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Quality System Manual
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Phone 325-643-2277 Fax 325-643-2221


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P. O. Box 2217
Brownwood, Texas 76804
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Document No. QSM 208
Section i Page 1 of 1
Revision 5
Date Issued: 4/4/2012
Quality System Manual

TABLE OF CONTENTS REV DATE


Section i Table of Contents 5 4/4/2012
Section ii Management Approvals of QSM 5 11/1/2011
Section 0 Quality Policy and Manual Control 5 3/29/2012
Section 1 Scope, Definitions, and Objectives 5 1/23/2012
Section 2 Management Organization and Responsibilities 4 3/29/2012
Section 3 RFQ, Contract, and Specification Review 3 11/1/2011
Section 4 Supplier/Contractor Quality Verification 3 3/27/2012
Section 5 Inspection and Test Plan 4 11/1/2011
Section 6 Receiving Inspection 4 11/1/2011
Section 7 In-Process Inspection 4 11/1/2011
Section 8 Final Inspection 4 11/1/2011
Section 9 Inspection Status 4 11/1/2011
Section 10 Identification and Traceability 4 11/1/2011
Section 11 Special Processes 4 11/1/2011
Section 12 Preservation, Packaging and Shipping 4 11/1/2011
Section 13 NCR, Corrective and Preventive Action 4 11/1/2011
Section 14 Document Control 4 11/1/2011
Section 15 Drawing Review, Control and Issuance 6 3/26/2012
Section 16 Quality Program Procedures 4 11/1/2011
Section 17 Quality Program Review and Manual Revision 4 11/1/2011
Section 18 Quality Records and Documentation 4 11/1/2011
Section 19 Quality Audit 2 3/28/2012
Section 20 Training and Qualification of Personnel 2 11/1/2011
Section 21 Measuring and Test Equipment Calibration 2 11/1/2011
Section 22 Measurements of Quality 1 11/1/2011
Exhibits Documents used for verification of activities 2 11/1/2011

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Document No. QSM 208
Section 0 Page 1 of 2
Revision 5
Date Issued: 3/29/2012
Quality System Manual

QUALITY POLICY AND MANUAL CONTROL

Quality Policy Statement


It is the policy of Barr Fabrication, L.L.C. to satisfy the expectations and needs of its
Customers, by providing products of the highest quality of manufacture which fully
meet their requirements, delivered on time and at the agreed price.

Barr Fabrication, L.L.C. is committed to providing our customers with consistently


high quality products/services by implementing a Quality System which recognizes
that everyone is responsible for the quality of their work, which must be consistent
in quality and produced in a cost effective and efficient manner. The aim of each
and every employee is to satisfy our performance standard of producing at the first
attempt defect free work which conforms to requirements every time, or have them
officially changed.

To achieve our company goal of defect free work, we have established the
following items to be monitored as a measurement of our on-going commitment to
achieve set goals and continuously improve our products and service to our clients.
Maintain weld repair rate less than 5% measured monthly
Maintain dimensional errors less than 250 per month
Limit Customer complaints to less than 50 annually

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Document No. QSM 208
Section 0 Page 2 of 2
Revision 5
Date Issued: 3/29/2012
Quality System Manual

Manual Control
The Quality System Manual is a Company wide document. The requirements stated
in this manual describe the official management position and directives which
establish the Quality System and Quality Assurance Program by which the
companys quality objectives are achieved.

This Manual is issued and controlled by Barr Fabrication, L.L.C. (BF) Quality
Assurance Department. Copies are issued on a controlled and uncontrolled basis.
A Copy Number inserted in the appropriate space on the title page identifies a
controlled copy of this document. A watermark stating Uncontrolled Copy shall be
placed on every page to identify a document that is not subject to updates and/or
revisions.

Controlled copies, and subsequent updates, are issued to assigned Controlled


Manual Holders via a transmittal and acknowledgement sheet accompanied by any
new or revised document(s). The manual holder is responsible for updating their
assigned manual by removing obsolete or superseded pages, if applicable, and for
signing and returning the transmittal and acknowledgement sheet.

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Document No. QSM 208
Section 1 Page 1 of 2
Revision 5
Date Issued: 1/23/2012
Quality System Manual

SCOPE, OBJECTIVES, AND DEFINITIONS

Scope
This Quality System Manual establishes the companys Quality Policy and
describes the Quality Assurance Program, company management responsibilities,
procedures and activities performed to assure conformance with all applicable
requirements. These controls and procedures provide for early detection of
nonconforming items, the timely corrective action of identified discrepancies, and
actions necessary to prevent their re-occurrence.

This Quality Assurance Program describe herein, shall apply to materials, products
and services used in the manufacture and repair of products/parts by Barr
Fabrication, LLC. The requirements outlined by this Quality System Manual shall
apply throughout the entire process of manufacture or repair, including
procurement, identification, stocking, issue of raw material, fabrication, processing,
inspection and assembly; and the identification, packaging, and shipping of
completed items.

Objectives of the Quality Program


Compliance with all client requirements as specified
Prevention, early detection, and effective correction of non-conforming items
Provide our customers with consistently high quality in all products
Assurance of the quality of materials and workmanship from suppliers
Continuously improving the quality of our products and processes

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Document No. QSM 208
Section 1 Page 2 of 2
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Date Issued: 1/23/2012
Quality System Manual

Definitions

Defect free
The term used by Barr Fabrication, L.L.C. to define our company goal of
zero defects. All welding activities are tracked by inches of weld deposited
and inches of repairs made, monthly reports are provided to management
as part of our continuing quality improvement process.
Quality System
The network of processes specifically designed to identify and ensure
compliance with all customers, regulatory, and company requirements
related to the quality of products and services provided by the company.
Quality Policy
A directive to all employees to comply with all requirements and to make
customer satisfaction a priority in all work performed. The written and
signed policy by the senior executive of this organization is evidence of the
commitment to quality, and the mission of the companys leadership to the
development and effective implementation of the quality system.
Quality System Manual
A written description in manual format, of all elements of the quality system
by which contract requirements are satisfied and company objectives
regarding quality are met.
Quality Assurance Program
The combination of all written descriptions, activities, actions, methods and
other features of the Quality System, that specifically addresses prescribed
requirements of standard or specification defining item Critical To Quality.
Quality Assurance
A department with the responsibility and authority for administering a
Quality Management System which includes conducting evaluations,
performing inspections, monitoring processes, evaluating performance to
requirements, initiating or causing to be initiated, corrective actions and
improvements to the Quality System and Quality Assurance Program.
Quality Control by inspection is one of the elements of the Quality
Assurance Program and is the responsibility of the Quality Assurance
Department.

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Document No. QSM 208
Section 2 Page 1 of 9
Revision 4
Date Issued: 3/29/2012
Quality System Manual

MANAGEMENT ORGANIZATION AND RESPONSIBILITIES

1. Purpose
To define the responsibilities and authority for quality related activities for
those managing and performing the work; and verifying conformance to
quality requirements; and their relationship within the organizational structure.

2. Scope
Applies to all personnel who perform or are responsible for activities
described in this Quality System Manual and the Quality Assurance Program
established and maintained by Barr Fabrication, L.L.C.

3. Responsibilities
3.1 General
3.1.1 Management personnel are responsible for identifying and
providing adequate resources for the performance and
verification of the work affecting quality.
3.1.2 This section of the Manual summarizes the authorities and
responsibilities for those who perform activities described in
various sections of the manual. Detailed and specific Quality
System elements are provided in other sections of this Manual.
The organizational relationships of key positions describe herein
are depicted in the Functional Organizational Chart contained in
this section.
3.1.3 Each activity shown in the Functional Organizational Chart shall
be performed by competent personnel who have the knowledge,
experience, and qualifications to fulfill the responsibilities for the
position to which they are assigned. Minimum qualifications for
key positions shall be established by the executive to whom the
position is to report. The qualifications of each position will be
defined in job descriptions which have been included in the
company Standard Operating Procedures Manual (SPM) for
record purposes only. HR shall maintain personnel files for each
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incumbent assigned to key positions in sufficient detail to
provide objective evidence of meeting the established minimum
qualification requirements for the position assigned.
3.2 Company Management
3.2.1 The Functional Organization Chart identifies the members of the
Senior Management (SMT) of Barr Fabrication, L.L.C. The
President, in conjunction with this Senior Management Team,
establishes the company Quality Policy, and together, is
responsible for the development of the Quality System, Quality
Assurance Program, and the review and approval of the Quality
System Manual. The President, by utilization of the SMT,
oversees all company activities including marketing, operations,
procurement and material traceability, production activities,
quality management, and all administrative activities required to
support company operations.
3.2.2 Department Managers are responsible for ensuring the
management, administrative and support functions are
performed in accordance with the applicable requirements of the
Quality Policy and this Quality System Manual including the
referenced mandatory procedures which support the Quality
Assurance Program.
3.3 Project Management
3.3.1 On occasion, a Project Manager may be assigned by the
Executive Vice President to manage all activities associated
with a special and/or unique project to ensure continuity of
production flow and success of the project. The Project Manager
shall report directly to the Executive Vice President for all
activities relating to the project.
3.3.2 Special projects and/or proto types are entered into the
processing system and are processed according to the
established policies, procedures and requirements of the Quality
System described in this Manual.
3.3.3 The Project Manager is responsible for coordinating various
functions required to fulfill the scope of the special project.
Personnel performing those functions shall have indirect
responsibility to the Project Manager for the performance of
those duties until project completion.
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3.4 Marketing
3.4.1 The Executive Vice President, oversees all sales activities
including the following:
Obtaining all customer requirements or specifications pertaining
to the order.
Documenting and communicating all order requirements
including subsequent change orders, using a defined order
entry and change order process.
Coordinating marketing activities with operations personnel to
fully utilize the available resources.
3.4.2 Contract and Specification review is initiated as a function of
marketing coordination activities. The review of contract
requirements is required by the Quality Assurance Program as
described in Section 3 of this manual as soon as practical after
receipt of an Request for Quote. This process is to ensure that
all personnel involved from the customer and Barr Fabrication,
L.L.C. understand the scope and requirements of the project.
Review meetings of this nature are of paramount importance for
first time customers, products, and/or with new and unfamiliar
specifications or CTQs.
3.5 Operations Management
3.5.1 The Executive Vice President also oversees all plant and
production operations.
3.5.2 The Manger, Operations reports to the Executive Vice President
and manages all manufacturing activities at the Plant Level. The
Manager, Operations is responsible for directing all plant
manufacturing and support functions, including material storage,
welding, packaging, shipping, training, and safety.
3.5.3 Plant supervisory personnel, who may include Supervisors,
Team Leaders or Lead persons, report to the Manager,
Operations. Supervisory or Lead personnel are responsible for
directing and supervising the work and assuring that the workers
are provided sufficient instruction to perform the assigned work
safety. Supervisory personnel, or their designees, are
responsible for verifying satisfactory completion of
manufacturing operations performed in their area of

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responsibility and for the quality of work produced under their
supervision.
3.5.4 Plant workers, who may include operators, welders, fitters,
assemblers, packers, and helpers, report to plant supervisory or
lead personnel and are responsible for performing and verifying
their work in accordance with all applicable requirements. Plant
workers are ultimately responsible for the quality of their own
work.
3.6 Quality Management
3.6.1 The Manager, Quality Assurance reports to the Executive Vice
President independently of production. This reporting structure
ensures Quality Assurance requirements, inspection results, or
quality resolution decisions are not subordinated to production
concerns.
3.6.2 The Manager, Quality Assurance has the overall responsibility
and authority for directing and managing the Quality Assurance
Program. These responsibilities include:
Ensuring compliance with the company Quality Policy
Developing, issuing and controlling the Quality System Manual,
including the formulation of policies and procedures by which
the elements of the Quality System are addressed.
Maintaining the Quality Assurance Program in compliance with
this manual.
Making final decisions and resolutions in matters regarding
quality when Quality Policy direction is required.
Reviewing all drawings received from clients, subcontractors or
developed in-house (Shop Drawings) for correctness, fabrication
details and required quality requirements.
Working with suppliers and client to resolve quality issues and
establish systems/procedures to prevent reoccurrence of non-
conforming items/activities.
Reporting on the status and improvement of the Quality
Assurance Program to Senior Management Personnel.
3.6.3 In addition to the day-to-day oversight and administration of the
quality program at the plant level, including supervision of plant
Quality Assurance final Inspection personnel, the Manager,
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Quality System Manual
Quality Assurance shall have the authority and the
organizational freedom to:
Initiate action to prevent the occurrence of any non-
conformances relating to products, processes or the Quality
System.
Identify and document any deficiencies relating to products,
processes and the Quality System.
Initiate and/or recommend solutions to problems through
designated channels.
Verify the implementation of solutions or corrective action
required to resolve non-conformances.
Prevent further processing, delivery or assembly of non-
conforming items until the deficiency or unsatisfactory condition
has been resolved.
3.6.4 Production Quality Control Inspectors report to the Manager,
Operations and are responsible for performing specified in-
process Quality Control inspection activities. Each is delegated
the responsibility and authority to identify and document non-
conformances and quality system problems.
3.7 Drafting Department
3.7.1 Barr Fabrication, L.L.C. does not perform in-house design or
develop design drawings and specifications for products it
manufactures. Our customers provide engineering design
drawings that are used as-is or to produce detailed shop
drawings. Barr Fabrication, L.L.C. does provide sketches for
preliminary proto type components for our clients information
and production drawing development. However, when Barr
Fabrication, L.L.C. is responsible for the design of a particular
product, a qualified professional engineer (or engineering
company) is contracted to develop the design and appropriate
drawings.
3.7.2 Drafting personnel prepare shop drawings and bills of material
and shop instructions as may be required. The drafting function,
wither contract or performed in-house, is under the supervision
of the Drafting Supervisor who reports directly to the Manager,
Operations. Shop drawings will provide sufficient details and
instructions to comply with applicable industry standards, codes,
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client requirements, and Quality Program requirements
described in this Quality System Manual.
3.7.3 Shop detail drawings are reviewed for adequacy of detail and
code compliance by a Drawing Review Team (DRT), which
includes Quality Assurance, Operations, and the Client, prior to
the release of the drawings to the Shop Floor.
3.7.4 Customer furnished drawings are reviewed by the DRT for
adequacy of detail, fabrication concerns and client specified
items Critical to Quality (CTQ). Any changes resulting from
these reviews shall be processed through a change order.

3.8 Welding Program Administration


3.8.1 Production welding performed by Barr Fabrication, L.L.C. shall
be performed in compliance with approved procedures in
accordance with AWS D1.1, AWS D1.2, AWS D1.5 or ASME
SEC IX as applicable.
3.8.2 The Welding Administration function is the responsibility of the
Manager, Quality Assurance. This function is responsible for the
initiation, development and control of Weld Procedure
Specifications (WPS), Procedure Qualification Records (PQR),
Welder Qualification Records (WQR) and documenting
compliance with the plant Welding Program.

3.9 Purchasing and Material Services


3.9.1 Purchasing activities are the responsibility of the Material
Services Manager who reports to the Manager, Operations. The
Manager, Operations reviews and approves all purchase orders
as described in written procurement procedures. This function is
responsible for overseeing activities regarding the procurement
of raw materials, parts, components, sub-assembles and
subcontracted services to meet specified project requirements
and schedules.
3.9.2 Material Services is comprised of various functions which
include, estimating, purchasing, materials control and inventory
control.

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3.9.3 Material Services personnel shall provide input and feedback to
the Manager, Quality Assurance as to supplier performance and
ability to meet quality requirements as specified in the
appropriate purchasing documents to assure the ongoing
acceptable quality of procured materials and/or services.
3.9.4 The Materials Services Manager is responsible for establishing
and maintaining the Materials Traceability and Inventory Control
programs, including the maintenance of accurate records of
materials transactions.
3.10 Shared Responsibilities
3.10.1 Management and Supervisory personnel of the departments
which affect quality are responsible for the development,
updating and implementation of written descriptions/procedures
for activities performed by their departments to assure
compliance with the requirements of this Manual, and for
meeting Barr Fabrication, L.L.C. s quality objectivities and
Quality Policy.
3.10.2 Department management for each of these areas is to define
the process used to accomplish the activities assigned. Process
descriptions may be in the form of written procedures,
documented training, demonstrated performance and
competency of the worker, or other appropriate documented
evidence.
3.10.3 In those cases where the duties and responsibilities span
departments, one (1) department shall be assigned ownership
of the overall process and coordinate the development of
interdepartmental procedures to ensure continuity of workflow.
3.10.4 To achieve compliance with the Quality Policy, individual
workers in production and other processes may require training
to perform the assigned work, which includes instructions for
performing specified self-checking to verify quality. In some
cases, individual certification is required to perform special
processes. Managers and Supervisors have the responsibility to
implement the Quality Program, communicate the requirements,
and to assure compliance in their area of responsibility. Quality
Assurance and Quality Control personnel have the duty and
responsibility to perform inspections and record results where

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called for, to monitor processes, to assure all requirements of
the Quality Program are met.
3.10.5 Quality is not limited to workmanship in manufacturing.
Continuous improvement occurs through the Corrective Action
System, as describe in this Manual and other procedures. All
processes and resulting documents, which affect quality, fall
within the scope of the Quality Program, the Quality Policy and
this Quality System Manual.

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Section 2 Page 9 of 9
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Functional Organizational Chart


Barr Fabrication, L.L.C.

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Document No. QSM 208
Section 3 Page 1 of 2
Revision 3
Date Issued: 11/1/2011
Quality System Manual

RFQ, CONTRACT AND SPECIFIATION REVIEW

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1. Purpose
To assure that a planned and coordinated review of Requests for Quote
(RFQ), Contracts and contracting Specifications is performed at the earliest
practical date to ensure all parties, including the client, understand the scope
and complexity of the proposed project.

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2. Scope
Applies to all orders of products, parts, components, and proto types
contracted to Barr Fabrication, L.L.C. to manufacture, produce, or supply.
3. Responsibilities
3.1 General O
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3.1.1 Quotation review and Order Processing functions are performed
by marketing personnel in coordination with the Senior
Management Team (SMT), Production, Material Services, and
Quality Assurance.
3.2 Senior Management Team
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3.2.1 Before submission of a tender, or acceptance of a


contract/order, all applicable documents shall be reviewed to
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ensure that:
3.2.1.1 The requirements are adequately defined and
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documented; where no written statement of


requirements is available for a request received by
verbal or other means, Barr Fabrication, L.L.C. shall
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ensure that the project requirements are agreed upon


by those parties concerned prior to acceptance of the
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contract.
3.2.1.2 Any omissions or differences between the contract
requirements and those in the tender are resolved.
3.2.1.3 Barr Fabrication, L.L.C. has the capability to meet the
contract requirements.
3.2.2 Standard Specifications, client furnished drawings and/or bills of
material, checklists, or other standard forms and written
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requirements will be used to clarify, define, and communicate
the clients expectations and Barr Fabrication, L.L.C. s
understanding of the scope of the contracted work.
3.2.3 Marketing personnel, or the assigned Project Manager if
applicable, shall obtain and/or initiate the required

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documentation/drawings prior to releasing the contracted work
for production.
3.2.4 A formal Contract and Document Review meeting shall be
organized by Marketing personnel to include involvement or

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input from the customer or his representative for special projects
with complex or unfamiliar products or requirements.
Appropriate personnel from those departments expected to
execute the contract shall participate in the review meetings to
ensure the information needed to process their part of the work

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is complete and clearly understood.
3.2.5 Contract review notes and decisions shall be documented and
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maintained. Upon acceptance and finalizing the specifications,
the order is entered and the requirements, including any
changes made during the review process, are documented and
incorporated into the appropriate shop work instructions.
3.2.6 Changes in contract requirements shall be reviewed,
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documented and processed following a written Change Order


process. Resulting changes in drawings, specifications, and
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other controlled documents shall be processed and controlled


as described in Section 15 of this Manual.
3.3 Quality Assurance, Material Services, Operations
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3.3.1 Each of these departments is responsible for providing input


and assistance to Marketing and/or Project Management in
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case of special projects, regarding their needs for appropriate


information and specifications to fulfill contract requirements
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pertaining to their area of responsibility.

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Document No. QSM 208
Section 4 Page 1 of 2
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SUPPLIER/CONTRACTOR QUALITY VERIFICATION

1. Purpose

To assure that products/materials are procured from or subcontracted to


approved suppliers selected from the Approved Suppliers List; the process by
which suppliers utilized by Barr Fabrication, L.L.C. are evaluated, qualified,
re-evaluated and monitored.

2. Scope

Applies to all purchased items and materials or services used in the


production of products manufactured by Barr Fabrication, L.L.C. All related
Purchasing, Material Control, and Quality Assurance activities described
herein are performed by qualified Barr Fabrication, L.L.C. personnel.

3. Responsibilities

3.1 General
3.1.1 Suppliers and Subcontractors shall be evaluated and qualified
to supply products to Barr Fabrication, L.L.C. in accordance with
the requirements of this Manual and SOP-QA-2.
3.1.2 Suppliers and Subcontractors shall be evaluated and selected
based upon their ability to consistently meet Purchase Order
and CTQ requirements.
3.1.3 Suppliers may be qualified on the basis of the following or other
defined and documented methods as determined by Quality
Assurance and/or Purchasing such as:
3.1.3.1 a review of the Quality system manual describing the
suppliers Quality program
3.1.3.2 an audit of their Quality processes
3.1.3.3 a review of inspection and test plans
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3.1.3.4 a product evaluation audit to qualify the supplier or his


product
3.1.3.5 an on-going record of acceptable quality performance

3.1.4 The initial and continuing qualification process will include


reviewing records of supplier performance on an ongoing basis
and evaluating the suppliers capability to meet specified
requirements. This review will be the joint responsibility of
Purchasing and Quality Assurance
3.1.5 Suppliers and subcontractors verification of the quality of their
products or services shall be surveyed or audited when
determined necessary to assure conformance to requirements
3.2 Material Services, Quality Assurance and Production personnel are
responsible for reviewing requests for approval of new suppliers and
determine the appropriate approval method; based upon the items,
materials or services to be provided and the effect of the product on
fabrication operations and/or the final product.
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3.3 Purchasing shall be responsible for assuring that purchase orders are
issued to approved suppliers.

3.4 The Manager, Quality Assurance shall be responsible for assuring that
purchased items and materials and subcontracted services are
inspected in accordance with procedures for incoming inspection

3.5 The Manager, Quality Assurance Shall maintain a list of approved and
qualified suppliers.

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Document No. QSM 208
Section 5 Page 1 of 3
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Date Issued: 11/1/2011
Quality System Manual

INSPECTION AND TEST PLAN


1. Purpose

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To assure that all work including fabrication, inspection, testing activities are
planned, documented and performed as necessary to ensure conformance to
specified acceptance criteria and requirements as annotated in appropriate
contract documents, from receipt of raw material through fabrication, punch-
out, packaging and shipping.

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2. Scope

This procedure applies to all products and/or parts manufactured and/or

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repaired by Barr Fabrication, LLC and to all process, materials, and items
that may be subcontracted from time to time to be used in the manufacture
and/or repair of those products. Applicable portions of this Quality System
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Manual may be applied to subcontracted activities as necessary.

3. Responsibilities

It is the responsibility of all Barr Fabrication, LLC personnel to perform the


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duties specified for their appropriate departments and documenting these


actions as necessary to ensure compliance with this section of the Quality
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System Manual. Specified fabrication and inspection criteria shall be


referenced and/or specified in the appropriate Shop Traveler (ST) for the item
and/or product being manufactured and/or repaired.
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3.1.Management
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3.1.1. Production planning functions including scheduling activities,


shall be performed in coordination with Manufacturing, Material
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Services, Quality Assurance and when applicable, customer


representatives to ensure that appropriate customer
requirements are identified and included in the ST developed for
each project.

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3.2. Material Services


3.2.1. Purchasing in conjunction with Quality Assurance, is responsible for
selection of suppliers/subcontractors and the procurement of raw
materials, parts, components, sub-assemblies, and subcontracted

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services in accordance with applicable requirements as annotated
in specified contract documents. This includes specifying
appropriate quality program standards to be applied to all
suppliers/subcontractors as approved by Quality Assurance.
3.2.2. Receiving personnel are responsible for the inspection and

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verification of all purchased materials, items and/or subcontracted
services in accordance with Section 6 of this manual which includes
the documentation of nonconforming items.
3.2.3. Note: All suppliers and subcontractors are responsible for
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inspection and verification at their facilities of the materials, items or
services they provide, as defined in their approved Quality Manuals
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and applicable Sections of this Quality System Manual.
3.3. Quality Assurance
3.3.1. Quality Assurance, in coordination with Manufacturing, is
responsible for the development and maintenance of Shop
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Travelers for each product or item manufactured by Barr


Fabrication, L.L.C.
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3.3.2. The Shop Travelers shall indicate, identify or reference:


Each inspection hold point and its relative location in the fabrication
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Cycle;
Hold Points shall address applicable CTQ from receipt of material
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through identification, fabrication, packaging and shipping;


Where subcontractors services will be employed;
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Characteristics to be inspected, examined or tested at each hold


point and acceptance criteria to be used;
Measurement or test records to be maintained, if required;
Mandatory hold points which require witnessing or verification of
selected Characteristics of an item or process, beyond which the
work shall not proceed;
Quality program standards to be applied to subcontracted items and;

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Document No. QSM 208
Section 5 Page 3 of 3
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Date Issued: 11/1/2011
Quality System Manual

Method of verification of subcontractor services by subcontractor


inspection, source inspection or receiving inspection.
3.3.3. Quality Assurance is responsible for performing Final Inspection
activities in accordance with criteria as specified in applicable

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procurement documents.
3.3.4. Quality Assurance is responsible for performing reviews of
Supplier/subcontractor submitted Quality Programs, Surveillance
Activities as may be required, and approving the
Supplier/subcontractor for inclusion in Barr Fabrications Approved

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Suppliers List.
3.4. Manufacturing
3.4.1. Operations is responsible, in coordination with Quality Assurance,

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for the development of work instructions (as required), and
appropriate Shop Travelers which will specify the appropriate
fabrication sequencing, hold points establishment, and punch-out.
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3.4.2. Production workers are responsible for verifying their work in
accordance with all applicable requirements, including performing
In-Process Inspections of their own work.
3.4.3. Production supervisory personnel, or their designees, are
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responsible for verifying completion of all In-Process Inspection and


Test activities performed by Production Inspectors in their
respective areas and completing the appropriate Shop Traveler.
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Document No. QSM 208
Section 6 Page 1 of 3
Revision 4
Date Issued: 11/1/2011
Quality System Manual

RECEIVING INSPECTION

1. Purpose

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To ensure that incoming materials and items are inspected to verify Purchase
Order requirements and to identify these items as required by the applicable
Inspection and Test Plan.

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2. Scope

Applies to all incoming materials and items for use in the manufacture/repair of
products by Barr Fabrication, LLC.

3. Responsibilities O
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3.1. General

3.1.1. All incoming items and materials shall be visually inspected and
verified Purchase Order or supply order requirements.
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3.1.2. When applicable, the objective evidence provided by suppliers and


subcontractors shall be reviewed as a means of determining that
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adequate quality verifications were performed.

3.1.3. Incoming items and materials shall be held until all inspections are
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completed or the necessary inspection and test reports are


received and verified.
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3.1.4. Nonconforming items or materials shall be identified, documented


and dispositioned in accordance with applicable sections of this
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manual, and/or customer requirements.

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Document No. QSM 208
Section 6 Page 2 of 3
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Date Issued: 11/1/2011
Quality System Manual

3.2. Material Services / Materials Control / Receiving

3.2.1. The receiving process shall include:

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3.2.1.1. Visually inspect all incoming items and materials against
the shipping notice and Purchase Order or supply order
requirements.

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3.2.1.2. Count items to verify quantities and visually check for any
damage to shipment.

3.2.1.3. Verify that Material Test Reports or Certificates of


Compliance are received, if required by the Purchase
OOrder.
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3.2.1.4. Compare shipping documents and materials certificates to
Purchase Order to supply order requirements to assure
compliance with the specified material specifications, if
applicable.
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3.2.1.5. Assure items and materials are identified in accordance


with the applicable Inspection and Test Plan.
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3.2.1.6. Initial and date the shipping notice documents indicating


acceptance and perform the appropriate inventory entry if
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applicable.

3.2.1.7. Record any discrepancies found during the receiving


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inspection activity on a Receiving Inspection Report.


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3.3 Quality Assurance

3.3.1. Quality Assurance personnel shall verify that all incoming items and
materials are identified as required by the appropriate purchase
order and take custody of the received MTRs/CofCs.

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Document No. QSM 208
Section 6 Page 3 of 3
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Date Issued: 11/1/2011
Quality System Manual

3.4 Materials Expeditor


3.4.1 The Materials Expeditor shall off load materials received in
conjunction with receiving inspection activities.
3.4.2 The Materials Expeditor shall verify that all raw materials are

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identified correctly with the appropriate P.O. number, Heat number,
and Project number if required.
3.4.3 The Materials Expeditor will ensure that the each part or lot of
material is marked with the information noted in 3.4.2.

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3.4.4 The Materials Expeditor shall be responsible for the appropriate
documentation when moving material into and out of production
areas to facilitate the maintenance of the Materials Traceability
Program.

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Document No. QSM 208
Section 7 Page 1 of 2
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Date Issued: 11/1/2011

Quality System Manual

IN-PROCESS INSPECTION
1. Purpose

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To ensure that in-process parts, sub-assemblies and assemblies are fabricated
inspected, tested and identified as required by the applicable Inspection and
Test Plan to verify conformance to specific requirements.

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2. Scope
Applies to all manufacturing/repair processes performed by Barr Fabrication,
LLC and to all parts, sub-assemblies and assemblies produced.

3. Responsibilities
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3.1. General

3.1.1. In-process items shall be inspected, tested and identified as required


by the applicable ST.
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3.1.2. In-process items shall be held until all inspections are completed and
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the appropriate sections of the associated ST signed off or the


necessary inspection and test reports are received and verified.
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3.1.3. Nonconforming items or materials shall be segregated, identified,


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documented and dispositioned in accordance with applicable sections


of this manual, and/or customer requirements.
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3.1.4. When items or materials are provided by the customer that are to be
incorporated into the manufacturing or assembly of the final product,
they shall be verified, identified, stored and maintained in
accordance with the requirements of this manual applicable to
purchased items and materials.
3.1.4.1. Any customer supplied item or material that is lost
damaged or is otherwise unsuitable for use shall be
documented on a Corrective Action Request and reported
to the customer.
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Document No. QSM 208
Section 7 Page 2 of 2
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Date Issued: 11/1/2011

Quality System Manual

3.2. Manufacturing / Quality Assurance


3.2.1. Production workers are responsible for verifying their work in
accordance with all applicable requirements; designated Production

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Inspectors are responsible for performing In-Process Inspections in
accordance with the applicable standards and documenting their
actions on the appropriate Shop Traveler.

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3.2.2 Production supervisory personnel, or their designees, are
responsible for verifying completion of all In-Process Inspection
activities performed by Production Inspectors in their respective
areas and documenting such verification on the appropriate ST.

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3.2.3. Quality Assurance personnel are responsible for verifying In
Process Inspections and process monitoring activities in
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accordance with the applicable standards and documenting such
activities on the applicable product Shop Traveler.
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Document No. QSM 208
Section 8 Page 1 of 2
Revision 4
Date Issued: 11/1/2011
Quality System Manual

FINAL INSPECTION

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1. Purpose

To assure that completed products are inspected, tested and identified as required by
the applicable Inspection and Test Plan to verify conformance to specific requirements
and completion of all previous inspections and tests.

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2. Scope

Applies to all manufacturing/repair processes performed by Barr Fabrication, LLC and


to all completed products produced.

3. Responsibilities O
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3.1. General

3.1.1. All completed products shall be inspected, tested and identified as required
by the applicable ST.
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3.1.2. All inspection and test records shall be reviewed to verify that the
completed product has been inspected at all points shown in the
applicable ST and that the inspection records and Shop Travelers are
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complete.

3.1.3. Nonconforming items or materials shall be segregated, identified,


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documented and dispositioned in accordance with applicable sections of


this manual, and/or customer requirements.
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3.2. Quality Assurance


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3.2.1. Quality Assurance personnel or their designees are responsible for


performing Final Inspections and reviewing inspection and test records in
accordance with the applicable Inspection and Test Plan and/or customer
requirements and the issuance of Green Tags as applicable.

3.2.2 Final Inspections and the results of each element of inspection shall be
documented using Shop Travelers, checklists, as-built drawings or other
appropriate written reports.

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Document No. QSM 208
Section 8 Page 2 of 2
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Date Issued: 11/1/2011
Quality System Manual
3.2.3 Final inspection will verify that all items are complete and are ready to ship
prior to release from the shop.

3.2.4 Items are not to be released for shipment until final acceptance by Quality
Assurance.

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Document No. QSM 208
Section 9 Page 1 of 3
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Date Issued: 11/1/2011

Quality System Manual

INSPECTION STATUS
1. Purpose

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To provide a means for assuring that required inspections and tests are
performed and that the acceptability of items with regard to inspections and
tests are known throughout the manufacturing process.

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2. Scope
Applies to all materials, items, parts, sub-assemblies and assemblies
processed or produced by Barr Fabrication, LLC and/or subcontractors.

3. Responsibilities
3.1. General
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3.1.1. Methods shall be provided for assuring that required inspections
and tests are performed and the acceptability of items is known
throughout processing.
3.1.2. A system for tags, markings, stamped impressions or other
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physical indicators on the item or its container shall be established


and maintained to indicate acceptance of items, including final
acceptance of completed items.
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3.1.3 The inspection status of lots or batches of materials or items shall


be indicated as follows; for stacks or bundles, the status indicator
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shall be applied to the top or most visible and accessible item in


the lot. For smaller items in containers, the status indicator shall
N

be applied to the container.


3.1.4 The identity of the Company and Inspector shall be shown on all
inspection stamps used. The identity of the Inspector shall always
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be shown on final acceptance status indicators.

3.2. Incoming Materials and Items


3.2.1. Acceptance of incoming materials or items is documented by
initialing and dating the shipping notice documents and completing
a Receiving Inspection Report.

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Document No. QSM 208
Section 9 Page 2 of 3
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Date Issued: 11/1/2011

Quality System Manual


3.3. In-Process Items
3.3.1. Acceptance of in-process items is documented on the appropriate
Shop Traveler, Drawing or other suitable document. Acceptance is
indicated on the accepted items by marking those items as shown
herein:

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1> Black-White Tag/Flag indicates completion of Production
Inspection and the item is ready for QA verification.
2> Solid Blue Tag/Flag indicates that the part has been verified by
QA and is ready for the next operation

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3 > Blue-White Tag/Flag indicates that QA has verified the fit-up
and the unit is ready for welding.
4> Red-White Tag/Flag indicates that repairs are required before
further processing. Each tag must be initialed by the person
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applying the tag, because the tag can only be removed by the
person who applied it.
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5> Solid Red Tag/Flag indicates that the item is scrapped as-is
3.4. Completed Items, Sub-assemblies and Assemblies
3.4.1. Acceptance of completed items, sub-assemblies and assemblies
is documented on the appropriate Shop Traveler, Drawing or other
N

suitable document. Acceptance is indicated on the accepted items


by marking as noted herein:
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1> Yellow-White Tag/Flag indicates that QA has verified the


welding and the unit is acceptable as-is.
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2> Solid Lime/Green indicates that the item is approved to be


shipped for outside processing (i.e. coatings).
3> Green-White Tag/Flag indicates acceptance by QA/Prod and is
N

ready for shipment.


4> Solid Green indicates that the unit is acceptable and can be
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shipped directly to the client.

3.5. Nonconforming Materials and Items


3.5.1. Nonconforming materials and items are documented on a NCR
Form and identified with a Red Hold Tag or other suitable form of
identification.

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Document No. QSM 208
Section 9 Page 3 of 3
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Date Issued: 11/1/2011

Quality System Manual


3.6. Authority for Application and Removal of Status Indicator
3.6.1. Red Hold Tags may be applied to nonconforming items by
anyone, but may only be removed by the personnel that applied
the original tag. Any conflicts between Quality and Production
must be resolved by the Executive Vice President.

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3.6.2 Green Accepted Tags to indicate acceptance of final inspection
may only be applied by Quality Assurance personnel.

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Document No. QSM 208
Section 10 Page 1 of 2
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Date Issued: 11/1/2011
Quality System Manual

IDENTIFICATION AND TRACEABILITY

1. Purpose

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To assure that each item, lot or batch is identified to the applicable drawing, work order
and customer order from receipt of incoming items and materials through the various
manufacturing/repair processes and shipping.

2. Scope

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Applies to all materials, items, parts, sub-assemblies and assemblies processed or
produced by Barr Fabrication, LLC.

3. Responsibilities

3.1.1 General
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3.1.1. Each item (lot, component or part) shall be identified to applicable drawing,
specification or other technical document, from receipt through processing and
shipping.
N

3.1.2. For stacks or bundles of items or materials, the top piece or most visible and
accessible item shall be identified. For smaller items in boxes, baskets, crates,
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bins, etc., the items or their container shall be identified.

3.1.3. Where traceability is specified, each item (lot or batch) shall be identified by
C

the Heat Number that is unique to that particular item, which shall distinguish
those items from others, which are identical but have been processed in
separate lots or batches with different Heat Numbers. The applicable Heat
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Number shall be recorded on all applicable process, inspection and test


records.
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3.2. Shop Numbers

3.2.1. Each customer order shall be assigned a Shop Number, which is used to
identify requirements, materials, items and documents related to the order.
The Shop Number is derived from the original customer order and accounting
File Number and provides traceability to the applicable customer order and
end product design.

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Document No. QSM 208
Section 10 Page 2 of 2
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Date Issued: 11/1/2011
Quality System Manual
3.3. Incoming Materials and Items
3.3.1. Accepted lots of incoming materials and items shall be marked with the
assigned Shop Number, piece count and, when applicable, Heat Number.
For stacks or bundles the top piece or most visible and accessible item is
marked. For smaller items in boxes, baskets, crates, bins, etc., the container

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is marked or tagged.
3.3.2 When materials are issued from inventory, the identification markings shall
be transferred to assure that both the items issued and the items remaining
are identified as required.
3.4. In-Process Items

LL
3.4.1. Upon completion of each operation acceptable in-process items, sub-
assemblies and assemblies shall be marked, tagged or labeled with Part
Number, piece count and when applicable Shop Number.
3.4.2. When partial stacks, bundles, or containers of materials and items are issued

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from inventory locations, the identification markings shall be transferred to
the top most item left in inventory. To assure that both the quantity issued
and the quantity remaining is identified, a Materials Request Pick Ticket or a
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Materials Returned To Stock form shall be completed and submitted to the
Material Services Manager.
3.5. Completed Items, Sub-assemblies and Assemblies
3.5.1. Upon completion and acceptance, items, sub-assemblies and assemblies
N

shall be marked, tagged or labeled with applicable Part Number, piece count
and when applicable Shop Number.
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Document No. QSM 208
Section 11 Page 1 of 3
Revision 4
Date Issued: 11/1/2011
Quality System Manual

SPECIAL PROCESSES

1. Purpose
To assure that special processes, including welding, nondestructive testing,

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and if, applicable heat treating and plating are accomplished under controlled
conditions in accordance with applicable codes, specifications, and contractual
requirements, using qualified personnel, equipment and procedures.

LL
2. Scope
Applies to all special processes performed or subcontracted by Barr
Fabrication, LLC.

3. Responsibilities O
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3.1. General
3.1.1. Measures shall be established and documented to assure that
special processes, including but not limited to welding, heat treating,
plating and nondestructive testing, are accomplished under
controlled conditions in accordance with applicable codes,
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standards, specifications, criteria, governmental and contractual


requirements, using qualified personnel, equipment and procedures.
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3.1.2. Special process personnel, procedures and equipment shall be


qualified in accordance with the requirements of applicable codes,
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standards and specifications.


3.1.3. Documentation for currently qualified personnel, processes and
equipment shall be maintained in accordance with the
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requirements of applicable codes, standards and specifications.


3.2. Welding, Heat Treating and Plating
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3.2.1 Drawings Shall detail welding requirements and joint details and if
applicable, heat treating and plating criteria as required for
manufacturing parts/ products in accordance with customer and
applicable requirements.

3.2.2 The Welding Program shall be administered by the Manager, Quality


Assurance who shall assure that all welding procedures, welders

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Document No. QSM 208
Section 11 Page 2 of 3
Revision 4
Date Issued: 11/1/2011
Quality System Manual
and welding operators, and welding equipment are qualified in
accordance with the applicable codes and specifications; including
the following:
3.2.2.1 Develop, approve, and qualify, and issue and control Weld
Procedure Specifications (WPS) in accordance with the

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American Welding Society (AWS) Specification for
Welding Procedure and Welder Performance Qualification.
3.2.2.2 Administer the welder welding operator qualification
testing program in accordance with AWS requirements

LL
and maintain the required documentation.
3.2.2.3 Maintain a list of all qualified welders and welding
operators.
3.2.2.4 Assure that welding equipment is calibrated maintained in

3.2.2.5
O accordance with applicable codes and specifications.
Manufacturing supervisory personnel are responsible for
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assuring that all welding operations are performed by
qualified welders, or welding operators using approved
Weld Procedure Specifications.
3.2.2 All Heat Treating activities shall be performed by a qualified sub-
contractor which has been approved by Barr Fabrication, L.L.C. to
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provide such services. Activities associated with heat treating


operations may be witnessed by Quality Assurance personnel.
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3.2.3 Coating (Galvanizing/Plating/Painting)


3.2.3.1 Galvanized coating, when specified, shall be performed by
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a qualified supplier according to specified requirements.


Quality of the galvanizing shall be inspected and
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monitored to assure uniform and consistent coating


meeting the established quality standards.
3.2.3.2 Paint coating shall be in accordance with customer
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specifications, shop drawings, and the paint manufactures


process control, surface preparation and application
recommendations. Painting operations shall be sub-
contracted to an approved supplier, the finished coating
shall be inspected and monitored to ensure uniform,
continues, and tightly adhered coating which meets the
specified paint mil requirements.

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Document No. QSM 208
Section 11 Page 3 of 3
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Date Issued: 11/1/2011
Quality System Manual
3.2.3.3 Plating activities, when specified, shall be performed by a
qualified supplier according to specified requirements.
Quality of the plating shall be inspected and monitored to
assure uniform and consistent coating meeting the
established quality standards.

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3.3. Nondestructive Testing
3.3.1. Drawings shall specify any nondestructive testing as required to
verify material or weld integrity in accordance with customer
specification and applicable code requirements.

LL
3.3.2. The nondestructive examination (NDE) processes, when required,
shall be performed by approved subcontractors or appropriately
trained and qualified in-house personnel. The administration of the
NDE program be the responsibility of the Barr Fabrication, L.L.C.

following: O
appointed Level III Examiner, responsibilities shall include the

3.3.2.1. Establishment and control the NDE program written practice


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applicable to the service to be provided by, or on be-half of,
Barr Fabrication, LLC in accordance with applicable codes
and industry standards.
3.3.2.2 Develop, qualify and control Nondestructive Examination
N

procedures in accordance with the established written


practice.
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3.3.2.3. Administer the NDE personnel qualification program, in


accordance with the written practice and SNT-TC-1A;
maintain all associated records and listing of all qualified
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NDE personnel.
3.3.2.4. Assure that NDE services provided to Barr Fabrication, LLC
N

are performed using procedures and personnel qualified as


required by applicable codes and standards and SNT TC-
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1A specifications.

3.3.2.5 A letter of appointment of the qualified Level III NDE


Examiner and the approval of the written practice for NDE
processes used at Barr Fabrication, L.L.C. signed by the
Executive Vice President shall be kept on file in the Quality
Assurance department files to indicate compliance with the
above requirements.

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Document No. QSM 208
Section 12 Page 1 of 2
Revision 4
Date Issued: 11/1/2011
Quality System Manual

PRESERVATION, PACKAGING AND SHIPPING

1. Purpose
To assure that cleaning, preservation, packaging and marking of all

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parts/products are inspected and shipping operations are verified to ensure
contract requirements are met.

2. Scope

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This procedure applies to all completed parts and products produced by and
to be shipped from Barr Fabrication, LLC.

3. Responsibilities
3.1. General O
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3.1.1. The cleaning, preservation, packaging and marking of parts/ products
shall be inspected and shipping operations shall be verified to
ensure that contract requirements are met.
3.2. Customer
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3.2.1. By way of Engineering drawings or written instructions, customer


shall provide cleaning, preservation, marking and identification
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requirements for each order, as necessary to assure conformance


with contract requirements.
3.3. Manufacturing
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3.3.1. Production personnel shall perform and verify cleaning, preservation,


coating application, marking and identification operations as
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specified by the applicable written instructions, and document such


activities on the appropriate Shop Traveler as required.
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3.4 Material Services / Shipping


3.4.1. Material Services personnel shall be responsible for assuring that
handling, storage and shipping operations are performed and
verified in a manner to prevent damage and deterioration, and to
comply with applicable written instructions and documenting such
verifications on a Shipping Ticket as required.

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Document No. QSM 208
Section 12 Page 2 of 2
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Date Issued: 11/1/2011
Quality System Manual
3.5. Quality Assurance
3.5.1 Quality Assurance personnel shall be responsible for inspection
of cleaning, preservation, packaging and marking of
part/products and verification of shipping operations as required
by applicable written instructions and verifying that such

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activities were completed by signing the appropriate Shipping
Ticket .
3.6 Project Management
3.6.1 Project Management or their designee, shall be responsible for

LL
development of a Shipping Ticket for each project/client, which
has been tailored to meet the requirements of that particular
project/client. As a minimum, each Shipping Ticket shall include
(as a minimum) data on the following:

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Shipping Ticket Number
Invoice Number
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Ship From address
Ship To address
Client P.O.
Project/Job Number
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How Shipped
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Truck Number if applicable


Trailer Number if applicable
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P.O. Line Item Number as required


Drawing/Part Number
N

Quantity
Description
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Date Shipped
Approval Signatures of Shipper, Quality Assurance/Quality
Control, Loader, Driver, and Client Receiver plus a date line
for each signature.

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Document No. QSM 208
Section 13 Page 1 of 4
Revision 4
Date Issued: 11/1/2011
Quality System Manual

NONCONFORMANCE, CORRECTIVE AND PREVENTIVE ACTION

1. Purpose
To assure that nonconforming materials, parts and products are identified,

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documented and held until final disposition has been made and the corrective
and preventive action is taken as necessary.

2. Scope

LL
Applies to all materials parts, sub-assemblies and assemblies received,
processed or produced at Barr Fabrication, LLC including purchased and
subcontracted items.

3. Responsibilities O
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3.1. General
3.1.1. Measures shall be established and maintained for controlling
nonconforming items which:
3.1.1.1. Define the responsibility and the authority to those who
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disposition nonconforming items;


3.1.1.2. Detect and record nonconformances;
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3.1.1.3. Identify and hold nonconforming items for evaluation;


3.1.1.4. Develop a disposition which has the concurrence of all
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responsible parties;
3.1.1.5. Implement the accepted disposition;
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3.1.1.6. Provide requirements for re-inspecting and re-testing


repaired and reworked items; and
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3.1.1.7. Advise purchasing and affected department heads in writing


of the final disposition of returned, rejected, or recalled
items which are identified as nonconforming to preclude
unauthorized use.

3.1.2. Holding areas or methods for segregating nonconforming items


shall be provided to prevent unauthorized use. Where physical

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Document No. QSM 208
Section 13 Page 2 of 4
Revision 4
Date Issued: 11/1/2011
Quality System Manual
segregation is not practical, tagging, marking or other positive
means of identification is acceptable.
3.1.3. Records shall be established and maintained identifying
nonconforming items; the nature and extent of nonconformance, its
disposition and objective evidence that repaired and reworked

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items have been re-inspected or re-tested according to applicable
documented procedures.
3.1.4. Corrective Action activities shall include the following:
3.1.4.1. Handling of customer complaints and reports of

LL
products/service nonconformance;
3.1.4.2. Investigation of the cause of the nonconformance;
3.1.4.3. Determination of the corrective action needed to eliminate
the cause f the nonconformance.
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3.1.4.4. Application of controls to assure corrective action is taken
and is effective;
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3.1.4.5. A Corrective Action Request (CAR) shall be issued to
document the need for and type of corrective and
preventive actions required to assure that the described
nonconformance can not re-occur.
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3.1.5 Preventive action activities shall include the following:


3.1.5.1 Use of appropriate sources of information, such as
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measurements from process and work operations that


affect product quality, in-process problem reports, audit
reports, quality records, client complaints to detect, analyze
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and eliminate causes of non-conformance


3.1.5.2 Initiation of appropriate measurements to assure that the
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procedure is implemented and affective


3.1.5.3 Conformation that relevant information on actions taken is
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submitted for management review.

3.2. Incoming Materials and Items


3.2.1. Incoming and purchased materials and items which are found to be
nonconforming shall be identified using a Red Hold Tag or other
suitable means and documented on Materials Received to Stock
Report.

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3.2.2. Nonconforming items and materials shall be placed in a designated
Hold area and conspicuously marked with a Red Tag to prevent
unintentional use.
3.2.3. A Nonconformance Report (NCR) will be initiated to notify all parties
concerned so that the nonconforming item may be dispositioned in a

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timely manner.
3.2.4. Purchasing, in conjunction with Manufacturing and Quality
Assurance, or their designee shall contact the responsible supplier to
determine, coordinate and arrange disposition of the nonconforming

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items or materials, e.g. return for replacement, credit or refund;
scrap, rework or repair at suppliers expense.
3.3. In-Process and Completed Items
3.3.1. Production workers and supervisory personnel shall assure that

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nonconforming items detected during production, in-process
inspection or upon completion that cannot be repaired or reworked
within the work center shall be Red Tagged and reported to Quality
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Assurance.
3.3.2. Nonconformances involving in-process items and completed items
except those detected and corrected within the responsible work
center, shall be identified using a Red Hold Tag or other suitable
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means.
3.3.3. A Nonconformance Report will be initiated to notify all parties
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concerned so that the nonconforming item may be dispositioned in a


timely manner.
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3.3.4. The responsible Production supervisory personnel shall be


responsible for assuring that all nonconformances are either:
Reworked or repaired to meet specified requirements or
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Scrapped and properly disposed of; or


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Accepted As is by responsible parties.


3.3.5. Upon notification of completion of rework or repair, as applicable,
Quality Assurance Personnel shall assure that the items are re-
inspected and/or re-tested to verify correction of the
nonconformance and remove the Red Hold tag, update the
Nonconformance Report to indicate completion of disposition, and
distribute the closed NCR to specified personnel.

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3.4 Corrective and Preventive Action
3.4.1 Quality Assurance personnel shall be responsible for
periodically reviewing nonconformance data, customer input,
and other inspection and test data to identify the need for
corrective and preventive action.

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3.4.2 Where corrective and preventive action is required, a
Corrective Action Request shall be initiated and processed by
Quality Assurance; the resulting responses and actions will be
monitored for effectiveness.

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3.4.3 Corrective and Preventive Action data shall be utilized for
Senior Management review purposes.

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Document No. QSM 208
Section 14 Page 1 of 4
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Quality System Manual

DOCUMENT CONTROL

1. Purpose
To outline a system of responsibility to ensure that the appropriate revisions of all

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documents affecting quality are reviewed, approved and controlled by authorized
personnel; and are readily accessible to the personnel concerned.

2. Scope

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Applies to all essential documents and forms which may affect the quality of products
produced by Barr Fabrication, L.L.C. These include the Quality System Manual (QSM),
Standard Operating Procedures (SOPs), Welding Procedure Specifications (WPS),
Procedure Qualification Records (PQR), Welders Qualification Records and other
special process procedures, Shop Travelers, and Shop Drawings. Customer supplied

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drawings and work instructions (e-mails, faxes, etc.) that are part of the purchase order
shall be controlled as if they were company originated documentation.
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3. Responsibilities
3.1 General
3.1.1 This section identifies the documents, forms, and manuals that fall under
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the jurisdiction of the Quality Assurance Program and require distribution


and revision level control. A master list shall be established and
maintained for each type of controlled document. These lists shall be
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made available to document users to preclude the use of invalid and/or


obsolete documents.
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3.1.2 Documents affecting quality shall be reviewed for adequacy and


approved by authorized personnel prior to use.
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3.1.3 The current revision of applicable drawings and Shop Travelers shall be
made available to personnel who are performing essential operations
affecting the overall quality of the products produced at Barr Fabrication,
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L.L.C.
3.1.4 Obsolete controlled documents shall be promptly removed from all areas
of use or otherwise assured against unintended use. Any obsolete
controlled documents being retained for legal or reference purposes shall
be so identified as to preclude their use in production activities.

3.1.5 Changes to controlled documents shall receive the same level of


review and approval as the original document. Changes shall be
processed in a manner to facilitate the prompt review of the revised
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documents. A record of revisions shall be maintained and shall include
a brief summary of the revision made and reasons why it was
necessary. Hand written notes annotated on controlled documents
may be acceptable provided they were made by authorized personnel
and were signed and dated by the person making the annotation.
Copies of such documents shall be kept on file with the earlier issue

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they are modifying.
3.2 Quality System Manual (QSM)
3.2.1 The Quality System Manual and revisions thereto, shall be reviewed
and approved by senior management prior to release for distribution.

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The Manager, Quality Assurance is responsible for the issuance and
control of the QSM and all associated quality records pertaining to
QSM distribution and control.
3.2.2 Controlled copies of the QSM, and subsequent changes, shall be
issued to key personnel in each department. A record of QSM
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issuance and revision shall be maintained. Controlled QSM holders
are responsible for returning or destroying obsolete pages.
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3.3 Standard Operating Procedures (SOP)
3.3.1 Standard Operating Procedures contain written instructions that
describe how key and cross-functional activities of Barr Fabrication,
L.L.C. are accomplished and documented.
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3.3.2 All SOPs are controlled by revision level and are reviewed and issued
in the same manner as other controlled documents.
3.4 Welding Procedures Manual
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3.4.1 The Welding Procedures Manual shall contain master copies of all
welding procedures (WPS), welding procedure qualifications (PQR),
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and welder qualification records.


3.4.2 The Manager, Quality Assurance is responsible for administration of
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the welding program and for the development, issuance, and control
of all Welding Procedures Specifications and supplemental
instructions and revisions. All Welding Procedure Specifications
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must be reviewed by Senior Management personnel and the


Manager, Operations for adequacy and approval for release.

3.4.3 Controlled copies of WPSs are issued to key personnel in each


department. If revised, the Manager, Quality Assurance or his
designee is responsible for replacing all issued copies with the
appropriate revised pages and destroying obsolete copies.
3.5 Special Process Procedures

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3.5.1 All Non-destructive Examination (NDE) Procedures must be reviewed
and approved by a Level III Examiner. The Manger, Quality
Assurance is responsible for ensuring that all NDE personnel,
including the Level III is qualified in accordance with the American
Society for Non-destructive Testing standard practice, SNT-TC-1A.

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3.5.2 When NDE is specified, the Manager, Quality Assurance shall over
see the development of all approved NDE procedures and records. If
NDE services are provided by a third party, the Manager, Quality
Assurance shall verify that the applicable NDE procedures to be used
have been reviewed and approved in accordance with the
subcontractors quality program and that the NDE personnel are

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appropriately trained. These records may be maintained by the
applicable Level III or Manager, Quality Assurance.
3.6 Forms and Exhibits
3.6.1 Quality Assurance shall be responsible for maintaining a master file of
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all Forms and Exhibits. This file shall contain masters of all
authorized standard forms to be used in processing and documenting
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work within the scope of the Quality Assurance Program at Barr
Fabrication, L.L.C.
3.7 Quality Plan Documents
3.7.1 Quality Assurance, in coordination with Manufacturing, is responsible
for developing, specifying, and producing documents of planned
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inspections and tests, as needed. These consist of the appropriate


Shop Traveler and may include additional documents as may be
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required by the Inspection and Test Plan for a particular product. All
Quality Program documents must be reviewed for adequacy and
approval for release by the Manager, Quality Assurance.
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3.7.2 Approved copies of Shop Travelers are issued to personnel in the


areas where they will be used and shall become the inspection and
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test record for those activities cover by the applicable Shop Traveler.
Quality Assurance is responsible for replacing all copies of the forms
in use and for destroying obsolete copies.
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3.8 Purchase Orders


3.8.1 Purchasing is responsible for the initiation and control of Purchase
Orders for raw materials, parts, components, sub-assemblies, and
sub-contracted services. All Purchase Orders, and changes to P.O.
requirements, must be reviewed and approved for release by the
appropriate Project Manager or his designee. Quality Program
requirements for each Purchase Orders shall be reviewed and
approved by the Manager, Quality Assurance prior to P.O. issuance.
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3.8.2 Purchase Orders and P.O. Change Orders are issued directly to the
appropriate supplier by the Purchasing Department after the
applicable approvals have been obtained.
3.9 Drawings and Specifications
3.9.1 All Drawings and Specifications and revisions thereto must be

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reviewed for adequacy and approved for release by the Manager,
Quality Assurance and/or the appropriate Project Manager or
designee. Master copies of all approved Drawings, Specifications,
and associated records are maintained by the Quality Assurance
Department.

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3.10 Documents of External Origin
3.10.1 Customer supplied drawings and specifications that are to be used to
convey work level instructions are obtained by Project Management
and issued as a controlled document as though the document was

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originated by Barr Fabrication, L.L.C. Quality Assurance has been
designated as the responsible party for issuance of revisions to
customer supplied drawings. When customer supplied drawings and
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specifications require additional work not contained in the original
Order, approval to commence the additional work shall be obtained
through the Change Order process.
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Document No. QSM 208
Section 15 Page 1 of 2
Revision 6
Date Issued: 3/26/2012
Quality System Manual

DRAWING REVIEW, CONTROL AND ISSUANCE

1. Purpose

To assure those drawings and other documents that affect end products fabricated
by Barr Fabrication, L.L.C. are controlled to ensure that the only current revisions
are used.

2. Scope

Applies to all projects and activities for products produced or processed by Barr
Fabrication, L.L.C.

3. Responsibilities

3.1 General

3.1.1 Design activities are not performed by Barr Fabrication, L.L.C.


personnel. When required, Barr Fabrication, L.L.C. contracts with
qualified professional engineering organizations to perform the
required design functions. Drafting of shop drawings, if required, are
performed in-house by qualified drafting personnel.

3.2 Drawings

3.2.1 Shop drawings shall be prepared for the products to be manufactured


for each order as required. Standard structural steel drawing
convention showing details sufficient to fabricate the parts and
complete the assembly, including AWS welding symbols, appropriate
bolting arrangements, paint notes, and other details shall be clearly
depicted or stated.

3.2.2 Customer furnished drawings that are intended to be used for


production will be reviewed to insure the details in 3.2.1 are shown or
provisions shall be made to provide other supplemental documents to
furnish the required details

3.2.3 Drawings shall be reviewed to ensure that design requirements -

relating to the product, including applicable statutory and code


requirements are identified; any inadequacy, Incomplete, ambiguous
or conflicting requirements shall be resolved with those responsible for
imposing these requirements. Drawing review shall take into
consideration the results of contract review activities.
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Section 15 Page 2 of 2
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3.2.4 The Shop drawing package shall include Bills of Material that have
been reviewed for completeness and checked for accuracy and
formatted in a manner that can be verified and validated against the
order and contract requirements. The completed drawing package
shall be forwarded to the client for review and approval prior to
release. Wavier of such approvals shall be documented and
annotated on the affected drawings.

3.2.5 All drawings shall be stamped with a Job Number and/or annotated
with a Released for Production stamp that includes the date of
release.

3.3 Design Changes

3.3.1 All design changes and modifications shall be identified, documented


and reviewed prior to submittal to the client for approval or waiver of
such approvals. Such changes shall be transmitted to the applicable
client personnel via company email which become a permanent part
of the project quality records.

3.4 Controlled Copies

3.4.1 Quality Assurance has been assigned the duties of drawing review,
control and retention. File copies of all controlled drawings and
associated document modifications shall be maintained in the Quality
Assurance department for reference and reproduction as may be
required.

3.4.2 Currently the Shop Drawing department will produce as many sets of
controlled drawings for each project as required to adequately perform
the work. Each set shall be marked RELEASED FOR PRODUCTION
and shall include the date of release; the original set shall be retained
by Quality Assurance and shall become the control copy for that
project. All other copies of drawing not so marked shall be destroyed
and prevented from use during production; there shall be no
exceptions.

3.4.3 Drawings received in an electronic format shall be reviewed by the


Manager, Quality Assurance and management personnel, then
approved and stamped by Quality Assurance prior to printing. When
these drawings are printed, they shall be controlled in the same
manner as original hard copies.

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Document No. QSM 208
Section 16 Page 1 of 1
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Quality System Manual

QUALITY PROGRAM PROCEDURES

1. Purpose

To assure that documented procedures are established and implemented to assist

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personnel in meeting established standards and requirements as defined by the
Quality Assurance Program.

2. Scope

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Applies to all activities which may affect the quality of products produced by Barr
Fabrication, L.L.C.; including those functions related to the implementation of the
Quality Assurance Program.

3. Responsibilities

3.1 O
Quality Assurance is responsible for development, control and updating of
this Quality System Manual and other Quality Assurance Procedures and
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Standards as may be required by this manual.

3.2 Every department who performs activities defined by this manual shall
document those activities affecting quality and/or defined by the Quality
Assurance Program in written procedures that comply with the criteria as
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specified in the appropriate sections of this manual. Controlled procedures


shall be developed for the following activities and functions, as a minimum:
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Procurement of materials
Special Processes (Welding, NDE, etc.)
Document Control (Drawings, procedures, forms, etc.)
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Supplier Quality Programs


Material Traceability
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Nonconformance and Corrective Action


Quality Records
Management Reviews
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Supplier Qualification and Evaluation

3.3 Some of the above procedures are described in sufficient detail in this
manual. Others may be in the form of Standard Operating Procedures or
some other appropriately controlled document format.

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Document No. QSM 208
Section 17 Page 1 of 2
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Quality System Manual

QUALITY PROGRAM REVIEW AND MANUAL

1. Purpose

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To assure that this Manual accurately describes the Quality Assurance Program
of Barr Fabrication, L.L.C. and that it is reviewed at least annually and updated,
as necessary to reflect current Quality Assurance practices.
2. Scope

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Applies to this Quality System Manual, and to the quality-related activities,
procedures, processes and documents described by this Manual.
3. Responsibilities
3.1 General
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3.1.1 The Barr Fabrication, L.LC. Quality System Manual may be reviewed
and updated at any time that changes to processes or procedures may
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require. All personnel may make suggestions for revisions to this
Manual, which may enhance its accuracy and overall effectiveness. All
Manual revisions shall be processed by Quality Assurance.
3.2 Quality Assurance
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3.2.1 The Manager, Quality Assurance shall be responsible for assuring that
a review of this System is performed at least annually to assure that
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the Manual reflects current QA practices and BF Standard Operating


Procedures.
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3.2.1.1 The Manual shall be updated to reflect actual practice and to


address any deficiencies identified and documented by third
party audits or other reviews of the Quality Assurance
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Program.
3.2.1.2 Manual revisions shall be reviewed, approved, and issued in
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accordance with Section 14 of this Manual.

3.2.2 The Manager, Quality Assurance, or designee, shall coordinate


pending revisions with all affected department activities:
3.2.2.1 All revisions to the Manual shall be issued with a cover letter to
those persons holding controlled copies of this Manual.

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Document No. QSM 208
Section 17 Page 2 of 2
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Quality System Manual
3.2.2.2 Signing or initialing the cover letter and returning it to Quality
Assurance shall indicate receipt of Manual revisions by
authorized personnel. The updating of individual manuals and
the destruction of obsolete documents is the responsibility of
the Manual holder.

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3.2.2.3 Receipt of a signed, or initialed, cover letter shall indicate that
the manual has been updated by the authorized manual holder.

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Document No. QSM 208
Section 18 Page 1 of 2
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Date Issued: 11/1/2011
Quality System Manual

QULAITY RECORDS AND DOCUMENTATION

1. Purpose

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To assure that records and documents that have a direct affect on product quality
are maintained to provide evidence of conformance to specified quality
requirements.

2. Scope

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Applies to all quality records including, material traceability documents, inspection
and test records, welding and company procedures, and personnel qualification and
training records associated with the production/repair of products fabricated by Barr
Fabrication, L.L.C.

3. Responsibilities
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3.1 General

3.1.1 Quality records shall be maintained to verify that:


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3.1.1.1 Completed products meet contractual requirements;

3.1.1.2 Personnel, procedures, and equipment are qualified;


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3.1.1.3 Suppliers and subcontractors are evaluated and


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selected on the basis of their ability to meet quality


requirements on an ongoing basis.
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3.1.2 Quality records shall include Inspection and Test records which
identify:
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3.1.2.1 The drawing and revision number or part number


applicable to a specific purchase order;

3.1.2.2 Applicable requirements, Shop Instructions, specification


sheets, Shop Travelers and checklists;

3.1.2.3 Specific inspections made and results obtained;

3.1.2.4 Nonconformance reports;

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3.1.2.5 Corrective action requests;

3.1.2.6 Receiving inspection reports.

3.1.3 All quality records identified by this Quality System Manual shall
be:

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3.1.3.1 Made available for audit and review;

3.1.3.2 Identified, indexed and filed for easy retrieval;

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3.1.3.3 Retained for a minimum of five (5) years unless
otherwise specified by the applicable contract
documents, customer request, or other Barr Fabrication,
L.L.C. SOP;

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3.1.3.4 Quality records shall be stored in a suitable environment
to minimize deterioration or damage, and to prevent
loss. Quality records may be archived electronically,
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unless otherwise specified.

3.2 Company Records

3.2.1 Company records shall be retained as specified in the applicable Barr


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Fabrication, L.L.C. Standard Operating Procedure.


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Document No. QSM 208
Section 19 Page 1 of 2
Revision 2
Date Issued: 3/28/2012
Quality System Manual

QULAITY AUDITS

1. Purpose
To assure that internal quality audits are carried out at least once per year to verify
whether actual practices are in accordance with the requirements of this Manual
and to determine the effectiveness of the quality system.

2. Scope
Applies to all activities addressed by this Quality System Manual performed by Barr
Fabrication, L.L.C. (BF) covered within the scope of the Quality Assurance
Program.

3. Responsibilities
3.1 . General
3.1.1 Internal Quality Audits shall be conducted to verify compliance
with this Quality System Manual and applicable AISC
requirements
3.1.2 Internal audits shall be planned and conducted as a minimum
on an annual basis; all internal audits shall be completed prior
to the annual anniversary date of the SMT review of the Quality
System Manual. Additional audits may be conducted of specific
elements of the Quality Assurance Program to ensure all
elements of the Quality System Manual are reviewed within a
twelve-month period.
3.1.3 Internal quality audits shall be performed using detailed audit
checklists and other approved supplemental checklists to
ensure all elements of the QMS are effectively implemented.
3.1.4 Trained personnel who have the organizational freedom to
record deficiencies shall be designated to perform the internal
audits.
3.1.5 The results of the audits shall be documented and brought to
the attention of the personnel having responsibility in the area
audited. The supervisory personnel responsible for the area
shall take timely corrective action on the deficiencies found by
the audits.

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Section 19 Page 2 of 2
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3.2 Quality Assurance
3.2.1 The Manager, Quality Assurance is responsible for directing the
Internal Quality Audit Program, including:
3.2.1.1 Scheduling internal Quality Audits addressing all
requirements of the Quality System Manual.
3.2.1.2 Assigning qualified personnel to perform scheduled
Internal Quality Audits. Those assigned to conduct audits
shall not have responsibility for the area being audited.
3.2.1.3 Assuring that a program of follow - up activities is
conducted to assure that corrective action is completed,
documented and verified.
3.2.1.4 Training personnel in the proper audit methods and
techniques to be employed when conducting audits of
both internal and external activities.

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Document No. QSM 208
Section 20 Page 1 of 1
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Quality System Manual

TRAINING AND QUALIFICATION OF PERSONNEL

1. Purpose

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To assure that the training needs of all personnel involved in activities
affecting quality are identified and that the required training is provided.

2. Scope

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Applies to the training requirements for all personnel involved in activities
affecting quality

3. Responsibilities
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3.1 Management personnel shall be responsible for determining the
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personnel qualification requirements for key positions and assigning
qualified personnel to those positions
3.2 Supervisory personnel in each area are responsible for identifying
training needs and arranging for training of all personnel involved in
activities affecting quality during production and assembly operations.
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3.3 Personnel performing specific tasks shall be qualified on the basis of


appropriate education, training, experience, and/or demonstration of
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competency to perform the task according to requirements


3.4 Personnel in training shall perform activities affecting quality only
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under the supervision of fully trained and qualified personnel


3.5 Appropriate records of training and other records of qualification shall
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be established and maintained.


3.6 All personnel performing activities described or required by this Manual
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shall be trained in the quality requirements applicable to those activities

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Document No. QSM 208
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Quality System Manual

MEASURING AND TEST EQUIPMENT CALIBRATION

1. Purpose

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Assure that all measuring and testing equipment and devices used to
establish or verify item quality or to monitor special processes are controlled,
maintained and calibrated at prescribed intervals.

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2. Scope
Applies to specific measuring and testing equipment used by Barr
Fabrication, L.L.C. Applies to all master gauges and standards used to
calibrate equipment and to gage points on jigs, fixtures, and machines

3. Responsibilities
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31 General
3.1.1 Documented procedures shall be established to control, calibrate
and maintain specified measuring and test equipment and
devices recording and maintaining a Master List of measuring
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and test equipment and maintaining calibration requirements for


these devices in an electronic database or in a spreadsheet will
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satisfy this requirement.


3 1 2 Quality Assurance shall maintain a listing of all active measuring
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and testing equipment and monitor calibration due dates to


assure they are calibrated within the prescribed intervals
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3.1.3 At prescribed intervals determined for each item, or prior to use,


specified measuring or test instruments shall be verified for
accuracy or calibrated and adjusted against certified equipment
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traceable to nationally recognized standards. Where no national


standard exists, the basis employed for calibration shall be
documented This can include industry or user standards New
equipment may be considered calibrated if certified to the
required accuracy by the manufacturer. Calibration may be
performed by BF to a calibrated master or may be
subcontracted to the equipment manufacturer or an approved
subcontractor. Accuracy checks and inspection for wear or
damage may be performed by Manufacturing personnel or
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Document No. QSM 208
Section 21 Page 2 of 3
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users of measuring devices for items not on the Master List and
for simple measuring devices, such as tape measures, steel
rules, squares, etc. These items are not required to be included
under the scope of this policy. When these devices show signs
of wear or damage that could cause inaccuracy of

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measurements, they are to be repaired or replaced.
3.1.4 Measuring and testing equipment under the scope of this policy
shall be labeled or marked with a unique identifier; either the
manufacturers serial number or an identification number which
shall be annotated on the appropriate documentation.

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3 1 5 Calibrated measuring and test equipment shall be identified with
a Calibration sticker, tag or other suitable indicator to show the
calibration status of the item.
3 1 6 Environmental conditions shall be suitable for the calibrations
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being carried out Unless otherwise specified, shop and/or office
atmosphere may be considered to be a suitable environment.
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3.1.7 Measuring and test equipment shall be handled, stored and
preserved in a manner to prevent damage and deterioration to
assure that accuracy and fitness for use are maintained
3.1.8 Measuring and test equipment shall be safeguarded from
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adjustments that would invalidate the calibration setting.


Placement of the calibration sticker over adjusting screws, etc
may be considered to be an acceptable method.
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3.1.9 For short tapes, the standard manufactures calibration certificate


may be used for Starrett and Stanley brand tapes. When these
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tapes are found to be worn and/or broken, the entire tape unit
shall be replaced, not just the blade.
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3.2 Calibration Records


3 2 1 Quality Assurance shall maintain calibration records, including
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manufacturer or subcontractor Calibration Certificates Calibration


records shall contain the following records:
Equipment type
Identification number (and Serial Number, if applicable)
Location or owner/user
Calibration interval or frequency of checks
Description of calibration I check method, or Procedure No
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Document No. QSM 208
Section 21 Page 3 of 3
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Acceptance criteria
Action taken when results are unsatisfactory
Calibration results
Date of last calibration

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Person or company performing the calibration
Next calibration due date
3.3 Action When Results Are Unsatisfactory

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3.3.1 When any measuring or test equipment is found to be out of date
or out of calibration, it shall be promptly re-calibrated or removed
from service and Quality Assurance shall be notified The
Manager, Quality Assurance is responsible for evaluating and
documenting the validity of previous inspections and tests made
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with the item and initiating any necessary corrective action.
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Document No. QSM 208
Section 22 Page 1 of 2
Revision 1
Date Issued: 11/1/2011
Quality System Manual

MEASURMENTS OF QUALITY
1. Purpose
To assure that measurements are established to evaluate the performance of

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the organization with respect to the stated objectives of the Quality
Assurance Program and the Quality Policy.

2. Scope

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Applies to all departments and operations of Barr Fabrication, L.L.C. and to
all suppliers or subcontractors whose performance is essential to meeting
stated company objectives and the Quality Policy

3. Responsibilities
3.1 General
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3.1.1 Performance measurements shall be established for appropriate
processes to, evaluate and monitor quality performance and
progress toward quality improvement. Following are some
examples of measurements of key performance indicators that will
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satisfy this requirement:


3.1.1.1 Conformance to requirements
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3.1.1.2 Customer Satisfaction


3.1. I. 3 Improvement trends for key processes
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Manufacturing quality
Supplier Quality
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On time delivery
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3.1.I.4 Effectiveness of Prevention and Corrective Actions


3.1.1.5 Internal QSM Audit scores
3.1.1.6 Safety

2008 Barr Fabrication, LLC. Contains proprietary information. Not to be copied or released without authorization.
Document No. QSM 208
Section 22 Page 2 of 2
Revision 1
Date Issued: 11/1/2011
Quality System Manual

3.1.2 Where statistical methods are used to satisfy requirements of this


manual:
3.1.2.1 Their use for the assurance and control of quality and the
acceptance or rejection of lots or batches based on data

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from key measurement characteristics shall be identified,
classified and documented.
3.1.2.2 Their use to measure key performance indicators of the
Quality Assurance Program shall be documented in

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reports to management.

3.2 Quality Assurance

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3.2.1 Quality Assurance shall identify key areas where performance
data can be readily compiled and used to provide measurement
information that will be helpful in determining quality performance
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and quality trends
3.2.2 Quality Assurance shall assure that any statistical techniques or
sampling practices used as the basis for assurance of quality and
acceptance or rejection of lots are identified and are valid for the
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application being used.


3.2.3 The products, processes or their characteristics to be accepted or
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rejected on such a basis shall be identified and the statistical


process control charts and records will be maintained as objective
evidence of assurance of quality
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2008 Barr Fabrication, LLC. Contains proprietary information. Not to be copied or released without authorization.
Document No. QSM 208
Section Exhibits Page 1 of 1
Revision 2
Date Issued: 11/1/2011
Quality System Manual
EXHIBITS

The exhibits listed in this section, are for information only and show examples of the
types of documentation utilized by Barr Fabrication, L.L.C. to verify compliance with
the Quality Assurance Program addressed in this Quality System Manual. Each

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document or form is controlled by detailed procedures developed by the department
utilizing the document/form.

No. Description of Document/Form Department Revision

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QA-332-09 Materials Received to Stock Report Material Services 11/1/11 R3
QA-1032 Nonconformance Report Quality Assurance 10/26/05
QA-1034 Corrective Action Request Quality Assurance 02/06/06
QA-432-11
QA-432-10
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Shop Traveler Unit
Shop Traveler Pre-Fab
Production
Production
12/16/05
12/16/05
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QA-432-12 Shop Traveler Sub-Assemblies Production 12/19/05
QA-432-13 Shop Traveler Cut Ticket Production 02/02/06
QA-734-09 Materials Pick Ticket Material Services 02/06/06
QA-734-08 Materials Return To Stock Material Services 12/28/05
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QA-1531-1 Daily Inspection Report Shop Quality Assurance 02/2/08 R3


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QA-1331 Red Tag Resolution Quality Assurance 10/31/06 R1


QA-1331A Red Tag Resolution Tracking Log Quality Assurance 11/1/06
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QA-431-1 Stamp Receipt and Control Log Quality Assurance 05/2/07


D-201-1 Number Request Drafting 08/02/11 R2
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A-100-1 Change Order Management 11/30/05


A-101-5 Form Review Record Management 11/29/05
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A-102-4 Procedure Review Record Management 01/02/06


A-103-OM Internal Memo Form Administration 02/21/06
QA-832-1 Weld Tracking Report Quality Assurance 07/30/07
P-001 Purchase Order Addendum Purchasing 12/5/05

2008 Barr Fabrication, LLC. Contains proprietary information. Not to be copied or released without authorization.
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Weld Tracking Report
Stamp Job Item In. Insp In. Rej Defect Proc Code Date Type Inspector

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QA 832-1 Rev 0 7/30/07


Stamp Receipt and Control Log
Name Insp Rec Audit Issue Date Rtn Date Signature

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QA 431-1 Rev 0 5/02/07


Red Tag Resolution Report
Date: Red Tag No: RTR No:
Client: Project:
Shop No: P.O. No:
Drawing: Description:

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Job Site: Supplier:
Quantity Rejected: Submitted by:
Description of Non-conformance:

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Proposed Resolution:
Damaged By Job Site Personnel (Client) - must purchase new unit
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Request Deviation to use AS-IS


Damaged in TransitReplace unit and Back-charge Hauler
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Manufacturing errorunit to be repaired or replaced


Supplier error, not built to drawingSupplier to replace
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No erroruse AS-IS

Concurrence Required Concurrence Signature Date


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Management Mgt:
Manufacturing Mfg:
Quality Assurance Q.A.:
Customer Cust:

QA1331-07 Rev 1 10/31/2006


Corrective Action Request
Date: CAR No: Submitted By:
Cust: Shop No: Project:

Description of Problem requiring corrective action:

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Proposed Resolution:

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N

Basis for Resolution:


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N

Concurrence Required Concurrence Signature Date


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Engineering:

Manufacturing:

Verification of Implementation of Corrective Action: Date

Verified By:
QA1034 Rev 0 02/06/06
Non-Conformance Report
Date: NCR No: Submitted By:
Cust: Shop No: Project:
Supplier: P.O. No: Sub-Assembly (Y/N):
Drawing: Item No: Description:

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Location: Responsible Department:
Qty Inspected: Qty Rejected: RIR No:
Description of Non-conformance:

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Proposed Resolution:

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Remarks:
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Disposition of Problem Solution:


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Use As Is
Re-work
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Repair as Marked
Scrap/Reject
Return to Supplier
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Other
Concurrence Required Concurrence Signature Date
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Engineering Eng:
Manufacturing Mfg:
Quality Assurance Q.A.:
Customer Cust:
Re-Inspection of Non-conforming Items Date

Re-Inspected By:
QA1032 Rev 1 10/26/2005
PAGE ___ OF___

UNIT ID: JOB No: CUSTOMER: DATE:

Materials Request Pick Ticket

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Total Yard
Item Description/Drawing No. Qty Qty Qty
Length Heat No. Bin
Pull Left

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Requested By: _________________________________ Date: __________________________

Authorized By: _________________________________ Date: __________________________

Pulled By: _____________________________________ Date: __________________________

ORIGINALMATERIALS COPYSHOP QA-734-9 Rev 1 8/13/07


UNIT ID: JOB No: CUSTOMER: :

Materials Returned to Stock

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Total Yard
Item Description Heat No. Total

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Length Bin
Qty

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Authorized By: _______________________________ Date: __________________________

Returned to Stock By: _________________________ Date: __________________________

ORIGINAL MATERIALS COPYSHOP


QA - 734 - 08 Rev 1 12/28/05
PAGE OF

Pre-Fabricated Cut Sheet


UNIT ID: JOB No. CUSTOMER: DATE:

QTY MAT COMPLETED QC INSPECTION


ITEM DESCRIPTION/DRAWING No. REQD TYPE
DATE WASTE INT DATE QTY STAMP

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Authorized by: Date:


QA-White SHOP-Yellow

QA 432-13 REV 1 8/13/07


PAGE OF

SUB-ASSEMBLY TRAVELER
UNIT ID: JOB No. CUSTOMER: DATE:

DRAWING No.: REV: DESCRIPTION:

COMPLETED QA INSPECTION
ITEM ACTION REQUIRED DEPT
QTY DATE INT DATE INT

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QA-White SHOP-Yellow

QA 432-12 REV 0 12/19/2005


PAGE OF

UNIT TRAVELER
UNIT ID: JOB No. CUSTOMER: DATE:

DRAWING No.: REV: DESCRIPTION:

COMPLETED QA INSPECTION
ITEM ACTION REQUIRED DEPT
DATE INT DATE INT

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QA-White SHOP-Yellow

QA 432-11 REV 1 3/28/07


PAGE OF

Pre-Fabricated Assemblies/Details
UNIT ID: JOB No. CUSTOMER: DATE:

DRAWING No.: REV: DESCRIPTION: PART:

HEAT QTY QTY COMPLETED QA INSPECTION


ITEM DESCRIPTION/DRAWING No. No. REQD COM
DATE WASTE INT ACC REJ INT

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QA-White SHOP-Yellow

QA 432-10 REV 0 12/16/2005


4501DanhilDrive,Brownwood,TX76801
P:3256432277,F:3256432221

Materials Received to Stock Report


Date: Inspector:

Supplier: P. O. Number:
Customer: Shop Number:

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Qty Description Heat Number Location
BIN Tot Qty

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Dimensions Correct: Yes No


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Material Identified: Yes No

All documentation correct, signed and turned in to Material Services


Yes No

QA 332-09 REV-3 11/1/2011


PURCHASE ORDER ADDENDUM

Purchase Order No: ______________________________ Dated: ________________________

Addendum No: __________________________________ Dated: ________________________

THE FOLLOWING CONDITIONS HAVE BEEN ADDED TO THE ABOVE ORDER

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Please acknowledge receipt of this Addendum at once. Per our discussions of ____________________, the following
documentation criterion is herein added to the requirements of this Order.

All documentation regarding this order must include the following: (i.e. invoices, packing lists, bills of lading etc.) in the body
of the document to ensure proper distribution and action:

a) Purchase order number.

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b) Tag information as shown on purchase order.
c) Ship to information as shown on purchase order.
d) Barr Fabrication, L.L.C. part number as shown on purchase order.
e) Purchase order line item number.
f) Material Traceability data (i.e., Heat Number, etc. as may be required)

1. Original packing list and/or bill of lading must accompany shipment.


2.

3.
4.
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Material Test Reports (MTRs) and/or Certificates of Compliance (CofCs) must accompany shipment (required for
ALL steel products).
Tag each Pallet with the HEAT NUMBER and quantity for the Items (part numbers) contained on each Pallet.
Annotated the Bill of Lading with each HEAT NUMBER for each item (or group of items) being shipped.
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5. If the manufactured parts will be shipped to a sub-vendor and then to Barr Fabrication, L.L.C., note appropriate
HEAT NUMBERS on ALL shipping documents and mail the ORIGINAL MTRs/CofCs to our Brownwood office with
a copy of the applicable shipping documents.
6. Where the parts provided contain 90 degree edges, break all edges prior to shipment; i.e. smooth out the edges.

All terms and conditions of the original Order remain the same except as noted herein. No other changes are made or
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implied by reference or omission. Please Sign and return to Barr Fabrication, LLC Purchasing Dept.
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BARR FABRICATION, LLC.


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_____________________________ Dated: _________ ____________________________ Dated: __________


SUPPLIER ACKNOWLEDGEMENT AUTHORIZED SIGNATURE
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P-001 Rev 0 12/05/2005


Daily Inspection Report
(Mechanical and Welding)
Date:

CTQ Items Inspected


Job No. Part Description First Article In-Process (other) Time

Office Work
Dimensions

W/M Settings
or

Each Entry
De-burring
or

Weld Tests
Stair Assy.
Punch Proc.

Bend Ops
Assembly

Clean Up

Total
Lay-out
Part No. Activity

Welds
Fit-up

Tacks

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Inspector: ____________________________ Verified By: _______

QA1531-1 Rev 3 02/02/08



4501DanhilDrive,Brownwood,TX76801
P:3256432277,F:3256432221

Drawing/Part Number Assignment Request

Client: Project: Date:

Description:

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Controlling Discipline:

Piping Structural Mechanical Vessels Tools Misc


(10) (20) (30) (40) (50) (60)

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1 Power 1 Platform 1 Support Systems 1 Tanks 1 Pullers 1 Signs
2 High Pressure 2 Roofing 2 Containers 2 Silos 2 Fit-up Jigs 2 Bridges
3 Distributions 3 Architectural 3 Stairs 3 Pressure 3 Measuring 3 Docks
4 Water 4 Highways 4 Elevators-Lifts 4 Boiler 4 Sockets
5 Sewerage 5 Reactor
6 Gate
7 Butterfly
8 Ball
9 Check O
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Materials:
1 A36 Carbon Steel (CS)
2 A572 Gr50 CS
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3 A523 CS
4 A304L Stainless Steel (SS)
5 A308L SS
6 A410 SS
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7 A5052 Aluminum (AL)


8 A6062 H2 AL
9 AL Not Specified
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0 Exotic Metals

Notes:
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1>There are several types and classifications of materials we may use; the basics are Carbon Steel
(CS), Stainless Steel (SS), Aluminum (AL). Although each has several grades it is not as important to
show this in the drawing number but on the drawing itself.
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2>When stating the size of the main part keep in mind that space is limited; for sizes less than one (1)
inch, use metric values. The number positions for sizing are hindered feet-feet-inches (000).

Requested By:

Assigned Number: Date:

Number Log in Master List: Yes No Temp

D201-1 Rev 2 8/02/2011


Barr Fabrication, LLC.
Internal Memo

To: Date: 3/18/2008

From:

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Subject:

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A-103-OM Rev 0 02/21/2006


Procedure Review Record
Please review the attached Procedure and annotate your comments on the document
its self, and/or approval below. Thank you.

Subject: ___________________________________________________________

Purpose: ___________________________________________________________

Senior Management:

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Approved: ________________________ Date: _________________

Project Management/Engineering:
Approved: ________________________ Date: _________________

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Procurement:
Approved: ________________________ Date: _________________

Production:
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Approved: ________________________ Date: _________________
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Administration:
Approved: ________________________ Date: _________________

Quality Assurance:
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Approved: ________________________ Date: _________________

Materials Services:
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Approved: ________________________ Date: __________________


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Procedure Developer: ______________________________________________

Date issued for Review: ____________________________________________


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Current Revision: __________________ New or Revised: _________________

Documentation (forms) associated with procedure: _______________________

A102-4 Rev 0 01/02/06


Form Review Record
Please review the attached Quality Assurance/Standard Operating Procedure
Form and annotate below your comments and/or approval.
Thank you.

Subject: ____________________________________________________

Purpose: ____________________________________________________
____________________________________________________

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Senior Management: ____________________________________________
_____________________________________________________________

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Approved: ________________________ Date: _________________

Project Management/Engineering: _________________________________


_____________________________________________________________

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Approved: ________________________ Date: _________________
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Procurement: __________________________________________________
_____________________________________________________________

Approved: ________________________ Date: _________________


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Production: ___________________________________________________
_____________________________________________________________
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Approved: ________________________ Date: _________________


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Accounting: ___________________________________________________
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_____________________________________________________________

Approved: ________________________ Date: _________________


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Quality Assurance: _____________________________________________


_____________________________________________________________

Approved: ________________________ Date: _________________

A101-5 Rev 0 11/29/2005


Change Order
Customer: ________________________ Purchase Order: ________________ Date: ________

Drawing: _________________________ Description: ________________________________


Project Engineering:
Comments: __________________________________________________________________
____________________________________________________________________________

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____________________________________________________________________________
Additional Work: ____________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
Other Effected Drawings: _______________________________________________________

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____________________________________________________________________________
Production:
Required Material: ____________________________________________________________
____________________________________________________________________________
Required Man-hours:
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Labor Grade _______ Hours ________ Position _____________________
Labor Grade _______ Hours ________ Position _____________________
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Labor Grade _______ Hours ________ Position _____________________
Labor Grade _______ Hours ________ Position _____________________

Estimated Completion Date: _________________ Total Hours Required: _________________


Procurement:
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Material Required:
Type: ________________ Size: ___________ Grade: ______________ Quality: _______________________
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Unit Cost: _____________________ Freight: __________________ ETA Shop: _______________________


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MTR/C of C Required: Yes _______ No _________

Accounting:
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Total Labor Hours: ___________ Total Labor Costs: ___________ Total Material Costs: _________________
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Total Cost This Change Order: ___________________ Revised Total Project Costs: ____________________

Approvals:

____________________________________ ____________________________________
Barr Fabrication, LLC Date Client Representative Date

COPIES: ORIGINALBARR FABRICATION, LLC COPYCLIENT


A10001 Rev 0 11/30/2005