Transcript Check Support Sheet

Check Support Sheet
CSS
Issued June 2013
7/17/2015
Footer
Abbrevation
Abbrevation
Description
eSMD
electronic Single Manufacturing
Document
MRB
Manufacturing Record Book
SLS
Standard Limit Sheet
MD
MD
MD
MD
MRB
(MRB)
Reports
Certificates
CSS
Check Support Sheet. Each
MD will have its own CSS
MD-SLS
Procedures
Material
Material
Certificate
Material
Certificate
Certificate
Manufacturing Documentation
Standard Limit Sheet, for
material certificate.
MD
Manufacturing Document;
documents received in the
MRB
OTD
On-Time Delivery
ZD
Zero Defect
7/17/2015
Plans
Footer
Pressure
test rapport
ITP
ITP
Welding
Procedure
1
FAT
Rapport
NDT
Rapport
Welding
Rapport
CSS – Check Support Sheet
• To avoid late mistakes.
• To avoid unecessary QN – loss of time and money.
• A tool for suppliers, QA, Good Receipts, MRB reviewer,
etc.
• To support the review of production plans, certificates
and reports
• To raise FMC standard requirement for each different
MD
• To make the MD checking process more efficient and
cost-saving.
7/17/2015
Footer
2
Purpose – for FMC and suppliers
Purpose for FMC
To ensure right information in MD’s sent to FMC
X
To eliminate the work of checking MD in-house
X
To realize a ZD process of issuing and reviewing MD at
suppliers
X
To be in alignment with eSMD process
X
Purpose for
supplier
To be in alignment with eSMD process
X
To provide MD according to FMC standard quality
requirement
X
To strengthen the role of Good Receipt and QA/QC
X
To minimize the possibility of applying wrong material into
production
To realize OTD, of both equipment and document
7/17/2015
Footer
3
CSS in Workflow
7/17/2015
Footer
4
Introduction of CSS
•
•
A check support sheet for each type of MD
Call-outs from the most significant data fields in a MD with
supporting text on how and what to check
* How to verify this parameter
* What is acceptance criteria
* How to check this parameter
* What is FMC requirement
7/17/2015
Footer
5
Available Check Support Sheets
Examples with explanations
7/17/2015
Footer
6
Available Check Support Sheets
CATEGORY
MD
Supplier Master Documentation Register
Tracebility list
Plans
Inspection & Test Plan (ITP)
Certificates
Certificate Of Conformance
Lifting Declaration of Conformity
Lifting Certification of application
Lifting certificates Loose Gear and Sling Set
Material
Hardness test report
Weld record sheet
Welders certificate
Welding Procedure Specification
NDT - Ultrasonic Examination
NDT - Radiographic Examination
NDT - Magnetic partical Examination
NDT - Operators Certificate
Reports
Surface Treatment Report
Dimentional Report
Factory Acceptance Test Report
Weight Report
General
7/17/2015
General rules of CSS
Footer
7
MD CHECK PROCESSES – SUPPLIER MASTER DOCUMENTATION REGISTER (SMDR)
Verify:
SMDR Doc No
SMDR Revision
DRL No: Document Requirement List
-if listed
Verify:
-Part number – if listed
-Project ref – if listed
Verify:
PO. NO: Purchase Order Number
-compare with MRB Front Page
Verify:
Approval status: 1
7/17/2015
Footer
8
MD CHECK PROCESSES – Traceability list
Verify:
-PO. NO: Purchase Order Number
-Project ref
Verify:
-Batch number reference – if
applicable
Verify:
-Part number and revision - by comparing with MRB front page
-Serial number - by comparing with MRB front page
-If there is no P.NO or S.NO then this can be verified in other
documents listed MRB and referred to in the traceability list.
7/17/2015
Footer
9
Verify:
-Assy Part number - by comparing with MRB front page
-Assy Serial number - by comparing with MRB front
page
-If there is no P.NO or S.NO then this can be verified in
other documents listed MRB and referred to in the
traceability list.
MD CHECK PROCESSES – Inspection & Test Plan (ITP)
Verify:
Client PO. NO: if referred
Client Project ref:
Verify:
DOC ID. & REVISION:
-That document is released; in SAP (code 1) or in
e-plan (final issue).
-Same document ID and revision as in SMDR
DESCRIPTION
-requirement is listed in QRL-0010001, version 15,
revision N, section 11.5.
7/17/2015
Footer
10
MD CHECK PROCESSES –
Certificate of Conformance (COC)
Verify:
Date of issue
Verify:
Name and address of issuing company
Verify:
PO. NO: Purchase Order Number
Project ref
Verify:
Part number - by comparing with MRB front page
Part number revision - by comparing with MRB
front page
Serial number - by comparing with MRB front page
Batch Number – original Batch Number if applicable
Delivered quantity
Designation / Decription
Verify:
NCR reference including any
FMC approved concession
Verify:
Compliance statement
-to Purchasing Order requirements
-to relevant official specification
Verify:
Date of issue
Name, job title and signature of person authorizing the COC
DESCRIPTION
-requirement is listed in QRL-0010001, version 15, revision N, section 11.9
7/17/2015
Footer
11
MD CHECK PROCESSES – Lifting
Declaration of Conformity (DOC)
Verify:
Part number
Verify:
Name and adress of
manufacturer
Part number revision:
Revision of part number is no longer listed in the DOC. Reason
is to avoid need for reviewing the DOC for minor changes in the
part number not effecting the lifting capabilities of the part.
-If changes are having effect on lifting capability, a new part
Verify:
Name and/or
description of
equipment
number is to be created.
DESCRIPTION
Declaration that equipment is in conformity with standards
listed.
-may also be used for listing other standards related to the
machinery directive or other EEC directive
Document only required if CE marking is required.
-Typically: sling, lifting tool, handling tool etc
-No CE marking required and therefore no DOC: portable
offshore units, containers and baskets
NB:
-document only valid if COC is signed by manufacturer
-if individual test is required, test report refering to equipment
must be enclosed
Verify:
Standard Reference
-DNV 2.22, VMO etc.
Verify:
Date & Signature
7/17/2015
Footer
12
Verify:
Validity Date – must not expire
less than 6 month after delivery
MD CHECK PROCESSES – Lifting
Certificate of Application
Verify:
Certificate number
Verify:
Name and/or description
of equipment
Verify:
S.NO: Serial Number
P.NO: Part Number
Verify:
Standard reference
-see references in ”Lifting
Documents” page.
DESCRIPTION
Issued first time together with ”Control Card” at first
annual control.
-May however be issued together with other
documents at delivery.
Verify:
Date & Signature
Separate documents for the different lifting
equipments part of the delivery; sling, lifting/handling
tool
7/17/2015
Footer
13
MD CHECK PROCESSES - Lifting Certificate Loose Gear
Verify:
S.NO: Serial Number
P.NO: Part Number
Verify:
Number tested
Date of testing*
Testload (Alt: Proofload test) is correct
Verify:
Name and/or description
of equipment
-information on back of certificate.
-Example for lifting/handling tool; 2.5 x MGM
Verify:
Standard reference
SWL (Safe Working Load) is correct compared to
DBI
-also called Payload
-see references in ”Lifting
Documents” page.
DESCRIPTION / NOTES
Separate certificates for each part; lifting tool, handling frame/skid,
sling etc.
*Date of testing
– Anual inspection by 3. party required; see ”Certificate of Application”
-If no ”Certificate og Application” issued, check date of testing.
-FMC prequirement that expiry date is later than 6 month after shipment.
Definitions:
Loose Gear: same as lifting equipment
MGM (Max gross mass) – total weight of lifting equipment (except
slingset) and load
Verify:
Date & Signature
7/17/2015
Footer
14
MD CHECK PROCESSES
Lifting Certificate Sling set
Verify:
Standard reference
-see references in ”Lifting Documents” page.
Verify:
Name and/or description
of equipment
Verify:
P.NO: Part Numbers
-Verify all Part Numbers
Verify:
Number tested
Date of testing *
Verify:
Proof Load is correct
-using information on back side of certificate.
-example (Wire sling): Proof load = 2x WLL
Verify:
(7) Requirements that sling
are tested by manufacturer
WLL = similar to SWL on appurtenant
”Linfting Certificate Loose Gear”
-Working Load Limit
DESCRIPTION / NOTES
Separate certificates for each part; lifting
tool, handling frame/skid, sling etc.
*Date of testing
– Anual inspection by 3. party required; see
”Certificate of Application”
-If no ”Certificate og Application” issued, check
date of testing.
-FMC prequirement that expiry date is later
than 6 month after shipment.
7/17/2015
Footer
Verify:
Date & Signature
15
MD CHECK PROCESSES –
Hardness test report
Verify:
Part number - by comparing with MRB front
page
Serial number - by comparing with MRB front
page
Drawing number
Delivered quantity
Designation / Decription
Verify:
-Hardness as specified in referred Mspec
Verify:
-Date & Signature
DESCRIPTION
Separate hardness tests are performed:
-after machining causing a hardening of the
material
-after forging causing a change in mechanincal
properties
7/17/2015
Footer
16
MD CHECK PROCESSES – Weld Record Sheet
Verify:
All welds are listed by
comparing with drawing
Verify:
-S.NO: Serial Number
-P.NO: Part Number
-Drawing number
Verify:
-Welders ID is listed
If Welders Certificate is
enclosed to MRB - verify:
-Welder is certified for the
avtual welding method
Verify:
Date
Verify:
-NDT is OK
Verify:
WPS approved in SMDR;
-code 1 or 2
If NDT is not OK – verify
1. Report for unaccepted weld is enclosed
2. Sign. for repair performed
3. NDE report after repair is enclosed
If WPS is enclosed in MRB - verify:
-ensure that WPS is correct for
actual Base Material
DESCRIPTION
Also: ”Weld Log”, ”Weld Summary List”
Verify:
Verify:
Date
Date for
for welding
welding is
is earlier
earlier
than
than Date
Date for
for control
control
-To
-To ensure
ensure that
that the
the weld
weld is
is
controlled
controlled
7/17/2015
Footer
17
Limitations:
MRB reviewer is only performing check of the
document, and to a limited extent verifying the reported
parameters. More extended verification of reported
parameters requires special comptetency.
MD CHECK PROCESSES –
Welders Certificate
text
Verify:
Welding Method is according to WPS
Verify:
-External approvement – every 2 years
-compared to when welding was
performed.
-if not ok – ask for updated certificate
Verify:
-Internal approvement - every 6 month
-compared to when welding was
performed.
-if not ok – ask for updated certificate
DESCRIPTION
Limitations:
Control of this document as part of MRB is limited to a few variables. A
detailed control must be performed by a specialist as part of a technical
audit.
Certificate Duration:
-Certification effectivity : 2 years
-Regular internal control: every 6 month
7/17/2015
Footer
18
Verify:
Stamp from 3rd party
certificate organ
7/17/2015
Footer
19
MD CHECK PROCESSES –
NDT - Ultrasonic Examination
Verify traceability according to:
Traceablility list
-Base material for
-components
Verify:
Drawing No as
listed in DBI
Weld
List:
VerifySummary
traceability
according to:
-Welds
for list
Traceablility
-welded components
-Base material
for
-welded assemblies
Verify:
-Test result – OK / ACC
or similar
Verify:
-Signature
-Stamp
Verify:
Ultrasonic procedure as listed in SMDR
-If required in DRL
DESCRIPTION
Limitations:
Control of this document as part of MRB
is limited to a few variables. A detailed
control must be performed by a
specialist as part of a technical audit.
7/17/2015
Footer
20
MD CHECK PROCESSES –
NDT –
Radiographic Examination
Verify:
Drawing No as
listed in DBI
Verify traceability according to:
Traceablility list
-Base material for
-components
Weld Summary List:
-Welds for
-welded components
-welded assemblies
Verify:
Radographic procedure
as listed in SMDR
-If required in DRL
Verify:
-Signature
-Stamp
Verify:
-Test result – OK / ACC or similar
DESCRIPTION
Limitations:
Control of this document as part of MRB
is limited to a few variables. A detailed
control must be performed by a
specialist as part of a technical audit.
7/17/2015
Footer
21
MD CHECK PROCESSES –
NDT –
Magnetic Partical Examination
Verify:
Drawing No as
listed in DBI
Verify traceability
traceability according
according to:
to:
Verify
Traceablility list
list
Traceablility
-Base material
material for
for
-Base
-components
Weld Summary List:
-Welds for
-welded components
-welded assemblies
Verify:
Radographic procedure
as listed in SMDR
-If required in DRL
Verify:
-Signature
-Stamp
Verify:
-Test result – OK / ACC
or similar
DESCRIPTION
Limitations:
Control of this document as part of MRB
is limited to a few variables. A detailed
control must be performed by a
specialist as part of a technical audit.
7/17/2015
Footer
22
MD CHECK PROCESSES –
NDT Operators Certificate
Verify:
-External approvement – every 5 years
-compared to when welding was
performed.
text
Verify:
Correct Method acc. to
WPS or NDT report
-if not ok – ask for updated certificate
Verify:
-Internal approvement – every 1 year
-compared to when welding was
perfromed.
-if not ok – ask for updated certificate
Verify:
Stamp from 3rd party
certificate organ
DESCRIPTION
Limitations:
Control of this document as part of MRB is limited to a
few variables. A detailed control must be performed by
a specialist as part of a technical audit.
Certificate Duration:
-Certification effectivity : 5 years
-Regular internal control: annually
7/17/2015
Footer
23
MD CHECK PROCESSES – Surface Treatment Report
Verify:
-Procedure reference
-Procedure is released
in SAP
Verify:
Name and/or description
of equipment
Verify:
S.NO: Serial Number
P.NO: Part Number
-be sure there are reports
for all partnumbers ether in one or several
reports
Verify:
-Coating spec for the
actual part.
-Coating system
-requirements are listed as
notes in DBI …. ?
Verify:
Adhersion test results
listed or Report
reference listed.
-if not, supplier must be
contacted for results or
for performing the test
Verify:
Surface temperature > Dew point + 3ºC
DESCRIPTION
Verify:
Date & Signature
7/17/2015
Surface treatment requirements are
listed in DBI. It is important to verify all
treatment is documented done.
Footer
24
MD CHECK PROCESSES – Dimensional Report
Verify:
Customer PO. NO
Verify:
Drawing no
Verify:
Drawing approval
status in SAP
Verify:
That deviations are
handled in technical
queries or NCR or similar.
DESCRIPTION
Verify that all dimensions are as required by
comparing with drawings.
7/17/2015
Footer
25
MD CHECK PROCESSES
Factory Acceptance Test report (FAT report)
DESCRIPTION
Purpose of the FAT is to verify that the equipment is functioning.
Verify:
PO.NO: Purchasing order
Part number
Serial number
FAT Procedure reference – if applicable
Verify:
-”accepted”, ”OK” or NA
-if ”not accepted” a NCR
must have been issued.
Verify:
-coloumns to be completed
-validity compared to
acceptance criterias if listed
Verify:
-”completed”, ”OK” or NA
-if ”not completed” a NCR
must have been issued.
Verify:
Date & Signature
-also other signatures – for
example ”client” and ”Test
leader”
Verify:
cross-reference to be valid
7/17/2015
Footer
26
MD CHECK PROCESSES –
Weight Report
DESCRIPTION
-same as weight certificate
-requirement for all parts heavier than 25 kg
-not always requires in MRB
Verify:
PO. NO: Purchase Order Number
Project ref.
P.NO: Part number (sometimes assy P.NO).
Verify:
S.NO: Serial Number
P.NO: Part Number
Verify:
Weight: compare with drawing
Verify:
Date
Signature
7/17/2015
Footer
27