C L A R K W E S T E R F I E L D

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Quality Assurance in the Amusement Industry

General Overview 2

Steps to building a successful QA Program Put Someone in Charge with Authority to Act Understand the Basic Requirements Adopt Industry Standard Requirements Be Aware of All Codes and Regulations Affecting Ride

Maintenance Document Your Policies and Procedures Train Your Inspectors Define Your Inspection Criteria Understand the Checks and Balances of the Program Make a Decision to Fully Support the Program

QA Inspection Program Questions 3

Why Do You Need to Inspect? What Do You Need to Inspect? Who Will Do Your Inspections? What Techniques Will They Use? What Equipment Will They Need? What Training is Needed? How Often Are Inspections Performed? What Needs to be Documented?

Inspection Requirements 4

State Amusement Laws and Regulations Provides for Inspection of Rides 42 States Reference ASTM F24 Standards

ASTM F24 Committee Standards Covers Amusement Rides and Devices 500 Members from Around the World 17 Currently Released Standards F770 Covers Owner Inspection Requirements F1193 Defines Inspection Requirements

ASTM F770 Overview 5

Title: Standard Practice for Ownership, Operation, Maintenance, and Inspection of Amusement Rides and Devices

Current Revision: 2011 Covers: Owner/Operator’s Responsibility Maintenance Program Requirements Inspection Program Requirements

Owner/Operator’s Responsibility 6

Conduct Daily Pre-Opening Inspections Visual Check of Vehicles , Including Restraints and

Latches Note: Although Not Required by the Standard, a Daily Track

“Walk” Should be Considered

Visual inspection of Entrances, Exits, Stairways, and Ramps

Ride Communication Equipment Testing Ride Vehicle Operation Check Through One

Complete Cycle Without Passengers

Maintenance Program Requirements 7

Follow the Manufacturer’s Recommendations Create Inspection Checklists to Include: Inspection Descriptions Training Requirements Pre-Opening Inspection Requirements Re-Opening Inspection Requirements

Inspection Program Requirements 8

Owner/Operator Inspection Program to be Consistent with Requirements found in F770 and F1193

Inspection Documents to be Maintained in Accordance with the Procedures found in F770 and F1193

Prompt Notification to Manufacturer Required for any Incident, Failure, or Malfunction which Seriously Affects Continued Proper Operation

ASTM F1193 Overview 9

Title: Standard Practice for Quality, Manufacture, and Construction of Amusement Rides and Devices

Current Revision: 2006 Covers: Quality Assurance Program Inspections (Welding, NDT, Procedures, Bulletins) Inspection Requirements

Quality Assurance Program 10

A Formal QA Program (e.g. ISO 9001) is Not Required for Owner/Operators

A Formal Inspection Program is Required and Includes: Inspection of Purchased Ride Parts Inspection of Ride Parts and Structural Elements Inspection of Used Parts Prior to Re-Use Proper Disposition of Nonconforming Parts

Quality Assurance Program (cont) 11

Formal Process and Procedure Documentation Documentation (Configuration Management and

Record Retention Policy) Formal Inspector Training Program Dimensional Visual Nondestructive Testing (MT, UT, PT, AT, RT, etc.) Documentation (Reports and Training Records)

Inspection 12

Receiving Inspection of Purchased Parts Inspection Procedure Required Parts Meet Drawing Requirements/Specifications

Assembly Inspection Inspection Procedure Required

Nonconforming Parts Segregated Properly Dispositioned, Reworked, or Destroyed

Inspection (cont) 13

Welding Process Checks Processes in Conformance with the American Welding Society

(AWS) Standards Performed by Certified or Qualified Welders Documentation Maintained

Operational Requirements Operator Safety Checks

Documented Performed Prior to Each Ride Cycle

Inspection (cont) 14

Nondestructive Testing Qualified Inspector Required Conforms to Manufacturer’s Requirements

Documented Scheduled NDT Type Specified Acceptance Criteria Defined

Manufacturer’s Maintenance Manual Follow All Recommended Inspections

Inspection (cont) 15

Manufacturer’s Bulletins Follow All Inspection Requirements

Inspection Procedures Provided by the Manufacturer Must Normally Provide an Acceptable Result During the

Expected Life of the Part Must be Practical and Reasonably Able to be Performed by a

Trained and Competent Inspector

Documenting Policies and Procedures 16

Internal Development Document Your Procedures “As Is” – Improve Them Later Use Manufacturer’s Documentation as much as Possible Keep Documentation Secure and Under Control

External Development Bring in a Third-Party Use or Modify “Canned” Documentation

Inspector Training 17

Training – Internal and External Training Records Inspector Types Mechanical Inspectors Electrical Inspectors Certified Weld Inspectors NDT Technicians

ASQ Certifications Quality Inspectors, Quality Technicians, Quality Calibration

Technicians

Inspection Equipment 18

Match the Tools to the Inspections Provide for Equipment Maintenance Account for Calibration Requirements Set Up a Calibration System Check Non-Inspector -Used Calibrated Equipment (Torque

Wrenches, Go/No-Go Gages, Pressure Gages, etc.) Track All Tools by Asset Number Recheck Suspect Equipment Immediately and Re-Inspect Any

Parts Checked By This Equipment (Especially Torque Wrenches)

Inspection Reporting 19

Use Standardized and Numbered Paper or Electronic Forms

Review All Nonconforming Parts Reports Provide Parts Traceability (S/Ns or Tagging) Require Disposition Log All Reports Manually or Electronically Analyze Inspection Reports on a Periodic Basis to

Uncover Trends Keep Copies According to Record Retention Policy

Inspection Criteria 20

Established by the Manufacturer or Industry Standards

Includes: Drawing Specifications and Wear Limits Industry Standards (ANSI, AWS, ASNT, etc.)

Acceptance Sampling Plans Used Mainly for Receiving Inspection Standards Include ANSI Z1.4 or MIL-STD-105E

Checks and Balances 21

You Can’t Inspect In Quality 100% Inspection is Not 100% Effective Lack of Documentation Brings Inconsistency Poor Training Ensures Poor Performance Prevention is Cheaper Than Failure Learn From Your Failures to Develop Added or More

Effective Inspections and Procedures Consider Instituting a Process Audit Program It All Comes Down to Management

Conclusion 22

An Effective Inspection Program is a Vital Component of Ensuring Attraction Safety

Even if It was Not Required by Law, a Properly Set Up and Maintained Inspection Program Pays for Itself

A Good Inspection Program Keeps You in Control of Your Future

It Just Makes Good Sense

Questions?

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