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IWE course

Moduo 4- Fabrication, applications engineering


4.1. Introduction to quality assurance in welded fabrication

4.1.1 Concepts
See ISO 9000
Quality
Totality of characteristics of an entity that bear on its ability stated
to satisfay stated and implied needs.
Grade
Category or rank given to entities having same functional use but
different requirements for quality.
Requirements for quality
Expression of the needs or their translation into a set of
quantitatively or qualitatively stated requirements for the characteristics
of an entity to enable its realization and examination.
Requirements for society
Obligations resulting from laws, regulations, rules, codes, statutes
and other considerations.
Nonconformity
Nonfulfilment of a specified requirement.
Defect
Nonfulfilment of an intended usage requirement or resonable
expectation, including one concerned with safety.
Qualification process
Process of demonstrating whether an entity is capable of fulfilling
specified requirements.
Inspection
Activity such as measuring, examining, testing or gauging one or
more characteristics of an entity and comparing the results with
specified requirements in order to establish whether conformity is
achieved for each characteristic.
Verification
Confirmation by examination and provision of objective evidence
that specified requirements have been fulfilled.
Validation
Confirmation by examination and provision of objective evidence
that the particular requirements for a specific intended use are fulfilled.
Quality policy
Overall intention and direction of an organization with regard to
quality, as formally expressed by top management.
Quality management
All activities of the overall management function that determine
the quality policy, objectives and responsabilities and implement them
by means such as quality planning, quality control, quality assurance
and quality improvement within the quality system.
Quality planning
Activities that establish the objectives and requirements for quality
and for the application of quality systemelements.
See chapter 4.1.4 Quality plan
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Moduo 4- Fabrication, applications engineering


4.1. Introduction to quality assurance in welded fabrication

Quality control
Operational techniques and activities that are used to fulfil
requirements for quality.
Quality control involves operational techniques and activities
aimed both at monitoring a process and at eliminating causes of
unsatisfactory performance at all stages of the quality loop in order to
achieve economic effectiveness.
Quality loop
Conceptual model of interacting activities that influence quality at
the various stages ranging from the identification of needs to the
assessment of whether these needs have been satisfied.
The quality spiral is a similar concept.
Quality assurance
All the planned and systematic activities implemented within the
quality system and demonstrated as needed, to provide adequate
confidence that an entity will fulfil requirements for quality.
Quality system
Organizational structure, procedures, processes and resources
needed to impelement quality management.
Quality improvement
Actions taken throughout the organization to increase the
effectiveness and efficiency of activities and processes in order to
provide added benefits to both the organization and its customers.
Management review
Formal evaluation by top management of the status and adequacy
of the quality system in relation to quality policy and objectives.
Contract review
Sytematic activities carried out by the supplier before signing the
contract to ensure that requirements for quality are adequately defined,
free from ambiguity, documented and can be realized by the supplier.
Design review
Documented, comprehensive and systematic examination of a
design to evaluate its capability to fulfil the requirements for quality,
identify problems, if any and propose the development of solutions.
4.1.2. Quality manual
Document stating the quality policy and describing the quality
system of an organization.
Notes:
1. A quality manual may relate to the totality of an organization's
activities or only to a part of it. The title and scope of the manual reflects
the field of application.
2. A quality manual will normaly contain or refer to, as a minimum:
a) quality policy;

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IWE course

Moduo 4- Fabrication, applications engineering


4.1. Introduction to quality assurance in welded fabrication

b) the responsibilities, authorities and inter-relationschips of


personnel who
manage, perform, verify or review work affecting quality;
c) the quality system procedures and instructions;
d) a statement for reviewing, updating and controlling the manual.
3. A quality manual can vary in depth and format to suit the needs
of an organization. It may comprise more than one documents.
Depending on the scope of the manual, a qualifier may be used, for
example quality assurance manual, quality management manual.
(ISO 9000)
Procedure
Specified way to perform an activity:
Notes:
In many cases, rpocedures are documented (e.g. quality sytem
procedures).
When a procedure is documented, the term written procedure or
documented procedure is frequently used.
A written or documented procedure usually contains the purposes and
scope of an activity; what shall be done and by whom; when, where
and how it shall be done; what materials, equipment and documents
shall be used; and how it shall be controlled and recorded.
(ISO 9000)
Requirements of written procedures
Title of chapter
IS
ISO
ISO
O 9001
9002
9003

Contract review (4.3.1)

NA
NA
Design control (4.4.1)

Document and data control

NA
(4.5.1)

Purchasing (4.6.1)

Control
of
customer-supplied

NA
product (4.7)

Product
identification
and

traceability (4.8)
Process control (4.9.a)
Inspection and testing (4.10.1)

Control of inspection, measuring

and test equipment (4.11.1)

Inspection and test status (4.12)


Control
of
nonconforming

product (4.13.1)

Corrective and preventive action

(4.14.1)

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IWE course

Moduo 4- Fabrication, applications engineering


4.1. Introduction to quality assurance in welded fabrication

Handling,
storage,
packing,
NA
preservation and delivery (4.15.1)
Control of quality records (4.16)
Internal quality audits (4.17)
Training (4.18)
Servicing (4.19)
Statistical techniques (4.20.2)
NA - Not applicable
4.1.3 Quality plan
Quality planning covers:
a) product planning: identifying, classifying and weighting the
characteristics for quality as well as establishing the objectives,
requirements for quality and constraints;
b) managerial and operational planning: preparing the application
of the quality system including organizing and scheduling;
c) the preparation of quality plans and the making of provisions for
quality improvement.
Quality plan
Document setting out the specific quality practices, resources and
sequence of activities relevant to a particular product, project or
contract.
A quality plan usually makes reference to the parts of the quality
manual applicable to the specific case.
4.1.4 Personnel and equipment
See 4.1.10 (EN 729) and 4.2
4.1.5 Maintenance
See 4.1.10 (EN 729)
4.1.6. Inspection
See 4.1.10 (EN 729)
4.1.7 Activities of the welding engineer in the different
functions in industry
See 4.2 (EN 719)
4.1.8 Standards
ISO 3834 / EN 729 series
Special process
These are processes, the results of which cannot be fully verified by
subsequent inspection and testing of the product and where, for
example, processing definicies may become apparent only after the
product is in use. Accordingly, continuous monitoring and/or compliance
with documented procedures is required to ensure that the specified
requirements are met.
Within the ISO 9000 series of standards for quality sytems, welding
is to be treated as a special process since welds cannot be fully
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4.1. Introduction to quality assurance in welded fabrication

verified by subsequent inspection and testing of the product to ensure


that the required quality standards have been met.
ISO 3834 / EN 729 series of standards have been prepared to
describe welding quality requirements suitable for application by
manufacturers using welding as a means of fabrication.

Selection of welding quality requirements:


Contract
Quality requirements
welding
requirements
Whem quality system*
When quality
to ISO 9001 or ISO
system to
9002
ISO 9001 or ISO
is required use
9002
is not required use
comprehensive quality
ISO 3834-2*
ISO 3834-2
requirements
standard quality
ISO 3834-2*
ISO 3834-3
requirements
elementary quality
ISO 3834-2*
ISO 3834-4
requirements
* Within the scope of ISO 9001 and ISO 9002 the requirement of
EN 3834-2 may be minimised to an appropiate level to suit the type of
welded construction.

Summary comparision of welding quality requirements with regard


to ISO 3834-2,
ISO 3834-3 and ISO 3834-4
Elements
ISO 3834ISO 3834ISO
2
3
3834-4
contract review
full documents
less extensive
establish that
review
review
capability and
design review
design for welding to be confirmed information is
available
sub-contractor
treat like a main fabricator
shall comply
to standard
welders
approval to the appropiate part of EN 287 or EN
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4.1. Introduction to quality assurance in welded fabrication

operators
welding
coordination

1418
welding coordination personnel
with appropiate technical
knowledge according to ISO 14731,
or persons with similar knowledge

inspection
personnel

sufficient and competent personnel


to be available

production
equipment

required to prepare, cut, weld,


transort, lift, with safety equipment
and protective clothes

equipment
maintenance

has to be carried no
specific
out, maintenance requirement,
plan necesarry
shell
be
adequate
necessary
restricted
plan
necessary
instruction to be available to
welder, see apropiate part of EN ISO
15614

no
requirement

to appropiate part of EN 288,


approved as application standard of
contract demands
welding procedure specification
(WPS)
or
dedicated
work
instructions to be available
necessary
not specified

No specific
requirement

production plan
welding
procedure
specification
(WPS)
welding
procedure
approval
work instructions
documentation

not requires
but personal
responsibility
of
manufacturer
sufficient and
competent,
acces for
third parties,
as needed
no specific
requirement

no
requirement
no
requirement

no
requirement

no
requirement
batch testing or only if specified not specified
no
cunsumable
in contract
requirement
batch testing of only if specified not specified
no
consumable
in contract
requirement
storage and
as per supplier recommended as minimum
handling of
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Moduo 4- Fabrication, applications engineering

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4.1. Introduction to quality assurance in welded fabrication

welding
consumable
storage
of protection required from influence
parent materials by the environment; identification
shall be maintained
post-weld heat
specificatio
confirmatio
treatment
n and complete n
to
record necessary specification
necessary
inspection
as required for specified operations
before,
during,
after welding
nonconformances
calibration
identification
traceability
quality records

no
requirement
no
requirement
responsibiliti
es
as
specified
in
contracr

procedures shall be available


procedures shall not specified
be available
required, when
required, when
appropiate
necessary
shell be available to meet the rules
for product liability
retained for five years minimum

not specified
not specified
as
required
by contract

Literature:
1. BAGJAGIC, S. Zahtevi za odrzavanje i ispitivanje proizvodne
opreme. Zavarivanje i zavarene konstrukcije, 1/1996, p. 53-57
2. DELIC, B. Zahtevi za kvalitet u analizi ugovora, Zavarivanje i
zavarene konstrukcije, 1/1996, p. 45-48
3. FERTILIO, A. Ispitivanje bez razaranja zavarenih spojeva,
Zavarivanje i zavarene konstrukcije, 1/1996, p. 64-68
4. GRUJIC, N. Mehanicko - tehnolosca ispitivanja zavarenih spojeva,
Zavarivanje i zavarene konstrukcije, 1/1996, p. 69-72
5. ILIC, V. Potrosni materijali, Zavarivanje i zavarene konstrukcije,
1/1996, p. 58-60
6. ISO 3834 - 1: 1994 (EN 729 - 1:1994), Quality requirements for
welding. Fusion welding of metallic materials. Part 1: Guidelines for
selection and use.
7. ISO 3834 - 2: 1994 (EN 729 - 2: 1994), Quality requirements for
welding. Fusion welding of metallic materials. Part 2: Comprehensive
quality requirements.
8. ISO 3834 - 3: 1994 (EN 729 - 3: 1994), Quality requirements for
welding. Fusion welding of metallic materials. Part 3: Standard quality
requirements

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4.1. Introduction to quality assurance in welded fabrication

9. ISO 3834 - 4: 1994 (EN 729 - 4: 1994), Quality requirements for


welding. Fusion welding of metallic materials. Part 4: Elementary quality
requirements.
10. ISO 8402: 1994, Quality management and quality assurance.
Vocabulary.
11. ISO 9001: 1994, Quality systems. Model for quality assurance in
design, development, production, installation and servicing.
12. ISO 9002: 1994, Quality sytems. Model for quality assurance in
production, installation and servicing.
13. ISO 9003: 1994, Quality systems. Model for quality assurance in
final inspection and test.
14. ISO 9004-1:1994, Quality management and quality system
elements. Part 1: Guidelines

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