Presentation on NTPC Inspection Services

Presentation Outline

Introduction Objectives of Inspection Services Functions of Inspection Services Organization Structure Roles of Inspection Engineer Customers (External &Internal) Inspection Process Summary

Quality Assurance & Inspection

Quality is a relative term and is generally expressed with reference to end use of product Planned and systematic actions necessary to provide confidence thereby assure the suitability of product for its intended purpose Control is a system for measuring and inspecting a phenomenon

Inspection means checking the acceptability of product

Inspection measure the quality of product
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QUALITY IS DEFINED AS
FITNESS FOR USE
FITNESS IS DEFINED BY CUSTOMER JOSEPH M. JURAN

CONFORMANCE TO THE REQUIREMENTS

PHILIP B. CROSSBY DEGREE TO WHICH A SET OF INHERENT

CHARACTERISTICS FULLFILLS REQUIREMENTS

ISO 9000

QUALITY IS DEFINED AS
THE CHARACTERISTICS OF A PRODUCT OR SERVICE
THAT BEAR ON ITS ABILITY TO SATISFY STATED OR IMPLIED NEEDS A PRODUCT OR SERVICE FREE OF DEFICIENCIES

AMERICAN SOCIETY OF QUALITY

Quality By-design & not By-chance

TWO KEY PRINCIPLES CHARACTERIZE QA

FIT FOR PURPOSE THE PRODUCT SHALL BE SUITABLE FOR THE INTENDED PURPOSE

RIGHT FIRST TIME

MISTAKES SHOULD BE ELIMINATED

QUALITY ASSURANCE INCLUDES

REGULATIONS OF QUALITY OF RAW MATERIAL, ASSEMBLIES,PRODUCTS AND COMPONENTS, SERVICES RELATED TO PRODUCTION AND INSPECTION

QUALITY CONTROL
THOSE QUALITY ASSURANCE ACTIONS WHICH PROVIDE MEANS TO
CONTROL AND MEASURE THE CHARACTERISTICS OF AN ITEM, PROCESS OR FACILITY TO ESTABLISH FITNESS FOR USE VARIATION IS LAW OF NATURE FOR EACH PROCESS THE VARIATIONS NEED TO BE IDENTIFIED AND

CONTROL

MAINTAINED

TO

LIMIT

THE

VARIATIONS

WITHIN

SPECIFICATIONS. THIS IS QUALITY CONTROL.

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INSPECTION
THE PROCESS OF MEASURING , EXAMINING, TESTING ,
GAUGING OR OTHERWISE COMPARING ONE OR MORE CHARACTERISTICS OF A PRODUCT OR SERVICE WITH THE SPECIFIED REQUIREMENTS. A process of segregating good from bad

QUALITY MANAGEMENT SYSTEM

A SET OF POLICIES, PROCESSES AND PROCEDURES REQUIRED FOR PLANNING AND EXECUTION (PRODUCTION / DEVELOPMENT / SERVICE) IN THE CORE BUSINESS AREA OF AN ORGANIZATION.

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OBJECTIVES OF INSPECTION SERVICES

TO ENSURE THAT DEFECT FREE PLANT & EQUIPMENT COMPLIANT WITH TECHNICAL SPECIFICATIONS AND OF SPECIFIED QUALITY. TO UNDERSTAND INSPECTION TECHNICAL SPECIFICATION REQUIREMENTS OF

ON-LINE PLANNING OF INSPECTION CALLS WITH A VIEW TO IMPROVE TIME SCHEDULE FOR DISPOISITIONING OF INSPECTION CALLS AND TO ATTEND INSPECTION CALLS IN LINE WITH CUSTOMER REQUIREMENTS.

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Functions of Inspection Services

Verify specified quality level of equipment by carrying out inspection at contractors / sub-Contractors premises, or by review of test certificate in accordance with agreed Quality Plan and contract requirements, for equipment ordered from Corporate Contract, consultancy assignment and from project ordered equipment and to carry out inspection activities as per agreed schedule matching Project Schedule and requirements.
Ensure implementation of agreed documented quality system and programme at contractors / sub- contractors works by verifying inspection records, process control records, calibration status during inspection of equipment.
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Contd..

Provide feedback to CQA and contractor (need base) for improvement of contractors / sub- contractors manufacturing capabilities, inspection and test facilities and implementation of Quality Programme. Assist contractors / sub- contractors, wherever required, to improve quality of equipment, manufacturing facilities and process. Provide Inspection Services for Consultancy jobs as per contract for the same. Provide feedback to Corporate Contracts/ Engineering/CQA in respect of hold ups in manufacturing activities or likely delays for speedy redressal of these hold ups by concerned departments.
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ORGANIZATIONAL STRUCTURE
DIRECTOR (TECHNICAL) ED (ENGINEERING)

HEAD QA & I
INSPECTION SERVICES

RIO DELHI

RIO HWR

RIO MUB

RIO BPL

RIO BRD

RIO PUN

RIO KOL

RIO TRY

RIO RPN

RIO HYD

RIO BLR

RIO CHN

RIO TRVN

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Role of Inspection Engineer

Product identification & traceability wherever applicable.

Verification of clearance of earlier inspection stages, wherever applicable.

Ensure calibration of the measuring equipment used during inspection.

comprehensive review of the internal quality records of the Contractor as per the quality plan ensuring adherence to the requirement and dispositioning of deviations, if any. Surveillance check on the quality programme of the Contractor agreed as per the contract.
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Contd..

Provide feed back on Contractors process control, manufacturing facilities & quality. Reporting Non conformities observed.
Provide regular feedback to Corporate Contracts/ Engg. regarding holdups or likely delays in Manufacturing Programme. Causes for such hold ups / likely delays are identified in their reports for speedy redressal.

Monitoring of Inspection Calls, Issue of MDCC for dispatch of equipment after satisfactory final inspection and clearance of CHPs & verification of implementation of corrective action, as agreed, for dispositioning of Non conformities.
Association with CQA, as required, for audit of Quality system of Contractors,/Sub Contractors. Assess the actual manufacturing Progress of the critical items required by the Project Contract Services, identify any hold ups in their manufacturing and send a report to Project, Engg/CQA Corporate Contracts.
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Calibration of Instruments

Ensures Correct reading Appropriate reference Logical approach Minimum inconsistencies Better accuracies Repeatability of measurements All time confidence Traceability of records Integrity of reports Optimum performance
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Customers
External Contractors/Suppliers

Internal

Projects/Sites

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DOCUMENTS FOR INSPECTION

Quality requirements and testing provisions needs to be the part of contract for its effective implementation. Documents needed for inspection are prepared and submitted by suppliers and processed and finalized by other groups/div of NTPC and therefore close coordination by inspection services is needed with all these groups and suppliers Pre award finalization/commitments include List of agreed make/model/manufacturer of various subcomponents submitted by supplier and mutually agreed with CQA Finalization of manufacturing quality plan(MQP) containing a) listing all tests and checks to be done during manufacturing and records to be kept for review by inspection engineer during inspection b)List all test/checks with sampling plan for test to be witnessed by NTPC These documents are submitted by supplier and approved by CQA
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Contd..

List of type tests to be done by supplier and to be approved by NTPC Engg List of type tests to be done by supplier and to be approved by NTPC Engg list of drawing/datasheet requiring approval by NTPC Engg Billing breakup for purpose of on account payments and issuance of MDCC approved and issued by Contract Div Contract agreements jointly signed by supplier and NTPC Standards such as IS , BIS, ASME, IEC Etc which broadly specify testing procedures , acceptance norms etc[Checks identified in MQP are broadly derived from these standards]

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Process of Inspection and Issuance of CHP and MDCC

Complete process is mapped and controlled through a web based application (known as WINDSORx) accessible through Internet by all inspection offices, suppliers and sub-suppliers and other users of inspection related data Suppliers submits offer for inspection listing details of BBU no , item , total qty , qty already supplied and qty offered for inspection with proposed date for inspection using online portal The inspection call is scanned for completeness of approved documents

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Contd..

The inspection planning is done through the same portal by the In-charge of inspection office. Inspection engineers visit the place of manufacture and checks the following before starting inspection/testing: Quality plans are approved. Drawing/ Datasheets are approved. Review all internal test records maintained by the manufacturer. Check that all the sub-components are of approved/agreed make. All the testing equipments are calibrated and are in working conditions.
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Contd..

After ensuring the above, the preliminary work involvesVerification of availability of complete material for inspection. Identification(stamping)of the offered lot.{to the extent feasible} Performing random sampling of items for testing.{Inline with quality plan} After selecting sample for testing, witnessing of actual testing starts . Few parameters to check areVisual Dimensional Conformity. Functional compatibility checks. examples pressure parts/rotary parts Quality of welds by RT and DP Hydro test/pneumatic pr test at 2.0 times working pressure Mechanical testing and chemical composition of body material hardness test 23 Efficiency test for pumps/blowers/motors

Contd..

After completion of tests , inspection report(CHP) is generated on line using inspection portal from the place of inspection and MDCC is also issued from the portal and handed over to supplier if item is found acceptable in all respect.
The data thus generated, updated and modified by NTPC as well as its suppliers and manufacturers (as a normal course of discharging their functions) provides comprehensive and customized online information to various groups and monitoring agencies as well as the clients and suppliers who in turn take immediate corrective actions for ensuring timely availability of materials and components at the project site.

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SNAPSHOTS OF WINDSORx

Inspection call entry screen

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SNAPSHOTS OF WINDSORx
A typical list of contracts awarded for NTPC Mauda project

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SNAPSHOTS OF WINDSORx Inspection Planning sheet

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SNAPSHOTS OF WINDSORx Inspection weekly grid

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SNAPSHOTS OF WINDSORx

CHP report

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SNAPSHOTS OF WINDSORx MDCC Reports

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SNAPSHOTS OF WINDSORx Inspection Planning sheet

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SNAPSHOTS OF WINDSORx Inspection weekly grid

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Quality is not an act .It is a habit

Quality By-design & not By-chance

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