FPC manual XXXX Ltd. FPC manual XXXX Ltd. Address BS-‐EN 1090-‐1+A1 Version 1.0 _________________________________________________ xxx xxx, CEO Table of contents 1. Introduction ................................................................................................................ 4 1.1. Scope ................................................................................................................................... 4 2. The structure of the quality control system ..................................................... 5 2.1. The structure of the documentation ........................................................................ 5 2.2. File management ............................................................................................................ 6 Updated documents and quality documentation ...................................................................... 6 Naming of the files .................................................................................................................................. 6 2.3. Managerial audits ....................................................... Error! Bookmark not defined. 2.4. Conformity to standards .............................................................................................. 8 2.5. Standards in the quality control system ................................................................. 8 3. Resource managemet ............................................................................................... 9 3.1. Human resources ............................................................................................................ 9 Trainings .................................................................................................................................................. 10 Identification of training needs ...................................................................................................... 11 Orientation of new employees ........................................................................................................ 11 3.2. Equipment ....................................................................................................................... 11 Production machines .......................................................................................................................... 11 Measuring and testing equipment ................................................................................................ 12 Inspection and maintenance ............................................................................................................ 12 4. Product realization ................................................................................................ 14 4.1. Component specifications ......................................................................................... 14 4.2. Structural design process .......................................................................................... 14 4.3. Purchasing ...................................................................................................................... 14 Verification of purchased product ................................................................................................ 15 4.4. Production provisions ................................................................................................ 15 4.5. Evaluation of conformity ........................................................................................... 15 4.6. Product evaluation and CE marking ...................................................................... 16 4.7. Handling and storage .................................................................................................. 16 Handling ................................................................................................................................................... 16 Storage ....................................................................................................................................................... 16 5. Welding ...................................................................................................................... 18 5.1. Welding personnel ....................................................................................................... 19 Welders ..................................................................................................................................................... 19 Responsible welding coordinator ................................................................................................. 19 Responsibly and authority ............................................................................................................... 19 5.2. Reviews ............................................................................................................................ 20 5.3. WPS and welding plan ................................................................................................. 21 5.4. Subcontracting .............................................................................................................. 21 5.5. Inspection and testing ................................................................................................. 21 5.6. Control of monitoring devices .................................................................................. 22 6. Measuremetn, analysis and improvemetn ..................................................... 23 6.1. Control of nonconforming products ....................................................................... 23 Small mistakes ....................................................................................................................................... 23 Serious mistakes ................................................................................................................................... 23 Handling of records ............................................................................................................................. 24 Corrective procedures ........................................................................................................................ 24 Preventive measures ........................................................................................................................... 24 6.2. Tracebility ....................................................................................................................... 24 1. Introduction We maintain a quality management system to ensure that all structural steel fabrications released in the market meet the required quality standards and conform to the declaration of performance delivered together with the assembly. The person responsible for the maintenance of our quality management system is [FIRST NAME] [SURNAME]. S/he is responsible for the quality management system in regard to: •
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Documentation, Maintenance and Continuous verification of functionality. In addition to this, [FIRST NAME] is responsible for ensuring that all employees who are involved with manufacturing of structural steel fabrications understand their individual responsibilities and duties when manufacturing products that meet the requirements, and that the subcontractors conform to our quality standards. The informing and internal communication in regard to the responsibilities, authorizations and changes related to the quality management system in the production is conducted in meetings, via e-‐mail and via personal communication. 1.1. Scope This documented quality management system encompasses the manufacturing of structural steel fabrications only. The quality management system has been drafted so that it conforms to the relevant requirements of standards BS-‐EN 1090-‐1 and BS-‐EN 1090-‐2 and it includes a non-‐certified quality management system for welding compliant with standard BS-‐EN ISO 3834-‐3. Our quality management system does not include structural design process because we do not give declarations of characteristics related to structural design. In addition to structural steel fabrications, we also manufacture other steel products, but the manufacturing of these products is not included in this FPC system. The structural steel fabrications are bespoke/series production with base materials and working methods compliant with standard BS-‐EN 1090-‐2, and the manufactured assemblies fall into execution classes EXC 1 and EXC 2.
2. The structure of the quality control system This FPC manual includes the descriptions of intra-‐production inspections and assessment that we apply to •
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The structural steel fabrications manufactured by us, The intermediate products, The raw materials and components used in the production, Production machines and Inspection and test apparatus. With the help of the written descriptions that accompany the quality management system, it is possible, where necessary, to demonstrate to the interest groups that the assemblies are manufactured in controlled conditions and the used appliances have been subjected to appropriate maintenance and inspection. FPC manual and the documentation of the quality control system also include descriptions of measures and procedures for handling products that are do not conform with the requirements. To ensure the efficiency of the quality management system of the production we update the documents continuously. The records and other documents produced within the quality management system are stored for five (5) years after their creation. 2.1. The structure of the documentation FPC manual Exectuion documentation Quality documentation Figure 1. The documentation hierarchy of the quality control system The FPC manual, meaning this document, offers a general description of the factory's production and quality control system and its functions. Execution documentation includes written instructions related to and descriptions of for example the control of raw materials, production machines and the manufacturing of products. The execution documentation also include the most relevant standards used in the manufacturing process. FPC manual
X.X.2014 BS-‐EN 1090-‐1+A1 Quality documentation includes the objective documentation based in the quality procedures. These documents include for example the field books, assembly specifications, test results, complaints and other quality documentation. 2.2. File management Documents in the quality management system are stored in a secure place that can only be accessed by people authorized by the company. A person assigned by the company, or an authorized person has made all the changes in these documents. The person who makes the change is responsible for the verification of the changed information, communication of the change to other employees in the company, and, where applicable, of organizing training. For all documents in the quality management system, the aim is to use a ready-‐made document template -‐ ”L1 document template” -‐ with which files can easily be identified as belonging to the quality management system. The quality management system also includes documents that have not been drafted in a ready-‐made document template. Essential standards are examples of this kind of documents. Updated documents and quality documentation The FPC system is comprised of two types of documents: updated documents and quality documentation. Updated documents are guiding documents that exist already in the beginning of the work. The updated documents include guidelines, process descriptions, internal policies etc. The updated documents are updated when necessary and they come with a consecutive version number that identifies the changes. Quality documentation refers to documents that are drafted as the work proceeds. The quality records contain informaton about quality control, procedure entries, reports etc. In addition to these, the quality records also include the employees' qualification certificates, material certificates and other quality documentation. Naming of the files As to documents drafted in a ready-‐made document template, the naming of the documents follows the general naming policy so that each file contains the clear name, identification code, date and, where applicable, a version number. Sivu 6/25 FPC manual
BS-‐EN 1090-‐1+A1 X.X.2014 The folders in the FPC system follow the naming and numbering system as follows: Figure 2. Naming of FPC documents. 2.3. Management review Once a year, the management team of our company performs an internal audit on the quality management system to ensure that the system is suitable and functional. The management review is performed during the last quarter of the year, or, alternatively, prior to a quality control system assessment performed by an external auditor. The managerial audit includes the assessment of the following aspects where applicable: •
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The observations from previous managerial audits External audit reports The flaws and deficits that have arisen internally and in the form of customer feedback The implementation and effects of corrective measures for these flaws and deficits The monitoring of the suppliers The assessment of the company's security of supply The sufficiency of the production process monitoring The assessment of the profitability The sufficiency of resources The effectiveness and sufficiency of preventive measures The overall assessment of the effectiveness and suitability of the quality management system for the requirements of the quality policy and quality goals given the potentially changed customer needs Follow-‐up goals Based on the managerial reviews, a separate memo ”L3 – managerial audit” is drafted and saved as a part of quality documentation. Sivu 7/25 FPC manual
BS-‐EN 1090-‐1+A1 X.X.2014 2.4. Conformity to standards The company's quality system and this FPC manual have been drafted in accordance with standards BS-‐EN 1090-‐1, BS-‐EN 1090-‐
2, BS-‐EN ISO 3834-‐3 and their related reference standards. The conformity of the standards to this FPC manual is presented in the table below: Table 1. Conformity of our quality management system to the requirements of standar BS-‐EN 1090-‐1. BS-‐EN 1090-‐1+A1 Personnell Equipment Constituent products Component specification Evaluation of conformity Non conforming products FPC manual 3.1 3.2 4.3 4.1 4.6 6.1 Document H1 K1 T2-‐1 T1-‐2 T T6-‐3 2.5. Standards in the quality control system The following standards related to the manufacturing of struvtural steel fabrications are part of the quality control system. The standards are available to all employees to read and the company management is responsible for the access and validity of the standards. Standard BS-‐EN 1090-‐1 BS-‐EN 1090-‐2 Description / contents Execution of steel structures and aluminium structures. Part 1: Requirements for conformity assessment of structural components. Execution of steel structures and aluminium structures. Part 2: Technical requirements for steel structures. Sivu 8/25