Transcript ITP – Inspection & Test Plan

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)
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August 22, 2013
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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)
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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
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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
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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
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August 22, 2013
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.
Inspection & Test Plan (ITP)
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FMC required ITP template – Q00392
August 22, 2013
Inspection & Test Plan (ITP)
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MPQP requirement driven through Qspec
• Q00398
FMC Required ITP template in section 7
• Applicable to many parts following the same manufacturing process.
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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)
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FMC required Process MPQP template - Q00398
August 22, 2013
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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:
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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
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Q00394 continued
• Forging Template (MPQ & MPQP):
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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
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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.
August 22, 2013
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August 22, 2013
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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.
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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
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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.
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August 22, 2013
The procedure for submitting, reviewing and approving a supplier’s MPQP
(Q00398 or Q00394) is described in Q00399.
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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
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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
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Intervention Codes
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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.
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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.
August 22, 2013
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August 22, 2013
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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:
[email protected]
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August 22, 2013
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
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Notification of Witness/Hold points - Content
Shall as a minimum include (as applicable):
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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:
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August 22, 2013
http://www.fmctechnologies.com/en/SupplyChain/SubseaSystems/Subsea%20Requirements
/Global.aspx
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Notification Format
August 22, 2013
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Issue formal notification to [email protected]
W and H points, acc to approved ITP/MPQP. Period acc to
contact
Supplier
If not ok, state
actions and ask
Supplier to
reschedule
Evaluate notification
Notification period, information and documentation, check
availability
FMC (Quality)
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
availability
FMC Client
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
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Internally in FMC
FMC Customer
Contact FMC purchaser if delay in documents
Typing errors
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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.
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For BP projects requirements for intervention will be included in the
Part Report (DBI). Include those on first revision of ITP /MPQP
• Notifications
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August 22, 2013
Any special agreements with FMC or FMC’s Client (shorter
notification time, document approvals etc) shall be clearly stated in
the notification.
Inspection & Test Plan (ITP)
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QUIZ
August 22, 2013
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