Inspection & Test Plan (ITP) /

Manufacturing Process Quality Plan (MPQP)

- training of suppliers to FMC Technologies, Norway
QRL-0010001 FMC Standard Administration Requirements
- Revision Q, released June, 2013
- Appendix 3 - Quality Requirements, section 11.1.1 & 11.1.2
- Appendix 4 - Technical Correspondence and Doc. Administration, section 5

Q00392 – Supplier Inspection & Test Plan

Q00394 – Product MPQP
Q00398 – Process MPQP

August 22, 2013 Inspection & Test Plan (ITP)

 Learning Objectives

• Why and when FMC require an Inspection & Test Plan

(ITP) or Manufacturing Process Quality Plan (MPQP).
• What the requirements are.
• The responsibilities of issue, review and handling.
• Why and when FMC require intervention points.
• The different types of intervention codes.
• Notification requirements – content & communication.

August 22, 2013 Inspection & Test Plan (ITP) 2

August 22, 2013 Inspection & Test Plan (ITP) 3
 Purpose

• Inspection & Test Plan / Manufacturing Process Quality Plan

is a basis for verifying conformity with specified contractual
requirements.
• For FMC and the Supplier to establish and agree upon the
following prior to production start;
• Quality Control activities
• Interventions for the Supplier, FMC, FMC’s Client and/or
Third Party
• Intervention points allow the parties to go into different steps
in the production process to assure the quality. (mitigating
risk)

August 22, 2013 Inspection & Test Plan (ITP) 4

 Requirement for ITP and/or MPQP

• The requirement for ITP / MPQP can be found on the Part

Report either by:
• Throught DRLs (to be phased out)
• Quality specification (Q00392, Q00394, Q00398)

• There will be Intervention points on all ITPs / MPQPs

• Product-, Project-, and Supplier Criticality decides the level

of intervention

August 22, 2013 Inspection & Test Plan (ITP) 5

 ITP requirement driven through DRLs

• Listed in the Part Report referencing a Document

Requirement List (DRL).

• Requirement will be from QRL-0010001

August 22, 2013 Inspection & Test Plan (ITP) 6

 ITP requirement driven through Qspec
• Q00392

• FMC Required ITP template in section 6

• Listing the sequence of inspection and test activities required by
Agreement as applicable for the Parts covered by the ITP
– Part Description for the part / group of parts covered by the ITP
– No Part Numbers listed, but all Parts covered shall follow the same
production process, procedures and intervention points
– ITP may be reused when there are no changes to the above

– "Yes" or "No" drop down menu for ‘Do the subcomponent (lower level) Part
Reports (DBIs) require Q00392? If so, are the lower level Part Report
requirements included in this ITP? ‘
– Note: The ITP may contain subcomponent Part Report (DBI) requirements
in one single ITP, only if the subcomponent Part Reports (DBIs) require
Q00392
– Note: If Q00394 (for Product MPQP) is on the Part Report for Raw Material,
subcontractor of the Raw Material shall provide an MPQP acc to Q00394 to
the Supplier that will ensure FMC approval.
August 22, 2013 Inspection & Test Plan (ITP) 7
 FMC required ITP template – Q00392

August 22, 2013 Inspection & Test Plan (ITP) 8

 MPQP requirement driven through Qspec
• Q00398
FMC Required ITP template in section 7

• Applicable to many parts following the same manufacturing process.

– For example, welding cladding operation on parts of the same base material
may use identical manufacturing processes and procedures.
• Supplier performing the actual process is accountable for generating the
MPQP and obtaining FMC (and FMC’s Client through FMC, when
required) approval.
• Supplier may list alternative subcontractors and approved alternate
special process procedure numbers.

• NOTE Q00398 shall only be used by suppliers executing document

approval through eSMDR/SMDR, otherwise Q00394 shall be used to
maintain traceability.

August 22, 2013 Inspection & Test Plan (ITP) 9

 FMC required Process MPQP template - Q00398

August 22, 2013 Inspection & Test Plan (ITP) 10

 MPQP requirement driven through Qspec
• Q00394
FMC Required ITP template in section 7

• Manufacturing process is unique to a specific part.

• FMC part number is required on the MPQP document. one PN per
MPQP.
• Three Types:
• Standard (any supplier commodity other than forging)
• Forging MPQ (Qualification)
• Forging MPQP

• Supplier performing the actual process is accountable for generating the

MPQP and obtaining FMC (and FMC’s Client through FMC, when
required) approval.

August 22, 2013 Inspection & Test Plan (ITP) 11

 Q00394 continued
• Forging Template (MPQ & MPQP):
– Process Parameters:
• Section does not apply to induction bends.
• Process Parameters G, H, I, L, M, and N do not apply to Forged
Bar. Supplier shall state “N/A” for these cells.
• All other forging suppliers shall complete all Process
Parameters.

August 22, 2013 Inspection & Test Plan (ITP) 12

 Q00394 continued

• MPQ (Manufacturing Process Qualification): Supplier shall state

the mill, starting ingot/billet size, NDE supplier/procedure and
heat treatment vendor that will be used.

• MPQP (Manufacturing Process Quality Plan): Supplier may list

alternative mills, alternative starting ingot/billet sizes, alternative
special process suppliers/procedures, and alternative heat
treatment vendors.
If alternatives are not approved by FMC or FMC’s Client, then the
supplier shall be notified through the MPQP review process.
Note: Alternative subcontractors may not be allowed for forgings
that required qualification. The Qualification test report (QTR) will
document any restrictions on alternatives.

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August 22, 2013 Inspection & Test Plan (ITP) 14
 Responsibilities; issue & handling

• ITPs / MPQPs shall be uniquely identified and revision controlled

documents to ensure proper communication of the latest
requirements.
• Supplier shall submit an ITP, MPQ and/or MPQP (regardless of
type) no longer than two weeks after receipt of FMC PO.
– FMC responsible to forward to FMC Client for review if required

• ITPs /MPQPs shall be listed on the SMDR (Supplier Master

Document Register) /eSMDR
• If any change in manufacturing process on an ITP/MPQP still in
use, the ITP shall be revised and resubmitted to FMC for review
and approval. (provided that change is applicable for all parts it’s
used for, unless issue a new document)

August 22, 2013 Inspection & Test Plan (ITP) 15

 Responsibilities; Review

• Cycle Times
• FMC to review and return document to Supplier within
twenty (20) Business Days.
• Supplier shall re-submit updated document within five (5)
Business Days.
• For every review cycle (revision) the supplier will receive a
DR-4 document (Document Review) from FMC.
• The DR-4 document will have an Approval Status Code and
may have comments for action or information.

• The procedure for submitting, reviewing and approving a supplier’s MPQP

(Q00398 or Q00394) is described in Q00399.

August 22, 2013 Inspection & Test Plan (ITP) 16

 Responsibilities; Review

• The Approval Status Code and the DR reference shall be

recorded in the SMDR – by the Supplier.

Approval Status Codes:

1 Accepted with no comments
2 Accepted with comments incorporated. Revise and resubmit.
2x Document returned before the Company's final approval/comments. Hold next
revision of the document until receipt of FMCs final comments, or document is
given approval status code 1.
3 Not accepted. Revise and resubmit
4 Information

August 22, 2013 Inspection & Test Plan (ITP) 17

 Intervention Codes

The following definitions apply unless otherwise specified by the

Part Report (DBI)
• R = Review:
Verification of a step in manufacturing or testing by FMC
and/or Company by review of objective evidence.

• M = Monitor:
A step in manufacturing and testing that proceeds as
scheduled, and may be subject to FMC and/or Company
observation at FMC and/or Company discretion. Advance
notification is not required. Monitor activities are intended for
process verification, not product inspection.

August 22, 2013 Inspection & Test Plan (ITP) 18

 Intervention Codes
• W = Witness:
A critical step in manufacturing or testing where it is desirable that FMC
and/or Company representative participates in the inspection / process
activity of the material / equipment in order to ascertain that the product for
delivery complies with the specified requirements. Formal advance
notification shall be given in accordance with appendix 4. The step can
proceed with or without the presence of FMC and/or Company
representative after the designated time has passed.
• H = Hold:
A critical step in manufacturing and testing where it is essential that FMC
and/or Company representative participates in the inspection /process
activity of the material / equipment in order to ascertain that the product for
delivery complies with the specified requirements. Formal advance
notification shall be given in accordance with appendix 4. The step shall not
proceed without the presence of FMC and/or Company representative, or
without a written statement giving a waiver.

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August 22, 2013 Inspection & Test Plan (ITP) 20
 Notification of Witness/Hold points

• Supplier shall notify FMC in writing prior to any hold/witness

activities as specified in the ITP or MPQP.

• Notification time - minimum ten (10) Business Days unless

otherwise is stated in the PO/Agreement.

• Submitted by Supplier latest 14:00 GMT+1 (2 PM).

• All notifications related to POs from Kongsberg (first issue,

postponements and updates) shall be sent to:
FKSnotifications@fmcti.com
– E-mail subject: FMC PO number and project number & name (not limited to)
– One e-mail shall only contain notification(s) for one project.
– Copy Commercial point of contact
– Copy Quality resource, if known

August 22, 2013 Inspection & Test Plan (ITP) 21

 Notification of Witness/Hold points - Content

Shall as a minimum include (as applicable):

• FMC project number and name.
• FMC Purchase Order ref, Part Number & Serial Number (quantity)
• Part description
• Start-up date & time for activity
• Duration
• Supplier approved ITP/MPQP doc number/rev with reference to activity
• Procedure document number and revision
• Location for activity
• Contact persons
• Other information needed (e.g. required personal protection equipment)

Global Notification of Intervention Point Form:

• http://www.fmctechnologies.com/en/SupplyChain/SubseaSystems/Subsea%20Requirements
/Global.aspx

August 22, 2013 Inspection & Test Plan (ITP) 22

 Notification Format

August 22, 2013 Inspection & Test Plan (ITP) 23

 Issue formal notification to FKSnotifications@fmcti.com
W and H points, acc to approved ITP/MPQP. Period acc to
Supplier
contact

If not ok, state

actions and ask
Supplier to Evaluate notification
reschedule
Notification period, information and documentation, check
FMC (Quality)
availability

Formally notify internally and to FMC Client (if Client W or H)

FMC ( Quality) Acc to Client contract

Evaluate notification
Notification period, information and documentation, check
FMC Client
availability

Revert with attendance information

Both FMC Client & FMC (Quality) Reject or give attendance info / waiver

Prepare for activity, if any changes, send an updated notification

Supplier
 Be aware

• Recurring problems:
– Documentation is a bottle neck
• Internally in FMC
• FMC Customer
• Contact FMC purchaser if delay in documents
– Typing errors
• wrong / misspelled Purchase Order Number or Part Number
• several cases of ”copy-paste”
• FMC is working on methods to inform about required intervention
points at PO award.
– For BP projects requirements for intervention will be included in the
Part Report (DBI). Include those on first revision of ITP /MPQP
• Notifications
– Any special agreements with FMC or FMC’s Client (shorter
notification time, document approvals etc) shall be clearly stated in
the notification.

August 22, 2013 Inspection & Test Plan (ITP) 25

 QUIZ

August 22, 2013 Inspection & Test Plan (ITP) 26