Download - Presentation on NTPC Inspection Services
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Presentation onNTPC Inspection Services
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Introduction
Objectives of Inspection Services
Functions of Inspection Services
Organization Structure
Roles of Inspection Engineer
Customers (External &Internal)
Inspection Process
Summary
PresentationOutline
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Quality Assurance & Inspection
Quality is a relative term and is generally expressed withreference to end use of product
Planned and systematic actions necessary to provideconfidence thereby assure the suitability of product forits intended purpose
Control is a system for measuring and inspecting a
phenomenon
Inspection means checking the acceptability of product
Inspection measure the quality of product
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QUALITY IS DEFINED AS
FITNESSFOR USE
FITNESS IS DEFINED BY CUSTOMER
JOSEPH M. JURAN
CONFORMANCE TO THE REQUIREMENTS
PHILIP B. CROSSBY
DEGREE TO WHICH A SET OF INHERENT
CHARACTERISTICS FULLFILLS REQUIREMENTS
ISO 9000
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THE CHARACTERISTICS OF A PRODUCT OR SERVICE
THAT BEAR ON ITS ABILITY TO SATISFY STATED OR
IMPLIED NEEDS
A PRODUCT OR SERVICE FREE OF DEFICIENCIES
AMERICAN SOCIETY OF QUALITY
QualityBy-design & not By-chance
QUALITY IS DEFINED AS
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QUALITY ASSURANCE INCLUDES
REGULATIONS OF QUALITY OF RAW MATERIAL,
ASSEMBLIES,PRODUCTS AND COMPONENTS,
SERVICES RELATED TO PRODUCTION ANDINSPECTION
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THOSE QUALITY ASSURANCE ACTIONS WHICH PROVIDE MEANS TO
CONTROL AND MEASURE THE CHARACTERISTICS OF AN ITEM,
PROCESS OR FACILITY TO ESTABLISH FITNESS FOR USE
VARIATION IS LAW OF NATURE
FOR EACH PROCESS THE VARIATIONS NEED TO BE IDENTIFIED AND
CONTROL MAINTAINED TO LIMIT THE VARIATIONS WITHIN
SPECIFICATIONS. THIS IS QUALITY CONTROL.
QUALITY CONTROL
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THE PROCESS OF MEASURING , EXAMINING, TESTING ,
GAUGING OR OTHERWISE COMPARING ONE OR MORE
CHARACTERISTICS OF A PRODUCT OR SERVICE WITH
THE SPECIFIED REQUIREMENTS.
A process of segregating good from bad
INSPECTION
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A SET OF POLICIES, PROCESSES AND PROCEDURES
REQUIRED FOR PLANNING AND EXECUTION
(PRODUCTION / DEVELOPMENT / SERVICE) IN THE CORE
BUSINESS AREA OF AN ORGANIZATION.
QUALITY MANAGEMENT SYSTEM
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OBJECTIVES OF INSPECTION SERVICES
TO ENSURE THAT DEFECT FREE PLANT & EQUIPMENTCOMPLIANT WITH TECHNICAL SPECIFICATIONS AND OFSPECIFIED QUALITY.
TO UNDERSTAND INSPECTION REQUIREMENTS OFTECHNICAL SPECIFICATION
ON-LINE PLANNING OF INSPECTION CALLS WITH A VIEWTO IMPROVE TIME SCHEDULE FOR DISPOISITIONING OFINSPECTION CALLS AND TO ATTEND INSPECTION CALLS
IN LINE WITH CUSTOMER REQUIREMENTS.
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Functions of Inspection Services
Verify specified quality level of equipment by carrying outinspection at contractors / sub-Contractors premises, orby review of test certificate in accordance with agreedQuality Plan and contract requirements, for equipment
ordered from Corporate Contract, consultancy assignmentand from project ordered equipment and to carry outinspection activities as per agreed schedule matchingProject Schedule and requirements.
Ensure implementation of agreed documented qualitysystem and programme at contractors / sub- contractorsworks by verifying inspection records, process controlrecords, calibration status during inspection of equipment.
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ORGANIZATIONAL STRUCTURE
DIRECTOR (TECHNICAL)
ED (ENGINEERING)
HEADQA & I
INSPECTION SERVICES
RIO
DELHI
RIO
HWR
RIO
BPL
RIO
BRD
RIO
KOL
RIO
TRY
RIO
RPN
RIO
HYD
RIO
BLR
RIO
TRVN
RIO
MUB
RIO
PUN
RIO
CHN
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Role of Inspection Engineer
Product identification & traceability wherever applicable.
Verification of clearance of earlier inspection stages, whereverapplicable.
Ensure calibration of the measuring equipment used duringinspection.
comprehensive review of the internal quality records of theContractor as per the quality plan ensuring adherence to therequirement and dispositioning of deviations, if any.
Surveillance check on the quality programme of theContractor agreed as per the contract.
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Contd..
Provide feed back on Contractors process control, manufacturing facilities &quality. Reporting Non conformities observed.
Provide regular feedback to Corporate Contracts/ Engg. regarding holdups orlikely delays in Manufacturing Programme. Causes for such hold ups / likely
delays are identified in their reports for speedy redressal.
Monitoring of Inspection Calls, Issue of MDCC for dispatch of equipment aftersatisfactory final inspection and clearance of CHPs & verification ofimplementation of corrective action, as agreed, for dispositioning of Nonconformities.
Association with CQA, as required, for audit of Quality system ofContractors,/Sub Contractors.
Assess the actual manufacturing Progress of the critical items required by theProject Contract Services, identify any hold ups in their manufacturing andsend a report to Project, Engg/CQA Corporate Contracts.
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Calibration of Instruments
Ensures Correct reading
Appropriate reference
Logical approach
Minimum inconsistencies
Better accuracies
Repeatability of measurements
All time confidence Traceability of records
Integrity of reports
Optimum performance
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Customers
External - Contractors/Suppliers
Internal - Projects/Sites
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DOCUMENTS FOR INSPECTION
Quality requirements and testing provisions needs to be the part ofcontract for its effective implementation.
Documents needed for inspection are prepared and submitted bysuppliers and processed and finalized by other groups/div of NTPCand therefore close coordination by inspection services is neededwith all these groups and suppliers
Pre award finalization/commitments include List of agreed make/model/manufacturer of various subcomponents
submitted by supplier and mutually agreed with CQA Finalization of manufacturing quality plan(MQP) containing
a) listing all tests and checks to be done during manufacturing andrecords to be kept for review by inspection engineer duringinspectionb)List all test/checks with sampling plan for test to be witnessed byNTPCThese documents are submitted by supplier and approved by CQA
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Contd..
List of type tests to be done by supplier and to be approvedby NTPC Engg
List of type tests to be done by supplier and to be approvedby NTPC Engg
list of drawing/datasheet requiring approval by NTPC Engg Billing breakup for purpose of on account payments and
issuance of MDCC approved and issued by Contract Div Contract agreements jointly signed by supplier and NTPC Standards such as IS , BIS, ASME, IEC Etc which broadly
specify testing procedures , acceptance norms etc[Checks
identified in MQP are broadly derived from these standards]
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Process of Inspection and Issuance of CHP
and MDCC Complete process is mapped and controlled
through a web based application (known asWINDSORx) accessible through Internet by allinspection offices, suppliers and sub-suppliersand other users of inspection related data
Suppliers submits offer for inspection listingdetails of BBU no , item , total qty , qty alreadysupplied and qty offered for inspection withproposed date for inspection using online portal
The inspection call is scanned for completenessof approved documents
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Contd..
The inspection planning is done through the same portalby the In-charge of inspection office.
Inspection engineers visit the place of manufacture andchecks the following before starting inspection/testing:
Quality plans are approved. Drawing/ Datasheets are approved. Review all internal test records maintained by the
manufacturer.
Check that all the sub-components are ofapproved/agreed make. All the testing equipments are calibrated and are in
working conditions.
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Contd..
After ensuring the above, the preliminary work involves- Verification of availability of complete material for inspection. Identification(stamping)of the offered lot.{to the extent feasible} Performing random sampling of items for testing.{Inline with quality
plan} After selecting sample for testing, witnessing of actual testing starts . Few parameters to check are- Visual Dimensional Conformity.
Functional compatibility checks.examplespressure parts/rotary partsQuality of welds by RT and DPHydro test/pneumatic pr test at 2.0 times working pressureMechanical testing and chemical composition of body materialhardness test
Efficiency test for pumps/blowers/motors
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Contd..
After completion of tests , inspection report(CHP) isgenerated on line using inspection portal from theplace of inspection and MDCC is also issued fromthe portal and handed over to supplier if item is
found acceptable in all respect.
The data thus generated, updated and modifiedby NTPC as well as its suppliers and manufacturers(as a normal course of discharging their functions)
provides comprehensive and customized onlineinformation to various groups and monitoringagencies as well as the clients and suppliers who inturn take immediate corrective actions for ensuringtimely availability of materials and components at
the project site.
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Inspection call entry screen
SNAPSHOTS OF WINDSORx
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SNAPSHOTS OF WINDSORx
A typical list of contracts awarded for NTPC Mauda project
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SNAPSHOTS OF WINDSORx
Inspection Planning sheet
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SNAPSHOTS OF WINDSORx
Inspection weekly grid
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SNAPSHOTS OF WINDSORx
CHP report
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SNAPSHOTS OF WINDSORx
MDCC Reports
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SNAPSHOTS OF WINDSORx
Inspection Planning sheet
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SNAPSHOTS OF WINDSORx
Inspection weekly grid
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QualityBy-design & not By-chance
Quality is not an act .It is a habit
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