Inspection and Test Plan

Fatkhy Baridwan

FZB2020
 Background

• Inspection and Test have been considered as core of the quality

control process.
• In most of the cases, a product / service will not be considered as
meeting quality requirements if it is not supported by inspection
and/or test result(s).
• It is not always clear what kind of inspection and test to be carried
out, when it should be carried out, etc. Based on this view, the
organization develops Inspection and Test Plan (ITP) as a control
measure and to streamline the inspection and test program
FZB2020
 Coverage

• Generic ITP vs Specific ITP

• Basic data requirement for developing ITP
• ITP contents & format
• Implementation

FZB2020
 Generic ITP vs Specific ITP
Generic ITP
• Developed as a foundation
• Applicable for generic product /
service or mass products
• Only require one time criticality
assessment
• Authorized by internal organization
FZB2020
Specific ITP
• Developed for a specific purpose
• Applicable for specific product /
service or some of typical products /
services
• Require criticality assessment for
each specific product
• May require review and approval
from external parties
 Basic Data Requirement

• Criticality rating of the product / service

• Product / service realization flow and activities
• References
• Specific requirements
• Parties involved
FZB2020
 Criticality Assessment

• Criticality of the product / service will be useful to define level of inspection, by mean of how
much intervention or involvement will need to be applied during product realization
(manufacturing / fabrication / construction) process
• Degree of inspection and level of involvement of other parties (especially external parties)
should be defined as early as possible to streamline inspection’s execution process
• Applying high criticality approach to low critical products / services will definitely increase cost
and also slow down the progress. In other way, applying low criticality approach to high
critical products / services is dangerous as it will increase risk.

FZB2020
 Criticality Assessment Consideration
• Operating conditions: Service medium, pressure, temperature, human contact, etc.
• Probability of failure: Products that have high probability of failure or have record of frequent failure during
operation should be considered more critical than products that have low probability of failure

• Consequence of failure: Product with high consequence of failure, including schedule impact, cost impact,
exposure to environment, human life, etc. should be considered more critical than products with low consequence of
failure

• Application of new technology or features: Application of new technology, or even proven to industry but
the organization has no or less experience with it will be considered more critical than the common technology /
features

• Utilization of special process or material during manufacturing / fabrication / construction: Special

process, or special material usually require higher concern and care during manufacture / fabrication / construction

• Manufacturer / Fabricator / Contractor quality and integrity , including organization’s experience with
them: Manufacturer / Fabricator / Contractor that implement a rigid manufacturing / fabrication / construction
process control and quality management system and has generally known for its product quality is normally
FZB2020 considered less critical than Manufacturer / Fabricator / Contractor that unknown or less knowledge (to the
organization)
 Criticality Assessment Result

FZB2020
 Product Realization Flow and Activities

• Product / service realization processes and sequences are required to assess and define
critical activity where supervision / involvement need to be applied
• It is recommended to use product service realization flowchart as basis. Or, if it is not
available, production / execution procedures may also be used
• It is optional whether all activities will be detailed, or only activity with possibility of other
party involvement
• Special product / service realization activities should be detailed

FZB2020
 ITP Contents and Format
• Once Organization has adequate input, they can start developing an Inspection and Test Plan. To
ensure the developed Inspection and Test Plan is informative and workable, it should contain at least 5
elements:
• Activity
• Reference
• Acceptance Criteria
• Documentation
• Intervention Point

• There is no specific rules on how to present an ITP. Some companies even merge it with quality plan or
even production / execution procedure. However, since its main purpose is to streamline the process,
ITP should be presented in simple form, easy to be understood, but at the same time include adequate
and clear information to avoid confusion during implementation
FZB2020
 ITP Contents and Format (Cont’d)
• Activity
From manufacturing / fabrication / construction process and sequence it can be defined the critical activities where intervention /
involvement needs to be applied.
• Reference
An inspection / test shall be done in accordance with applicable and agreed reference. The reference should be detail and clear. This
would ensure the process can be done properly and repeatable (whoever doing the inspection/test, and whenever it need to be
revisit)
• Acceptance Criteria
Acceptance criteria may be included in the inspection / test reference, but it may be stated in the other documents. For the
avoidance of doubt or multiple interpretations, acceptance criteria should be stated in the Inspection and Test Plan.

• Documentation
Once the inspection/carried out. It needs to be documented as a report / record for further process.

• Intervention Point
This is the point where most of the dispute occurred. Many ITP developers define intervention / involvement point based on their
subjective opinion, which may be completely different with other personnel. Using Criticality of the product as basis of defining
FZB2020 intervention point will avoid / reduce the dispute and the level of intervention / involvement can be standardized.
 ITP Contents & Format (Cont’d)

FZB2020
 Implementation

• Approval
Inspection and Test plan shall be agreed by all parties involved in the product realization process as it
needs to be followed not only by the person doing inspection / test, but also other parties involved

• Availability
As ITP will be used as a guidance to streamline the inspection’s execution. It should be available at the
inspection’s location or at least distributed to the responsible person from each parties

• Sign-off
Some organization require sign-off or stamp-off to indicate that an inspection activity has been
completed. In that case, sign-off column(s) is required to be added in the format. This can be done
either on each line of activity (typically applied for specific ITP prepared for one or few typical
products) or as a completion sign-off indicating that all activities are completed (typically applied for a
generic or mass product, or specific product with many quantities)
FZB2020
 THANK YOU
HOPE THIS PRESENTATION WILL BENEFIT THOSE WHO READ IT

FZB2020