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Rokonma-RKM (DongGuan) Co., Ltd.
Project:
Project No.
Contract Numbers:
Order Numbers: WO74832
RKM Sales Order Numbers: 281, 282
CONV. No:
Report No: RKM / MDR / FRAME / 01 / Del: 1
MANUFACTURER'S DATA RECORD [ M.D.R.]
SUPPLY OF CONVEYOR FRAMES FOR:
Rokonma-RKM (DongGuan) Co., Ltd.Client: Contract No: 45019551 (SL1) 45019552 (SL2)
Project: PO No: WO74832 (SL1) WO74833 (SL2)
Project No. RKM Sales Order No: 281 (SL1) 282 (SL2)
VOLUME SECTION SUB SECT.A
A-1A-2A-3A-4
BB-1B-2B-3B-4B-5B-6
C
DD-1D-2
EE-1E-2
FF-1
G
II-1I-2
JJ-1J-2
PP-1
QQ-1
R
Certificates of Compliance
Welding Procedure Records
FRAME MDR INDEX
ITEM DESCRIPTION
Consumable Certificates Register
Material Certificates - Test Reports - Material Traceability RecordsRolled Steel Angle - Material Certificates
Frame Process Flow Chart
Frame Inspection Frequency
Circular Hollow Section - Material Cretificates
Inspection & Test Plans
Frame Inspection and Test PlanFrame Inspection Levels
Material Traceability Register
Steel Plates and Flats - Material CertificatesRectangular Hollow Section - Material Certificates
Assembly and Dimensional Check FormFinal QA Check
Non-Conformances and ConcessionsNon-Conformance Report Register
As-Built DrawingsDrawing Register
Welding Procedure Specification (WPS)
Welder Qualification Record
Customer/Third Party Inspection FormPackaging and Delivery Form
Weld Traceability & Non-Destructive Testing Records.
MPI Test Report
Welder and Welding Operator RecordsWelder Qualification Register
Procedure Qualification Record
TQ Register
Miscellaneous Certificates and Forms
Dimensional Records
Surface Treatment Procedures and Records
DOCUMENT NO :
RKM \ QP \ 4.10 \ ITP\ BKT \ C.01
Rokonma-RKM (DongGuan) Co., Ltd.Date: REVISION
17-Apr-13 No. 04
Equal Angles Misc.Items/components Flat Bars
REJECT QC: 1 REJECT QC: 1 REJECT QC : 1
CUTTING SHEARING
STAMPING /
QC: 2 QC: 2 BENDING etc.
BENDING
and REWORK REWORK
DRILLING
( FOR SAG -
ETC MODELS) TACK
WELDING
REWORK QC: 3
FULL
WELDING
REWORK QC: 4
PAINTING HOT -DIP
GALVANISED.
REWORK QC: 5
FINISHED
PRODUCT
REWORK QC: 6
STORAGE
A-1 Frame Process Flow Chart
Doc No: RKM / MDR / I .T . P / A .01
Rokonma-RKM (DongGuan) Co., Ltd. Page No : 01 of 01 Rev: 04
Inspection Location: RKM-Rokonma, China.
Client: * H = Hold point; W = Witness point
Project: * R = Review Point; M = Monitor point
* S = Self Inspection.
CONTROL CATEGORIES: H = Inspection Hold Point (Work must not proceed to the next step until this activity is completed and a signature obtained from the column placing the HOLD; i.e.. QA or Client);
W = Witness Point (Notify to permit witness, work can proceed if witness does not attend at agreed time); S = Surveillance Point (Monitor operations); R = Review Documentation (Sign or Stamp to record review).
CONTROL POINT
1 Submission/Approval of Documentation
1.1 Inspection & Test Plan and MDR Index. Review contract requirementsITP's
MDR Index
H H/R
1.2Weld Procedure Specifications (WPS) & Weld
Procedure Qualification Records (WPQR)
Review Qualifications & register
& update as required
(AS1554.1.SP) AWS
D1.1/AWS D1.1M:2010
equivalent to ISO5817 : 1992
Quality level.
WPS, PQR, Register & Test
reports
H H/R Records held in job file
1.3Welder Qualifications
Submit Welder Qualifications & Register.
Review Qualifications & register
& update as required
(AS1554.1.SP) AWS
D1.1/AWS D1.1M:2010
WQT, Welder Register &
Test reports
H H/R Maintained in RKM
employee files
2 Materials
2.1
Inspect materials including welding consumables for
damage or contamination and verify that they are
correct in accordance with Purchase Order, Delivery
Docket and Material Certificates.
Purchase orders to request
material certificates. Inspect &
verify delivery dockets.
As per approved drawings
Purchase Order
Material Certificates
Delivery Docket
H / R S Records held in job file
2.2Store material and welding consumables to eliminate
damage and contamination.
Store materials in designated
areas.
S S Records held in job file
3 Pre Processing & Assembly
3.1Material allocation, preparation, cutting, drilling,
pressing and Identification Marking
Drafting office to produce cutting
list, factory drawings &
identification tags
As per approved drawingsCutting List
Drawing / Item Mark
S S Records held in job file
3.2
Assembly of components prior to welding.
Fit-up & alignment Cutting & bending lists actioned
& signed off.
Approved drawings
Qualified WPS
(AS1554.1.SP) BS EN 288 Part
3 : 1992
Drawings
S S Records held in job file
4 Welding
4.1
Welding to be performed by qualified welder in
accordance with approved Welding Procedure
Specification.
Check & Sign off factory drawing(AS1554.1.SP) AWS
D1.1/AWS D1.1M:2010
WPS, PQR, WQT Welder
Register & Test Reports
R/S S Records held in job file
4.2
Welding visual Inspection, Check:
Root pass/weld size/profile & finished welds
Closing weld size/profile & finishCheck & Sign off factory drawing
(AS1554.1.SP) AWS
D1.1/AWS D1.1M:2010
H S Records held in job file
4.3Weld repairs (if any) remove defect (e.g. sharp edges)
in accordance with qualified procedure.
Check & Sign off factory drawing.
Notify client rep.
(AS1554.1.SP) AWS
D1.1/AWS D1.1M:2010
H S Records held in job file
5 Inspection & Testing
5.1100% Final visual inspection of all welds and check for
distortion, sharp edges & holes de-burred.Check & Sign off factory drawing
Approved drawings
(AS1554.1.SP) AWS
D1.1/AWS D1.1M:2010
ITP
H S Records held in job file
5.2 Dimensional check after welding 'As Built' Check & Sign off factory drawing(AS1554.1.SP) AWS
D1.1/AWS D1.1M:2010
As Built Drawings Check
Sheets
H S As built drawings provide in
MDR6 Surface Treatment
6.1 Protective Coatings Galvanising procedure S S
6.2 Final Inspection of Surface Treatment Verify test report H/R S/R
7 Final Inspection & Dispatch
7.1
Final inspection to ensure internals are clean, all
necessary inspection & testing has been conducted
with all necessary contract requirements completed.Verify delivery dockets
Inspection Release, Delivery
Docket
H S
7.2 Protect and secure components for transport Visual inspection Delivery DocketH S
8 Finalise Documentation
8.1 Sign off Inspection & Test Plan ITP H/R H/R Provided with MDR
8.2 Complete MDR MDR R R Client Approval of
Completed MDR
Provided with MDR
REMARKS /
CLIENT APPROVALRKM Signature CLIENT Signature
Subcontractor ITP Surface Treatment ReportProvided with MDR
A-2 Frame Inspection Test Plan
Customer Contract No:
RKM Order No:
VERIFYING
DOCUMENTATION
ACT.
No.ACTIVITY ROKONMA PROTOCOL
PROCEDURE or
SPECIFICATION
REFERENCE
ACCEPTANCE CRITERIA
Rokonma-RKM (DongGuan) Co., Ltd. Doc. No: RKM / MDR / I .L / A .01
Page No : 01 of 01 Rev: 03
Client: Customer Contract No: Inspection Location:
Project: RKM Order No: Rokonma (DongGuan) Co., Ltd.
China.
Item : CONVEYOR FRAMES
3 - 5% of total qty / delivery
3 - 5% of total qty / delivery
3 - 5% of total qty / delivery
3 - 5% of total qty / delivery
Meets RKM Specification or
as per Client's Specifications.
8
9
10
Note* Type of Inspection;Inspection
Prepared:Factory Manager APPROVED BY CLIENT : Date : 17-04-2013 Levels & Acceptance Criteria are
…………………………….. CLIENT SIGNATURE: Latest Revision: 03 subjected to changes upon mutual
agreement between both parties.
5 Packaging 100% of total qty / order Advise: Client- "Ready to Dispatch"
3 Finished product Meets RKM Specification or as
per Client's Specification Records Held in Job File
4 Surface Finish & Galvanising to Specification Meets RKM Specification or as
per Client's Specification Records Held in Job File
1 Incoming Materials Meets RKM Specification Records Held in Job File
2 In-Process Meets RKM Specification or as
per Client's Specification Records Held in Job File
Remarks.
A-3 Frame inspection Levels
No. Type of Inspection Inspection Level Acceptance Criteria
DOCUMENT NO :
Rokonma-RKM (DongGuan) Co., Ltd. RKM \ QP \ 4.10 \ ITP\ BKT \ C.01
REVISION
No. 05
QC check points: From Incoming till Finished Products.
QC NO TEST / INSPECTION FREQUENCY
1.Documentation from supplier
- Delivery order
2. Dimensional check
- Length 3- 5 % of total
- Width & Thickness quantity per delivery
QC 1
1.Documentation from supplier
- Delivery order 3- 5 % of total
2: Quantity & Packaging. quantity per delivery
QC 2 1.Dimensional check
- Length 3- 5 % of total
- Width & Thickness quantity per model
QC 3 FLAT BARS :- - Slot height & width 3- 5 % of total
STAMPING, SLOT - Width & Thickness quantity per model
FABRICATION etc.
QC 4 "TACK" WELDING 1.Components / parts 3- 5 % of total
and 2.Frame- dimensional check quantity per model
FULL WELDING 3. Weld characteristics
QC 5 1. Surface ~ De-slagged & clean
2. Appearance:- Free from 3- 5 % of total
injurious defects etc quantity per model
3. Thickness, Colour & Finish
1. Surface ~ De-burred & clean
2. Appearance:- Free from 3- 5 % of total
injurious defects etc. quantity per model
3. Thickness.
QC 6 1. Model 3- 5 % of total
2. Specifications quantity per model
GRIND ETC
PAINTING
GALVANISING
FINISHED PRODUCT
FLAT BAR,
PIPE, RHS
CUT, BEND, DRILL,
Date:
17-Apr-13
RHS
PAINTS
ANGLES, PLATE
A-4 Frame Inspection Frequency
ITEMS INSPECTED
PLATE
ANGLES
FLAT BAR
PIPE
Doc. No:RKM / MDR / I.Q.C./A.01 Page No : 01 of 01 Rev: 01
Client: Contract No: 45019551(SL1) / 45019552(SL2)
Project: PO No: WO74832(SL1) / WO74833(SL2)
B-1 Rolled Steel Angle - Material Certificates
Conveyor Frame - Rolled Steel Angle 125 x 125 x 8 - Material Certificate
Conveyor Frame - Rolled Steel Angle 140 x 140 x 10 - Material Certificate
Rokonma-RKM (DongGuan) Co., Ltd.
RKM Sales Order No: 281(SL1) / 282(SL2)
Doc. No:RKM / MDR / I.Q.C./A.01 Page No : 01 of 01 Rev: 01
Client: Contract No: 45019551(SL1) / 45019552(SL2)
Project: PO No: WO74832(SL1) / WO74833(SL2)
B-2 Plate and Flats - Material Certificates
Conveyor Frame - 6mm Plate and Flats - Material Certificate
Conveyor Frame - 8mm Plate and Flats - Material Certificate
Conveyor Frame - 10mm Plate and Flats - Material Certificate
Conveyor Frame - 12mm Plate and Flats - Material Certificate
Rokonma-RKM (DongGuan) Co., Ltd.
RKM Sales Order No: 281(SL1) / 282(SL2)
Doc. No:RKM / MDR / I.Q.C./A.01 Page No : 01 of 01 Rev: 01
Client: Contract No: 45019551(SL1) / 45019552(SL2)
Project: PO No: WO74832(SL1) / WO74833(SL2)
B-3 Rectangular Hollow Section - Material Certificates
Conveyor Frame - RHS 100 x 50 x 4 - Material Certificate
RKM Sales Order No: 281(SL1) / 282(SL2)
Rokonma-RKM (DongGuan) Co., Ltd.
Doc. No:RKM / MDR / I.Q.C./A.01 Page No : 01 of 01 Rev: 01
Client: Contract No: 45019551(SL1) / 45019552(SL2)
Project: PO No: WO74832(SL1) / WO74833(SL2)
B-4 Circular Hollow Section - Material Certificates
Conveyor Frame - CHS Ø88.9 x 5.5mm - Material Certificate
RKM Sales Order No: 281(SL1) / 282(SL2)
Rokonma-RKM (DongGuan) Co., Ltd.
Rokonma-RKM (DongGuan) Co., Ltd.
B-5 Material Traceability Register
Client: Contract No: 45019551 (SL1) 45019552 (SL2)
Project: PO No: WO74832 (SL1) WO74833 (SL2)
Project No. RKM Sales Order No: 281 (SL1) 282 (SL2)
Unique ID
No.Material Grade Material Description
Thickness
(mm)Heat No.
Batch/ Serial
No.Material Certificate No. Manufacturer
Test Report
No. (if
applicable)
Sampling
DateRemarks
1 Q345B Steel Angle 125 x 125 x 8 8 13/03/2013
2 Q345B Steel Angle 140 x 140 x 10 10 13/03/2013
3 Q235B 6mm Steel Plate 6 22/07/2013
4 Q235B 8mm Steel Plate 8 15/08/2013
5 Q345B 10mm Steel Plate 10 01/04/2013
6 Q235B 12mm Steel Plate 12 16/06/2013
7 SPHC Steel RHS 100 x 50 x 4 4 14/01/2013
8 13F7503 Steel CHS Ø88.9 x 5.5 5.5 05/09/2013
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Rokonma-RKM (DongGuan) Co., Ltd.
B-6 Consumable Certificate Register
Client: Contract No: 45019551 (SL1) 45019552 (SL2)
Project: PO No: WO74832 (SL1) WO74833 (SL2)
Project No. RKM Sales Order No: 281 (SL1) 282 (SL2)
Product Description Manufacturer/Supplier Classification Size Batch / Lot Number Certificate Number
Welding wire AWS A5.15 ER70S-6 Ф1.2MM
Rokonma-RKM (DongGuan) Co., Ltd.
C - Certificates of Compliance
Client: Contract No: 45019551 (SL1) 45019552 (SL2)
Project: PO No: WO74832 (SL1) WO74833 (SL2)
Project No. RKM Sales Order No: 281 (SL1) 282 (SL2)
We hereby certify that the goods provided against the above purchase order have been carried out under
our supervision and, that to the best of our knowledge and belief, fabricated and tested satisfactory in
accordance with the contract requirements, and to the applicable codes, standards and specifications
noted below and complies in all and every respect with these requirements.
Code: AS1554.1:2011 SP Frame Welding
AS4680 Hot Dip Galvanising
Additional Requirements:
For Supplier:
Position:
Name:
Place:
Signature:
SUB-CONTRACTOR
Doc No: RKM / MDR / W.P.S / A .01
Page No : 01 of 01 Rev: 03
Rokonma-RKM (DongGuan) Co., Ltd.
Client:
Project:
FRAME WELDING PROCEDURE SPECIFICATION
Inspection Location:Rokonma,China
Contract No: 45019551(SL1) / 45019552(SL2)
PO No: WO74832(SL1) / WO74833(SL2)
RKM Sales Order No: 281(SL1) / 282(SL2)
D-1 Welding Procedure Specification (WPS)
Doc No: RKM / MDR / W.P.S / A .01
Page No : 01 of 01 Rev: 03
Rokonma-RKM (DongGuan) Co., Ltd.
Client:
Project:
RKM Sales Order No: 281(SL1) / 282(SL2)
Inspection Location: Rokonma,China
Contract No: 45019551(SL1) / 45019552(SL2)
PO No: WO74832(SL1) / WO74833(SL2)
D-2 Procedure Qualification Record
Rokonma-RKM (DongGuan) Co., Ltd.
E-1 Welder Qualification Register
Client: Contract No: 45019551 (SL1) 45019552 (SL2)
Project: PO No: WO74832 (SL1) WO74833 (SL2)
Project No. RKM Sales Order No: 281 (SL1) 282 (SL2)
WELDER NAME WELDER ID WPS NoCODE
QUALIFIEDDATE QUALIFIED REPORT No PROCESS QUALIFIED POSITION QUALIFIED
THICKNESS
RANGE
RE-VALIDATION
DATE
RE-VALIDATION
REPORTOTHER QUALIFICATIONS
Ye DG-WPS-01 AWSD1.1 Sep.22,2012 120705005 GMAW-Semiautomatic 2F 6.5mm 2 years
Fu DG-WPS-01 AWSD1.1 Sep.22,2012 120705002 GMAW-Semiautomatic 2F 8.5mm 2 years
Xue DG-WPS-01 AWSD1.1 Sep.22,2012 120705001 GMAW-Semiautomatic 2F 8.5mm 2 years
Yang DG-WPS-01 AWSD1.1 Sep.22,2012 120705003 GMAW-Semiautomatic 2F 8.5mm 2 years
Huang DG-WPS-01 AWSD1.1 Sep.22,2012 120705004 GMAW-Semiautomatic 2F 8.5mm 2 years
Doc No: RKM / MDR / W.P.S / A .01
Page No : 01 of 01 Rev: 03
Rokonma-RKM (DongGuan) Co., Ltd.
Client:
Project:
RKM Sales Order No: 281(SL1) / 282(SL2)
Inspection Location: Rokonma,China
Contract No: 45019551(SL1) / 45019552(SL2)
PO No: WO74832(SL1) / WO74833(SL2)
E-2 Welder Qualification Record
Doc No: RKM / MDR / W.P.S / A .01
Page No : 01 of 01 Rev: 03
Rokonma-RKM (DongGuan) Co., Ltd.
Client:
Project: PO No: WO74832(SL1) / WO74833(SL2)
F-1 MPI Test ReportInspection Location: Rokonma,China
RKM Sales Order No: 281(SL1) / 282(SL2)
Contract No: 45019551(SL1) / 45019552(SL2)
Doc No: RKM / MDR / W.P.S / A .01
Page No : 01 of 01 Rev: 03
Rokonma-RKM (DongGuan) Co., Ltd.
Client:
Project:
Inspection Location: Rokonma,China
Contract No: 45019551(SL1) / 45019552(SL2)
F-1 MPI Test Report
PO No: WO74832(SL1) / WO74833(SL2)
RKM Sales Order No: 281(SL1) / 282(SL2)
Doc. No: RKM / MDR / Q.A.F / A .01
Page No : 01 of 01 Rev: 01
Client: MODEL/BW/TYPE : SVIL1800C615NS-RKM1840
Project:
Report No: 01 of 01
Batch NO :10 of 10
Conv. No: SL1 & SL2 BOOM
FRAME TYPE.
Carry Trough: Jackdown Tag No. DWG1840
Carry Transition
Carry Retractable
Carry other Inspected By:
Return Vee
Return Flat
Return Other
FRAME :DIMENSIONAL CHECK AGAINST RKM DRAWING.
Transom size :mm
End Brackets size :mm
End Brackets Gusset size :mm
Centre Brackets size :mm
Feet size :mm
Troughing Angle :⁰
Rolling Height :mm
Bolt Centres Longitudinal :mm
Bolt Centres Tranverse :mm
Mounting Feet Slots :mm
Distance between the mounting flats. :mm
Across the flats of slot :mm
FRAME CHECKS.
CHECK REQUIREMENT
Manufacturer - Record name.
Full Dimensional Check wrt Drawing Drawing specification & tolerances /
Weld Check / Inspection Full penetration,continuous and smooth /
Corrosion Prevention Hot dipped Galvanised /
General Appearance Free of Imperfections & Injurious defects etc /
Others:- /
Name: ………………………………….
Signed : …………………………….. Date: ………………………
966
Flat: 6 & Slot: 22.5
40 x 6
250 x 6
150
2210
65 x 6
REMARKS:
SATISFACTORYYES / NO (tick box)
17 x 30
Rokonma-RKM (DongGuan) Co., Ltd.
I-1 Assembly & Dimensional Check Form
Contract No: 45019551(SL1) / 45019552(SL2)
RKM Sales Order No.: 281(SL1) / 282(SL2)
-216
✔
Ø88.9x5.5 CHS
NA
15
Rokonma-RKM (DongGuan) Co., Ltd.
Inspected by : QC Dept ./ Approved by
{O.Q.C} REV: 01 Report No: 01 of 01
Batch No : 10 of 10
Client: Contract No: 45019551(SL1) / 45019552(SL2) All dimensions on Drawing are to be checked & ticked off. Appearance :- Free of any defects, tick box
Project: PO No: WO74832(SL1) / WO74833(SL2) Total Qty. - this delivery: 20
RKM Sales Order No: 281(SL1) / 282(SL2) Tag No. DWG1840 Total Qty. / order / conveyor number: 20/281/282/WO74832 (SL1)/WO74833 (SL2)
Doc. No: RKM / MDR / O.Q.C / A.01
Page No : 01 of 10
Rokonma-RKM (DongGuan) Co., Ltd.
J-1 Non-Conformance Report Register
Client: Contract No: 45019551 (SL1) 45019552 (SL2)
Project: PO No: WO74832 (SL1) WO74833 (SL2)
Project No. RKM Sales Order No: 281 (SL1) 282 (SL2)
OriginatorIssued
toIssued Closed
NCR
No.Date Raised Description
Date
Rokonma-RKM (DongGuan) Co., Ltd.
J-2 TQ Register
Client: Contract No: 45019551 (SL1) 45019552 (SL2)
Project: PO No: WO74832 (SL1) WO74833 (SL2)
Project No. RKM Sales Order No: 281 (SL1) 282 (SL2)
Date
Yes NoIssued (to
Client)
Received (from
Client)Actioned
Date
TQ Prepared by Subcontractor
Title No. Description
Variation to Scope of
Work
Rokonma-RKM (DongGuan) Co., Ltd.
P-1 Drawing Register
Client: Contract No: 45019551 (SL1) 45019552 (SL2)
Project: PO No: WO74832 (SL1) WO74833 (SL2)
Project No. RKM Sales Order No: 281 (SL1) 282 (SL2)
All items fabricated on the drawings listed on this register have been built as per the supplied drawings with no alterations.
Drawing No Rev
RKM1840-SVIL1800C615NS 3
RKM1842-SRSIL 1800D430NS 3
RKM1844-SRSIL1800D445NS 3
RKM1845-STIIL 1800D345NS 5
RKM1847-SRSIIL 1800D345NS 3
RKM1848-STIL 1800D445NS 5
RKM1849-STTSIL 1800D43045NS 6
RKM1850-STTSIL 1800D41530NS 6
RKM1851-STTSIL 180040520NS 6
RKM1852-SRIL 1800C600NLS 3
RKM1854-SVIL 1800C615NS 3
RKM1855-SVIL 1800C610NS 3
RKM7856-SRIL 1800C600NS 3
RKM1857-SRIL 1800C600NS 3
RKM1858-SRIL 1800C600NRLS 3
RKM1880-SRSIL 1800D445NS 2
RKM1881-SRSIIL 1800D345NS 2
RKM1882-WG-1 1
RKM1883-ESG178X30 1
Comments
Rokonma-RKM (DongGuan) Co., Ltd. Doc. No: RKM / MDR / P-List / A .01
Page No : 01 of 01 Rev: 01
Client: Contract No: 45019551 (SL1) 45019552 (SL2)
Project: PO No: WO74832 (SL1) WO74833 (SL2)
Project No. RKM Sales Order No: 281 (SL1) 282 (SL2)
DELIVERY No:
Crate No.: 1 of
QTY. TAG No. Conveyor No. Delivery Advise Note
Inspected by : QC Dept./Approved by:
………………………. / …………………….
Q-1 Packaging and Delivery Form
Deliver To:
Above & below information to be min. 20mm letter size on 2 opposite sides of box
Dimensions: 0000 mm x 0000mm x 0000mm
Any labels & tags to be visible & legible for 12 months
Weight (kg):
Description
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