CSWIP 3.

2 Senior Welding Inspection

Duties of the Senior Welding Inspector

TWI Training & Examination Services
Course Reference WIS 10 Course notes section reference 1
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Visual Inspection Procedures

Important things to consider:
When do I carry out inspections How do I carry out inspections? What do I look for? What equipment do I need? How do I interpret the code or standard requirements? What is the nature of the product? What operating conditions will be present? What is the quality of welding required? Is there a code or standard available to inspect the welds against
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Duties of the Senior W.I.

What attributes does a Senior Welding Inspector need ?

Technical skills Leadership skills Compassion Good communicator

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Duties of the Senior W.I.

What Technical skills are required:

1. 2. 3. 4. 5.

Knowledge of Technology Knowledge of Codes & Standards Knowledge of Planning Knowledge of Organization Knowledge of Auditing

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Duties of the Senior W.I.

What Leadership skills are required:

1. 2. 3. 4. 5.

Ability to do so if required Willingness to direct Acceptance of responsibility Ability to delegate (trust staff) Commitment to ones staff

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Duties of the Senior W.I.

What Compassion skills are required:

1. 2. 3.

Understanding of problems Willingness to help Compromise if possible.

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Motivation
What Motivates You?

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MONEY

What motivates you ?

Money Appreciation Flexibility Job Satisfaction

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Lack of motivation

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Lack of motivation

Late for work Sickness Poor productivity Lack of job satisfaction Signing off poor quality documents Arguments No enthusiasm

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Supervisory Skills Motivation

Abraham Maslows Hierarchy of needs
SELF ACTUALIZATION SELF ESTEEM SOCIAL SAFETY PHYSIOLOGICAL

Achievement Attainment Creativity Fulfilment

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Protection Hunger Thirst Sleep Warmth Security Shelter

Power Acceptance Status Respect Affiliation Appreciation Belonging Recognition Socialising Friendship

Development

Supervisory Skills Motivation

Intrinsic Motivation Extrinsic Motivation

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Supervisory Skills Motivation

Theory's (1)
People inherently dislike work and will avoid it if they can. Because they dislike work they have to be offered rewards to work, and threatened with punishments if they dont.
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They prefer to be controlled and directed, want to avoid responsibility, have little ambition and desire security more than anything else.

Supervisory Skills
Motivation Theory's (2)

People do not dislike work; under the right conditions they can enjoy it. If they are committed to the objectives of the group, they will direct and control themselves, rather than having to be controlled from above.
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People will be committed to objectives if they are getting enough personal satisfaction from the job.

Supervisory Skills
Motivation
The average human being learns to accept and to seek responsibility, if conditions are right. Ingenuity and creativity are widely distributed and generally under-utilized
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Wanting
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Th in

k in g

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Supervisory Skills
Sense of achievement Recognition Responsibility Nature of work Personal growth Salary Job security Working conditions Supervision level & quality Company policy and administration
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Herzberg,s Theory

Maintenance factors

Interpersonal relations Motivational or growth factors

Supervisory Skills
Motivational Needs
Motivation needs change with each person, situation & time. You must know your people well enough to provide the best motivational factors in the work place

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Supervisory Skills
Summary
Supervision - getting things done through other people Communications is the key Managing people requires establishing work goals, monitoring performance & providing feedback Focus on positive reinforcement, reprimand & redirect poor performance, not the person Plan activities - what, where, when, who & how?
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Supervisory Skills
Listening Skills

What does it mean to really listen?

Hearing. Understanding. Judging.

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Supervisory Skills
FILTERS SENDER MESSAGE
EMOTIONS/ATTITUDES ROLE EXPECTATIONS NON VERBAL CUES

RECEIVER

BARRIERS

BARRIERS

FILTERS
EMOTIONS/ATTITUDES ROLE EXPECTATIONS NON VERBAL CUES

FEEDBACK
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Supervisory Skills
Listening Skills When we listen attentively
We empower the speaker Receive all the message Use facial and body language to encourage the speaker Read facial and body language coming from the speaker The speaker becomes motivated
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We let the speaker finish his message

SUPERVISORY SKILLS
LISTENING SKILLS ARE A VITAL PART OF COMMUNIVATIONS
TUNING IN - SHORT VERBAL SIGNALS THAT ENCOURAGE THE SPEAKER TO CONTINUE UH-HUH, I SEE, MMHMMM ETC. PARAPHRASING - HELPING THE SPEAKER ORGANISE INFORMATION & CHECK UNDERSTANDING BY: PULLING OUT A CENTRAL IDEA OR COMBINING SEVERAL POINTS INTO ONE YOU THINK THAT ADDITIONAL PEOPLE WILL BE REQUIRED TO MAINTAIN THE SCHEDULE. REPHRASING - REPEATING THE INFORMATION IN YOUR OWN WORDS WHAT YOU ARE SAYING THEN IS THAT BECAUSE OF LACK OF TRAINED PEOPLE, YOUR GROUP IS FALLING BEHIND SCHEDULE.

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SUPERVISORY SKILLS
LISTENING SKILLS ARE A VITAL PART OF COMMUNIVATIONS
ACKNOWLEDGING - INDICATING THAT YOU ACCEPT THE SPEAKERS RIGHT TO FEEL OR THINK THAT WAY, OR THAT YOU MAY EVEN AGREE WITH CERTAIN POINTS I CAN UNDERSTAND YOUR FRUSTRATION YOU A RE REALLY UPSET ABOUT THIS THATS A GOOD POINT I KNOW YOU HAVE HAD A HARD TIME FINDING TRAINED PEOPLE LISTINING - ENCOURAGING THE LOGIC, ORDER & FLOW OF INFORMATION OK, SO FAR YOU HAVE MENTIONED THAT MANY OF YOUR PEOPLE LACK SUFFICIENT TRAINING TO DO THE WORK, & SECONDLY, THE SCHEDULE DEADLINES ARE IN JEOPARDY

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SUPERVISORY SKILLS
Barriers to listening
Time Importance of the subject Importance of the speaker Attention Distractions Defensive Discarding the feelings of the speaker
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Supervisory Skills
Types of communications
VERBAL - MOST COMMUNICATIONS NON - VERBAL:
WRITTEN - LETTER, ADVERTISING VISUAL - BODY LANGUAGE, ACTIONS

YOUR ACTIONS SPEAK LOUDLY, I CANNOT HEAR A WORD YOU ARE SAYING People believe visual communications more than verbal. when visual and verbal messages conflict, people believe the visual message

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Supervisory Skills
Planning and Organization
What? Where? When? Who? How?

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Supervisory Skills
Maintenance Factors
Moral Regular Meetings with your Team

Quality

Conduct Mini Audits

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Duties of the Senior W.I.

Exam Compulsory question:

Signing off a product

What does this consist of?

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Signing off a product

Quality Plan: All stages signed off Weld History Sheet (weld map? Materials): All stages signed off Materials: All certificates checked and signed off (welding consumables Parent materials) Procedures: Approved for cutting, welding, repair, NDT, PWHT, Testing Coating Qualification of: Welders NDT Personnel Inspectors (All approved and up to date)

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Signing off a product

Inspection Reports for: Visual NDT Dimensional, ensure they cover all appropriate joints Calibration Reports: For those items of equipment deemed necessary gauges etc PWHT Charts: Ensure all necessary information is on the chart speed data etc Hydro Tests: Reports are complete and signed off etc As built drawings: Are completed and are marked as As built

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Signing off a product

Nameplate Rubbings: When applicable Concessions: Engineering Query's, Deviations etc Permits: Degas certificates, hot work etc Coatings: Final painting or coating certificates signed off

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Signing off a product

QA Procedures Drawings Specifications Material test certificates (Mill sheets, chemical analysis & mechanical properties) Transfer of cast numbers markings etc Welding procedures Welder approvals Production welds (weld history) Any problems with interruptions of the welding cycle Documentation (welding consumables)
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Signing off a product

Non Conforming items Pre & post weld heat treatment Visual inspection report NDT Done in accordance with procedure NDT Reports Repairs & repair procedures Pressure test reports Dimensional reports (random check carried out) Visual checks on welding Concessions Inspectors Qualifications
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Quality pack content

Documents supplied before manufacture certificate of conformance with different codes/standards design calculations (optional) manufacturing drawings WPS with supporting WPQR (copies) welder qualifications qualification of NDT personnel NDT procedures PWHT oven calibration record (optional) Documents supplied after manufacture material test certificates (list!) welding production tests (if required) PWHT record (if required) NDT test reports: dimensional, pressure test and coating thickness are included quality plan and weld map as-built drawings non-conformity reports operating/mounting instructions

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Quality pack content

Reference to the specification As Built Weld Maps Weld Traceability log Weld Numbers Welder Numbers Material Classification & Certification Welding Procedure Numbers (WPS PQR's) and Documentation Material Traceability & Material Certificates Consumable Control Procedures & Consumable Certificates Welder's register and all approval Certificates Weld Visual Inspection Procedures & Visual Inspection Reports List of NDT Operators & Approval Certificates NDT Procedures NDT Reports R/T Report Numbers U/T Report Numbers MPI Report Numbers Dye/Pen Report Numbers Dimensional Control Procedures & Dimensional Control Reports PWHT Procedures & PWHT Reports + Calibration Cert.'s Hydro-test Procedures & Hydrotest Reports + Calibration Cert.'s Painting Procedures & Painting Conformance Reports Non-Conformance Reports Load Out Procedure Engineering Queries As Built Drawings

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Quality pack content

See Appendix 1

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Any Questions
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