O TR N O C N U © 2008 Barr Fabrication. Not to be copied or released without authorization.4.

LLC and to all parts.1.1. they shall be verified. LL 2. 3. Purpose ED To ensure that in-process parts. N 3. Not to be copied or released without authorization.4. N documented and dispositioned in accordance with applicable sections of this manual. U 3. QSM – 208 Section 7 Page 1 of 2 Revision 4 Date Issued: 11/1/2011 Quality System Manual IN-PROCESS INSPECTION 1. tested and identified as required by the applicable ST. LLC. sub-assemblies and assemblies produced. identified. In-process items shall be inspected. Responsibilities O TR 3. Document No.1.2.1. tested and identified as required by the applicable Inspection and Test Plan to verify conformance to specific requirements. identified. General 3. 3. stored and maintained in accordance with the requirements of this manual applicable to purchased items and materials. © 2008 Barr Fabrication. In-process items shall be held until all inspections are completed and O the appropriate sections of the associated ST signed off or the necessary inspection and test reports are received and verified. Scope Applies to all manufacturing/repair processes performed by Barr Fabrication.1.1. and/or customer requirements. Any customer supplied item or material that is lost damaged or is otherwise unsuitable for use shall be documented on a Corrective Action Request and reported to the customer.3. . C 3. When items or materials are provided by the customer that are to be incorporated into the manufacturing or assembly of the final product. sub-assemblies and assemblies are fabricated inspected. Nonconforming items or materials shall be segregated.1. Contains proprietary information.1.4.

are responsible for verifying completion of all In-Process Inspection activities performed by Production Inspectors in their respective areas and documenting such verification on the appropriate ST.2.2. LLC. designated Production ED Inspectors are responsible for performing In-Process Inspections in accordance with the applicable standards and documenting their actions on the appropriate Shop Traveler. .2. O 3.2. Not to be copied or released without authorization. Production workers are responsible for verifying their work in accordance with all applicable requirements. Document No. QSM – 208 Section 7 Page 2 of 2 Revision 4 Date Issued: 11/1/2011 Quality System Manual 3. Manufacturing / Quality Assurance 3.2 Production supervisory personnel. N O C N U © 2008 Barr Fabrication. LL 3. or their designees.3. Quality Assurance personnel are responsible for verifying In Process Inspections and process monitoring activities in TR accordance with the applicable standards and documenting such activities on the applicable product Shop Traveler.1. Contains proprietary information.

Document No. QSM – 208
Section 8 Page 1 of 2
Revision 4
Date Issued: 11/1/2011
Quality System Manual

FINAL INSPECTION

ED
1. Purpose

To assure that completed products are inspected, tested and identified as required by
the applicable Inspection and Test Plan to verify conformance to specific requirements
and completion of all previous inspections and tests.

LL
2. Scope

Applies to all manufacturing/repair processes performed by Barr Fabrication, LLC and
to all completed products produced.

3. Responsibilities O
TR
3.1. General

3.1.1. All completed products shall be inspected, tested and identified as required
by the applicable ST.
N

3.1.2. All inspection and test records shall be reviewed to verify that the
completed product has been inspected at all points shown in the
applicable ST and that the inspection records and Shop Travelers are
O

complete.

3.1.3. Nonconforming items or materials shall be segregated, identified,
C

documented and dispositioned in accordance with applicable sections of
this manual, and/or customer requirements.
N

3.2. Quality Assurance
U

3.2.1. Quality Assurance personnel or their designees are responsible for
performing Final Inspections and reviewing inspection and test records in
accordance with the applicable Inspection and Test Plan and/or customer
requirements and the issuance of Green Tags as applicable.

3.2.2 Final Inspections and the results of each element of inspection shall be
documented using Shop Travelers, checklists, as-built drawings or other
appropriate written reports.

© 2008 Barr Fabrication, LLC. Contains proprietary information. Not to be copied or released without authorization

Document No. QSM – 208
Section 8 Page 2 of 2
Revision 4
Date Issued: 11/1/2011
Quality System Manual
3.2.3 Final inspection will verify that all items are complete and are ready to ship
prior to release from the shop.

3.2.4 Items are not to be released for shipment until final acceptance by Quality
Assurance.

ED
LL
O
TR
N
O
C
N
U

© 2008 Barr Fabrication, LLC. Contains proprietary information. Not to be copied or released without authorization

Document No. QSM – 208
Section 9 Page 1 of 3
Revision 4
Date Issued: 11/1/2011

Quality System Manual

INSPECTION STATUS
1. Purpose

ED
To provide a means for assuring that required inspections and tests are
performed and that the acceptability of items with regard to inspections and
tests are known throughout the manufacturing process.

LL
2. Scope
Applies to all materials, items, parts, sub-assemblies and assemblies
processed or produced by Barr Fabrication, LLC and/or subcontractors.

3. Responsibilities
3.1. General
O
TR
3.1.1. Methods shall be provided for assuring that required inspections
and tests are performed and the acceptability of items is known
throughout processing.
3.1.2. A system for tags, markings, stamped impressions or other
N

physical indicators on the item or its container shall be established
and maintained to indicate acceptance of items, including final
acceptance of completed items.
O

3.1.3 The inspection status of lots or batches of materials or items shall
be indicated as follows; for stacks or bundles, the status indicator
C

shall be applied to the top or most visible and accessible item in
the lot. For smaller items in containers, the status indicator shall
N

be applied to the container.
3.1.4 The identity of the Company and Inspector shall be shown on all
inspection stamps used. The identity of the Inspector shall always
U

be shown on final acceptance status indicators.

3.2. Incoming Materials and Items
3.2.1. Acceptance of incoming materials or items is documented by
initialing and dating the shipping notice documents and completing
a Receiving Inspection Report.

© 2008 Barr Fabrication, LLC. Contains proprietary information. Not to be copied or released without authorization.

Document No. QSM – 208
Section 9 Page 2 of 3
Revision 4
Date Issued: 11/1/2011

Quality System Manual
3.3. In-Process Items
3.3.1. Acceptance of in-process items is documented on the appropriate
Shop Traveler, Drawing or other suitable document. Acceptance is
indicated on the accepted items by marking those items as shown
herein:

ED
1> Black-White Tag/Flag indicates completion of Production
Inspection and the item is ready for QA verification.
2> Solid Blue Tag/Flag indicates that the part has been verified by
QA and is ready for the next operation

LL
3 > Blue-White Tag/Flag indicates that QA has verified the fit-up
and the unit is ready for welding.
4> Red-White Tag/Flag indicates that repairs are required before
further processing. Each tag must be initialed by the person
O
applying the tag, because the tag can only be removed by the
person who applied it.
TR
5> Solid Red Tag/Flag indicates that the item is scrapped as-is
3.4. Completed Items, Sub-assemblies and Assemblies
3.4.1. Acceptance of completed items, sub-assemblies and assemblies
is documented on the appropriate Shop Traveler, Drawing or other
N

suitable document. Acceptance is indicated on the accepted items
by marking as noted herein:
O

1> Yellow-White Tag/Flag indicates that QA has verified the
welding and the unit is acceptable as-is.
C

2> Solid Lime/Green indicates that the item is approved to be
shipped for outside processing (i.e. – coatings).
3> Green-White Tag/Flag indicates acceptance by QA/Prod and is
N

ready for shipment.
4> Solid Green indicates that the unit is acceptable and can be
U

shipped directly to the client.

3.5. Nonconforming Materials and Items
3.5.1. Nonconforming materials and items are documented on a NCR
Form and identified with a Red “Hold” Tag or other suitable form of
identification.

© 2008 Barr Fabrication, LLC. Contains proprietary information. Not to be copied or released without authorization.

2 Green “Accepted” Tags to indicate acceptance of final inspection may only be applied by Quality Assurance personnel. QSM – 208 Section 9 Page 3 of 3 Revision 4 Date Issued: 11/1/2011 Quality System Manual 3. Document No. ED 3.6. but may only be removed by the personnel that applied the original tag. LLC. Any conflicts between Quality and Production must be resolved by the Executive Vice President. Contains proprietary information. LL O TR N O C N U © 2008 Barr Fabrication. Authority for Application and Removal of Status Indicator 3.1.6. Red “Hold” Tags may be applied to nonconforming items by anyone.6. . Not to be copied or released without authorization.

N 3. . Responsibilities 3. 3.1. Purpose ED To assure that each item. etc.1. which are identical but have been processed in separate lots or batches with different Heat Numbers.2. items and documents related to the order. The applicable Heat N Number shall be recorded on all applicable process. Each customer order shall be assigned a Shop Number. U 3.1. from receipt through processing and shipping. inspection and test records. the items or their container shall be identified. 3. Where traceability is specified. © 2008 Barr Fabrication. which is used to identify requirements. LLC. Shop Numbers 3.1. baskets.1 General O TR 3. Each item (lot.1. Contains proprietary information. For smaller items in boxes.2. The Shop Number is derived from the original customer order and accounting File Number and provides traceability to the applicable customer order and end product design. items. work order and customer order from receipt of incoming items and materials through the various manufacturing/repair processes and shipping. sub-assemblies and assemblies processed or produced by Barr Fabrication. the top piece or most visible and accessible item shall be identified. Document No. component or part) shall be identified to applicable drawing. crates. O bins.1. parts. For stacks or bundles of items or materials.. LLC. materials. Not to be copied or released without authorization.3. each item (lot or batch) shall be identified by C the Heat Number that is unique to that particular item. which shall distinguish those items from others. specification or other technical document. 2.2. QSM – 208 Section 10 Page 1 of 2 Revision 4 Date Issued: 11/1/2011 Quality System Manual IDENTIFICATION AND TRACEABILITY 1. Scope LL Applies to all materials. lot or batch is identified to the applicable drawing.

the identification markings shall be transferred to the top most item left in inventory. the identification markings shall be transferred to assure that both the items issued and the items remaining are identified as required.4. sub- assemblies and assemblies shall be marked. bins. Upon completion and acceptance.3. bundles. Heat Number. tagged or labeled with Part Number. . For smaller items in boxes. or containers of materials and items are issued O from inventory locations. Upon completion of each operation acceptable in-process items. Accepted lots of incoming materials and items shall be marked with the assigned Shop Number. sub-assemblies and assemblies N shall be marked.5. 3. crates. piece count and when applicable Shop Number.. items. LLC. Completed Items. O C N U © 2008 Barr Fabrication.4. Sub-assemblies and Assemblies 3. a Materials Request Pick Ticket or a TR Materials Returned To Stock form shall be completed and submitted to the Material Services Manager.1.2.3. etc. For stacks or bundles the top piece or most visible and accessible item is marked. To assure that both the quantity issued and the quantity remaining is identified. When partial stacks.4. Not to be copied or released without authorization. piece count and when applicable Shop Number. Incoming Materials and Items 3.1.2 When materials are issued from inventory.1. tagged or labeled with applicable Part Number.5. Contains proprietary information. 3. the container ED is marked or tagged. QSM – 208 Section 10 Page 2 of 2 Revision 4 Date Issued: 11/1/2011 Quality System Manual 3. when applicable. baskets. 3. piece count and. In-Process Items LL 3. Document No. 3.3.

3.2. C standards and specifications.1.1. equipment and procedures. Heat Treating and Plating U 3.1. including welding. criteria. welders © 2008 Barr Fabrication. N standards.1. General 3. 3. ED and if. Scope Applies to all special processes performed or subcontracted by Barr Fabrication. Documentation for currently qualified personnel. Quality Assurance who shall assure that all welding procedures. LL 2.2. equipment and procedures. using qualified personnel. . Welding. procedures and equipment shall be qualified in accordance with the requirements of applicable codes. heat treating. are accomplished under controlled conditions in accordance with applicable codes. standards and specifications. governmental and contractual requirements. Responsibilities O TR 3.1 Drawings Shall detail welding requirements and joint details and if applicable. and contractual requirements. Contains proprietary information. nondestructive testing. LLC.2. applicable heat treating and plating are accomplished under controlled conditions in accordance with applicable codes. 3. 3.2. Special process personnel. specifications. Measures shall be established and documented to assure that special processes. LLC. O 3. specifications. processes and equipment shall be maintained in accordance with the N requirements of applicable codes. heat treating and plating criteria as required for manufacturing parts/ products in accordance with customer and applicable requirements. using qualified personnel. Not to be copied or released without authorization. plating and nondestructive testing. Purpose To assure that special processes.2 The Welding Program shall be administered by the Manager. Document No.1. QSM – 208 Section 11 Page 1 of 3 Revision 4 Date Issued: 11/1/2011 Quality System Manual SPECIAL PROCESSES 1.3. including but not limited to welding.

approve.2.2 Paint coating shall be in accordance with customer U specifications. including the following: 3. and issue and control Weld Procedure Specifications (WPS) in accordance with the ED American Welding Society (AWS) Specification for Welding Procedure and Welder Performance Qualification.3. 3. Activities associated with heat treating operations may be witnessed by Quality Assurance personnel. to N provide such services. and welding equipment are qualified in accordance with the applicable codes and specifications.2.3. 3.2. Quality of the galvanizing shall be inspected and N monitored to assure uniform and consistent coating meeting the established quality standards. Document No.2.2. the finished coating shall be inspected and monitored to ensure uniform.2.2 All Heat Treating activities shall be performed by a qualified sub- contractor which has been approved by Barr Fabrication. Manufacturing supervisory personnel are responsible for TR assuring that all welding operations are performed by qualified welders. 3. surface preparation and application recommendations.2. when specified. L. QSM – 208 Section 11 Page 2 of 3 Revision 4 Date Issued: 11/1/2011 Quality System Manual and welding operators.2 Administer the welder welding operator qualification testing program in accordance with AWS requirements LL and maintain the required documentation. © 2008 Barr Fabrication.2. O 3. 3. .4 Assure that welding equipment is calibrated maintained in 3.2. or welding operators using approved Weld Procedure Specifications. Painting operations shall be sub- contracted to an approved supplier.2.1 Develop.2. continues. LLC. Not to be copied or released without authorization.2.2.5 O accordance with applicable codes and specifications.1 Galvanized coating.L.3 Coating (Galvanizing/Plating/Painting) 3. and the paint manufactures process control. shall be performed by C a qualified supplier according to specified requirements. shop drawings. Contains proprietary information.2. and qualify.3 Maintain a list of all qualified welders and welding operators. and tightly adhered coating which meets the specified paint mil requirements.C. 3.

L. Assure that NDE services provided to Barr Fabrication.3.3.3. LL 3. in accordance with the written practice and SNT-TC-1A. Barr Fabrication. Drawings shall specify any nondestructive testing as required to verify material or weld integrity in accordance with customer specification and applicable code requirements. LLC in accordance with applicable codes and industry standards.L. Quality of the plating shall be inspected and monitored to assure uniform and consistent coating meeting the established quality standards. responsibilities shall include the 3.3.3.3. Establishment and control the NDE program written practice TR applicable to the service to be provided by. Not to be copied or released without authorization. following: O appointed Level III Examiner.2. qualify and control Nondestructive Examination N procedures in accordance with the established written practice.3.2. 3.3. The administration of the NDE program be the responsibility of the Barr Fabrication.C.3.1. LLC N are performed using procedures and personnel qualified as required by applicable codes and standards and SNT TC- U 1A specifications. when specified. ED 3.2. © 2008 Barr Fabrication. O 3. 3. or on be-half of. shall be performed by a qualified supplier according to specified requirements. maintain all associated records and listing of all qualified C NDE personnel.2.5 A letter of appointment of the qualified Level III NDE Examiner and the approval of the written practice for NDE processes used at Barr Fabrication.1.2. Contains proprietary information.C. The nondestructive examination (NDE) processes. when required. Nondestructive Testing 3.2.4.3 Plating activities.2 Develop. LLC. . L.2. 3. signed by the Executive Vice President shall be kept on file in the Quality Assurance department files to indicate compliance with the above requirements. QSM – 208 Section 11 Page 3 of 3 Revision 4 Date Issued: 11/1/2011 Quality System Manual 3. Document No. Administer the NDE personnel qualification program.3. L. shall be performed by approved subcontractors or appropriately trained and qualified in-house personnel.

3.4. preservation. packaging and marking of all ED parts/products are inspected and shipping operations are verified to ensure contract requirements are met.1. storage and shipping operations are performed and verified in a manner to prevent damage and deterioration. Material Services personnel shall be responsible for assuring that handling. and to comply with applicable written instructions and documenting such verifications on a Shipping Ticket as required. General O TR 3. The cleaning. Scope LL This procedure applies to all completed parts and products produced by and to be shipped from Barr Fabrication. Production personnel shall perform and verify cleaning.1.2. U 3. Responsibilities 3. Customer N 3. coating application. By way of Engineering drawings or written instructions. 3. QSM – 208 Section 12 Page 1 of 2 Revision 4 Date Issued: 11/1/2011 Quality System Manual PRESERVATION.1. Contains proprietary information. 3. preservation. PACKAGING AND SHIPPING 1.1.3. Manufacturing C 3.1. packaging and marking of parts/ products shall be inspected and shipping operations shall be verified to ensure that contract requirements are met. marking and identification O requirements for each order. LLC. .1. Purpose To assure that cleaning. LLC. marking and identification operations as N specified by the applicable written instructions.2. Not to be copied or released without authorization. Document No. as necessary to assure conformance with contract requirements. and document such activities on the appropriate Shop Traveler as required. customer shall provide cleaning. 2. preservation. 3.4 Material Services / Shipping 3. © 2008 Barr Fabrication. preservation.

. LLC.5. 3.5. © 2008 Barr Fabrication. packaging and marking of part/products and verification of shipping operations as required by applicable written instructions and verifying that such ED activities were completed by signing the appropriate Shipping Ticket . QSM – 208 Section 12 Page 2 of 2 Revision 4 Date Issued: 11/1/2011 Quality System Manual 3. which has been tailored to meet the requirements of that particular project/client.1 Quality Assurance personnel shall be responsible for inspection of cleaning. Not to be copied or released without authorization. Quality Assurance/Quality Control. preservation.O. Document No. each Shipping Ticket shall include (as a minimum) data on the following: O  Shipping Ticket Number  Invoice Number TR  Ship From address  Ship To address  Client P.6. As a minimum.  Project/Job Number N  How Shipped O  Truck Number – if applicable  Trailer Number – if applicable C  P. Contains proprietary information. Loader. and Client Receiver plus a date line for each signature. Quality Assurance 3. Line Item Number – as required  Drawing/Part Number N  Quantity  Description U  Date Shipped  Approval Signatures of Shipper. shall be responsible for LL development of a Shipping Ticket for each project/client.O.1 Project Management or their designee.6 Project Management 3. Driver.

1.1. Detect and record nonconformances. 3. CORRECTIVE AND PREVENTIVE ACTION 1.1. parts and products are identified. Define the responsibility and the authority to those who N disposition nonconforming items. Implement the accepted disposition. LLC including purchased and subcontracted items.1. Identify and hold nonconforming items for evaluation. Develop a disposition which has the concurrence of all C responsible parties.5. ED documented and held until final disposition has been made and the corrective and preventive action is taken as necessary. processed or produced at Barr Fabrication. Provide requirements for re-inspecting and re-testing repaired and reworked items. Holding areas or methods for segregating nonconforming items shall be provided to prevent unauthorized use. Contains proprietary information. 3. Where physical © 2008 Barr Fabrication.2. Responsibilities O TR 3.1.2. sub-assemblies and assemblies received. N 3.1.1. Not to be copied or released without authorization.1. 3.1. General 3.6. 3.1.1. . 2. Document No.4.1. Scope LL Applies to all materials parts.1.1.1.1.1. Measures shall be established and maintained for controlling nonconforming items which: 3.1. 3. or recalled items which are identified as nonconforming to preclude unauthorized use.3. Purpose To assure that nonconforming materials. and U 3. rejected. O 3. QSM – 208 Section 13 Page 1 of 4 Revision 4 Date Issued: 11/1/2011 Quality System Manual NONCONFORMANCE.7. Advise purchasing and affected department heads in writing of the final disposition of returned. LLC.1.

3.2 Initiation of appropriate measurements to assure that the N procedure is implemented and affective 3. Handling of customer complaints and reports of LL products/service nonconformance. Document No. marking or other positive means of identification is acceptable.2. Investigation of the cause of the nonconformance. Application of controls to assure corrective action is taken and is effective.1. the nature and extent of nonconformance.1.5. O 3.5. Not to be copied or released without authorization. audit reports.4. QSM – 208 Section 13 Page 2 of 4 Revision 4 Date Issued: 11/1/2011 Quality System Manual segregation is not practical. Records shall be established and maintained identifying nonconforming items.4.4.1. Determination of the corrective action needed to eliminate the cause f the nonconformance. Incoming Materials and Items 3. TR 3.1.2.4. Incoming and purchased materials and items which are found to be nonconforming shall be identified using a Red “Hold” Tag or other suitable means and documented on Materials Received to Stock Report.1.4.4. A Corrective Action Request (CAR) shall be issued to document the need for and type of corrective and preventive actions required to assure that the described nonconformance can not re-occur.3 Conformation that relevant information on actions taken is U submitted for management review. LLC.3.1.5. 3.1. its disposition and objective evidence that repaired and reworked ED items have been re-inspected or re-tested according to applicable documented procedures.1. N 3.4.1. quality records. tagging.5 Preventive action activities shall include the following: 3.1. Contains proprietary information. analyze C and eliminate causes of non-conformance 3. © 2008 Barr Fabrication. in-process problem reports.1. 3. client complaints to detect.1. 3. such as O measurements from process and work operations that affect product quality. 3.2.1 Use of appropriate sources of information.1. . Corrective Action activities shall include the following: 3.3.5.

coordinate and arrange disposition of the nonconforming LL items or materials. 3. Nonconformance’s involving in-process items and completed items except those detected and corrected within the responsible work center.2.1. Purchasing. Contains proprietary information. Quality Assurance Personnel shall assure that the items are re- inspected and/or re-tested to verify correction of the nonconformance and remove the Red “Hold” tag. as applicable. LLC. rework or repair at supplier’s expense.3. C 3. Nonconforming items and materials shall be placed in a designated “Hold” area and conspicuously marked with a Red Tag to prevent unintentional use.2. © 2008 Barr Fabrication.3. A Nonconformance Report (NCR) will be initiated to notify all parties concerned so that the nonconforming item may be dispositioned in a ED timely manner.3. in-process inspection or upon completion that cannot be repaired or reworked within the work center shall be Red Tagged and reported to Quality TR Assurance. 3. Upon notification of completion of rework or repair. return for replacement. Document No. or U  Accepted “As is” by responsible parties.3. shall be identified using a Red “Hold” Tag or other suitable N means. or their designee shall contact the responsible supplier to determine.3. 3.2.2.3.5. in conjunction with Manufacturing and Quality Assurance. and distribute the closed NCR to specified personnel. In-Process and Completed Items 3. credit or refund. scrap. Production workers and supervisory personnel shall assure that O nonconforming items detected during production. 3. The responsible Production supervisory personnel shall be responsible for assuring that all nonconformances are either:  Reworked or repaired to meet specified requirements or N  Scrapped and properly disposed of. QSM – 208 Section 13 Page 3 of 4 Revision 4 Date Issued: 11/1/2011 Quality System Manual 3.4. A Nonconformance Report will be initiated to notify all parties O concerned so that the nonconforming item may be dispositioned in a timely manner. e. 3.g.3. Not to be copied or released without authorization.4. update the Nonconformance Report to indicate completion of disposition.3. 3.2. .

2 Where corrective and preventive action is required. customer input. Not to be copied or released without authorization.4 Corrective and Preventive Action 3. ED 3.4. the resulting responses and actions will be monitored for effectiveness.1 Quality Assurance personnel shall be responsible for periodically reviewing nonconformance data.4. a Corrective Action Request shall be initiated and processed by Quality Assurance. LL 3. QSM – 208 Section 13 Page 4 of 4 Revision 4 Date Issued: 11/1/2011 Quality System Manual 3. Document No. O TR N O C N U © 2008 Barr Fabrication.3 Corrective and Preventive Action data shall be utilized for Senior Management review purposes.4. . LLC. and other inspection and test data to identify the need for corrective and preventive action. Contains proprietary information.

Contains proprietary information. etc.1.1 This section identifies the documents.1.2 Documents affecting quality shall be reviewed for adequacy and approved by authorized personnel prior to use.1. Procedure Qualification Records (PQR).L. Customer supplied O drawings and work instructions (e-mails. Welding Procedure Specifications (WPS). and manuals that fall under N the jurisdiction of the Quality Assurance Program and require distribution and revision level control. Standard Operating Procedures (SOP’s).1 General 3.L. U L. Any obsolete controlled documents being retained for legal or reference purposes shall be so identified as to preclude their use in production activities. TR 3. Welders Qualification Records and other special process procedures. LLC.3 The current revision of applicable drawings and Shop Travelers shall be made available to personnel who are performing essential operations affecting the overall quality of the products produced at Barr Fabrication. Purpose To outline a system of responsibility to ensure that the appropriate revisions of all ED documents affecting quality are reviewed.C. . C 3. QSM – 208 Section 14 Page 1 of 4 Revision 4 Date Issued: 11/1/2011 Quality System Manual DOCUMENT CONTROL 1. L. Document No. A master list shall be established and maintained for each type of controlled document. faxes. N 3. Changes shall be processed in a manner to facilitate the prompt review of the revised © 2008 Barr Fabrication. These include the Quality System Manual (QSM).1. These lists shall be O made available to document users to preclude the use of invalid and/or obsolete documents.5 Changes to controlled documents shall receive the same level of review and approval as the original document. Shop Travelers. approved and controlled by authorized personnel. Scope LL Applies to all essential documents and forms which may affect the quality of products produced by Barr Fabrication. 2. and are readily accessible to the personnel concerned. 3.4 Obsolete controlled documents shall be promptly removed from all areas of use or otherwise assured against unintended use. forms.) that are part of the purchase order shall be controlled as if they were company originated documentation. 3. Not to be copied or released without authorization.1.C. and Shop Drawings. Responsibilities 3.

3 Controlled copies of WPS’s are issued to key personnel in each department. 3. Not to be copied or released without authorization. Quality Assurance is responsible for administration of N the welding program and for the development.1 Standard Operating Procedures contain written instructions that describe how key and cross-functional activities of Barr Fabrication.2 The Manager. QSM – 208 Section 14 Page 2 of 4 Revision 4 Date Issued: 11/1/2011 Quality System Manual documents.L.4. the Manager. LL The Manager. All Welding Procedure Specifications U must be reviewed by Senior Management personnel and the Manager. 3.2 Quality System Manual (QSM) 3. and control of all Welding Procedures Specifications and supplemental instructions and revisions. Contains proprietary information.C. Hand written notes annotated on controlled documents may be acceptable provided they were made by authorized personnel and were signed and dated by the person making the annotation. Quality Assurance is responsible for the issuance and control of the QSM and all associated quality records pertaining to QSM distribution and control.2.2 Controlled copies of the QSM. are accomplished and documented.2.2 All SOPs are controlled by revision level and are reviewed and issued in the same manner as other controlled documents.4 Welding Procedures Manual O 3. If revised.3 Standard Operating Procedures (SOP) 3. Document No.4. Controlled QSM holders are responsible for returning or destroying obsolete pages. TR 3.3. Operations for adequacy and approval for release.1 The Quality System Manual and revisions thereto. C and welder qualification records. Copies of such documents shall be kept on file with the earlier issue ED they are modifying. L. 3. . 3.3. and subsequent changes. A record of revisions shall be maintained and shall include a brief summary of the revision made and reasons why it was necessary. issuance. N 3.5 Special Process Procedures © 2008 Barr Fabrication. shall be reviewed and approved by senior management prior to release for distribution. LLC. 3. A record of QSM O issuance and revision shall be maintained. Quality Assurance or his designee is responsible for replacing all issued copies with the appropriate revised pages and destroying obsolete copies. shall be issued to key personnel in each department.1 The Welding Procedures Manual shall contain master copies of all welding procedures (WPS).4. 3. welding procedure qualifications (PQR).

5. is responsible for developing. including the Level III is qualified in accordance with the American Society for Non-destructive Testing standard practice. These consist of the appropriate Shop Traveler and may include additional documents as may be O required by the Inspection and Test Plan for a particular product. and changes to P. Quality Assurance shall over see the development of all approved NDE procedures and records. SNT-TC-1A. ED 3. L. and producing documents of planned N inspections and tests. components. This file shall contain masters of all authorized standard forms to be used in processing and documenting TR work within the scope of the Quality Assurance Program at Barr Fabrication.O.2 When NDE is specified. QSM – 208 Section 14 Page 3 of 4 Revision 4 Date Issued: 11/1/2011 Quality System Manual 3. sub-assemblies.O.8.1 Quality Assurance. requirements.8 Purchase Orders 3. The Manger.L. © 2008 Barr Fabrication. 3.7. C 3. Quality Assurance shall verify that the applicable NDE procedures to be used have been reviewed and approved in accordance with the subcontractor’s quality program and that the NDE personnel are LL appropriately trained. the Manager. Quality Assurance prior to P.C. Document No. These records may be maintained by the applicable Level III or Manager. 3. issuance. LLC.1 Quality Assurance shall be responsible for maintaining a master file of O all Forms and Exhibits. Contains proprietary information. must be reviewed and approved for release by the appropriate Project Manager or his designee.1 Purchasing is responsible for the initiation and control of Purchase Orders for raw materials.6.6 Forms and Exhibits 3. Quality Assurance. in coordination with Manufacturing. Quality Assurance is responsible for ensuring that all NDE personnel. parts.1 All Non-destructive Examination (NDE) Procedures must be reviewed and approved by a Level III Examiner.5.2 Approved copies of Shop Travelers are issued to personnel in the areas where they will be used and shall become the inspection and N test record for those activities cover by the applicable Shop Traveler. Quality Assurance is responsible for replacing all copies of the forms in use and for destroying obsolete copies. If NDE services are provided by a third party. as needed. . the Manager. U 3. All Purchase Orders.7. specifying. Quality Program requirements for each Purchase Orders shall be reviewed and approved by the Manager. and sub-contracted services. Not to be copied or released without authorization.7 Quality Plan Documents 3. All Quality Program documents must be reviewed for adequacy and approval for release by the Manager. Quality Assurance.

10 Documents of External Origin 3. LL 3. Quality Assurance has been designated as the responsible party for issuance of revisions to customer supplied drawings. .O.8.10. Not to be copied or released without authorization. 3.2 Purchase Orders and P. approval to commence the additional work shall be obtained through the Change Order process.C. N O C N U © 2008 Barr Fabrication. Master copies of all approved Drawings.9 Drawings and Specifications 3. L. LLC. Document No.L. QSM – 208 Section 14 Page 4 of 4 Revision 4 Date Issued: 11/1/2011 Quality System Manual 3. Specifications. When customer supplied drawings and TR specifications require additional work not contained in the original Order. Quality Assurance and/or the appropriate Project Manager or designee. Change Orders are issued directly to the appropriate supplier by the Purchasing Department after the applicable approvals have been obtained.1 All Drawings and Specifications and revisions thereto must be ED reviewed for adequacy and approved for release by the Manager.1 Customer supplied drawings and specifications that are to be used to convey work level instructions are obtained by Project Management and issued as a controlled document as though the document was O originated by Barr Fabrication. and associated records are maintained by the Quality Assurance Department.9. Contains proprietary information.

Not to be copied or released without authorization. QSM – 208 Section 15 Page 1 of 2 Revision 6 Date Issued: 3/26/2012 Quality System Manual DRAWING REVIEW.1. 2. Scope Applies to all projects and activities for products produced or processed by Barr Fabrication. 3. Drawing review shall take into consideration the results of contract review activities.1 General 3.3 Drawings shall be reviewed to ensure that design requirements - relating to the product. L. 3. including applicable statutory and code requirements are identified.1 Shop drawings shall be prepared for the products to be manufactured for each order as required. Responsibilities 3. if required. L.L. personnel. L.C. and other details shall be clearly depicted or stated. Standard structural steel drawing convention showing details sufficient to fabricate the parts and complete the assembly.2. are performed in-house by qualified drafting personnel.2. Barr Fabrication. Document No. LLC. Drafting of shop drawings. Purpose To assure those drawings and other documents that affect end products fabricated by Barr Fabrication.2.C.2 Customer furnished drawings that are intended to be used for production will be reviewed to insure the details in 3. any inadequacy. including AWS welding symbols. paint notes. . are controlled to ensure that the only current revisions are used.L.1 are shown or provisions shall be made to provide other supplemental documents to furnish the required details 3.L. When required. L.C. Incomplete.C. contracts with qualified professional engineering organizations to perform the required design functions.L. © 2008 Barr Fabrication.1 Design activities are not performed by Barr Fabrication. 3.2. CONTROL AND ISSUANCE 1. appropriate bolting arrangements.2 Drawings 3. Contains proprietary information. ambiguous or conflicting requirements shall be resolved with those responsible for imposing these requirements.

. control and retention. Wavier of such approvals shall be documented and annotated on the affected drawings.3. there shall be no exceptions. Not to be copied or released without authorization.5 All drawings shall be stamped with a Job Number and/or annotated with a Released for Production stamp that includes the date of release. they shall be controlled in the same manner as original hard copies.4. Contains proprietary information. Each set shall be marked RELEASED FOR PRODUCTION and shall include the date of release. 3. All other “copies” of drawing not so marked shall be destroyed and prevented from use during production. Document No.4.4. The completed drawing package shall be forwarded to the client for review and approval prior to release.1 All design changes and modifications shall be identified. QSM – 208 Section 15 Page 2 of 2 Revision 6 Date Issued: 3/26/2012 Quality System Manual 3. Such changes shall be transmitted to the applicable client personnel via company email which become a permanent part of the project quality records.4 The Shop drawing package shall include Bills of Material that have been reviewed for completeness and checked for accuracy and formatted in a manner that can be verified and validated against the order and contract requirements. © 2008 Barr Fabrication. 3.3 Design Changes 3.1 Quality Assurance has been assigned the duties of drawing review.3 Drawings received in an electronic format shall be reviewed by the Manager.2 Currently the Shop Drawing department will produce as many sets of controlled drawings for each project as required to adequately perform the work. then approved and “stamped” by Quality Assurance prior to printing.2. 3. 3. LLC. 3. File copies of all controlled drawings and associated document modifications shall be maintained in the Quality Assurance department for reference and reproduction as may be required.4 Controlled Copies 3.2. When these drawings are printed. the original set shall be retained by Quality Assurance and shall become the control copy for that project. Quality Assurance and management personnel. documented and reviewed prior to submittal to the client for approval or waiver of such approvals.

3 Some of the above procedures are described in sufficient detail in this manual. Not to be copied or released without authorization.C.L. etc. Scope LL Applies to all activities which may affect the quality of products produced by Barr Fabrication. Document No. L. Others may be in the form of Standard Operating Procedures or some other appropriately controlled document format. control and updating of this Quality System Manual and other Quality Assurance Procedures and TR Standards as may be required by this manual. QSM – 208 Section 16 Page 1 of 1 Revision 4 Date Issued: 11/1/2011 Quality System Manual QUALITY PROGRAM PROCEDURES 1.) C  Supplier Quality Programs  Material Traceability N  Nonconformance and Corrective Action  Quality Records  Management Reviews U  Supplier Qualification and Evaluation 3. Responsibilities 3. 3. Purpose To assure that documented procedures are established and implemented to assist ED personnel in meeting established standards and requirements as defined by the Quality Assurance Program. 2. 3. NDE. procedures..2 Every department who performs activities defined by this manual shall document those activities affecting quality and/or defined by the Quality Assurance Program in written procedures that comply with the criteria as N specified in the appropriate sections of this manual. including those functions related to the implementation of the Quality Assurance Program. Controlled procedures shall be developed for the following activities and functions. LLC. forms. as a minimum: O  Procurement of materials  Special Processes (Welding. etc. © 2008 Barr Fabrication. Contains proprietary information. .)  Document Control (Drawings.1 O Quality Assurance is responsible for development.

LC.1. Quality Assurance shall be responsible for assuring that a review of this System is performed at least annually to assure that O the Manual reflects current QA practices and BF Standard Operating Procedures. as necessary to reflect current Quality Assurance practices. QSM – 208 Section 17 Page 1 of 2 Revision 4 Date Issued: 11/1/2011 Quality System Manual QUALITY PROGRAM REVIEW AND MANUAL 1. All Manual revisions shall be processed by Quality Assurance. C 3.2. Not to be copied or released without authorization .1 The Barr Fabrication. Purpose ED To assure that this Manual accurately describes the Quality Assurance Program of Barr Fabrication.1 The Manual shall be updated to reflect actual practice and to address any deficiencies identified and documented by third party audits or other reviews of the Quality Assurance N Program.1 The Manager.2 Manual revisions shall be reviewed.C. 3.L. L. Responsibilities 3. LLC.1. 3. Quality Assurance. and that it is reviewed at least annually and updated. and issued in U accordance with Section 14 of this Manual.1.2.2 Quality Assurance N 3. Contains proprietary information. © 2008 Barr Fabrication. Document No. approved.2 The Manager.2.1 All revisions to the Manual shall be issued with a cover letter to those persons holding controlled copies of this Manual. Scope LL Applies to this Quality System Manual. and to the quality-related activities. Quality System Manual may be reviewed and updated at any time that changes to processes or procedures may TR require.2. or designee.1 General O 3. 2. processes and documents described by this Manual.2. which may enhance its accuracy and overall effectiveness. 3.2. shall coordinate pending revisions with all affected department activities: 3. L. 3. All personnel may make suggestions for revisions to this Manual. procedures.

or initialed. The updating of individual manuals and the destruction of obsolete documents is the responsibility of the Manual holder. QSM – 208 Section 17 Page 2 of 2 Revision 4 Date Issued: 11/1/2011 Quality System Manual 3. cover letter shall indicate that the manual has been updated by the authorized manual holder. Contains proprietary information.2.2 Signing or initialing the cover letter and returning it to Quality Assurance shall indicate receipt of Manual revisions by authorized personnel. LL O TR N O C N U © 2008 Barr Fabrication. LLC.2.3 Receipt of a signed.2. Not to be copied or released without authorization .2. ED 3. Document No.

Not to be copied or released without authorization.2 Quality records shall include Inspection and Test records which identify: U 3.1 Completed products meet contractual requirements.1. O 3.1 Quality records shall be maintained to verify that: N 3.1. inspection and test records. Scope LL Applies to all quality records including.4 Nonconformance reports.1 General 3.1. Shop Travelers and checklists. QSM – 208 Section 18 Page 1 of 2 Revision 4 Date Issued: 11/1/2011 Quality System Manual QULAITY RECORDS AND DOCUMENTATION 1. and personnel qualification and training records associated with the production/repair of products fabricated by Barr Fabrication.1.2.1. material traceability documents. Contains proprietary information.1. LLC. specification sheets.2. 3. welding and company procedures.L.1 The drawing and revision number or part number applicable to a specific purchase order.2.1. L. Document No. 3.1. Shop Instructions. 3.2. N 3. Responsibilities O TR 3.1. 2. and equipment are qualified.3 Specific inspections made and results obtained.3 Suppliers and subcontractors are evaluated and C selected on the basis of their ability to meet quality requirements on an ongoing basis.C. © 2008 Barr Fabrication. Purpose ED To assure that records and documents that have a direct affect on product quality are maintained to provide evidence of conformance to specified quality requirements.1. 3. procedures. .2 Personnel.1.2 Applicable requirements.1. 3.

customer request.1. 3. O 3. TR unless otherwise specified.2 Company Records 3. Quality records may be archived electronically.1. SOP. 3. L. L.1 Company records shall be retained as specified in the applicable Barr N Fabrication.2.6 Receiving inspection reports.1. O C N U © 2008 Barr Fabrication.L.2 Identified. 3.3 All quality records identified by this Quality System Manual shall be: ED 3.4 Quality records shall be stored in a suitable environment to minimize deterioration or damage. or other Barr Fabrication. Not to be copied or released without authorization. Contains proprietary information.1. QSM – 208 Section 18 Page 2 of 2 Revision 4 Date Issued: 11/1/2011 Quality System Manual 3.3.3.3.C. Standard Operating Procedure.C.3.2. LLC. Document No.L. and to prevent loss. LL 3. indexed and filed for easy retrieval.1.1.3 Retained for a minimum of five (5) years unless otherwise specified by the applicable contract documents. . 3.2.1.5 Corrective action requests.1 Made available for audit and review.

1.1. The supervisory personnel responsible for the area shall take timely corrective action on the deficiencies found by the audits. 3. L. Additional audits may be conducted of specific elements of the Quality Assurance Program to ensure all elements of the Quality System Manual are reviewed within a twelve-month period.1 Internal Quality Audits shall be conducted to verify compliance with this Quality System Manual and applicable AISC requirements 3.3 Internal quality audits shall be performed using detailed audit checklists and other approved supplemental checklists to ensure all elements of the QMS are effectively implemented. all internal audits shall be completed prior to the annual anniversary date of the SMT review of the Quality System Manual. .1 . Responsibilities 3. 3.1. Contains proprietary information. 3. Not to be copied or released without authorization.1. (BF) covered within the scope of the Quality Assurance Program. 2.L. Document No.1.5 The results of the audits shall be documented and brought to the attention of the personnel having responsibility in the area audited. 3. General 3. © 2008 Barr Fabrication. LLC. Scope Applies to all activities addressed by this Quality System Manual performed by Barr Fabrication. Purpose To assure that internal quality audits are carried out at least once per year to verify whether actual practices are in accordance with the requirements of this Manual and to determine the effectiveness of the quality system.C.4 Trained personnel who have the organizational freedom to record deficiencies shall be designated to perform the internal audits. QSM – 208 Section 19 Page 1 of 2 Revision 2 Date Issued: 3/28/2012 Quality System Manual QULAITY AUDITS 1.2 Internal audits shall be planned and conducted as a minimum on an annual basis.

1.2 Quality Assurance 3.1 Scheduling internal Quality Audits addressing all requirements of the Quality System Manual. 3. Those assigned to conduct audits shall not have responsibility for the area being audited. documented and verified. Contains proprietary information.4 Training personnel in the proper audit methods and techniques to be employed when conducting audits of both internal and external activities.2.2.2. Not to be copied or released without authorization.1. Document No. .1.3 Assuring that a program of follow . 3. Quality Assurance is responsible for directing the Internal Quality Audit Program.1. 3.2. LLC. © 2008 Barr Fabrication.up activities is conducted to assure that corrective action is completed.2 Assigning qualified personnel to perform scheduled Internal Quality Audits.1 The Manager. including: 3.2. QSM – 208 Section 19 Page 2 of 2 Revision 2 Date Issued: 3/28/2012 Quality System Manual 3.

Not to be copied or released without authorization. and/or demonstration of O competency to perform the task according to requirements 3. Scope LL Applies to the training requirements for all personnel involved in activities affecting quality 3. LLC.6 All personnel performing activities described or required by this Manual U shall be trained in the quality requirements applicable to those activities © 2008 Barr Fabrication. Document No. Contains proprietary information.3 Personnel performing specific tasks shall be qualified on the basis of appropriate education. 2. . QSM – 208 Section 20 Page 1 of 1 Revision 2 Date Issued: 11/1/2011 Quality System Manual TRAINING AND QUALIFICATION OF PERSONNEL 1. Purpose ED To assure that the training needs of all personnel involved in activities affecting quality are identified and that the required training is provided.2 Supervisory personnel in each area are responsible for identifying training needs and arranging for training of all personnel involved in activities affecting quality during production and assembly operations.5 Appropriate records of training and other records of qualification shall N be established and maintained. 3. training. N 3. Responsibilities O 3.1 Management personnel shall be responsible for determining the TR personnel qualification requirements for key positions and assigning qualified personnel to those positions 3.4 Personnel “in training” shall perform activities affecting quality only C under the supervision of fully trained and qualified personnel 3. experience.

and machines 3. Scope Applies to specific measuring and testing equipment used by Barr Fabrication.3 At prescribed intervals determined for each item. maintained and calibrated at prescribed intervals. Not to be copied or released without authorization.1.L. fixtures. . LLC. Responsibilities O TR 31 General 3. 3 1 2 Quality Assurance shall maintain a listing of all active measuring C and testing equipment and monitor calibration due dates to assure they are calibrated within the prescribed intervals N 3.1 Documented procedures shall be established to control. Purpose ED Assure that all measuring and testing equipment and devices used to establish or verify item quality or to monitor special processes are controlled. Accuracy checks and inspection for wear or damage may be performed by Manufacturing personnel or © 2008 Barr Fabrication. Contains proprietary information.1. L. or prior to use. Calibration may be performed by BF to a calibrated master or may be subcontracted to the equipment manufacturer or an approved subcontractor. the basis employed for calibration shall be documented This can include industry or user standards New equipment may be considered calibrated if certified to the required accuracy by the manufacturer. QSM – 208 Section 21 Page 1 of 3 Revision 2 Date Issued: 11/1/2011 Quality System Manual MEASURING AND TEST EQUIPMENT CALIBRATION 1.C. Document No. specified measuring or test instruments shall be verified for accuracy or calibrated and adjusted against certified equipment U traceable to nationally recognized standards. LL 2. Applies to all master gauges and standards used to calibrate equipment and to gage points on jigs. Where no national standard exists. calibrate and maintain specified measuring and test equipment and devices recording and maintaining a Master List of measuring N and test equipment and maintaining calibration requirements for these devices in an electronic database or in a spreadsheet will O satisfy this requirement.

3 1 6 Environmental conditions shall be suitable for the calibrations O being carried out Unless otherwise specified. or Procedure No © 2008 Barr Fabrication. the standard manufacture’s calibration certificate may be used for Starrett and Stanley brand tapes. such as tape measures. etc may be considered to be an acceptable method. Document No. Not to be copied or released without authorization. O 3. These items are not required to be included under the scope of this policy. LL 3 1 5 Calibrated measuring and test equipment shall be identified with a Calibration sticker. they are to be repaired or replaced. TR 3. LLC. including U manufacturer or subcontractor Calibration Certificates Calibration records shall contain the following records:  Equipment type  Identification number (and Serial Number. steel rules. Contains proprietary information. shop and/or office atmosphere may be considered to be a suitable environment.9 For short tapes. .8 Measuring and test equipment shall be safeguarded from N adjustments that would invalidate the calibration setting. stored and preserved in a manner to prevent damage and deterioration to assure that accuracy and fitness for use are maintained 3.4 Measuring and testing equipment under the scope of this policy shall be labeled or marked with a unique identifier. When these C tapes are found to be worn and/or broken. Placement of the calibration sticker over adjusting screws. tag or other suitable indicator to show the calibration status of the item. N 3. either the manufacturer’s serial number or an identification number which shall be annotated on the appropriate documentation. squares.1. the entire tape unit shall be replaced.1. QSM – 208 Section 21 Page 2 of 3 Revision 2 Date Issued: 11/1/2011 Quality System Manual users of measuring devices for items not on the Master List and for simple measuring devices. etc. not just the blade.1. When these devices show signs of wear or damage that could cause inaccuracy of ED measurements.2 Calibration Records 3 2 1 Quality Assurance shall maintain calibration records. 3.1. if applicable)  Location or owner/user  Calibration interval or frequency of checks  Description of calibration I check method.7 Measuring and test equipment shall be handled.

it shall be promptly re-calibrated or removed from service and Quality Assurance shall be notified The Manager. Not to be copied or released without authorization. Contains proprietary information. TR N O C N U © 2008 Barr Fabrication. Document No. Quality Assurance is responsible for evaluating and documenting the validity of previous inspections and tests made O with the item and initiating any necessary corrective action. .3 Action When Results Are Unsatisfactory LL 3. LLC. QSM – 208 Section 21 Page 3 of 3 Revision 2 Date Issued: 11/1/2011 Quality System Manual  Acceptance criteria  Action taken when results are unsatisfactory  Calibration results  Date of last calibration ED  Person or company performing the calibration  Next calibration due date 3.1 When any measuring or test equipment is found to be out of date or out of calibration.3.

1. Not to be copied or released without authorization.1 Conformance to requirements O 3.1.L. 2.1.1. evaluate and monitor quality performance and progress toward quality improvement. QSM – 208 Section 22 Page 1 of 2 Revision 1 Date Issued: 11/1/2011 Quality System Manual MEASURMENTS OF QUALITY 1. I.1.1. Scope LL Applies to all departments and operations of Barr Fabrication.1. Responsibilities 3.I. Following are some examples of measurements of key performance indicators that will N satisfy this requirement: 3.1. L.2 Customer Satisfaction 3.C. LLC. Document No.5 Internal QSM Audit scores 3. .6 Safety © 2008 Barr Fabrication.4 Effectiveness of Prevention and Corrective Actions 3. 3 Improvement trends for key processes C  Manufacturing quality  Supplier Quality N  On time delivery U 3.1.1 General O TR 3. Purpose To assure that measurements are established to evaluate the performance of ED the organization with respect to the stated objectives of the Quality Assurance Program and the Quality Policy. Contains proprietary information. and to all suppliers or subcontractors whose performance is essential to meeting stated company objectives and the Quality Policy 3.1 Performance measurements shall be established for appropriate processes to.1.1.

Contains proprietary information.2. .2. Document No.1. 3.2.2.2 Quality Assurance O 3. QSM – 208 Section 22 Page 2 of 2 Revision 1 Date Issued: 11/1/2011 Quality System Manual 3. Not to be copied or released without authorization.3 The products.1. processes or their characteristics to be accepted or O rejected on such a basis shall be identified and the statistical process control charts and records will be maintained as objective evidence of assurance of quality C N U © 2008 Barr Fabrication.2 Their use to measure key performance indicators of the Quality Assurance Program shall be documented in LL reports to management.1 Their use for the assurance and control of quality and the acceptance or rejection of lots or batches based on data ED from key measurement characteristics shall be identified.2. 3. 3.2 Where statistical methods are used to satisfy requirements of this manual: 3.2 Quality Assurance shall assure that any statistical techniques or sampling practices used as the basis for assurance of quality and acceptance or rejection of lots are identified and are valid for the N application being used.1. LLC. classified and documented.1 Quality Assurance shall identify key areas where performance data can be readily compiled and used to provide measurement information that will be helpful in determining quality performance TR and quality trends 3.

Description of Document/Form Department Revision LL QA-332-09 Materials Received to Stock Report Material Services 11/1/11 R3 QA-1032 Nonconformance Report Quality Assurance 10/26/05 QA-1034 Corrective Action Request Quality Assurance 02/06/06 QA-432-11 QA-432-10 O Shop Traveler – Unit Shop Traveler – Pre-Fab Production Production 12/16/05 12/16/05 TR QA-432-12 Shop Traveler – Sub-Assemblies Production 12/19/05 QA-432-13 Shop Traveler – Cut Ticket Production 02/02/06 QA-734-09 Materials Pick Ticket Material Services 02/06/06 QA-734-08 Materials Return To Stock Material Services 12/28/05 N QA-1531-1 Daily Inspection Report – Shop Quality Assurance 02/2/08 R3 O QA-1331 Red Tag Resolution Quality Assurance 10/31/06 R1 QA-1331A Red Tag Resolution Tracking Log Quality Assurance 11/1/06 C QA-431-1 Stamp Receipt and Control Log Quality Assurance 05/2/07 D-201-1 Number Request Drafting 08/02/11 R2 N A-100-1 Change Order Management 11/30/05 A-101-5 Form Review Record Management 11/29/05 U A-102-4 Procedure Review Record Management 01/02/06 A-103-OM Internal Memo Form Administration 02/21/06 QA-832-1 Weld Tracking Report Quality Assurance 07/30/07 P-001 Purchase Order Addendum Purchasing 12/5/05 © 2008 Barr Fabrication. L. . No.C. LLC. Not to be copied or released without authorization.L. to verify compliance with the Quality Assurance Program addressed in this Quality System Manual. Contains proprietary information. QSM – 208 Section Exhibits Page 1 of 1 Revision 2 Date Issued: 11/1/2011 Quality System Manual EXHIBITS The exhibits listed in this section. are for information only and show examples of the types of documentation utilized by Barr Fabrication. Each ED document or form is controlled by detailed procedures developed by the department utilizing the document/form. Document No.

U N C O N TR O LL ED .

Weld Tracking Report Stamp Job Item In. Rej Defect Proc Code Date Type Inspector ED LL O TR N O C N U QA 832-1 Rev 0 7/30/07 . Insp In.

Stamp Receipt and Control Log Name Insp Rec Audit Issue Date Rtn Date Signature ED LL O TR N O C N U QA 431-1 Rev 0 5/02/07 .

must purchase new unit O Request Deviation to use AS-IS Damaged in Transit—Replace unit and Back-charge Hauler C Manufacturing error—unit to be repaired or replaced Supplier error. No: Drawing: Description: ED Job Site: Supplier: Quantity Rejected: Submitted by: Description of Non-conformance: LL O TR N Proposed Resolution: Damaged By Job Site Personnel (Client) .: Customer Cust: QA—1331-07 Rev 1 10/31/2006 .O.A. not built to drawing—Supplier to replace N No error—use AS-IS Concurrence Required Concurrence Signature Date U Management Mgt: Manufacturing Mfg: Quality Assurance Q. Red Tag Resolution Report Date: Red Tag No: RTR No: Client: Project: Shop No: P.

Corrective Action Request Date: CAR No: Submitted By: Cust: Shop No: Project: Description of Problem requiring corrective action: ED LL Proposed Resolution: O TR N Basis for Resolution: O C N Concurrence Required Concurrence Signature Date U Engineering: Manufacturing: Verification of Implementation of Corrective Action: Date Verified By: QA—1034 Rev 0 02/06/06 .

O.: Customer Cust: Re-Inspection of Non-conforming Items Date Re-Inspected By: QA—1032 Rev 1 10/26/2005 . No: Sub-Assembly (Y/N): Drawing: Item No: Description: ED Location: Responsible Department: Qty Inspected: Qty Rejected: RIR No: Description of Non-conformance: LL Proposed Resolution: O TR Remarks: N Disposition of Problem Solution: O Use As Is Re-work C Repair as Marked Scrap/Reject Return to Supplier N Other Concurrence Required Concurrence Signature Date U Engineering Eng: Manufacturing Mfg: Quality Assurance Q. Non-Conformance Report Date: NCR No: Submitted By: Cust: Shop No: Project: Supplier: P.A.

Bin Pull Left LL O TR N O C N U Requested By: _________________________________ Date: __________________________ Authorized By: _________________________________ Date: __________________________ Pulled By: _____________________________________ Date: __________________________ ORIGINAL—MATERIALS COPY—SHOP QA-734-9 Rev 1 8/13/07 . Qty Qty Qty Length Heat No. PAGE ___ OF___ UNIT ID: JOB No: CUSTOMER: DATE: Materials Request Pick Ticket ED Total Yard Item Description/Drawing No.

Total LL Length Bin Qty O TR N O C N U Authorized By: _______________________________ Date: __________________________ Returned to Stock By: _________________________ Date: __________________________ ORIGINAL— MATERIALS COPY—SHOP QA .734 . UNIT ID: JOB No: CUSTOMER: : Materials Returned to Stock ED Total Yard Item Description Heat No.08 Rev 1 12/28/05 .

REQD TYPE DATE WASTE INT DATE QTY STAMP ED LL O TR N O C N U Authorized by: Date: QA-White SHOP-Yellow QA – 432-13 REV 1 8/13/07 . CUSTOMER: DATE: QTY MAT COMPLETED QC INSPECTION ITEM DESCRIPTION/DRAWING No. PAGE OF Pre-Fabricated Cut Sheet UNIT ID: JOB No.

: REV: DESCRIPTION: COMPLETED QA INSPECTION ITEM ACTION REQUIRED DEPT QTY DATE INT DATE INT ED LL O TR N O C N U QA-White SHOP-Yellow QA – 432-12 REV 0 12/19/2005 . CUSTOMER: DATE: DRAWING No. PAGE OF SUB-ASSEMBLY TRAVELER UNIT ID: JOB No.

PAGE OF UNIT TRAVELER UNIT ID: JOB No. CUSTOMER: DATE: DRAWING No.: REV: DESCRIPTION: COMPLETED QA INSPECTION ITEM ACTION REQUIRED DEPT DATE INT DATE INT ED LL O TR N O C N U QA-White SHOP-Yellow QA – 432-11 REV 1 3/28/07 .

No. PAGE OF Pre-Fabricated Assemblies/Details UNIT ID: JOB No. REQD COM DATE WASTE INT ACC REJ INT ED LL O TR N O C N U QA-White SHOP-Yellow QA – 432-10 REV 0 12/16/2005 .: REV: DESCRIPTION: PART: HEAT QTY QTY COMPLETED QA INSPECTION ITEM DESCRIPTION/DRAWING No. CUSTOMER: DATE: DRAWING No.

Number: Customer: Shop Number: ED Qty Description Heat Number Location BIN Tot Qty LL O TR N O C N Dimensions Correct: Yes No U Material Identified: Yes No All documentation correct. 4501 Danhil Drive. F: 325‐643‐2221  Materials Received to Stock Report Date: Inspector: Supplier: P. O. TX 76801                    P: 325‐643‐2277. signed and turned in to Material Services Yes No QA –332-09 REV-3 11/1/2011 . Brownwood.

O BARR FABRICATION. 2. note appropriate HEAT NUMBERS on ALL shipping documents and mail the ORIGINAL MTRs/CofCs to our Brownwood office with a copy of the applicable shipping documents. 3.L. LLC Purchasing Dept. f) Material Traceability data (i. e) Purchase order line item number. C _____________________________ Dated: _________ ____________________________ Dated: __________ SUPPLIER ACKNOWLEDGEMENT AUTHORIZED SIGNATURE N U P-001 Rev 0 12/05/2005 . smooth out the edges. Tag each Pallet with the HEAT NUMBER and quantity for the Items (part numbers) contained on each Pallet. All terms and conditions of the original Order remain the same except as noted herein.) in the body of the document to ensure proper distribution and action: a) Purchase order number. Original packing list and/or bill of lading must accompany shipment. 4. L. Please Sign and return to Barr Fabrication.C. Per our discussions of ____________________. part number as shown on purchase order. O Material Test Reports (MTRs) and/or Certificates of Compliance (CofCs) must accompany shipment (required for ALL steel products).. LL b) Tag information as shown on purchase order. Heat Number.. LLC. L. Where the parts provided contain 90 degree “edges”. packing lists. If the manufactured parts will be shipped to a sub-vendor and then to Barr Fabrication.e. bills of lading etc. 6.e. i. PURCHASE ORDER ADDENDUM Purchase Order No: ______________________________ Dated: ________________________ Addendum No: __________________________________ Dated: ________________________ THE FOLLOWING CONDITIONS HAVE BEEN ADDED TO THE ABOVE ORDER ED Please acknowledge receipt of this Addendum at once.L. c) Ship to information as shown on purchase order. All documentation regarding this order must include the following: (i. etc. d) Barr Fabrication. the following documentation criterion is herein added to the requirements of this Order. break all edges prior to shipment.e. invoices. Annotated the Bill of Lading with each HEAT NUMBER for each item (or group of items) being shipped. No other changes are made or N implied by reference or omission. TR 5. as may be required) 1.C.

Bend Ops Assembly Clean Up Total Lay-out Part No. Activity Welds Fit-up Tacks ED LL O TR N O C N U Inspector: ____________________________ Verified By: _______ QA—1531-1 Rev 3 02/02/08 . Daily Inspection Report (Mechanical and Welding) Date: CTQ Items Inspected Job No. Punch Proc. Part Description First Article In-Process (other) Time Office Work Dimensions W/M Settings or Each Entry De-burring or Weld Tests Stair Assy.

 Brownwood. the basics are Carbon Steel (CS). The number positions for sizing are hindered feet-feet-inches (000). for sizes less than one (1) inch. use metric values. F:  325‐643‐2221 Drawing/Part Number Assignment Request Client: Project: Date: Description: ED Controlling Discipline: Piping Structural Mechanical Vessels Tools Misc (10) (20) (30) (40) (50) (60) LL 1 Power 1 Platform 1 Support Systems 1 Tanks 1 Pullers 1 Signs 2 High Pressure 2 Roofing 2 Containers 2 Silos 2 Fit-up Jigs 2 Bridges 3 Distributions 3 Architectural 3 Stairs 3 Pressure 3 Measuring 3 Docks 4 Water 4 Highways 4 Elevators-Lifts 4 Boiler 4 Sockets 5 Sewerage 5 Reactor 6 Gate 7 Butterfly 8 Ball 9 Check O TR Materials: 1 A36 Carbon Steel (CS) 2 A572 Gr50 CS N 3 A523 CS 4 A304L Stainless Steel (SS) 5 A308L SS 6 A410 SS O 7 A5052 Aluminum (AL) 8 A6062 H2 AL 9 AL Not Specified C 0 Exotic Metals Notes: N 1>There are several types and classifications of materials we may use. TX 76801  P:  325‐643‐2277. Stainless Steel (SS). Requested By: Assigned Number: Date: Number Log in Master List: Yes No Temp D201-1 Rev 2 8/02/2011 . U 2>When stating the size of the main part keep in mind that space is limited. Although each has several grades it is not as important to show this in the drawing number but on the drawing itself.  4501 Danhil Drive. Aluminum (AL).

LLC. Barr Fabrication. Internal Memo To: Date: 3/18/2008 From: ED Subject: LL O TR N O C N U A-103-OM Rev 0 02/21/2006 .

Procedure Review Record Please review the attached Procedure and annotate your comments on the document its self. and/or approval below. Subject: ___________________________________________________________ Purpose: ___________________________________________________________ Senior Management: ED Approved: ________________________ Date: _________________ Project Management/Engineering: Approved: ________________________ Date: _________________ LL Procurement: Approved: ________________________ Date: _________________ Production: O Approved: ________________________ Date: _________________ TR Administration: Approved: ________________________ Date: _________________ Quality Assurance: N Approved: ________________________ Date: _________________ Materials Services: O Approved: ________________________ Date: __________________ C N Procedure Developer: ______________________________________________ Date issued for Review: ____________________________________________ U Current Revision: __________________ New or Revised: _________________ Documentation (forms) associated with procedure: _______________________ A102-4 Rev 0 01/02/06 . Thank you.

Thank you. Subject: ____________________________________________________ Purpose: ____________________________________________________ ____________________________________________________ ED Senior Management: ____________________________________________ _____________________________________________________________ LL Approved: ________________________ Date: _________________ Project Management/Engineering: _________________________________ _____________________________________________________________ O Approved: ________________________ Date: _________________ TR Procurement: __________________________________________________ _____________________________________________________________ Approved: ________________________ Date: _________________ N Production: ___________________________________________________ _____________________________________________________________ O Approved: ________________________ Date: _________________ C Accounting: ___________________________________________________ N _____________________________________________________________ Approved: ________________________ Date: _________________ U Quality Assurance: _____________________________________________ _____________________________________________________________ Approved: ________________________ Date: _________________ A101-5 Rev 0 11/29/2005 . Form Review Record Please review the attached Quality Assurance/Standard Operating Procedure Form and annotate below your comments and/or approval.

LLC COPY—CLIENT A100—01 Rev 0 11/30/2005 . LLC Date Client Representative Date COPIES: ORIGINAL—BARR FABRICATION. Change Order Customer: ________________________ Purchase Order: ________________ Date: ________ Drawing: _________________________ Description: ________________________________ Project Engineering: Comments: __________________________________________________________________ ____________________________________________________________________________ ED ____________________________________________________________________________ Additional Work: ____________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ Other Effected Drawings: _______________________________________________________ LL ____________________________________________________________________________ Production: Required Material: ____________________________________________________________ ____________________________________________________________________________ Required Man-hours: O Labor Grade _______ Hours ________ Position _____________________ Labor Grade _______ Hours ________ Position _____________________ TR Labor Grade _______ Hours ________ Position _____________________ Labor Grade _______ Hours ________ Position _____________________ Estimated Completion Date: _________________ Total Hours Required: _________________ Procurement: N Material Required: Type: ________________ Size: ___________ Grade: ______________ Quality: _______________________ O Unit Cost: _____________________ Freight: __________________ ETA Shop: _______________________ C MTR/C of C Required: Yes _______ No _________ Accounting: N Total Labor Hours: ___________ Total Labor Costs: ___________ Total Material Costs: _________________ U Total Cost This Change Order: ___________________ Revised Total Project Costs: ____________________ Approvals: ____________________________________ ____________________________________ Barr Fabrication.