Professional Documents
Culture Documents
PRODUCTS, INC.
P.O. Box 34506
Houston, TX 77234-4506
Supplier Type: OEM
Facility
Quality Manual
UNCONTROLLED COPY
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 0.2
Rev. D
Section Page 1 of 3
GENERAL
0.1
Manual Approval
Rev. C
0.2
Rev. D
0.3
Rev. E
Rev. C
Rev. A
SECTION 3 INTRODUCTION
Rev. C
Rev. E
4.1
General Requirements
4.2
4.3
Control of Documents
Management Commitment
5.2
Customer Focus
5.3
Quality Policy
5.4
5.5
5.6
Management Review
Rev. E
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 0.2
Rev. D
Section Page 2 of 3
6.2
Provision of Resources
6.3
6.4
6.5
Work Environment
7.2
7.3
Customer Communication
7.4
7.5
Purchasing
7.6
7.7
Validation of Processes
7.8
7.9
Customer Property
7.10
Preservation of Product
7.11
Rev. A
Rev. B
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 0.2
Rev. D
Section Page 3 of 3
Planning
8.2
Statistical Techniques
8.3
Customer Satisfaction
8.4
Internal Audit
8.5
8.6
8.7
Analysis of Data
8.8
8.9
Continual Improvement
8.10
Rev. A
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 0.3
Rev. E
Section Page 1 of 1
Rev
Effective
No.
Date
6/19/06
Approvals
Section
Page
No.
No.
V.P. Eng.
QC Mgr.
All
All
R. Bailey
H. Lippold
8/20/09
10
R. Bailey
H. Lippold
8/20/09
R. Bailey
H. Lippold
7/28/08
R. Bailey
H. Lippold
8/20/09
11-12
R. Bailey
H. Lippold
8/20/09
R. Bailey
H. Lippold
8/20/09
4.1 &
4.2
1, 7
R. Bailey
H. Lippold
7/28/08
Quality Policy
R. Bailey
H. Lippold
5/11/11
Introduction
R. Bailey
H. Lippold
8/20/09
5.4
R. Bailey
H. Lippold
8/10/11
0.1
R. Bailey
A. Henrikson
5/11/11
4.2.5
R. Bailey
H. Lippold
5/11/11
7.4.1
R. Bailey
H. Lippold
6/10/11
5.5.1
R. Bailey
H. Lippold
6/10/11
0.3
R. Bailey
H. Lippold
Description of Revision
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 1
Rev. C
Section Page 1 of 1
QUALITY POLICY
Piping Technology & Products, Inc. and its wholly owned subsidiaries, U.S. Bellows, Inc.,
Sweco Fab, Inc., and Pipe Shields, are committed to the continuous improvement of our
products and services. We understand the industry challenges; we eagerly serve not only our
external customers, but also internal customers as well. Viewing ourselves as part of a team
which includes our customers and suppliers, we understand our role in meeting the teams
goal. We plan and execute our work to meet our customers specifications. Working
together we strive to... DO IT RIGHT THE FIRST TIME.
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 2
Rev. A
Section Page 1 of 1
QUALITY OBJECTIVES
QUALITY OBJECTIVES
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 3
Rev. C
Section Page 1 of 1
INTRODUCTION
Piping Technology & Products, Inc. and its wholly owned subsidiaries manufacture
products for the power, petrochemical, chemical and commercial markets. The scope of the
quality management system described in this manual is for the manufacture and delivery of
our Hot and Cold Pipe Supports product group.
The purpose of this manual is:
To identify the general procedures used for all activities composing the quality
system
Another purpose of this manual is to present the quality system to our customers and other
external interested parties and to inform them of the controls that are implemented at Piping
Technology & Products, Inc. to assure quality.
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 4
Rev. E
Section Page 1 of 9
4.0
SCOPE
This section defines the scope of the Quality Management System and the
documentation structure for control of the system documents and records.
4.1
GENERAL REQUIREMENTS
Piping Technology & Products, Inc. has established, implemented and maintained a
quality management system and its effectiveness continually improved in accordance
with the requirements of ANSI/ISO/ASQ Q9001.
The quality management system has been implemented as follows:
4.1.1
The Quality Manual provides the policy and intent of processes needed for the quality
management system. Where any requirement of the International Standard cannot be
applied and exclusion will be stated in Section 3 of the Quality Manual.
4.1.2
The sequence and interaction of these processes is described in section 4.1.12 Quality
System Description and graphically in Figure 4.1Quality System Structure.
4.1.3 The organization structure, responsibilities and procedures needed to ensure the
effective operation of the quality management process has been established in this
Quality Manual with reference to documented Quality Assurance Procedures.
4.1.4
4.1.5
4.1.6
Any identified corrective, preventative and improvement actions are documented and
implemented to ensure planned goals and continual improvement of these processes
is achieved.
4.1.7
Outsourced Processes
When processes that affect product confirmatory are outsourced, special controls are
implemented to ensure that these processes meet specified requirements. Such
controls may include, as appropriate, evaluation and prequalification of suppliers,
assessment of supplier realization process and requirements for inspection, testing or
other records demonstrating product conformity, or containment and verification of
the supplied product.
The Quality Manager is responsible for determining resources and information
requirements necessary to support the operation and monitoring of the quality system
processes and for communicating these requirements to Senior Management.
4.1.8
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 4
Rev. E
Section Page 2 of 9
4.1.9
The Quality Manager reports to the Vice President of Engineering and Quality
Assurance. The Quality Manager is the facility ISO representative and has the
authority to establish quality procedures, provide interpretation of customer quality
requirements and management data reports. The Quality Department establishes and
maintains a corrective action system and withholds from acceptance any product not
meeting workmanship, standards, drawings and customer or contractual requirements.
4.1.10 The Vice President of Engineering and Quality Assurance reports directly to the
President of Piping Technology & Products, Inc. and is responsible for the
effectiveness and status of the quality system. Senior Management is responsible for
ensuring the availability of necessary resources and information.
4.1.11 It is the responsibility of all company personnel involved directly or indirectly in
meeting the stated quality goal and objectives and to dedicate their efforts towards the
reduction, elimination and prevention of quality deficiencies.
4.1.12 Quality System Description
A description of the interaction between the processes of the quality management
system is described in the following paragraphs and illustrations in Figure 4.1 Quality
System Structure (next page).
A.
Operating Processes
Sales/Customer Services facilitate the negotiation of technical specifications
and pricing agreements that are distributed to inside sales representatives for
order taking. On going contact with the customer provides information to
management to respond to specific needs.
During order taking the inside sales representative will determine the order
requirements for delivery, pricing and generate a Job/Quote work order to
describe and initiate the product realization and control process.
The customer information and product specifications are entered into an
electronic data base for tracking job status and answering customer inquires.
The performance of product realization processes is monitored by measuring
product characteristics resulting from the processes and through the program
of inspections to the materials and product.
The performance of processes required for the quality management system is
monitored through internal quality audits. The overall performance of the
quality system is monitored by measuring customer satisfaction.
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 4
Rev. E
Section Page 3 of 9
SALES
CUSTOMER SERVICES
PRODUCT
REALIZATION
& CONTROL
ORDER
TAKING
Verbal Order
Job Quote
Work Order
Production Drawings
Job Folder
WAREHOUSE
& SHIPPING
Identification
Inventory Control
Handling Preservation
Shipping
Manage Information
(Procedures, Records, Databases)
INVOICING
& REPORTING
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 4
Rev. E
Section Page 4 of 9
B.
4.2
4.2.1
4.2.2
Quality Manual
4.2.2.1 The Quality Manager is responsible for the preparation, approval, control,
implementation, and updating of the manual. The manual is reviewed and approved
by the Vice President of Engineering and Quality Assurance.
4.2.3
4.2.3.1 The Quality Manager is responsible for the preparation, approval, control, and
implementation and updating of the procedures. The procedures are reviewed and
approved by the Vice-President of Engineering and Quality Assurance.
4.2.4
Work Instructions
4.2.4.1 The Quality Manager, in conjunction with the respective department manager, is
responsible for the preparation, approval, control, implementation, and updating of
work instructions. All work instructions are reviewed and approved by the Quality
Manager and the General Manager of Manufacturing.
Uncontrolled Copy Do Not Duplicate
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 4
Rev. E
Section Page 5 of 9
4.2.5
Industry Standards
4.2.5.1 All products offered shall comply with the industry standards listed in paragraph
4.2.5.2 Related Industry Standards.
4.2.5.2 Related Industry Standards
STANDARD
TITLE
AWS D1.1
ASTM A36/A 36M-08
ASTM A53/A 53M-07
ASTM A123/A 123M-09
ASTM A153/A 153M-09
ASTM A307-07
ASTM A325-10
ASTM D1621-10
ASTM D1622-08
ASTM D1623-09
ASTM D 4227-05
ASTM D4228-05
ASTM D4417-03
ASTM D4940-10
Structural Welding-Steel
Structural Steel
Black and Hot Dipped Zinc-coated Steel Pipe
Zinc Coatings on Steel Fabrication
Hot Dipped Zinc Coated Hardware
Bolts and Studs
Bolts and Studs
Cellular Plastics
Cellular Plastics
Cellular Plastics
Painter Qualification
Painter Qualification
Quality of Abrasives
Analysis of Water Soluble Ionic Contamination of Blasting
Abrasives
Indicating Oil or Water in Compressed Air
Quality Systems Management Systems
Pipe hangers and support materials and design
Pipe hangers and supports-selection and application
Pipe hangers and supports-fabrication and installation practices
Guidelines on terminology for pipe hanger and supports.
Standard Symbols for Welding, Brazing and Nondestructive
Examination
Process Piping
Power Piping
Qualification of Welding and Welders
ASTM D 4285-83
ISO 9001-2008
MSS-SP-58-09
MSS-SP-69-03
MSS-SP-89 Pipe-03
MSS-SP-90-00
AWS.A2.4-07
ASME B31.3
ASME B31.1
ASME SEC. 9
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 4
Rev. E
Section Page 6 of 9
TITLE
SSPC
SSPC
SSPC-PA2
SSPC-AB-1
SSPC-SP1
SSPC-SP5
SSPC-SP6
SSPC-SP7
SSPC-SP10
4.3
CONTROL OF DOCUMENTS
4.3.1
Documents in the quality management system are controlled to ensure the validity of
all documentation that may have an influence on product quality.
4.3.2
4.3.2.1 All controlled documents are reviewed and approved for adequacy by authorized
personnel prior to issue.
4.3.2.2 Documents are distributed to personnel and locations where they are used or needed
for the effective function of the quality management system.
4.3.2.3 Distribution of procedures is through a transmittal receipt system which ensures the
disposition of revised or outdated documentation.
4.3.2.4 QAP-42-05 Document Control Master List is issued to identify the current revision
status of controlled documents or data in the system.
4.3.3
Document Changes
4.3.3.1 The quality manual and procedures are reviewed periodically to ensure they conform
to the current issue of the international standard, regulatory requirements and
changing customer and company needs.
Uncontrolled Copy Do Not Duplicate
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 4
Rev. E
Section Page 7 of 9
4.3.3.2 The need for document revision is identified during internal audits, management
reviews and nonconformance investigations. Any employee may submit a request for
document change to the person responsible for review and approval.
4.3.3.3 If document revision takes place to correct a nonconformance, the outcome is verified
to ensure the desired effect of the change was obtained.
4.3.3.4 Document changes are reviewed, updated as necessary and approved by the same
authority as for the original document. Pertinent background information shall be
made available for the review.
4.3.3.5 The controlling authority retains a copy of all previous revisions for historical or legal
purposes (as electronic archives).
4.3.3.6 Obsolete controlled documents are promptly removed from all locations where they
are used to control or verify a process.
4.3.3.7 A description of the changes made shall be noted in a revisions log contained in each
document.
4.3.4
4.3.4.1 Controlled or Uncontrolled documents within the scope of this quality manual may be
issued to customer or other personnel outside the company at the discretion of the
Quality Manager.
4.3.4.2 Uncontrolled copies of controlled documents may be made for informational or
training purposes, but shall be destroyed after use or clearly marked as
Uncontrolled.
4.3.4.3 Controlled documents shall be clearly identified as Controlled.
4.3.5
Control of Records
4.3.5.1 Records are controlled to ensure they remain legible, readily identifiable and
retrievable. QAP-42-03 Control of Quality Records defines the requirements and
responsibilities for the identification, storage, protection, retrieval and disposition of
records.
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 4
Rev. E
Section Page 8 of 9
4.3.5.2 Retention periods vary with type of record and customer requirements. Table 4.3.5
Quality Records Requirements (next page) specifies the record types and minimum
retention time.
4.3.5.3 Pertinent supplier records are maintained as quality records.
Record
Responsibility
Retention Time
Sales/Customer Records
Sales/Customer Serv.
Job File Folder
1 year
Sales/Customer Serv.
Job File Folder
5 years
Purchasing
Purchasing
Purchasing Dept.
1 year
Training Records
Safety Department
QC Department
Calibration Records
Quality Manager
Shop Foreman
1 year
1 year
Quality Manager
1 Year
Purchasing
Job File Folder
1 year
Maintenance
-Daily Maintenance Checklist
-Equipment Maintenance Log
Nonconformance Reports
Corrective Action Reports
Verification of Purchased Product
In-Process Inspections
Final Inspections
Control of Nonconforming Product
Shipping Records
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 4
Rev. E
Section Page 9 of 9
Record
Responsibility
Retention Time
Quality Manager
3 Years
Customer Services/Sales
1 year
Quality Manager
1 year
Quality Manager
3 years
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 5
Rev. E
Section Page 1 of 6
MANAGEMENT RESPONSIBILITY
5.0
SCOPE
This section defines the management responsibility and authority in establishing,
implementing, maintaining and continually improving the effectiveness of the quality
system.
5.1
MANAGEMENT COMMITMENT
5.1.1
Ensuring that quality objectives are established through out the company
5.2
CUSTOMER FOCUS
5.2.1
5.2.1.1 Customer requirements are understood broadly to include all aspects of product
offering and associated services that are relevant to customer satisfaction. When
appropriate, this may also include customer needs and expectations.
5.2.1.2 Customer requirements are determined and verified through the process of order
review. This process is defined in this manual in Section 7.2 Customer and Product
Requirements, and in procedures QAP-72-01 Order Processing for Catalog Products,
and QAP-72-02 Order Processing for Custom Products.
5.2.2
5.2.2.1 All processes and elements of the quality system are designed and implemented
specifically to ensure that customer requirements are met. This starts with provision
of required training, adequate infrastructure and suitable work environment (see
Section 6 Resource Management). Next is planning and implementation of reliable
and effective product realization processes (see Section 7, Product Realization).
Finally, there are activities related to product and process monitoring and verification
(see Section 8, Measurement, Analysis and Improvement).
Uncontrolled Copy Do Not Duplicate
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 5
Rev. E
Section Page 2 of 6
MANAGEMENT RESPONSIBILITY
Customer satisfaction
5.2.3.1 Focusing on customer requirements and on meeting these requirements should result
in enhancing customer satisfaction. The level of customer satisfaction is used as a
measure of the effectiveness of the whole quality system. Specific methods for
determining customer satisfaction are defined in this quality manual in Section 8.3
and in the associated procedure QAP-82-01 Customer Satisfaction. This valuable
information is reported and used as described in Section 5.6 Management Review.
5.3
QUALITY POLICY
5.3.1
Piping Technology & Products, Inc. Quality Policy (Section 1) defines the companys
commitment to comply with customer requirements and continually improve the
effectiveness of the Quality Management System. Senior Management is responsible
for reviewing the Quality Policy for continuing suitability.
5.3.2
The Quality Policy provides a framework for establishing and reviewing Quality
Objectives (Section 2) at all levels of the organization.
5.3.3
The Quality Policy is implemented at all levels in the organization. All employees
are required to follow the processes described in this manual and supporting Quality
System Procedures.
5.3.4
The Quality Policy is posted in high traffic areas of each facility and provided in
written form to each employee.
5.4
5.4.1
Quality Objectives
5.4.1.1 Senior Management is responsible for establishing the Quality Objectives (Section 2)
that will ensure the implementation of the Quality Policy and the facilitation of
continual improvement.
5.4.1.2 Quality Objectives are reviewed at the annual Management Review (see QAP-56-01
Management Review)
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 5
Rev. E
Section Page 3 of 6
MANAGEMENT RESPONSIBILITY
5.4.2.1 The Quality Manual, Quality Assurance Procedures, Work Instructions and other
referenced documents (referenced in Section 4.2) provide evidence of Quality
Planning for the Quality Management System in order to meet the requirements of
our customers and ISO 9001.
5.4.2.2 Planning for Objectives and recording the activities completed occurs during the
Management Review (see QAP-56-01 Management Review).
5.4.2.3 Changes to the Quality Management System occur from time to time as a result of
changing circumstances such as organizational change, continual improvement
activities or changing customer needs. Senior Management has the responsibility and
authority for the following:
Ensuring that process and resource planning for the Quality Management
System meet the requirements of ISO 9001, the company quality policy and
objectives
5.5
5.5.1
5.5.1.1The Quality Manager is authorized to prepare, implement and maintain the Quality
Program described in this manual.
5.5.1.2 The Quality Manager has the authority to resolve all quality matters within the
facility and to liaise with the customers on all quality matters pertaining to the
product line.
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 5
Rev. E
Section Page 4 of 6
MANAGEMENT RESPONSIBILITY
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 5
Rev. E
MANAGEMENT RESPONSIBILITY
Section Page 5 of 6
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 5
Rev. E
Section Page 6 of 6
MANAGEMENT RESPONSIBILITY
5.6
MANAGEMENT REVIEW
5.6.1 The purpose of management review is to:
Evaluate the suitability, adequacy and effectiveness of the quality system
Consider changes to the quality management system and to the quality policy and
quality objectives
Identify opportunities for improvement of the quality system, processes and
products.
5.6.2 Management reviews are chaired by the Quality Manager and are attended by the
Vice President Engineering & QA, and all designated department managers as
specified in QAP 56-01 Management Review.
5.6.3
Management reviews are conducted at least once a year. More frequent reviews are
scheduled in periods when organizational or product changes, or other circumstances
require increased attention and input from senior management.
5.6.4
Input into the management reviews consists of information and data related to quality
performance of the organization. At a minimum, this includes:
Results of audits
Customer feedback and complaints
Process performance and product conformance data
Status of preventive and corrective actions
Changes that could affect the quality system
Follow-up actions from earlier management reviews
5.6.7
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 6
Rev. A
Section Page 1 of 5
RESOURCE MANAGEMENT
6.0
SCOPE
Resources required for the implementation and improvement of the quality system,
and for addressing customer satisfaction, may include people, suppliers, information,
infrastructure, work environment, and financial resources. This section describes
those activities.
6.1
6.1.1
The Quality Manager and other management personnel involved in the Quality
System are responsible for determining resource requirements for the implementation
and improvement of the system.
6.1.2
6.1.3
The principal forum for determining and communicating resource requirements are
management reviews of the quality system. Procedure QAP-56-01 Management
Review explains this process.
6.2
PROVISION OF RESOURCES
6.2.1
Senior Management has the authority and responsibility for the provision of
resources.
6.2.3
6.2.4
6.2.5
Management review of the quality system is the principal forum for allocation of
resources for the operation and improvement of the system. All actions initiated by
the review are supported by allocation of specific resources necessary for their
implementation. Procedure QAP-56-01 Management Review defines this process.
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 6
Rev. A
Section Page 2 of 5
RESOURCE MANAGEMENT
6.3
COMPETENCY AWARENESS AND TRAINING
6.3.1 The Human Resources department is responsible for identifying training needs and
awareness programs for company-wide participation, such as: general orientation,
rules and regulations and other company-wide systems and issues.
6.3.2 The Quality Manager, in coordination with Department managers, is responsible for
identifying and providing ISO orientation and quality system training to all
employees.
6.3.3
The Safety Department is responsible for identifying and providing training to all
employees on safety requirements and responsibilities.
6.3.4
Piping Technology & Products Inc. provides, or supports, the following categories of
company-wide and departmental training and awareness programs:
General ISO orientation and quality system awareness training explains
how the product is used and how the quality system works to ensure product
quality. Provided to all employees.
Safety training Instructs in safe working practices, use of personal protective
equipment, first aid, etc. Provided to all employees.
Use of company-wide systems Explains interdepartmental systems, such as
product numbering requirements, inventory systems, use of computers, etc.
Provided to wide groups of employees.
External training External seminars, conferences, and courses. Provided to
individual employees on as-needed basis.
Self-study Reading magazines, books, and reports. While all employees are
encouraged to broaden their knowledge through reading, in some cases self-study
may be required as formal training.
Skill training in engineering, production, and quality control departmental
training in specific skills. Often provided as on-the-job training.
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 6
Rev. A
Section Page 3 of 5
RESOURCE MANAGEMENT
6.3
6.3.7
Procedure QAP-62-01 Training and Awareness describes in detail the training and
awareness programs provided by Piping Technology & Products, Inc.
6.4.1
6.4.2
Departmental managers are responsible for identifying the need and requirements for
new, and/or modification of existing infrastructure and facilities in their departments.
Requests for significant changes and/or expansions of facilities are submitted to the
top management for review and approval.
6.4.3 When relevant, Quality Assurance reviews the proposed facilities changes to ensure
that they enhance the achievement of product conformity and quality.
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 6
Rev. A
Section Page 4 of 5
RESOURCE MANAGEMENT
6.4.4
Key process equipment, machines, hardware, and software are regularly maintained
in accordance with maintenance plans specified by equipment manufacturers or
departmental managers responsible for the equipment. Requirements for the
maintenance of production equipment are specified in procedure QAP-63-01
Equipment Maintenance.
6.5
WORK ENVIRONMENT
6.5.1
Human Resources and departmental managers are responsible for ensuring suitable
social and psychological conditions in the workplace. This is to include such aspects
as interaction and communication between employees, employee harassment and
conflict resolution. Relevant workplace policies are implemented mainly through
training and awareness programs and, where necessary, disciplinary actions. (Refer to
procedure QAP-62-01 Training and Awareness.)
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 6
Rev. A
Section Page 5 of 5
RESOURCE MANAGEMENT
6.5.2 Production and Quality Assurance are responsible for identifying those operations
where extreme environmental conditions could impact quality, performance of
personnel and result in product nonconformities. Where appropriate, limits of
exposure and/or mitigating measures shall be defined and implemented for these
operations.
6.5.3
The health and safety management system is independent from the quality
management system. It is administrated by the Safety Director and is documented in
the company Safety Policy and Procedures Manual.
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 7
Rev. B
Section Page 1 of 13
PRODUCT REALIZATION
7.0
SCOPE
This section describes Piping Technology & Products, Inc. methods for planning and
developing the processes needed for product realization.
7.1
7.1.1
Product requirements and quality objectives for product manufacture are defined and
communicated in drawings and specifications, contract documents, internal and
external standards, production shop files, and applicable legal and regulatory
requirements.
7.1.2
For custom products manufactured to customer design (or custom changes to standard
catalog products), product requirements and quality objectives are specified in the
technical documentation provided by the customer. Sales/Customer Services,
Estimating, Engineering/Design Liaison and Quality Assurance review these
specifications before acceptance of the contract and commencement of production, as
instructed in procedure QAP-72-02 Order Processing for Custom Products.
7.1.3
For standard catalog products that meet functional and performance requirements
defined by Sales, product requirements and quality objectives are determined by
Piping Technology & Products Inc.
7.1.4
Product verification and validation plans determine the inspection and testing
program for a product, and for materials and components incorporated into the
product. This includes:
PIPING TECHNOLOGY
& PRODUCTS, INC.
QUALITY MANUAL
Section 7
Rev. B
Section Page 2 of 13
PRODUCT REALIZATION
7.2
7.2.1
7.2.1.1 In determining and reviewing customer and product requirements, Piping Technology
& Products Inc. distinguishes between orders for standard catalog products and
custom products.
7.2.1.2 Standard catalog products are products manufactured from engineering standard
specifications and without any modification or customizing. Custom products are
products designed and/or manufactured to unique customer requirements.
7.2.2
7.2.2.1 For standard catalog products, orders are reviewed in conjunction with order
processing. These may be product availability, delivery requirements, special
packaging or handling requirements, etc. Procedure QAP-72-01 Order Processing for
Catalog Products, instructs on how to carry out this review.
7.2.3
7.2.3.1 For custom products, product requirements are determined and reviewed by the
Sales/Customer Services Manager. This often involves input from Engineering,
Production, Purchasing, Estimating and Quality Assurance, depending on the nature
and complexity of the order, and whether a similar order has been recently processed.
7.2.3.2 Custom product requirements are determined and reviewed with regard to
requirements specified by the customer; other relevant product requirements not
specified by the customer, and the companys capacity and capability to meet all
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7.2.4.1 Any incomplete or conflicting requirements are resolved with the customer before
acceptance of the order.
7.2.5
Verbal orders
7.2.5.1 Verbal orders are confirmed before acceptance. This may be by repeating the order
requirements back to the customer, or by sending a confirming fax or e-mail.
7.2.6
Amendments
7.2.6.1 Change orders are received and reviewed by the same functions that are responsible
for the review of the initial orders. Job Revisions are communicated to all functions
within the organization that may be affected by the change of customer requirements.
Procedures QAP-72-01 Order Processing for Catalog Products, and QAP-72-02
Order Processing for Custom Products, provide instructions on how to process
change orders.
7.2.7
Records
CUSTOMER COMMUNICATION
7.3.1
Product Information
7.3.2
7.3.3 Master copies and/or files of documents containing product information are
controlled. They are reviewed and approved before release, and identified by a unique
number and a revision level. Superseded and obsolete materials are withdrawn to
prevent them from being passed or communicated to customers.
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7.3.4
7.3.5
7.3.6.1 Customer Service department is responsible for receiving and processing customer
feedback and complaints. All received customer communication is recorded in the
customer feedback and complaints log.
7.3.6.2 Customer feedback and complaints are classified into categories to allow for better
tracking of trends and evaluating improvement in specific aspects. Every complaint is
communicated to relevant functions within and outside the organization.
Sales/Customer Services, the responsible department, and Quality Assurance decide
how to respond to the customer and, when appropriate, what corrective or preventive
actions should be implemented internally.
7.3.6.3 Procedure QAP-72-03 Customer Feedback and Complaints provides detailed
instructions on how to receive, process, and respond to customer feedback and
complaints.
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7.4
7.4.1
Piping Technology has the ability to design and develop Hot and Cold Pipe Supports.
All Design and Development activities are in accordance to Procedure QAP-73-01
7.4.2
Design Changes
7.4.2.1 All design changes are done in accordance to procedure QAP-73-01 Design and
Development
7.5
PURCHASING
7.5.1
Supplier Evaluation
7.5.1.1 All new suppliers are evaluated with regard to their quality and process capability.
Purchasing and Quality Assurance establish the criteria for selection of suppliers, and
conduct supplier evaluation. Suppliers are rated APPROVED, PROVISIONAL, or
NOT APPROVED. The Approved and Provisional suppliers are entered on the
approved supplier list. Existing suppliers with a satisfactory quality performance
history may be exempted from the initial evaluation and be initially rated as
APPROVED or PROVISIONAL. Records of the initial supplier evaluation are
maintained. Supplier evaluation process is governed by Procedure QAP-74-01
Supplier Evaluation.
7.5.2
7.5.3.1 Purchasing maintains an approved supplier list. Orders may only be placed with
vendors that are on the list.
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7.5.5.1 Purchased products are inspected by the receiving clerk. This includes verification of
product identity and quantity, visual inspection and, where applicable, verification
that all requested certificates and quality records are available. Designated products
are further inspected or tested by QC.
7.5.5.2 QC inspection or testing may not be necessary when products are supplied with
records or certificates demonstrating conformity; or when the supplier is qualified
based on their quality system certification or supplier audits, and a satisfactory quality
performance history.
7.5.5.3 Quality Assurance is responsible for selecting appropriate methods for purchased
product verification and acceptance. Procedure QAP-74-03 Verification of Purchased
Product sets forward detailed rules for selecting product verification methods.
7.5.5.4 When verification of purchased product is to be performed at suppliers premises,
purchasing documents specify the intended verification arrangements and method of
product release.
7.6
7.6.1
7.6.2
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7.6.3
Work Instructions
7.6.3.1 Work instructions may be in the form of manuals, procedures, sheets, posted signs, or
samples. They instruct on how to carry out a local process or perform an operation or
task. The need for work instructions is evaluated on the basis of criticality,
importance and complexity of the process; the ability to verify results of the process;
operator qualifications; and history of quality problems associated with the process.
7.6.3.2 Procedure QAP-42-04 Work Instructions specifies criteria for determining when work
instructions are needed and provides guidelines for issuing, authorizing and
controlling work instructions.
7.6.4
Equipment Maintenance
7.6.4.1 Maintenance of key process equipment, machines, hardware, and software are
addressed in procedure QAP-63-01 Equipment Maintenance.
7.6.5 Measuring and Monitoring Equipment
7.6.5.1 Requirements for measuring and monitoring equipment are determined by Production
and Quality Assurance. This is in accordance with product verification programs
defined in product realization planning (refer to Section 7.1.4 of this manual).
7.6.5.2 The control system for measuring and monitoring equipment is defined in procedure
QAP-76-01 Measuring and Monitoring Equipment.
7.6
7.6.6
7.6.6.1 Processes are monitored and controlled through a variety of approaches, activities and
techniques. The system is designed to control:
Information, material and human (operator) input into the process
Process environment and performance
Process output
Process monitoring activities are further defined in Section 8 of this manual.
Activities related to process control are defined in procedures QAP-75-01 Production
Control; QAP-42-04 Work Instructions; and QAP-82-03 Statistical Process Control.
7.6.7
7.6.7.1 Products are released for delivery only after all specified activities have been
satisfactorily completed and conformity of the product has been verified. Procedure
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QAP-82-05 Final Inspection defines the system for final product verification and
release.
7.7
VALIDATION OF PROCESSES
7.7.1
Special Processes
Processes where the resulting output cannot be verified by subsequent measurement
or monitoring are designated as special processes.
7.7.2
Production and Quality Assurance are responsible for identifying, validating, and
documenting special processes. Where applicable, the Engineering department may
assist with establishing validation specifications and testing of samples.
7.7.3
7.7.4
Production and Quality Assurance are responsible for selecting and implementing
appropriate process validation and control measures for each special process. At a
minimum, all special processes are documented in work instructions.
7.7.5
7.8
7.8.1 Purchased products are identified with unique numbers, colors, or names. The
identification is the same as, or is cross-referenced with, the designations used in
drawings, specifications, bills of materials, parts lists, purchase orders, work
instructions, etc. Purchased products are identified by marking, labeling, or tagging
the products or their packaging, or by identification of the area where the products are
held.
7.8.2
During all stages of production, products are identified by a production Job Number
and other documents contained in the Job File and Shop File folder that accompany
them through the production cycle. Parts and components may also be identified by
labels or tags, or the containers in which they are held.
7.8.3
Final products are identified by their model number or size, which is labeled or
marked on the products and/or is printed on the primary product packaging.
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7.8.4
7.8.5 Traceability
7.8.5.1 When required by contracts, laws and regulations, or voluntary standards traceability
is implemented to the extent specified. Traceability may also be implemented for
internal reasons to facilitate corrective action.
7.8.5.2 As required, traceability may apply to materials, components, parts, production
processes, environmental conditions, inspection and testing, and personnel
responsible for processing and verification of products. The scope of traceability is
documented in product manufacturing specifications or the production Shop File.
7.8.5.3 Activities related to establishment and maintenance of traceability is regulated by
procedures QAP-75-03 Product Identification and Traceability, and QAP-75-01
Production Control.
7.8.6
7.8.6.1 Following every inspection or test, products are identified to indicate whether they
have passed or failed the inspection. This is to prevent nonconforming product from
being used or dispatched. Physical location of product can only be used as inspection
status identification when the location is designated and contained.
7.8.6.2 QC inspectors, receiving clerks, and production personnel authorized to carry out
inspections and testing are responsible for identifying product inspection status. All
personnel handling products are responsible for maintaining the identification.
7.8.6.3 Products that have passed the receiving inspection are moved to the material stock
locations or designated material staging areas in production. Where intermingling
with other product is a possibility, the inspected items are also appropriately tagged or
labeled. Detailed rules for identifying inspection status of purchased products are
provided in procedure QAP-74-03 Verification of Purchased Product.
7.8.6.4 Status of an in-process inspection is identified by a sign-off on the production
Traveler document accompanying the product. The status may be also identified by
tagging or labeling, or holding products in designated containers or area. Procedure
QAP-82-04 In-process Inspections provides detailed instructions.
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7.8.6.5 Products that pass the final inspection are stamped by the QC Inspector with a QC
number stamp. Approval for product release is indicated on the work order on the line
where the final inspection is called out. Rules for identifying inspection status of
finished products are provided in procedure QAP-82-05 Final Inspection.
7.8.6.6 Products that fail any inspections or tests are labeled with a REJECTED sticker or
tag, and are segregated and/or quarantined. Whenever a nonconforming product is
identified, the nonconformity is documented using a Nonconforming Product Report.
Procedure QAP-83-01 Control of Nonconforming Product, instructs on how to
identify and process nonconforming product.
7.9.
CUSTOMER PROPERTY
7.9.1 Customer-supplied products are received and inspected following the same procedure
that applies to purchased products - QAP-74-03 Verification of Purchased Product. In
the event the supplied products fail receiving inspection or are not suitable for any
other reason, the customer is contacted.
7.9.2
7.9.2.1 Marking, storage, handling, and preservation of customer supplied products follow
the same procedures that apply to purchased products. The applicable procedures are
QAP-75-03, Product Identification and Traceability; QAP-75-04 Product Handling
and Preservation; and QAP-75-05 Storage Areas.
7.9.2.2 Customer-owned tooling and returnable packaging are permanently marked so that
ownership of each item is visually apparent.
7.9.2.3 Customers software, documents, and other intellectual property are protected to the
same extent as internal documents of similar content, unless there are contractual
requirements for special measure to protect customers intellectual property.
7.9.3
Special Requirements
7.9.3.1 When specified in a contract, special handling instructions from customers will take
precedent over the company's standard procedures.
7.9.4
Loss or damage
7.9.4.1 Customers are contacted in the event of loss, damage, deterioration, or unsuitability
of their products.
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7.10.9 Packaging and labeling activities are governed by procedure QAP-75-06 Packaging,
Labeling and Shipping.
7.10.10Shipping of finished products is initiated by the shipping order. The order identifies
the shipping consignee address, shipping due date, products to be shipped, labeling
requirements, and transportation mode or carrier. Before products are dispatched,
shipping personnel verify that the shipment contains the same products and quantities
as specified in the shipping order, and that packaging and labeling conform with
customer and/or carrier requirements. Only orders that have been verified and signed
off by the shipping department can be loaded for shipment.
7.10.11Activities related to shipping and delivery operations are regulated by procedure
QAP-75-06 Packaging, Labeling and Shipping.
7.11
7.11.1 The scope of the calibration control system extends to the measuring and test
equipment, comparative reference hardware (such as gauges and templates), and test
software used for:
Monitoring of environmental conditions
Verification of product conformity
Operations where defined accuracy of a measurement is required to assure product
conformity
7.11.2 Equipment used for other purposes may be exempted from calibration. Such
equipment is labeled with stickers warning that it is not calibrated or calibration is not
required. Uncontrolled measuring equipment is prohibited in QC inspection areas and
during QC inspection processes.
7.11.3 Gauges, instruments, and other measuring and monitoring equipment are selected on
the basis of their capability to provide the necessary accuracy of the measurement.
Quality Assurance is responsible for selecting appropriate measuring and monitoring
equipment.
7.11.4 Quality Assurance is responsible for calibrating and maintaining measuring and
monitoring equipment. All active equipment is inventoried in a controlled list,
indicating equipment calibration status and location.
7.11.5 Measuring equipment is calibrated using written instructions, unless calibration is
simple and obvious. Only calibration instruments and standards having known
relationship to the nationally recognized standards are used for calibrating measuring
and test equipment.
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7.11.6 Calibration is recorded in a calibration record and the calibrated equipment is labeled
with a calibration sticker.
7.11.7 Calibration-related activities are regulated by procedure QAP-76-01 Measuring and
Monitoring Equipment.
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8.0
SCOPE
This section describes the implementation, monitoring, measurement, analysis and
improvement process utilized in product manufacturing.
8.1.
PLANNING
8.1.1
Measurement and monitoring activities to assure and verify product conformity are
defined in engineering specifications and drawings, production Job Files, and
inspection and testing procedures.
8.1.2
8.2
8.2.1
Departmental managers are responsible for identifying the need for using statistical
techniques in their departments and in other activities for which they are responsible.
Quality Assurance may be called upon to assist other departments in selecting and
documenting specific techniques.
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8.3.
CUSTOMER SATISFACTION
8.3.1
8.3.2
Information and data pertaining to customer satisfaction are collected from several
sources. Specifically, these are:
Customer feedback and surveys,
Product returns and warranty claims,
Repeat customer rates, and
Market share.
8.3.3 Procedure QAP-82-01 Customer Satisfaction defines the system for collecting and
analyzing the pertinent information and data, and for reporting results to the top
management.
8.3.4
8.3.5
8.3.6
Information about the rate of product returns and warranty claims is extracted from
accounting, quality, and servicing records. Results and trends are reported and
analyzed at management review meetings.
8.3.7
Sales records are periodically analyzed to identify repeat customers and track their
ordering frequencies and patterns. The ratio of repeat customers is one of the most
important indicators of customer satisfaction. Statistics on repeat customers
frequencies and trends are presented and discussed at management reviews.
8.3.8
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8.4
INTERNAL AUDIT
8.4.1
The Quality Manager establishes an internal audit plan and schedule in accordance
with procedure QAP-82-02 Internal Quality Audits. Every activity and area is audited
at least once a year. Selected activities are audited more frequently, depending on
their importance and quality performance history.
8.4.2
Only personnel independent of the audited activities are assigned to conduct internal
audits. The Quality Manager leads the audit team except when QA activities are being
audited. Audits of QA activities are usually conducted by a designated outside
auditor.
8.4.3
8.4.4
Conducting the audit, auditors seek objective evidence indicating whether the audited
activities comply with the requirements of the documented quality system and ISO
9001, and whether the quality system is effective. The evidence is collected by
observing activities, interviewing personnel, and examining records.
8.4.5 Nonconforming conditions are documented and recorded using the Nonconformance
Report (form number QAP-85-02-form 1). Instructions on how to use the form are
provided in procedure QAP-85-02 Nonconformance Corrective & Preventative
Action.
8.4.6
Audits are conducted in a way that minimizes disruption of the audited activities.
8.4.7
When nonconforming conditions are identified, the manager responsible for the
affected area or activity is requested to propose and implement a corrective action.
Implementation and effectiveness of the action are verified by a follow-up audit. The
Corrective Action Response (form number QAP-85-02-form 2) is used for
verification and recording the implementation of the corrective actions.
8.4.8
When the auditing cycle is completed, all nonconformity reports established during
the cycle are compiled and analyzed, and are presented at the management review
meeting.
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8.5.
8.5.1
8.6.1
Inspection and testing requirements for a product are defined in the customer Shop
File folder which contains various types of documents, such as product drawings and
specifications, production work orders, purchasing documents, inspection and testing
procedures.
8.6.2
8.6.3
8.6.4
Final inspection: Finished products are subjected to the final QC inspection. First,
inspectors verify that all specified receiving and in-process inspections have been
carried out satisfactorily. Then they perform the remaining inspections and tests
necessary to complete the evidence of product conformity. Only products that pass
the final inspection can be shipped. Procedure QAP-82-05 Final Inspection regulates
these activities.
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8.6.
8.6.5
Results of inspections and tests are recorded. Instructions for establishing records for
specific types of inspections are defined in procedures QA-74-03 Verification of
Purchased Product, QAP-82-04 In-Process Inspection and QAP-82-05. Final
Inspection. Filing and maintenance of inspection records are regulated by procedure
QAP-42-03 Control of Quality Records.
8.6.6
Products are released for delivery only after all specified activities have been
satisfactorily completed and conformity of the product has been verified. Only
personnel performing final product inspections and tests have the authority to release
products. The identity of the person authorizing product release is recorded.
Procedure QAP-82-05 Final Inspection defines specific methods for product release.
8.7
ANALYSIS OF DATA
8.7.1 Data and information recorded in quality records are compiled and analyzed
periodically to determine trends in the performance and effectiveness of the quality
system and to identify opportunities for improvement.
8.7.2
Quality Assurance is responsible for coordinating these activities, and for reporting
conclusions and trends to the top management. This is usually done within the
framework of management reviews of the quality system, in accordance with
procedure QAP-56-01 Management Review.
8.7.3
The following categories of information and data are recorded, compiled and
analyzed:
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8.7
ANALYSIS OF DATA (continued)
8.7.3.3 Customer satisfaction and dissatisfaction:
Customer satisfaction levels recorded in customer satisfaction surveys and
reports (QAP-82-01-Customer Satisfaction) and evaluated for trends by the
Sales/Customer Services department.
Customer complaints recorded in customer satisfaction surveys and reports
(QAP-82-01 Customer Satisfaction) and evaluated for trends by the Sales/Customer
Services department.
8.7.3.4 Quality System:
Effectiveness of training recorded in evaluation reports (QAP-62-01-Training
and Awareness) and evaluated for trends by departmental managers.
Effectiveness of quality system recorded in internal audit reports (QAP-82-02
Internal Quality Audits) and evaluated for trends by top management.
8.8
8.8.1
Piping Technology & Products Inc. identifies and documents all product
nonconformities that cannot be easily or cost effectively resolved. Product
nonconformity records are invaluable for tracking performance and trends, and for
identifying areas where corrective or preventive actions should be implemented.
To prevent nonconforming products from being used or shipped, the products are
marked with a REJECTED tag or sticker and are segregated when applicable.
8.8.4
QC inspectors and the production foreman may make the disposition decision for a
nonconforming product when it is obvious that the product must be scrapped, regraded, returned to vendor or when it can be reworked by a simple process without
affecting its quality or appearance. In all other cases, the Quality Manager together
with production and, when required, the Engineering / Design Liaison are responsible
for making disposition decisions.
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8.8
8.8.5
The disposition decision may be: Rework, Repair, Use As-Is, Re-grade, Return to
Vendor or Scrap.
8.8.6
Detailed rules for nonconformity review, for making the disposition decision, and for
recording these activities are provided in procedure QAP-83-01 Control of
Nonconforming Product.
8.8.7
8.8.8
When product nonconformity is detected by the customer after delivery or use has
started, the customer is instructed to return the product, or a part, through the
Sales/Customer Services department for evaluation.
8.8.9
When product nonconformity is detected internally after delivery or use has started,
customers are informed and instructed what to do with the product. In situations when
the nonconformity may create a safety or other hazard, the product may be recalled.
Only the General Manager is authorized to make recall decisions.
8.9
CONTINUAL IMPROVEMENT
8.9.1
8.9.2
8.9.3
8.9.4
The process of facilitating continual improvement through the use of the quality
policy, objectives, and analysis of data, is defined in procedures QAP-85-01
Continual Improvement, and QAP-56-01 Management Review.
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8.9
8.9.5
8.9.6
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