Incoming inspection is carried out by the Quality Control Department (incoming inspection bureau), the organizational structure of which is determined depending on the scope of work on incoming inspection. The regulations on the incoming control unit must define the main tasks, rights and responsibilities of employees, the organizational form of control and the rules of relationships with other services of the enterprise.
To carry out incoming inspection of products arriving at the enterprise, a list of its types is compiled, a list of controlled parameters indicating their tolerances, requirements for measuring and testing instruments, and a description of the conditions for carrying out inspection for each parameter. Then the control technology is developed.
The incoming control service monitors the products presented to it and gives an opinion on the possibility of putting them into production.
If the quality of the product does not meet the requirements, then a complaint report is drawn up and presented to the supplier. Rejected products are subject to isolation until a decision on the complaint is made.
Incoming control can be carried out by:
Checking accompanying documentation, packaging and external inspection of products - if there is a certificate of conformity for the product or quality system;
- selective statistical control of the receipt of products in batches, the volume of which is sufficient to obtain samples with established risks of the consumer and supplier;
- complete control.
When carrying out random statistical control, the following standards should be followed:
GOST R 50779.30; GOST R 50779.51; GOST R 50779.50; GOST 18242 GOST 188321.
Well-established accounting and analysis of the results of incoming control allows the consumer enterprise to provide methodological assistance to suppliers in improving the quality of the products they supply.
Monitoring the accuracy of technological processes.
The purpose of monitoring the accuracy of technological processes is to obtain the information necessary to regulate them, assess the accuracy and stability of technological processes, and determine whether the accuracy characteristics of equipment comply with the accuracy standards established in regulatory and technical documentation.
Monitoring the accuracy of technological processes can be carried out both during established production and during the commissioning of new or repaired equipment, during product certification, during scheduled inspections, etc.
The accuracy of the technological process can be assessed by the deviation of the actual value of the parameter from the nominal value and by the coefficients of accuracy and stability, which are determined according to GOST 16.304 and GOST 16467, as well as the percentage of products delivered from the first presentation, the percentage of returns from consumer workshops and the percentage of complaints and defects.
As a result of accuracy control, factors are identified that lead to a violation of the accuracy of the technological process, the significance of the influence of various reasons on the accuracy of the technological process is established, and the boundaries for regulating the parameters of the technological process are calculated.
In conditions of serial and mass production, control of the accuracy of technological processes of mechanical processing is carried out in accordance with GOST 16.305, according to which assessments of the accuracy of technological operations are carried out using one of the following methods:
Graphic-analytical;
- accuracy estimates based on one implementation;
- analysis of dependencies between processing errors in two operations.
Methods for assessing accuracy in conditions of single and small-scale production are regulated by GOST 16.306, and GOST 16.307 establishes methods for determining the frequency of adjustment of automatic and semi-automatic equipment.
Inspection control.
During inspection control the following is carried out:
Systematic assessment of the actual level of product quality, identification of recurring defects, their analysis and elimination of the causes of their occurrence;
- checking the efficiency of the quality control department at various stages of production.
To ensure inspection control, an inspection group is organized within the Quality Control Department. The work of the group is carried out according to a plan approved by the head of the quality control department.
The inspection team periodically monitors product quality and the factors influencing it (compliance with technological discipline, quality of components, etc.). She can conduct tests.
Product testing.
The manufacturer carries out preliminary and acceptance tests of products in order to determine their compliance with the technical specifications, the requirements of regulatory and technical documentation and the possibility of putting the product into production.
To conduct acceptance tests, a commission is appointed, which includes representatives of the customer, the organization that developed the documentation, the manufacturer and state supervision authorities.
Based on the test results, a protocol is drawn up, which notes the data and results of product testing in accordance with the test program and methodology, a general assessment of product quality indicators and other data.
In the process of serial production of products, quality control department workers carry out control tests (acceptance and periodic).
Incoming inspection log
During the construction of a facility, it is necessary to carry out incoming quality control of incoming materials and equipment for compliance with those specified in the design documentation GOST, TU and other characteristics (for example, integrity, packaging integrity, geometric dimensions, color, frost resistance, water permeability, shelf life, warranty period, etc. .), while checking the presence and content of accompanying documents of the supplier (manufacturer), confirming the quality of the specified materials.The incoming inspection itself is carried out before the use of building materials. Actually, the very meaning of incoming inspection is to identify products that do not comply with the drawing or specification, to identify defective or low-quality materials.
In paragraph 7.1.3 of SP 48.13330.2011 Organization of construction. The updated version of SNiP 01/12/2004 states that, “The results of incoming inspection must be documented in the incoming inspection and (or) laboratory test logs.
Incoming inspection log form
A separate folder is created for quality documents, where they are all filed. You should make entries in the journal in a timely manner so that you don’t have to remember later when you brought what. When maintaining a journal, pay attention to the "Storage Conditions" column.
Some insulating materials and paints are stored only at positive temperatures (in a heated warehouse). Small things (In a closed warehouse). Cement in bags (Canopy). Reinforced concrete products, brick, sand, metal structures (open warehouse). Ready-made concrete mixture and mortar - immediately put to work. In columns 9 and 10, the persons who carried out the entrance control sign.
If the material does not correspond to the project according to some parameters, the journal will write “not suitable” and why. The possibility of its use can be agreed upon with the Designer and the Customer.
Incoming quality control
Incoming acceptance control should be understood as control of the quality and completeness of products during certification or during the delivery of these products by the supplier to the consumer (customer) before its transfer for construction or operation.Why is it necessary to carry out incoming product quality control?
First of all, to assess its compliance in terms of quality and completeness with the requirements of rules, technical specifications, national standards, as well as the terms of the agreement (contract).
Then, in order to timely identify shortages, as well as detect external, internal or hidden defects in the delivered products.
In order to prevent the launch into production, operation, which does not comply with established requirements, norms and rules, as well as product standards, which, as a result, may lead to an emergency situation or destruction causing harm to human life or health, as well as property, both physical and legal persons
Types of incoming acceptance inspection:
Continuous – 100% control of all mass-produced products;
Selective - this is when a sample or several samples of products are selected from a production batch;
Single is the incoming inspection of a certain amount of equipment or products that are supplied in batches under contracts (agreements).
Who carries out incoming quality control?
Typically, incoming acceptance inspection can be carried out:
Independently by the consumer unilaterally;
the consumer together with the supplier (manufacturer) of the product;
a third independent party usually engaged by the consumer of the product “Customer’s technical specialist”;
certification body, testing laboratory or expert organization when performing work related to the issuance of a certificate of conformity.
Technology for conducting incoming acceptance inspection?
First of all, it is necessary to develop and, if necessary, agree on a program or methodology (card) for conducting incoming acceptance control, in which it is necessary to determine the methods, parameters and sequence of actions when carrying out product control.
Next, you need to decide on the place, date and time at which the acceptance control will be carried out, and then create a commission, which may include both representatives of the supplier and representatives of the customer, as well as representatives of expert organizations and other third parties involved by agreement.
After all the previous steps have been completed, you can safely proceed to the main one, namely, the incoming acceptance inspection, which, if necessary, can be divided into several stages, namely:
Acceptance based on the quantity and labeling of products in packaging (in a box, box, container, etc.) without internal inspection, the so-called acceptance according to a delivery note or packing list;
acceptance of accompanying documentation for products, which, in addition to transport (shipping) documentation, may include technical, operational and permitting documents (certificates, permits, certificates, examinations, etc.) confirming the quality of products;
visual inspection and verification of completeness of products, performed after opening the packaging (container);
The final stage is checking the quality and warranty, technical characteristics and parameters of the product. If, for example, we consider this in the context of process equipment, then this final stage can be performed only after installation work has been completed and all commissioning tests have been completed.
Note. The decision on the need to introduce, tighten, weaken or cancel incoming control is made by the consumer based on the features, nature and purpose of the product.
Registration of the results of the completed incoming inspection?
There are several results: positive, negative, and that the product or its individual devices are partially non-compliant.
The result of the incoming inspection is a conclusion or a signed Act (Protocol) stating that the products comply in quality and quantity and that the consumer has no complaints. From this moment the warranty period established by the seller usually begins. In cases where a negative or partially negative act (protocol) on the results of control is drawn up, in this case, at the expense and efforts of the supplier (manufacturer), the product or its part, unit is modified or replaced in order to achieve positive results during repeated control, or the supplier and The consumer, upon agreement, can establish a procedure for compensation for losses from defective or incomplete products, but again, if this is provided for by the terms of the contract or other regulatory documents.
Incoming control act
An incoming inspection report is issued when materials or equipment are delivered to the enterprise. This document is an accompanying sheet on the basis of which the subsequent commissioning of equipment or use of materials takes place.This control, being the most important part of the technological process, largely ensures the smooth operation of the organization, as well as the high quality of the finished product. Thanks to timely inspection, only high-quality materials and equipment are used in the work, thereby significantly reducing the costs of repair and maintenance of production lines in the production of goods.
Incoming control allows you to determine the compliance of the quantity, configuration, quality of “incoming” products with the requirements of technical documentation, as well as when identifying flaws, defects, etc. make timely complaints to the supplier.
Who draws up the incoming control act
The preparation of this document is carried out by acceptance specialists (engineers, site foremen, department heads). In order to avoid claims to the contents of the act, a specially created commission (two or more people) is involved in its execution, which certify with their signatures all the information included in the act. Also, under certain conditions, representatives of third-party organizations, as well as representatives of the supplier, may be involved in incoming control.
Before drawing up this document, the supplied equipment or materials must be inspected or tested.
After the control has been successfully completed, the authorized employee fills out a report, which records the fact that the delivered products comply with the stated standards, regulations and requirements, and also enters all the information received in a special journal. After inspection, materials or equipment are delivered to the production department.
If the control is not passed, then the defect is also recorded in the report, and a complaint (i.e., a claim) is filed with the supplier. Further actions may be different: either the delivered products are returned, or exchanged for a similar product, or repaired at the expense of the supplier manufacturer.
Rules for drawing up an incoming control act
The incoming control report does not have a standard template, so it can be drawn up in free form or according to a template specially developed within the enterprise. This document can be written on a regular A4 sheet.
The document must include the following information:
The very fact of conducting incoming inspection,
its date and place,
result of checking,
complete information about the equipment or materials that have been tested.
Depending on the complexity of the delivered products, the act may be expanded and include additional clauses (about packaging, storage conditions, configuration, comments, additions, etc.).
The act is drawn up in one original copy, but if necessary, several more copies are printed (for all interested parties), each of which must be certified by the signatures of the commission members. It is not necessary to certify the document with a seal, because Legal entities may not use seals and stamps in their activities.
Instructions for writing an incoming inspection report:
At the top of the document in the middle is written its name with a short designation of the essence (in this case, “input control”), and also indicates the city in which it is created and the date: date, month, year. Then enter the full name of the enterprise that received the goods and carried out the incoming inspection (indicating its organizational and legal form of individual entrepreneur, LLC, CJSC, OJSC).
Next, we enter a list of the commission carrying out the inspection: the positions, surnames, first names, and patronymics of the employees are indicated.
Let's move on to the design of the main part. Here it is written about which equipment or materials were subject to control:
Name,
brand,
factory number,
quantity and other parameters.
Each type of product should be indicated on a separate line to avoid confusion.
Then the date of receipt is set, and the absence of flaws, malfunctions and defects is also certified, including compliance with technical documentation.
If there are any complaints about the received products, this must also be reflected in this document with a detailed description.
At the end, the act is signed by all members of the commission that carried out the inspection and control of incoming equipment or materials with the obligatory decoding of signatures and indication of positions.
Carrying out incoming inspection
Products accepted by the quality control department, the customer's representative office, the State acceptance of the supplier enterprise and received with accompanying documentation drawn up in the prescribed manner are allowed for incoming inspection.When conducting incoming inspection it is necessary:
1) check the accompanying documents certifying the quality of the products and register the products in the logbooks for recording the results of incoming inspection;
2) control the selection of samples or samples by warehouse workers, check the completeness, packaging, labeling, appearance and fill out the sampling or sampling report;
3) carry out quality control of products according to the technological process of incoming control or transfer samples or samples to the appropriate department for testing (analysis).
The department that received samples or samples for testing (analysis) conducts tests within the established time frame and issues a conclusion to the incoming control department about the compliance of the tested samples or samples with the established requirements.
The results of tests or analyzes (physical and mechanical properties, chemical composition, structure, etc.) must be transferred to production along with the tested products.
Products accepted based on the results of incoming inspection must be transferred to production with the appropriate mark in the accounting or accompanying documents.
Marking (stamping) of accepted products is allowed.
Products received from the supplier before incoming inspection must be stored separately from those accepted and rejected by incoming inspection.
Products rejected during incoming inspection must be marked “Reject” and sent to a defect isolation room.
Based on the results of the incoming inspection, they draw up a conclusion on the product’s compliance with the established requirements and fill out a logbook for recording the results of the incoming inspection.
In the accompanying documents for the products, a note is made about the incoming inspection and its results, and the products are marked (branded), if this is provided for in the list of products subject to incoming inspection.
If non-compliance with the established requirements is detected during the incoming inspection, the products are rejected and returned to the supplier with a complaint.
If you repeatedly receive low-quality products or receive them in large quantities, the consumer reports this to the territorial body of the Prosecutor's Office at the location of the supplier.
Based on the results of the incoming inspection, the consumer, if necessary, informs the supplier’s ministry, the customer’s representative office and (or) the State Acceptance Authority at the supplier enterprise about the non-compliance of the products with the established requirements, and in the absence of the latter - the territorial body of Gosstandart at the location of the supplier to take measures in accordance with those assigned to their functions.
For electrical and radio products accepted by the customer's representative office, information is sent to the customer's head institute for these products.
Incoming control of raw materials
Before acceptance, raw materials are weighed (checking the weight of all raw materials); it is allowed to accept raw materials delivered in standard containers (bags) according to the nominal weight of the packaging unit with a random check of the weight of individual packages.Flour and additives should be accepted from the supplier only if there are certificates of their quality, which should reflect the content of toxic elements, mycotoxins and pesticides, as well as the presence of pathogenic microorganisms. The quality certificate for additives of animal origin must indicate the presence of antibiotics.
An average sample is taken from each batch of received raw materials to control the quality and technological properties of the raw materials. Acceptance and selection of the average sample is carried out in accordance with the current regulatory documents for the corresponding product.
Containers with raw materials received at the enterprise (warehouse) must be clean, dry, strong and meet the requirements of the standards. The quality of the supplied main and additional raw materials is checked by the laboratory in accordance with current regulatory documents.
Incoming equipment control
Incoming control is the very first quality control of the three (input, operational and acceptance), the most routine, large in volume and difficult to perform, since it is most often neglected. Before installation, any product, equipment, cable or material must undergo input inspection. They will demand it as a percentage for exactly what you have installed and are trying to prove, but it is better to do it for the main hardware and materials for the entire volume at once and not before installation, because then there simply won’t be time for it. If at the beginning you don’t check the cable, the completeness of the equipment, and don’t find documents for this whole thing, then later, even if it’s possible, it’s very difficult to do, don’t make any claims to the customer after signing the acceptance papers, but if you did it well and properly designed in this way, then this is already from a third to half of the entire execution.Everything that is included in the specification must be reflected in the incoming inspection. There should also be materials not taken into account by the specification (provided by the PTO when revising drawings before signing contracts) and everything that is formalized by additional agreements, official changes (after the contract).
Done in accordance with GOST 24297-87 Incoming product inspection. There are not yet approved and it is unclear who developed INSTRUCTIONS for processing the results of incoming quality control of documentation, materials and equipment. There are samples of filling out the Transneft VK Journal.
Karyagin A.G. Materials for electrical installation work. Second edition, revised (Electrician's Library, issue 520) - Moscow: “Energoizdat”;
- Koptev A.A. Installation requirements for electrical equipment and materials (Electrician's Library, issue 539). - Moscow: “Energoizdat”;
- Gorzon O.F. Guidelines for transportation, acceptance, warehousing and storage of materials, products, structures and equipment in construction, 2nd edition, corrected and expanded.
There you will find a lot of things that you often have to invent when filling out the columns of the VK log and the absence of normal operational control schemes, for example, “storage conditions” and “controlled parameters.”
The main work consists of walking around warehouses, copying and removing documents, after which data is reconciled and paperwork is completed. All this in order must be done quickly so that there are no problems later.
Who should carry out incoming inspection when the supply is not ours is a complex and controversial issue. One way or another, the performers will have to conduct and formalize the VC, i.e. us, but at the same time, if they begin to demand an urgent VC, you can gain a little time by having it carried out by the customer, or at least in the presence of a representative of the manufacturer if he is not there. We must carry out and formalize our delivery unambiguously.
The incoming inspection should be done by the foreman or site manager together with the foremen and the storekeeper (if there is one), i.e. he instructs the craftsmen to check everything, and he himself draws up everything and collects the accompanying documents. This is his job because he signs the invoices and acts of acceptance and transfer of equipment for installation and then writes it off to him according to VPDM and M-29. If he is not engaged in decommissioning, then of course he will not care what came there and how to accept it, he will take anything and mount it anywhere just to get it done.
Conducting incoming inspection. During incoming inspection, the following are mainly checked:
1. Compliance of the supplied cable, products, materials and equipment (brand) with the project;
2. Correspondence of quantity to the project;
3. No visible defects or damage (appearance);
4. Completeness of equipment or product;
5. Compliance of the product with the technical characteristics specified in the passport or technical specifications, GOST;
6. Availability and completeness of accompanying documentation confirming the type and quality;
7. Date of manufacture according to the passport or marking;
8. Warehousing quality.
Compliance of the supplied cables, products, materials and equipment (brand) with the project. Everything that is included in the project specifications is divided according to the supplies of the contractor and the customer. The entry in the project specification “customer’s delivery” does not mean anything; this is divided when the contract is signed. Usually the customer undertakes the supply of all complex and expensive equipment, as well as cables with lengths exceeding 100 m; everything else - products, materials and cables up to 100 m - is supplied by the contractor (if interested, you can look at how this is done according to MDS 12-15.2003).
When concluding an agreement with the general contractor, a separation sheet is made and the 10th appendix is signed, according to which the customer completes the facility, everything that is not included in this appendix and everything that was missed (forgot to include in his) is supplied by the contractor. The 10th application is made on the basis of the very first isms of the project, which often changes during the construction process, and with it the brands and quantities of cables and equipment. This must be monitored in order to make approvals on time.
The brand, completeness, quantity and technical characteristics of the equipment are checked according to the project in the assignment to the manufacturer. Often in the project there is only a reference to the task that comes from the plant along with the equipment, in which case it is necessary to check the compliance of the equipment with the factory task or specification. If the brand of cable or equipment supplied by the customer contains at least one wrong letter or there are any differences with the project, you need to correctly compose a letter indicating exactly what the discrepancies are and reflect this either in the incoming control when everyone has already accepted it or not to accept it until a decision is made customer.
Dimensions do not match - width, height, etc. (which is very important when installing in a block box);
- the cable entry is not there (from below, but should be from above, or vice versa, even if they send a holey cover for cable entry from above, the power cable is not supposed to pass through the entire cabinet to the connection point, if this is not provided).
Usually no one checks the cable, products and materials supplied by the contractor; you simply draw up the IC for the project. You can find out how much of this material or product will be needed for all projects from the contractor’s delivery list (filled out by the technical documentation in the office). This statement may differ from what you actually bought due to substitutions and approvals that may not reach you at the site. Based on the PTO sheet, the kit makes its own summary, indicating the exact brands, suppliers and deadlines, so it is also very useful, especially if the PTO did not have time to affix the stamps. It is also more convenient to search for documentation if you know the actual suppliers and have an invoice. If what was delivered does not coincide with what should be according to the project, it is better to keep silent about it by falsifying the accompanying documentation because such things are usually not approved by the customer and in extreme cases you need to try very hard to convince him that what you delivered or you are going to deliver the quality better or no worse than the design and that it will be faster and more aesthetically pleasing.
Pay special attention to the boxes. If the specifications for it indicate specifications, then technical supervision may require a passport in which the same specifications must be indicated, and since such cases are often produced by the same installation organization, they may not match or may not have them at all. The only thing that the institute can agree on is the length of the box, for example from 3 or 2 meters to 2.5.
Quantity corresponds to the project. This is one of the important indicators that is needed primarily by the project manager (site manager, foreman). If the wrong brand arrived, then it will most likely be consistent, but if no one compared the quantity on the invoices with the project, then either there may simply not be enough materials and equipment, or you grab the excess and then you will need to return it, because you will not be able to report to him. At the same time, it often happens that it “gone in an unknown direction” and you have to buy it at someone else’s expense in order to return it. And of course, if no one puts invoices and OS-15 acts in one place, naturally you won’t be able to count anything in principle.
Since there may be a lot of this equipment or materials on site, in order to quickly check compliance with the quantity, a summary statement is needed. Upon delivery by the customer, you can use the tenth appendix, but it is better to check it with the latest drawings. You need to check your delivery against the materials supply list, which is made by the technical department, plus the delivery list, which the MTS department makes for itself. But there can and will only be data that was selected from the specifications, and therefore there is a risk that there will be errors there too. In general, you need to know that when comparing quantities, it is better to use more accurate data in each specific case. Cable is a special case, so it is better to keep a consolidated cable log for it.
No visible defects or damage. First of all, the packaging is inspected; if it is intact and was not hit on the road, then what may have survived inside is also inspected. Secondly, the appearance of the product itself is checked, the external coils on the cable drum are inspected, the paintwork on the equipment (bloating, abrasions, scratches), the absence of dents and damage. Sometimes, due to poor-quality fastening, the equipment inside the package breaks and rubs, and then after a while stops working, so it is better to document this. All defects in the equipment supplied by the customer must be corrected by the customer before installation. If necessary, for such complex equipment as 110-220 kV transformers, special documentation is also drawn up for equipment inspections before unloading and transportation to the installation site.
Completeness. Usually the equipment comes complete, there is a lot of it, and you have to deal with the manufacturer’s instructions or plant specifications, check the boxes, compliance with packing lists and invoices. This needs to be done quickly - the customer has strict requirements for the time frame within which this can and should be done. You can’t do it yourself, so hire craftsmen and a couple of workers to carry and open boxes and check.
The following problems are usually encountered when accepting equipment:
Lack of equipment fastenings or cable entries to them;
- absence of any parts according to the specification, although everything was sent according to the invoice.
First of all, you must have a waybill with the number of places (railway or road) and you need to check the number of boxes.
Secondly, check the completeness using the packing lists and the delivery note (invoice), whether what was delivered matches what was packaged.
Thirdly, check the picking list (invoice) with the assignment to the manufacturer or factory specifications and the availability of all accompanying documentation for the equipment. Often the plant itself approves any replacement during packaging and sends approval with documentation.
A representative of the manufacturer must be present and, if necessary, sign the documents. He often brings it with him and you can get a picking list, packing lists and order specifications in Excel from him, which is very useful. Take his contact numbers and call him if you find any mistakes or lack of documentation, it will be faster than through the customer.
Compliance of the product with the technical characteristics specified in the passport or technical specifications, GOST. Only a laboratory can check this for equipment and cables. In theory, before installation, measuring equipment must be calibrated on stands, which, as a rule, is not done (they do operation with the issuance of the necessary protocols). In theory, the manufacturer himself calibrates, assembles the equipment on stands and provides the appropriate documentation for this, and we only check its availability. Sometimes in the regulations you find requirements for laboratory control, this is left over from old reference books, which meant factory control (for example, concrete, if done in a factory) when there was still communism and the end-to-end system of regulatory technical documentation extended to them as well. The cable's insulation resistance must also be checked with a megohmmeter on the drum, even if there is a passport or test report in which these values are indicated, although for a high-voltage cable, factory tests with increased voltage will suffice (the customer himself must hire a laboratory for this, if there is no factory protocol ). For optical cables, before installation, technical supervision also requires checking with a reflectometer, even if there are factory certificates with reflectograms. In some cases, it is even necessary to check cable samples (bourgeois).
The geometric dimensions of a product or material are checked (not by a laboratory): for cable structures (racks, brackets, shelves, trays, boxes and components for them), rolled metal and m/structures, the width, height, length, wall thickness are checked; for pipes - diameter and wall thickness.
Availability of accompanying documentation confirming the type and quality. This is the biggest problem in the entire executive and takes up approximately a third to a half of all production documentation. All accompanying documents are of two types - a document issued to the manufacturer by a special certification body stating that its products are certified for compliance with any standards, or that these products do not require certification.
And a document issued by the manufacturer to the buyer stating that this product or batch has certain properties and qualities. They are all called differently, but the essence is the same. In theory, you should have both. Below is a table of an approximate list of products and the necessary documentation for them.
Certification. At Transneft, all supplied equipment, products, cables and materials must be certified. This means that the manufacturer must certify its products in special centers and receive the appropriate paper - either an appropriate certificate or a letter stating that the product does not require certification. There are a lot of these certification centers in every region and they provide certification in different systems. It’s always easy to find, online or from a supplier, so difficulties arise mainly with passports.
Centers for certification of products and services (by region) issue certificates of conformity in the GOST-R system or a letter (certificate) stating that these products are not subject to certification in this system (refusal of the need for certification). Essentially needed for absolutely everything.
The Ministry of Communications issues a certificate in the communication system (CCS). Needed for cables and equipment that are carried out at facilities under the jurisdiction and related to communications.
The Russian Ministry of Emergency Situations issues a fire safety certificate (SSPB). It is needed for flame retardant (ng) and LS cables (Lou Smoke - emitting little smoke), for cable ducts and PVC pipes, for equipment and devices responsible for fire safety, which are carried out for the work of subordinate firefighters (APT, AGT, GPT , PS, SOP, SGO).
The Federal Service for Environmental, Technological and Nuclear Supervision issues permits for the use of explosion-proof equipment on the territory of the Russian Federation. It is required for all explosion-proof equipment.
The State Sanitary and Epidemiological Service (regional) issues a sanitary and epidemiological conclusion. It is needed primarily for products that have direct contact with people or can somehow have a negative effect on them (building materials that can emit radiation, portable devices, etc.)
Certificate of type approval of measuring instruments. Issued for bourgeois measuring equipment.
A declaration of conformity issued by the manufacturer itself (if issued by a certification center is a different matter) stating that its products comply with some technical conditions does not mean anything in the process, but sometimes there is nothing besides it.
The ISO quality management certificate is also not quoted in the process, because no one separately requires certification in this system, although you need to look at what exactly it is given and by whom.
Separate components for products are usually not specified in certificates (everything that falls under the product number is included).
It is not possible to write exactly which products should be certified in which system; this can be seen on the official websites of certification bodies and the websites of organizations producing products. They are also beginning to issue various lists of products subject to mandatory certification.
In theory, the institute should design for Transneft taking into account that the products used are certified, which sometimes does not comply.
Having just a certificate is not even half the battle; it can be downloaded from the Internet or requested from the customer, but the documentation issued by the manufacturer to the customer can get lost and is very difficult to find if lost.
The manufacturer in the certificate must match the manufacturer in the passport if both documents are required.
The documentation issued by the manufacturer or supplier is also varied and depends on the product being manufactured. This documentation is more complex; it is issued for a product or batch with serial numbers, seals or quality control stamps and production dates. Therefore, it is more difficult to find if lost and difficult to “do.” Request these documents first of all, because certificates of conformity, etc., are nonsense that can always be found.
Materials or products (metal or HEV products) must have quality passports (certificates) that would indicate the name and brand of the product, production date and batch number, TU or GOST number.
If the product has any separately applied coating (usually rolled metal or metal structures), for example zinc, then there must be a document on galvanizing (protocol or act, as well as a certificate from the plant that it has the right to do this).
For electrical installation products (boxes, sockets, simple lamps), cable fittings (lugs, tags, etc.), usually the passport is a label and does not need to be attached, or one label per batch of products, i.e. Only a certificate or a letter of denial of the need for certification is attached to the incoming control.
Cable. The drum or reel with cable must have a marking or label indicating the serial number, brand, number of cores and cross-section, voltage, face-to-face length, month and year of manufacture, specifications or GOST, type of drum, quality control department stamp and manufacturer. Each manufacturer has different ones; they can be paper, metal or plywood. If there is nothing else, then sometimes you have to copy these labels and attach them along with the certificate.
There must also be an insulation test report, which can be combined with a passport or other tests, which duplicates everything that is on the label or marking of the drum.
The power cable must also have a high voltage test report. For optical - a protocol or passport of the characteristics of the optical fiber with reflectograms, the insulation resistance may also be indicated there.
Depending on its type, the communication cable must also have testing documents. Equipment. Measuring equipment must have certificates or calibration reports.
If the equipment is complex and must be assembled, then assembly drawings, or assembly or installation instructions, as well as a pre-assembly protocol are required. For what should be included in the operational documentation, see GOST 2.601-2006. There must be a passport, in which or on the protocols for the equipment there must be test data.
Bourgeois. Manufacturers (bourgeois) do not issue passports for bourgeois equipment, products and cables, and on the product itself there is a label with data: brand, serial number, date of manufacture, and manufacturer, so you often have to attach such installation instructions (label) or simply indicate in the input control serial number.
Documentation in a foreign language must be translated into Russian, and if you looked at this during the test, you will definitely be forced to translate everything.
The necessary certification, translations into Russian and testing, preliminary assembly with a formalized protocol or act (if necessary) must be carried out by the supplier. Sometimes the supplier issues one form for a system of such equipment, which contains technical data and certificates for the whole bunch of imported equipment. In other cases, you must have papers for all components of the completed equipment. A bourgeois cable must have technical specifications and testing methods, while high-voltage tests (if the cable is high-voltage) are carried out by suppliers, or the customer (depending on whose supply) must hire a laboratory at the site so that this is done before installation.
The date of manufacture on the quality document must not be expired, and the validity of the certificate (at the time of manufacture) must not have expired.
The Transneft system has the following requirements:
1. Equipment, products, materials or cables must be manufactured no later than one year before installation;
2. Also, at the time of purchase or delivery of products, all certificates must be valid (usually they are given to the plant for 3 years).
Many inspectors have dates on quality documents - the main remark is, of course, from the expiration of the fire certificate the cable cannot catch fire, but the above condition must be met (an expired certificate will pass if the passport bears the date of manufacture when this certificate was still valid and this passport is less than years at the time of installation).
Warehousing quality. Warehousing, depending on the need, can be indoor or outdoor, which is reflected in the incoming control log (by Transneft). Basically, a special temperature regime (which is usually prescribed for an automation kit) and the absence of precipitation are only necessary for special equipment; everything else is closed in containers just to prevent it from being stolen.
Sometimes technical supervision finds fault with the absence of any product in the register of technical specifications, technical specifications and PMI of Transneft, such as it was purchased from the wrong supplier. There’s nothing you can do about it, raise the issue at a planning meeting and let the top management change the policy, but it’s very difficult to persuade suppliers to buy from someone other than their own. Therefore, get this register, passports and certificates of exactly those manufacturers that are listed there and falsify them. You can delay time by convincing the technical supervision that this register was made for internal use by the Transneft equipment, and not for the contractor, then when everything is installed, it will be too late to stop the work and they will find fault with its non-compliance, which you will eliminate by making documents.
Some domestic equipment, such as switchgear switchgear, disconnectors for KTPB and other equipment pre-assembled on stands, require assembly protocols; sometimes it even happens that only what had such protocols is assembled. Organize the seizure of factory documentation from the warehouse before it reaches the facility, especially if we are talking about a line, because whether you ask the craftsmen or not, they will still be lost or thrown out. Talk about this need with the manager of the facility, explain that problems with delivery or interest will definitely arise if this is not done.
For very expensive, large equipment, transportation documents must sometimes be completed.
Where to look for customer delivery documentation. If the general contractor did not accept the equipment or cable supplied by the customer correctly, and then tries to transfer it to you in the same way, do not sign anything until you check it, let him be responsible for it too. The documentation is transferred to the contractor separately with an invoice or an equipment acceptance certificate for installation, or it must be looked for in boxes with equipment (in cable drums). If the customer tells you that all the documentation is there, but it’s in boxes or drums, don’t believe it, don’t sign anything that states that the documentation is all included, and don’t let your supplier or foreman sign. On the invoice or in the act, you can write “the documentation has not been verified” if they are trying to force you to urgently sign something. If there are problems with the equipment set or cable lengths, the supply or foreman will have problems, but if there are no documents for this matter, you will have problems. Therefore, never sign yourself or let someone else sign a document on acceptance of equipment or cable in a jump, knocking out the handle, without completely checking the presence of all the documentation. You can object to the customer that the documentation came in one copy, but they may require two from you, it is better to voice this so that the customer decides to submit it in one, than to then copy folders of 100-300 passports.
Request documentation for the cable from the customer, he must give you all of it according to the above table; just one document or label from a reel or reel does not mean that you have it all included. If the customer says that it’s in the drum, go with him to the drum, open it (take a pry bar with you) and look on the inside of the drum cheek, on the outside under the board, at the end of the cable, and sometimes even in the hole for the “pencil” (storekeepers stuff it in if it doesn't fit). If there is no document about the quality of the plant, indicate so in the invoice. In addition, the power cable (above 6-10-35 kV) must have a high-voltage test report; it is not allowed to be laid without it, and if it is laid, it will “not seem like much” after installation.
There are tags nailed onto the cable reels. These are small pieces of plastic, wood or paper in cellophane with cable information, sometimes even with blue stamps. But these are not passports or test documents. Depending on the manufacturer, there may be no tags, but all data is painted on the cheek of the drum. There must also be papers with data about the cable and the tests performed; they are called differently: passport, quality passport, quality or quality certificate, document or test report, protocol, etc.
Podolskcable usually does not nail passports either on the front side or inside, but sends it with an invoice (certificate of quality) and if you didn’t bring it separately, you don’t have to look on the drum - you won’t find anything except one plastic or wooden tag (there is the same tag inside called a passport , this is also nonsense).
Tomskcable nails the passports on the front side, so it is better to remove them immediately and replace them with tape with a piece of paper with information about the brand, cable length and drum number, because nothing is visible on the tag.
On the bay, there is usually a tag with the batch number and cable data hanging on a string; very rarely a passport with test data comes with it, so it is better to remove the tag immediately, gluing your piece of paper with data on top.
The customer can and does so that the chain of transfer of products and documentation for them “manufacturer-customer-general contractor-contractor-operation” ends with you and in the end it is you who are responsible for the quality and lack of anything after you sign the documents. Therefore, the most important thing is not to miss the flash and check the completeness in time, do not sign anything, and write letters if something is wrong.
The absence of one or another document can be documented in an act of product inspection results (in the accompanying documentation column, indicate that it is missing and, if possible, which one) unless, of course, someone besides you signs it; if they have signed it, you can present this document with a letter of complaint to the customer (after Naturally, he won’t sign something like that). When all the documentation is found or requested, draw up a new act retroactively or accept this documentation with the same act (this is allowed).
If you are attaching a copy of the customer’s delivery document, then be prepared for the fact that inspectors may require you to have this copy certified by the customer, therefore, when taking certificates from the supplier, make sure that he does not do this right away - the certificate will be needed again, and certification of the certified copy must be done not nice, better do it later.
Be sure to remove non-standard keys from equipment cabinets and drawers, hanging a signed tag indicating what it is from.
Technical documentation of manufacturers (passports, operating and installation instructions, assembly documentation, software for installed equipment and spare parts). In theory, this is not exactly executive production documentation; sometimes entries are made in it (on forms, etc.) or adjustments to diagrams.
If you lose this at the beginning or during the production process, then there will be problems. Sometimes the customer himself is responsible for completing and commissioning the technical documentation for the equipment; even earlier it was written that he should do this (this can be stated in the contract or in the list of design and estimate documentation). In principle, if they are already delivering, and they check for themselves the completeness of the documentation, then why not do this in one thing (like they are afraid that the contractor will lose, and they are doing the right thing). But, as a rule, the customer’s agents try to shift this to the contractor or general contractor (by the way, we can shift this to the general contractor if they have people specifically for this purpose). Operations will pay special attention to this documentation, since it is they who need it in the first place. Technical documentation must be complete for all equipment, translated into Russian (by the customer or supplier), if it is bourgeois, stored separately for equipment and kits. Regarding translations, it is better to agree in writing in a contract or other documents, because the customer first keeps silent or tries not to raise the issue, and then does not accept delivery without them.
When receiving any documentation, make a register and sign the document for the documentation according to this register, this way you will protect yourself if this register does not contain all the necessary documents.
When taking documentation out of boxes with equipment or from a cabinet, also put everything in separate bags (then into folders), be sure to indicate on it where the documentation came from (for example, cabinet or cell No.).
Immediately put it all in separate folders, and sign them according to what equipment, project and PID this documentation is, so as not to understand it later (you won’t understand it for sure later). If the documentation is collected by the supplier in a folder, it is better not to disassemble it, but leave it as is.
Often the documentation is attached to the equipment itself; do not lose it during installation and assembly, while walking around the facility, often look into cabinets, drawers, inspect the equipment in search of such documents (usually tied in plastic bags). Make it a habit to pick up all the papers from the ground at the site (only at the site), also check empty containers and equipment packaging, empty drums - there may be passports and labels that have not been removed. At one site I found cable passports in the toilet, prepared for wiping, who knows why this is needed when there is plenty of toilet paper nearby.
As a rule, there are twice as many technical documentation from manufacturers for equipment as there are folders with production documentation. There are two ways to submit it - with all the acceptance documentation or separately to the operation representative (energy engineer, automated control system engineer, overhead line and electrical protection foreman). If you immediately laid it out, checked the completeness of its availability and made registers, then it will be convenient to hand over this bunch of folders along with the entire design documentation before you prepare the production one and there will be fewer comments against you that you are not handing over anything at all. But it is better, of course, to submit it separately in view of the fact that they may be required to make copies of all this, while checking both its completeness and the presence of translations from bourgeois.
Where to look for contractor delivery documentation. A lot of materials have to be purchased locally in the nearest city, for example metal, hardware, all sorts of little things, this should be monitored and demanded from the supplier immediately when he brings something without quality documents and then periodically reminded, refreshing his memory. When he brings a bunch of passports and certificates, saying, I handed over everything and then don’t say that I didn’t give anything, ask for a waybill or invoice and check it. Usually, the suppliers themselves do not know what should actually be included in the documentation for any product; they do not require this from factories or suppliers, and they, in turn, provide a certificate of conformity or a letter of denial of the need for certification. Print out and hand the above plate to the supplier, explain that there are two types of documentation and there must be both, let him work. A lot of materials are taken directly on site from the builders (either bought, or borrowed, or simply borrowed), you, in turn, must not miss this moment and find documentation for this matter from the general contractor or subcontractors, so have good relations with everyone at construction site Periodically visit the general contractor and look through thick folders with certificates and other papers in search of the documentation you need: channel, pipe, fittings for it, electrodes, steel sheets, all kinds of profiles, paint, brick, sand, etc. (they have everything).
If a product or material came directly from your base, office or other facility, immediately check the documentation; if not, sound the alarm, call the supply, clearly demand from them what you want, if it doesn’t work, call your group leader, or other facilities (there may be similar) or directly to the factory (via delivery note or invoice). Warn the site manager that without this there will be no interest rate. If the documents are lost by a storekeeper, then these are problems with the picking to which he is subordinate; if the documents are lost by a foreman, then these are problems of the foreman or site manager, but only if this became known in time, otherwise in all cases of loss it will be your problem.
If none of the options work, “look” for papers. Surf the net looking for certificates; manufacturers usually post them for review. As a rule, most documents arrive either with an expired date, or the brand is slightly wrong, or GOST or TU are not the same. To do this, from each object I carry with me entire databases of scanned certificates, passports, Paint and other useful programs. Take data for searches about manufacturing plants from labels and plates. In general, this matter takes most of the time.
Certification of copies. Only copies need to be certified, and a document that has blue seals and signatures does not need to be certified.
If there is a document confirming the type and quality of the products of your delivery, then it is better to attach a copy (such as the organization’s policy). This is more convenient than unnecessary questions like: “why is there a copy, and why is there an original?” the inspectors will not have it, especially since you may have many such identical documents for different projects (subobjects). If the customer’s delivery document is, then it must be certified by the supplier or, in extreme cases, by the customer. Copies of these documents necessary for different projects must also be certified by the customer, so if you take a copy from the customer, do not immediately certify it for them, so that you can then duplicate it and have it certified by him (a copy of a copy somehow looks ugly). Also, some small documents that cannot be stapled and numbered in a folder are best copied.
With the stamp “Copy is correct” you do not certify the document, but make it easier for yourself to write, so there must also be a blue round official seal or a special seal for this matter. According to GOST R 6.30-2003, clause 3.26: “When certifying the compliance of a copy of a document with the original, below the “Signature” requisite, a certification inscription is affixed: “True”; position of the person who certified the copy; personal signature; decryption of the signature (initials, surname); certification date. It is allowed to certify a copy of the document with a seal determined at the discretion of the organization.”
Therefore, only the person to whom this seal was written can certify, i.e. who has a power of attorney, and all sorts of signatures of VET engineers with simple stamps “CORRECT COPY” are not valid, although they are often scanned.
Presentation of results. Having collected the necessary information about the work started and completed on certain projects, begin to do the EC for HEV structures and products. It is better to formalize the VC for the customer’s delivery as it should be, so that there are no claims against you later.
The VK act (act on the results of product inspection) confirms only the compliance of the product with the design documentation, GOST/TU and the availability of accompanying documentation confirming the type and quality of the product. Defects identified immediately upon acceptance or during the commissioning process are documented in another document.
The form of the act, if there is no sample in the list for these types of work, take as a basis the “Act on the results of product inspection” in form 3.3 VSN012-88 part 2. In principle, this act is current and is not included in the execution according to the list, but if you don’t have it, problems may arise (as a rule, I include it in the execution). For such types of work as PS, SOP, SOP, SGO and secret police, there is a VK act (for equipment and devices) - according to Appendix 3 of RD 78.145-93, equipment and devices must be issued to them additionally. There is also an act of acceptance of electrical equipment for installation, form 3.8 VSN012-88 part 2, this act is needed for equipping ECP equipment for route picketing, which is not required at a local facility, so immediately brush it off. Never change the form and text of the act, its subscripts, do not add anything to the form templates, if you really feel like it and it does not contradict the BSN, cross it out and add next to it by hand or directly in an email - this is allowed. Fill out the act template electronically, print it out in the required copies, attach documents about the quality of the product to them, sign them by everyone, and only after that can you fill out the VK journal. At the same time, do not put passports and manuals on the equipment (limit yourself to certificates), but indicate them in the act and put them in separate folders.
In the name of the product, indicate its name (abbreviated) and brand (in full), preferably as indicated in the specification, because often the specification states, for example: Power cable with copper conductors, with insulation and sheath made of fire-retardant polyvinyl chloride plastic... 0.66 kV , 4x6 mm2 (VVGng). “VVGng cable 4x6 0.66 -400m” is enough. Due to the fact that Transneft along the way began to prohibit design institutes from advertising the products of factories by registering in it the brands that an individual person sat on (although they require the purchase taking into account the list of Transneft’s specifications and PMI), you just need to register the brand of the product that you bought to the object, and not as stated in the analogue type specification.
Enter the volume either according to the volume according to the project specification or according to the volume that arrived. Some materials or products are the same for several projects; in this case, use the volume specified in the specification. If you received a cable of the same construction length for several projects, enter the construction length (because this is the length indicated in the passport or test report; in principle, more is possible, but less is not possible).
Write the unit of measurement either the same as in the specification if in fact it matches, or the same as in the invoice, but in total quantity.
Sometimes some equipment or products (when there are no separate documents for this) can be combined by incoming control with something for which there are documents (such as a kit), but it is better not to do this.
Materials and products. It is possible to combine different materials, products or structures in a document if they have a common specification or GOST. For example, in one act you can specify racks + shelves + brackets for prefabricated cable structures; trays or boxes with lids and corner sections. I also try not to design anything separately for the hardware for them and, if they are indicated in the specification, I write a tray or box in the kit.
If the length of one product does not coincide with the design one (for example, a BNT100 pipe or box), then you can register the total length in meters without indicating the length of a specific product as in the specification (in pieces), while writing the components (covers, connectors, partitions, hardware) included, and other brands (branches, turns, rises, descents of the box) in pieces.
Equipment. The certificate specifies the serial or serial number (if it is specified in the accompanying document). Similar equipment (by brand) is issued in one act (listing all serial numbers).
If the equipment is transferred as a “set”, the name is written in the same way, but “according to the attached statement” is added, in which you describe this set in full and attach it to the act. Sometimes it is very convenient to arrange it this way if you have not found all the accompanying documents for each part of the kit.
If there is a lot of accompanying documentation, you also write it down in the statement, and in the sections about accompanying documentation it is also written “according to the attached statement of accompanying documentation.” The statements are compiled in a form approximately like a register, only instead of a page according to the list, write the number of sheets or copies, signed and attached to the VC act. The documentation according to the statement is filed in a separate folder with the registration of the register based on the statement.
In principle, for the customer’s delivery, the report on the results of the product inspection or the IC report is not the main thing; this is conveyed by the equipment acceptance certificate for installation. The cable is issued for each construction length (drum, coil or winding) by brand and number of cores, i.e. In one act, you can issue a cable of only one brand (several reels are possible).
Documents needed:
Certificate of quality/compliance (comes with an invoice or downloaded from the internet);
- Passport or factory protocol for checking the insulation resistance (comes with the drum, the number bar is usually written on the paper, there is a Quality Control Department stamp).
In the absence of the manager protocol, data via cable is rewritten from the drum and the protocol is forged.
The construction length according to the numbers of the drums must be included in the act, or a rewind or b/n is written.
The contractor's supply cable (usually there is not much of it in the contract) is sometimes grouped from all specifications into common lengths and one protocol is forged for the construction length (within reasonable limits). The “done” protocol is copied to the subobjects and a VC act is drawn up for each subobject with a length according to the corresponding specification/statement (like we were equipped with one drum - less than a gemara).
The customer's supply cable is issued strictly on drums after signing the invoice for transfer to the contractor (although no one can check - invoices are not filed in the ID).
Also, when receiving and processing the customer’s supply cable for low-current networks, it is necessary to look at the lengths of the cable lines in the cable log so that the construction length of the cable (on a drum or rewind) is enough for one or more line lengths, i.e. taking into account that there are no couplings (in automation and APT this is unacceptable, although it is done all the time), if necessary, write a letter about this.
The protocol for inspecting and checking the resistance of the cable on the drum before laying is usually done on the same day as the VK act (usually immediately together with the VK act).
Everyone who participates (signs the VC - acts and journal) must have a VIC certification with copies of certificates and protocols in the permitting documentation, although, as a rule, such a certificate will be sufficient for the person exercising control.
The VC act is signed by:
Quality Control Representative;
- Contractor;
- Technical supervision (often does not sign in the line where the Customer is indicated in the act form, but signs at the bottom like “confirmation of the VC procedure”) if it has been proven that it is he.
Maintain VK logs according to the design (in the same way as you complete general logs), this way you will have to redo less and there will be less confusion.
You fill it out based on the signed acts. You fill out the column “controlled parameters” according to the technological map for incoming control, and if there is not enough information there, or there is none, based on the product passport or operating manual. In the “Results” column, write the number of the act according to which this was done and the word “corresponds”. Nowadays, inspectors pay more attention to the journal and not to reports on the results of product inspections because they are not required according to the list.
The log is signed by the site manager or foreman and foreman. Sometimes in the VK log (it needs to be clarified) in the “controller” position, “NOT OUR” is signed, although, as a rule, a representative of the construction control of the general contractor or, on our part, who has a VIC is sufficient.
All materials, products, cables and equipment, both contractor supplies and customer supplies, must pass incoming inspection in full according to the specifications, including spare parts (even for things that have not been and will not be in fact). The main thing is that the VC takes place earlier or on the same day of installation (according to papers), so check everything. Sometimes the specification does not contain sand for bedding and powdering the cable in the trench, but the project requires it - calculate its approximate amount and make a VC for the entire volume or divide it into several parts for convincing (for the technical supervisor).
Registration of defects. Identified equipment defects are identified either upon acceptance of the equipment (visible) and are reflected in the report on the results of product inspection and the VK journal. Or during its installation and commissioning, it is carried out with a representative of the manufacturer (otherwise the plant may not accept the claim).
Therefore, immediately find out whether it is possible to open boxes with equipment without a representative of the manufacturer. The act is filled out according to form OS-16. If you have drawn it up, everyone knows about it, and you are going to attach it to the ID, then there must be an act on the elimination of these defects; if there is not one, then it is better not to attach OS-16 to the ID.
Usually, the customer immediately draws up a report on the identified defects, in which they write that everything is fine, complete with documentation, but this report is also needed to document the identified defects during the installation and commissioning process (which cannot be immediately identified) according to the Resolution of the State Statistics Committee of Russia No. 7. So the customer will not excuse himself from defects if they were not identified during the incoming inspection.
Very often something arrives that is not right, with defects or without documentation. Many things can be corrected on the spot and, if possible, this is always done. If these bugs definitely don’t come to light later and they don’t pin it on the installers (since there were no defects, then there’s a bug in the installation), then it’s better not to raise a fuss, but to do as they say. If there is a risk that the jambs could be pinned on us, then it is better to file it properly. You can document everything with a certificate of product inspection results, including the absence of accompanying documentation. A report on identified defects can and should be used to document defects that could not be identified immediately, but only during testing and commissioning (non-working equipment, etc.). In the VK log, you can indicate that it is suitable for installation after checking the presence of missing accompanying documentation, and then conduct a separate VK for the received documentation. Or it is not suitable for installation at all if the defects are critical.
Incoming documentation control
During the incoming inspection of working documentation, its completeness and sufficiency of the information contained in it for the execution of work must be checked.Drawings and estimates received for construction must be registered in special journals of the general contractor.
Requirements for the composition and completeness of working documentation for new construction and reconstruction of existing structures are determined by sections 3 and 4 of chapter SNiP 1.02.01-85.
In accordance with clause 3.1 of chapter SNiP 1.02.01-85 and clause 7.9 of chapter SNiP 3.01.01-85, design organizations must include lists of the following in the general data on working drawings:
Types of work for which it is necessary to draw up inspection reports for hidden work;
- critical structures subject to acceptance during the construction process.
Working drawings and organizational and technological documentation (POS, PPR) must be recorded in a special journal.
The accepted documentation is sent to the construction site with the mark “For work” and the signature of the chief engineer.
Deviation from the working drawings of the structure being built and auxiliary structures and devices issued by the customer for the production of work, caused by clarification of the conditions for the work, is allowed only by agreement with the customer and the design organization with the introduction of appropriate changes to the working drawings.
During the incoming inspection of working documentation, the inspection is carried out by employees of the technical and production departments of construction organizations. Comments on design and estimate documentation and organizational and technological documentation are drawn up in the form of a conclusion for presentation to the design organization through the customer. The documentation accepted without comments is transferred to the construction site taking into account.
Each construction site must:
Keep a general journal of work in the form given in Appendix 6, special journals for certain types of work, the list of which is established by the general contractor in agreement with subcontractors and the customer, and a journal of designer supervision of design organizations (if any);
- draw up inspection reports for hidden work, intermediate acceptance of critical structures;
- draw up other technical documentation provided for by SNiP for certain types of work, and as-built documentation - a set of working drawings with inscriptions on the compliance of the work performed in kind with these drawings or changes made to them in agreement with the design organization, agreed upon by the persons responsible for the production of construction and installation works works
The general work log is the main primary production document, reflecting the technological sequence, timing, quality of execution and conditions of construction and installation work.
A general log of work is kept during the construction (during reconstruction, expansion) of individual or groups of similar structures under construction at the same time, located within the same construction site. During the construction of artificial structures included in the title of a railway line or highway, a general log can be kept for a group of simultaneously constructed small bridges under the direction of one work contractor.
When constructing medium-sized bridges, as well as large bridges, a general log of work must be kept at each site.
When constructing large bridges that have work areas formalized by order, a general journal may be kept at each construction site. The general work log is kept by the person responsible for the construction of the facility (work manager, senior work manager) and fills it out from the first day of work at the site personally or entrusts the filling to shift managers.
The title page of the magazine is filled out before the start of construction by the production and technical department of the unit.
The list of engineering and technical personnel involved in construction is compiled by the head of the department.
In table 2 of the journal contains a calendar list of all acts of intermediate acceptance of critical structures and inspection of hidden works of the facility under construction. This list should be compiled by the production and technical department together with a representative of the design organization, taking into account paragraphs. 1.32. and 1.34 "Benefits"
In table 3 journals - “Results of operational quality control of construction and installation works” include all work on parts and elements of structures, the quality of which is controlled.
Table 4 - “List of special work logs” is filled out by the person responsible for maintaining the general work log. It contains the names of special journals and the names of the persons responsible for their maintenance. After completion of special work, for example, installation, a note is made in the table about the delivery of the magazine with the signature of the official handing over and accepting the magazine.
Regular information about the production of work (from the beginning to its completion), included in the table. 5 - “Information on the production of work” - are the main part of the journal. It should contain information about the beginning and completion of work, reflecting the progress of their implementation.
A description of the work must be made for all structural elements of the structure as it is being erected, indicating the location of the work in height and location on the plan with reference to the axes and with reference to working drawings. Brief information about the methods of work, the materials, products and structures used, downtime of construction machines (indicating the measures taken), deviations from working drawings (indicating the reasons) and their approval, changes in the location of security, safety and signal fences should also be provided here. relocation of transport and fire passages, laying and dismantling of temporary engineering structures, the presence and implementation of operational quality control schemes, results of geodetic instrumental checks during operational quality control, data on corrections or alterations of work performed, indicating those responsible, as well as meteorological and other special production conditions works If the journal is issued for a group of bridges, then records must be kept for each structure separately. In the journal issued for large and medium-sized bridges, it is recommended that the description of the work be kept separately for enlarged structural elements, with the required number of journal pages allocated for each element.
Work on the construction of temporary structures, as well as preparatory work, is recorded in the log according to the start and end dates.
In table 6 of the journal - “Record of receipt of technical documentation” - the person responsible for maintaining the journal records the numbers of drawings and other documents received from the production and technical department at the site.
In table 7 of the journal - “Remarks of regulatory authorities and services” - comments are made from persons monitoring production and work safety in accordance with the rights granted to them, as well as authorized representatives of the design organization or its design supervision. The general work log must be bound, signed with all signatures on the title page and sealed with the signature and seal of the construction organization that issued it.
Work performers of construction and installation organizations and the customer's representative are required to record in the designer's supervision journal the execution of instructions from employees of design organizations carrying out designer's supervision. Responsibility for the timely and high-quality fulfillment of the requirements of designer's supervision, as well as for the safety and maintenance of the journal in proper form rests with the head of the general contracting organization or the responsible representative of the organization appointed by his order. After accepting the facility into operation, the general contractor must transfer the designer's supervision log to the customer.
Data on the performance of certain types of construction and installation work should be entered daily into the appropriate special journals provided for by the current chapters of SNiP and listed in this “Manual”.
Special work logs are issued to work managers by the production and technical construction department with a completed title page and indicating the number of laced and numbered sheets. The journal must be registered and upon issuance signed by the head of the organization that issued the journal. Logs received for production are stored during work execution by the persons responsible for their maintenance, and during breaks - by site managers.
New logs can be issued only after the completed logs, which are the main documents presented when putting objects into operation, are submitted in the prescribed manner.
When filling out work logs, it is necessary to keep in mind that entries in them should be made either directly at the place of work, for example, when driving piles, shells, sheet piles, or at the end of the shift when maintaining shift logs of certain types of work.
It is prohibited to keep rough notes on separate sheets, notebooks, etc. followed by rewriting the data to the log.
Instructions for keeping a journal are given in the relevant chapters of the Manual. When a completed construction facility is put into operation, the general and special work logs are presented to the working commission and, after acceptance of the facility for operation, are transferred for storage to the customer or, on his behalf, to the operating organization.
Certificates of inspection of hidden work and acceptance of critical structures are drawn up taking into account the instructions in subsequent chapters of the “Manual”.
Each act must be assigned a number, which must correspond to the number in the list of the general work log.
Incoming pipe inspection
Incoming inspection of pipes and connecting parts should be carried out in accordance with the requirements of SNiP 3.01.01.-85.When incoming inspection of pipes and connecting parts, the following should be checked:
1. Pipe size;
2. Number and date of technical specifications;
3. Steel grade;
4. Batch number;
5. Results of mechanical tests indicating which melt numbers these tests relate to;
6. Results of hydraulic tests;
7. X-ray result (if necessary).
On the inner surface of each pipe at a distance of 500 mm from one of the ends, the following markings must be applied with indelible paint:
Manufacturer;
heat number;
nominal dimensions;
pipe number;
month and year of pipe manufacture;
carbon equivalent.
On the outer surface of the pipes, at a distance of 100 mm from the end of the pipe, the following data must be stamped:
Pipe number;
factory logo.
After checking the compliance of the use of pipes for a given construction according to the certificate, visual and measuring control is carried out.
The following are not allowed on the surface of pipes:
Cracks, flaws, sunsets of any size;
scratches, scratches and burrs more than 0.4 mm deep;
local kinks, corrugations and dents;
delamination at the ends of pipes.
If delaminations are detected, based on the results of additional ultrasonic testing, the ends of the pipes with delamination must be cut out. In areas affected by corrosion, the wall thickness of pipes or parts should not exceed the minus tolerances established by the delivery specifications. The wall thickness in this area must be measured using an ultrasonic thickness gauge with an accuracy of at least 0.1 mm.
Pipes are considered suitable provided that:
Less than 200 mm from the end does not exceed for pipes with a diameter see GOST 10705-80, 20295-80.3262-75, etc.
deviations in wall thickness at the ends do not exceed the limit values regulated by the relevant GOST 10705-80, 20295-80, 3262-75, etc.
The ovality of seamless pipes does not take their outer diameter beyond the maximum deviations, GOST 10705-80, 20295-80, 3262-75, etc.
the curvature of the pipes does not exceed 1.5 mm per 1 m of length, and the total curvature is no more than 0.2% of the pipe length, the cutting angle of the pipe ends does not exceed 2.0 mm.
It is allowed to clean scratches, scratches and burrs with a depth of more than 5% of the thickness on the surface of pipes and parts, as well as surface areas affected by corrosion, provided that the wall thickness after eliminating the defects does not exceed the established tolerances.
It is allowed to correct smooth dents at the ends of pipes with a depth of no more than 3.5% of the pipe diameter. Straightening should be carried out using shockless spreading devices. When the ambient temperature is below 5 degrees. C, and on pipes of strength class 42 and above - regardless of the ambient temperature, straightening must be carried out with mandatory heating at 100 - 150 degrees. WITH.
It is allowed to repair by welding defects in pipe edges (nicks, burrs) with a depth of no more than 5 mm, followed by mechanical cleaning of the defect correction areas until the required bevel of the edges is restored.
Pipe grading is carried out by representatives of the construction and installation organization, the customer, and the customer’s technical supervision.
A report is drawn up for rejected pipes, which must contain the following data:
Name of the supplier plant;
Diameter and wall thickness of pipes;
Steel grade;
Certificate number, pipe, heat;
Date of receipt of pipes and time of their examination;
The exact name of the detected defects, their configuration and location;
Possibility of using pipes for this construction.
Pipe quality control does not end with inspection at the unloading site. Monitoring the condition of the pipes continues throughout the entire period of pipeline construction.
When accepting pipes with a factory insulating coating, the condition of the coating is also checked by a visual method, and, if necessary, by an instrumental method (using a spark flaw detector).
If damage is detected, a report is drawn up containing the following data:
Place and date of inspection of pipe insulation coating;
Pipe number and location of the defect;
Type of defect (depth, area).
Incoming inspection results
Based on the results of the incoming inspection, it is recommended to draw up a conclusion on the product’s compliance with the established requirements and fill out a logbook for recording the results of the incoming inspection.The inspector must carefully check the data of the control, analysis or test protocol with the technical documentation for the product and, in the accompanying documents for the product, make a note about the incoming inspection and its results, mark (brand) the product, if this is provided for in the list of products subject to incoming inspection.
If the product meets the established requirements, the incoming control department makes a decision to transfer it to production.
If a defective or incomplete delivery of products is detected, the incoming control unit draws up a report on the defective or incomplete delivery.
The supplier company, having received a complaint report, conducts the necessary research into the reasons for the product’s non-compliance with the requirements of regulatory and technical documentation, agrees with the consumer and sends the consumer a research report indicating the measures taken to eliminate the reasons noted in the complaint with a conclusion on the effectiveness of the measures taken.
The quality control department must systematically inform the supplier about the results of incoming inspection.
The supplier, in agreement with the consumer, develops and implements measures aimed at improving product quality.
Based on data on the actual level of quality of supplied products accumulated by the incoming control department, OGK, OGT, OMTS, etc., Quality Control Department makes, in the prescribed manner, proposals to improve the level of its quality and, if necessary, revise regulatory and technical documentation.
Proposals and applications for the revision of the regulatory and technical documentation of the valley must be marked: “based on the results of incoming inspection.”
If products are rejected in the workshop due to the supplier's fault (hidden defect), a defective report is drawn up, according to which the products are sent to the defect isolation room along with defective reports signed by the workshop managers and the foreman of the incoming control unit.
Responsibility for defects arising from products during production that did not pass external acceptance or were rejected by the quality control department lies with the warehouse employees who gave the order for the release of these products into production.
Based on the results of the incoming inspection, the consumer, if necessary, informs the territorial body of the State Standard of Russia at the location of the supplier company about the non-compliance of the products with the established requirements in order to take measures in accordance with the functions assigned to them (Appendix 2, GOST 24297).
These recommendations establish the basic provisions for organizing, conducting and processing the results of incoming inspection of raw materials, materials, semi-finished products, components, etc., coming from suppliers to consumers.
The recommendations were developed to provide methodological and practical assistance to enterprise specialists in the implementation and use of a product quality management system based on the application of international standards ISO 9000 series. The recommendations reveal possible approaches to the implementation of GOST 40.9001-88, clause 4.20 and GOST 24297.
The recommendations can be used at enterprises in any industry, as well as for certification of products, quality systems and accreditation of testing laboratories.
| Designation: | 50-601-40-93 |
| Russian name: | Recommendations. Incoming product control. Basic provisions |
| Status: | current (Developed for the first time) |
| Date of text update: | 01.10.2008 |
| Date added to the database: | 01.02.2009 |
| Effective date: | 05.10.1993 |
| Designed by: | VNIIS Gosstandart of Russia |
| Approved: | VNIIS Gosstandart of Russia (05.10.1993) |
| Published: | VNIIS Gosstandart of Russia No. 1993 |
ALL-RUSSIAN RESEARCH INSTITUTE OF CERTIFICATION (VNIIS) OF THE RUSSIA STATE STANDARD
R 50-601-40-93
| R 50-601-40-93 |
These recommendations establish the basic provisions for the organization, conduct and registration of the results of incoming inspection of raw materials, materials, semi-finished products, components, etc. (hereinafter referred to as products) coming from suppliers to consumers.
The recommendations were developed to provide methodological and practical assistance to enterprise specialists in the implementation and use of a product quality management system based on the application of international standards MS ISO 9000 series. The recommendations reveal possible approaches to the implementation of GOST 40.9001-88, clause 4.20 and GOST 24297.
Terms and definitions according to MS ISO 8402-1;
GOST15895,
GOST16504,
GOST15467.
1. GENERAL PROVISIONS
1.1. Input control should be understood as
Quality control of the supplier’s products received by the consumer or customer and intended for use in the manufacture, repair or operation of the product.
1.2.The main tasks of incoming control can be:
Obtaining with high reliability an assessment of the quality of products submitted for control;
Ensuring the unambiguous mutual recognition of the results of product quality assessment by the supplier and the consumer, carried out using the same methods and the same control plans;
Establishing compliance of product quality with established requirements in order to timely submit claims to suppliers, as well as for prompt work with suppliers to ensure the required level of product quality;
Preventing the launch into production or repair of products that do not meet established requirements, as well as permitting protocols in accordance with GOST 2.124.
1.3. The decision on the need to introduce, tighten, weaken or cancel incoming control is made by the consumer based on the characteristics, nature and purpose of the product or the results of incoming control of the product over the past period or the results of its operation (consumption).
4.1.1. During continuous control, each unit of product in the controlled batch is subjected to control in order to identify defective units of product and make a decision on the suitability of the product for launch into production. Continuous inspection is recommended in cases where it is technically and economically feasible and the products are piecemeal. The use of continuous control must be indicated in the technical documentation for products in the “Acceptance” sections. With continuous control, both a fully formed batch of products and individual units of products in single and small-scale production can be presented.
4.1.2. During random control, samples (samples) are randomly extracted from the controlled batch of products in accordance with the sampling plan, and based on the results of control, a decision is made about the entire controlled batch of products.
During sampling control, only a fully formed batch of products (both piece and shapeless) can be submitted for inspection.
Note . It is not allowed to take samples or samples until a fully formed batch of products has been presented.
The rules for selecting product units for the sample are in accordance with GOST 18321.
4.1.3. With continuous control, each unit of product is subjected to control in the sequence in which they are produced until the number of usable units of product established by the control plan is obtained. After this, continuous control is stopped and they switch to selective (piece-piece products).
4.2. Sampling plans should be agreed upon between the supplier and the consumer and established in strict accordance with the requirements of state standards or ISO standards for statistical acceptance control.
4.2.1. When assigning incoming inspection plans based on an alternative criterion, you should use GOST 18242, GOST 16493, GOST 24660 or MS ISO 2859/0÷3.
4.2.2. When assigning incoming inspection plans based on quantitative characteristics, you should use GOST 20736 or MS ISO 3951.
4.2.3. When assigning continuous incoming inspection plans, you should use ST SEV293-76.
4.2.4. Instructions for ensuring and selecting a method and sampling plans are set out in RD 50-605, R 50-110, R50-601-32.
4.3. It is recommended to make a decision on compliance or non-compliance of product quality with the established requirements for each controlled batch separately.
4.4. The supplier and the consumer, when agreeing and establishing plans for incoming inspection (if these plans are not established in the technical documentation for products), can determine the procedure for compensation for losses from defective or incomplete products if this is discovered by the consumer during incoming inspection or during the production process.
4.5. When re-submitting products for incoming control, it is recommended to indicate in the accompanying documentation the reasons why it was rejected (or returned to the supplier) upon first presentation, so that the inspector pays special attention to the characteristics due to which it was rejected (or returned supplier).
Sampling plans for the repeated presentation of products for input control should be the same as for the first presentation (and not resort to the rule of “double the sample or sample volume”) in the case of using two-stage plans.
4.6. In practice, situations often arise when it is important not only to make a decision regarding whether to accept or reject a batch of products, but also to know its actual level of defects, since the level of defects characterizes the quality of the batch of products. The lower the level of defects in a batch, the higher its quality.
The level of defectiveness can be expressed as the percentage of defective units of production, determined from the ratio:
The number of defects per hundred units of production, determined from the ratio:
The first ratio is recommended to be used when it is enough to establish only the number of defective units of products from those inspected. In this case, a unit of production is considered defective if it has at least one defect.
The second ratio is recommended to be used when it is important to establish the number of defects in inspected units of production, if there may be one or more defects in a unit of production. In this case, each individual non-compliance of the product with the established requirements should be considered a defect.
4.6.1. The level of defects can be input and output. It is important for the consumer to know the input level of defects, which is understood as the level of defects in a batch or stream of products entering control over a certain time interval.
4.6.2. A more reliable idea of product quality will be given by the average input defect level, determined based on the results of inspection of several batches.
The average input defect level characterizes the quality of the supplied products and is determined by the technical capabilities of production and does not depend on the adopted control plan.
The value of the average input defectiveness level can be obtained from the results of continuous or selective inspection of several batches of products submitted for inspection according to the formulas given in clause 4.6.
4.6.3. The value of the average input defectiveness level can be used as an initial value to justify and select the acceptance defectiveness level ( AQL).
AQL represents the value of the level of defects to which the supplier and consumer agree and which serves as the basis for determining the control standard for selective plans for incoming inspection.
4.6.4. The value of the average input defectiveness level must be less than AQL ,.Therefore, the supplier must ensure that the average input defectiveness level does not exceed the specified value AQL . As the average input defect level increases, the supplier will incur losses from product returns and rejection. AQL determines the degree of rigor (rigidity) of sampling control.
5. REGISTRATION OF INPUT CONTROL RESULTS
5.1. Based on the results of the incoming inspection, it is recommended to draw up a conclusion on the product’s compliance with the established requirements and fill out a logbook for recording the results of the incoming inspection ().
5.2. The inspector must carefully check the data of the control, analysis or test protocol with the technical documentation for the product and in the accompanying documents for the product make a note about the incoming inspection and its results, mark (brand) the product, if this is provided for in the list of products subject to incoming inspection.
5.3. If the product meets the established requirements, the incoming control unit makes a decision to transfer it to production.
If defective or incomplete delivery of products is detected, the incoming control unit draws up a report on defective or incomplete delivery ().
5.4. The supplier company, having received a complaint report, conducts the necessary research into the reasons for the product’s non-compliance with the requirements of regulatory and technical documentation, coordinates with the consumer and sends the consumer a research report indicating the measures taken to eliminate the causes noted in the complaint with a conclusion on the effectiveness of the measures taken.
5.5. Quality Control Department must systematically inform the supplier about the results of incoming inspection.
The supplier, in agreement with the consumer, develops and implements measures aimed at improving product quality.
5.6. Based on data on the actual level of quality of supplied products accumulated by the incoming control department, OGK, OGT, OMTS, etc., Quality Control Departments make, in the prescribed manner, proposals to improve the level of their quality and, if necessary, revise normative and technical documentation.
Proposals and applications for the revision of the regulatory and technical documentation of the valley should be marked: “based on the results of incoming inspection.”
5.7. If products are rejected in the workshop due to the supplier's choice (hidden defect), a defective report () is drawn up, according to which the products are sent to the defect isolation room along with defective reports signed by the heads of the workshop and the foreman of the incoming control department.
5.8. Responsibility for defects arising from products during production that did not pass external acceptance or rejected by the quality control department lies with the warehouse employees who gave the order for the release of these products into production.
5.9. Based on the results of the incoming inspection, the consumer, if necessary, informs the territorial body of the State Standard of Russia at the location of the supplier enterprise if the product does not comply with the established requirements in order to take measures in accordance with the functions assigned to them (Appendix 2, GOST 24297).
Annex 1
FORM OF THE JOURNAL FOR ACCOUNTING THE RESULTS OF INPUT CONTROL
FOR____QUARTER 19____
Appendix 2
FORM OF THE REPORT ON SAMPLES OR SAMPLES SELECTION
ACT No.
on sampling (samples)
This act was drawn up "___"________19____.
admissions committee consisting of:
| representative | ||||
| (position of representative) |
||||
| Comrade | ||||
| (surname) | (signature) |
|||
| representative | ||||
| (name of supplier) |
||||
| (position of representative) |
||||
| Comrade | ||||
| (surname) | (signature) |
|||
| From products | ||||
| (Name of product) |
||||
received "___"___________19___ invoice No. ___________ dated "___"_______199___ according to the waybill No. ________ dated "___"_______199__. in the number______ places with the weight of products___________, samples were selected in the quantity_____________
from "_____"______19__
Samples are (not) provided with labels containing data required by standards or specifications.
To conduct (analyze) the test, additional samples in the amount of ________________ were selected from the products.
Samples were submitted for analysis (testing)"___"_________19____.
ACT No. ________ dated _________199
FOR REJECTION OF PRODUCTS IN DELIVERED CONDITION
2. Acceptance of products began at______hours______minutes_________199.
completed_________hours________minutes______________________199 g.
| 3. Acceptance deadlines were violated due to |
| (specify reasons) |
|||||
| No. p/p | Last name, I.O. | Place of work | Position held | Date and number of the document of authority | Reading the instructions (signature) |
6. Date and number of the telephone message and telegram about calling the manufacturer’s representative
| 7. Number and date of the contract for the supply of products | |||||||
| invoices | Waybill | ||||||
| 8. Date of arrival of the product at the destination station | |||||||
| 9. Time of delivery of products to the consumer | |||||||
10. Conditions for storing products in the recipient’s warehouse prior to acceptance
| 11. Condition of containers and packaging at the time of product inspection | ||||
| 12. Date of opening of containers and packaging | ||||
13. When randomly checking products ____________ the procedure for selecting products for random checking, indicating the basis for the random checking (GOST, TU, basic terms of delivery, contract)
Presence or absence of packaging labels and seals in certain places
16. Defects in the quality of products, the nature of the defects, and the quantity of complete products and the list of missing parts, assemblies, parts and their cost
| 17. Products | presented for inspection at the count. | ||||||||
| Name | |||||||||
| Product distribution: | The marriage will end. | ||||||||
| Valid | |||||||||
| To be corrected. | |||||||||
| Not appropriate. variety. | |||||||||
| Not a kit. | |||||||||
18. Numbers of GOSTs, technical specifications, drawings, samples (standards) for which product quality was checked
20. Conclusion on the nature of the identified defects in the products and the reasons for their occurrence
| 3. Name and address of the manufacturer | ||||||||||
| supplier | ||||||||||
| 4. Nomenclature and volume of products | ||||||||||
| 5. Date and number of the telephone message and telegram about calling the manufacturer’s representative | ||||||||||
| 6. Number and date of the contract for the supply of products | ||||||||||
| invoices | Waybill | |||||||||
| and a document certifying product quality | ||||||||||
| 7. Conditions for storing products at the recipient’s warehouse before acceptance | ||||||||||
8. When doing a random inspection of products__________ the procedure for selecting products for inspection, indicating the basis for the random inspection (GOST, TU, special delivery conditions, contract)
| 9. Where and when it is sent for research | ||
| 10. Defects in product quality, nature of the defects | ||
11. Numbers of GOSTs, technical specifications, drawings, samples (standards) for which product quality was checked
13. Other data; which, in the opinion of those involved s acceptance must be indicated in the act to confirm the poor quality or incompleteness of the product
| Chief Metrologist's Department | |
| TsZL | Central factory laboratory |
| NTD | Regulatory and technical documentation |
| OMTS | Logistics department |
| A QL | Acceptance defect level |
INFORMATION DATA
1. DEVELOPED by the All-Russian Scientific Research Institute for Certification (VNIIS)
PERFORMERS: Bogatyrev A.A., Ph.D. (topic leader), Gorshkova E.A.
2. APPROVED by Institute Order No. 119 dated. 5.10.93
3.DEVELOPED FOR THE FIRST TIME
4.REFERENCE REGULATIVE AND TECHNICAL DOCUMENTS
| Number of item, subitem of the listing |
|
| GOST 15895 GOST 16504 GOST 15467 MS ISO 8402-1 GOST 24297 GOST 18242 GOST 20736 GOST 18321 GOST 16493 ST SEV 293 MS ISO 2859/0÷3 |
This article discusses the problem of the quality of domestically produced automotive components. As a result of a review of scientific publications, it was found that in the Vladimir region, up to 40% of customer complaints about the quality of vehicle maintenance and repair are related to the low quality of spare parts. In this regard, based on the regulatory document GOST 24297-87, a methodology for conducting incoming quality control of spare parts at automotive service enterprises is proposed, which includes an algorithm for monitoring components. In this case, special attention should be paid to the control of spare parts installed in systems that affect the safety of vehicles. The implementation of these measures will not only prevent low-quality components from reaching the consumer, but will also contribute to the implementation of the basic principles of quality management: “Consumer Focus” and “Verification of Purchased Products.”
incoming quality control
spare parts
1. GOST 24297-87. Incoming product control. Basic provisions. – Enter. 1988-01-01. – M.: Publishing house of standards, 2003. – 8 p.
2. Russian Federation. Laws. Federal Law “On the Protection of Consumer Rights”: [Federal. Law No. 2300-1: adopted by the State. Duma February 7, 1992: ed. dated July 18, 2011].
3. Vereshchagin D. Trust, but verify // Correct car service. – 2011 – No. 4 (71). - P. 5-6.
4. Karagodin V.I. Car and engine repair: textbook. for students avg. prof. textbook institutions / V.I. Karagodin, N.N. Mitrokhin. - 2nd ed., erased. – M.: Publishing Center “Academy”, 2003. – 496 p., ISBN 5-7695-1125-7.
5. Latyshev M.V., Sergeev A.G. Quality management in car service processes: monograph. – Vladimir: VlSU Publishing House, 2005. – 160 p.
6. Stepanova E.G. Managing the quality of vehicle maintenance by improving the supply chain: abstract of thesis. dis. ...cand. tech. Sci. – Tolyatti, 2012. – 16 p.
7. Lada Priora: history of a faulty power steering [Electronic resource]. - Access mode: http://www.zr.ru/content/articles/451988-lada_priora_istorija_neispravnogo_usilitela_rula/ (access date: 10/15/2013).
Introduction. The work notes that the competitiveness of vehicle service stations (STS) largely depends on the system of interaction with suppliers of spare parts and materials, which operates within the framework of the principle of “Mutually beneficial relationships with suppliers”, and established procurement requirements (clause 7.4 of GOST ISO 9001-2011).
It is believed that cooperation with leading wholesalers and manufacturers is a guarantee of the quality of car components. In this case, the company of the Automotive Maintenance system has the opportunity to rely on the integrity of its regular partners. Those infrequent cases of defects that the workshop will encounter will bring lower costs than organizing incoming quality control. But such a situation is only possible if the company specializes in repairing cars from the world's leading manufacturers.
Purpose of the study: to develop a methodology for conducting incoming quality control of spare parts at an automobile maintenance system enterprise.
Research methods: analytical research.
Currently, the quality of domestically produced auto components remains at a relatively low level compared to foreign analogues. Thus, the paper presents the results of studies conducted on the basis of the Vladimir State University named after A.G. and N.G. Stoletovykh" (VlGU) in the Vladimir region, which showed that up to 40% of customer complaints about the quality of vehicle maintenance and repair are related to the low quality of spare parts or materials.
In the current situation, it is advisable to organize an incoming quality control post for spare parts at a service station. This mechanism will be especially important for companies specializing in the repair of domestically produced cars and cooperating with a large number of small suppliers. In this case, the costs of organizing a spare parts control post will be recouped by reducing the number of complaints and related costs.
In accordance with the Law of the Russian Federation “On the Protection of Consumer Rights” dated 02/07/1992 No. 2300-1, the consumer has the right to choose a product based on his needs and capabilities. The law prohibits the seller from conditioning the purchase of some goods on the mandatory purchase of other goods. The consumer has the right to choose an original spare part or assembly produced by an independent company.
Considering that, according to experts, factory defects are much more common among non-original auto components, the organization of an incoming quality control post for spare parts is one of the mechanisms included in the quality management system (QMS) of the enterprise and aimed at preventing low-quality components and assemblies from reaching the end consumer .
It should be noted that special attention should be paid to the control of spare parts installed in vehicle systems (ATS) that directly affect traffic safety. As an example, consider the electromechanical power steering of VAZ 2170 cars and its modifications. The work examines the problem of a malfunction of this unit, which consists in the fact that when a vehicle is moving at a speed of 40 km/h, spontaneous rotation of its steering wheel is possible. This defect, if it occurs during the operation of the vehicle, contributes to the loss of its controllability, which significantly reduces the active safety of the vehicle and increases the risk of a traffic accident.
Taking as a basis the requirements of GOST 24297-87 and the recommendations for organizing an incoming quality control post for spare parts in a car service center, set out in, an algorithm for conducting incoming quality control of spare parts at a service station has been developed.
Incoming quality control of products (in this case - spare parts), which is one of the elements of interaction between the supplier (manufacturer, dealers of spare parts) and service stations, provides for preventing the access to customers of enterprises of the Automotive Maintenance system of products that do not meet the requirements of regulatory, technical and design documentation (NTD and CD), as well as established requirements.
In accordance with GOST 24297-87, incoming inspection of components is carried out by the incoming inspection unit, which is part of the enterprise's technical quality control (QC) service.
The main tasks of incoming control are:
- monitoring the availability of accompanying documentation for products;
- control of compliance of the quality and completeness of products with the requirements of design and regulatory technical documentation;
- accumulation of statistical data on the actual level of quality of the resulting products and development on this basis of proposals to improve the quality and, if necessary, revise the requirements of the technical documentation for products;
- periodic monitoring of compliance with the rules and shelf life of suppliers’ products.
Incoming inspection is carried out in a specially designated room (area), equipped with the necessary means of control, testing and office equipment, and also meets occupational safety requirements.
Measuring instruments and testing equipment used during incoming inspection are selected in accordance with the requirements of the normative and technical documentation for controlled products and GOST 8.002-86. If metrological means and control methods differ from those specified in the technical documentation, then the quality control department of the service center coordinates the technical characteristics of the means used and control methods with the supplier.
To ensure compliance with the requirements of GOST 24297-87, as well as the GOST ISO 9001-2011 standard, an automobile maintenance and repair enterprise must develop its own technical documentation establishing the procedure for organizing, conducting and documenting the results of incoming inspection of spare parts supplied to the organization.
Taking into account that spare parts are supplied to service stations in small batches, it is advisable to introduce continuous quality control rather than selective control. In addition, control of incoming parts will be effective only if all spare parts entering the service pass through it.
Continuous quality control is control in which a decision on the quality of controlled products is made based on the results of checking each unit of product.
The main document on the basis of which the incoming inspection of parts is carried out is a working drawing containing information about the main parameters of the product.
The verification technology itself involves manual measurement of all parameters of a part using a special measuring tool or the use of digital equipment, if the organization has one. When inspecting a composite assembly, it is necessary to first disassemble it.
The proposed methodology for incoming inspection of components involves carrying out work activities in three stages:
- at the first stage, an external inspection of the product is carried out, checking the accompanying documents (passport, certificate, invoices), the presence of nameplates and supplier marks, the date of manufacture and compliance with the completeness;
- at the second stage - checking the quality characteristics of the products;
- at the third stage - checking the functionality of the element after installation in the car.
Only those components that fully comply with the documentation issued by the manufacturer and supplier are allowed to the second stage of incoming inspection. Work on incoming inspection should be entrusted to warehouse staff and quality control department personnel.
Based on the results of the incoming inspection, they draw up a conclusion on the product’s compliance with the established requirements and fill out a logbook for recording the results of the incoming inspection (Appendix 1 GOST 24297-87). The list, volume, and sequence of work must be determined by the instructions (routine chart, which describes the entire inspection procedure step by step).
Research results and discussion. In Fig. Figure 1 shows the proposed algorithm for conducting continuous quality control of spare parts at service stations.
Rice. 1. Algorithm for conducting incoming inspection of spare parts in a car service center.
In accordance with the algorithm for conducting incoming quality control, products received from the supplier must be subject to documentary and quantitative acceptance before incoming control. For this purpose, a “product acceptance zone” is organized at the enterprise’s warehouse. Warehouse personnel, in accordance with the enterprise standard (STP) of the service station, carry out control of accompanying documentation, external inspection and quantitative acceptance.
If non-conformities are identified, the entire batch of products is rejected and stored in a place that excludes the possibility of mixing with products that have passed the incoming control (“defect isolator”). Quality Control Department employees make an entry in the incoming inspection logbook, draw up a complaint report, and return the defective batch to the supplier.
In the absence of accompanying documentation certifying the quality and completeness of the product, if it is necessary to urgently replace a failed unit, the auto components, by decision of the quality control department, can be sent for incoming quality control with the mandatory drawing up of a completeness report indicating the missing documents.
If a batch of products is accepted at the first stage of control, then the parts and documentation are sent to the “incoming control waiting area”, where they are stored separately from products accepted and rejected by incoming control.
The time spent for components and documentation in the “incoming control waiting area” should be regulated by the enterprise’s STP.
Whereas, it is not recommended to disassemble mating pairs that are processed assembled or balanced at the manufacturer, because the service life of a vehicle's structural element decreases after the disassembly-assembly operation; at the second stage of incoming quality control of spare parts, the division of components into composite and non-component is provided.
If the inspected unit is non-separable, then it is sent for incoming inspection, which involves checking the documentation, dimensions and surfaces of the product (for scratches, cracks, chips, etc.).
In the case of inspection of a composite unit, service quality control department employees must be guided by information about previously received complaints related to failures of this spare part. If there was a repeated failure of the unit after installation on the automatic telephone exchange, then the spare parts received by the enterprise are subject to disassembly and inspection of each of its parts. Otherwise, the structural element of the car is subject to external inspection and verification of accompanying documentation. Based on the inspection results, a conclusion is drawn up about whether the part is suitable or defective, and a corresponding entry is made in the incoming inspection logbook (Appendix 1).
A spare part found to be suitable is returned to the warehouse in the “good product storage area”. The defective unit must be marked with red paint or a red marker with the inscription “Defective” and sent to the warehouse to the “defective isolation room”. Quality Control Department employees make a complaint, and the defective items are returned to the supplier.
The final stage of quality control of spare parts is checking the functionality of the parts immediately after installation on the serviced vehicle.
If a malfunction of the unit is detected after installation on the vehicle, this element must be dismantled and transported to a warehouse in a “defect isolation room”, followed by filing a complaint and returning it to the supplier.
Conclusion. Since one of the important goals of such a post is to implement the basic principle of quality management “Customer Focus” (clause 5.2 of GOST ISO 9001-2011), it is important that information about the availability of incoming quality control of spare parts is included in the advertising materials of the workshop. Also, the organization of incoming inspection of spare parts provides for the implementation of the quality management principle “Verification of purchased products” (clause 7.4.3. GOST ISO 9001-2011).
Information about the availability of such a post must also be provided to the spare parts supplier at the time of signing the cooperation agreement. And the contract itself must stipulate the mechanism for the action of the enterprise of the Automotive Maintenance system in the event of a defect being detected. It is also advisable to provide partners with information about the methods of analysis and obtain their consent in the event that if substandard products are detected, the wholesaler intends to challenge the results of the inspection. Such a preliminary agreement will subsequently avoid unnecessary disputes and promptly replace substandard products. Then the incoming control post for components will become a mechanism that helps improve the level of quality of automotive service at the enterprise and, as a result, increase the loyalty of its customers.
Reviewers:
Gots A.N., Doctor of Technical Sciences, Professor, Professor of the Department of Heat Engines and Power Plants, Vladimir State University. Alexander Grigorievich and Nikolai Grigorievich Stoletov,” Vladimir.
Kulchitsky A.R., Doctor of Technical Sciences, Professor, Chief Specialist of LLC “Plant of Innovative Products KTZ”, Vladimir.
Bibliographic link
Denisov I.V., Smirnov A.A. METHODOLOGY FOR INCOME CONTROL OF SPARE PARTS QUALITY AT AUTOMOTIVE SERVICE SYSTEM ENTERPRISES // Modern problems of science and education. – 2013. – No. 5.;URL: http://science-education.ru/ru/article/view?id=10753 (access date: 07/24/2019). We bring to your attention magazines published by the publishing house "Academy of Natural Sciences"
31-03-2011
In a modern market economy, the quality of a product is the main factor in the successful sale of it to consumers, as well as a decisive factor in a stable position in the market and in competition. The quality of products manufactured by our company largely depends on the quality of the materials used, semi-finished products and components. Therefore, when they arrive at the enterprise, they are subject to incoming control. Only those materials, semi-finished products and components for which the manufacturer’s quality control documents have been issued are allowed for incoming inspection and subsequent use. The performance of work on incoming inspection is entrusted, according to the regulations, to the quality control department personnel. The results of incoming inspection are recorded in the incoming inspection log. The list, scope, and sequence of work are determined by the instructions. Our company produces engineering products, so the main material in its production is rolled metal. Both low-carbon steels are used in the form of sheets and rolled profiles, as well as medium-carbon and medium-alloy steels. The quality of incoming metal is critical and is controlled from the moment it arrives at the enterprise (incoming control), and as it moves along the technological chain in the following sequence.
1. Checking the accompanying documentation:
- shipping documents for compliance with the name of the material across the entire range;
- documents certifying the quality of the metal (passports, certificates) for complete registration and compliance of the recorded steel grades with the markings on each rental unit;
- entering parameters into the incoming inspection log.
2. Geometry check:
- sheet steel for wave and deflection;
- round steel for bending, spiraling and ovality.
3. Checking geometric dimensions using a measuring tool:
- sheet thickness;
- strip in width and thickness;
- square in correct shape and size;
- hexagon on edge;
- pipe by outer diameter and wall thickness.
4. Checking the surface condition:
4.1. Casting
- for the presence of shrinkage cavities (closed or open cavities in the casting body that have an irregular shape, a rough or crystalline surface, sometimes oxidized);
- for the presence of gas porosity (occurs during the crystallization process due to the release of gases dissolved in the metal during its melting);
- for the presence of non-metallic inclusions (external or internal cavities filled with molding sand or slag);
- for the presence of cracks using an optical instrument (they can be of either a cold or hot nature, depending on the shrinkage conditions during the crystallization process);
- for the presence of segregation (this is a local discrepancy in the chemical composition in certain zones. In the segregation zone, mechanical characteristics may be underestimated. Therefore, this defect is most often detected during mechanical processing).
4.2. Rental
- for the presence of surface scratches (occur when small particles get on the rolls during rolling);
- for the presence of hairlines (they look like thin cracks located on the surface and elongated along the direction of deformation; they are the result of deformation of non-metallic inclusions or gas bubbles);
- for the presence of sunsets (layers arising due to excess metal in the rolls);
- for the presence of a film (films peeling off from the surface that occur when rolling out an ingot that has frozen drops of liquid metal on its surface).
Flocking defects that occur in medium-carbon and medium-alloy steel grades require special attention. They appear in the central part of round rolled products of medium and large cross-section and have the appearance of thin winding cracks, which are spots in the fracture with a surface of a characteristic silvery color, round in shape. They arise with an increased content of hydrogen, which fills all the voids, right down to defects in the crystal lattice and, transforming from atomic to molecular, develops enormous pressure, leading to the brittle destruction of the metal. Flocks are most often discovered during hardening, after removing allowance by cutting, or, worst of all, when the part breaks.
5. Application of color markings in accordance with the color chart approved by the enterprise according to the grades of steel used:
- on sheet metal, alphanumeric steel markings are applied around the perimeter of the sheet through a stencil with paint in a color corresponding to this mark;
- on a round rolled end.
6. The chemical composition is checked by taking a sample from each rolled unit, before cutting the blanks, using the method of spectral analysis using a steeloscope SL-13 installation.
Our company uses capillary and magnetic particle methods as non-destructive testing methods for detecting cracks, both in the material when cutting workpieces and in finished parts, before their further use.
Product quality control at enterprises is carried out by the technical control department (QC).
Product quality control is divided into three types: input, interoperational and output (acceptance).
Incoming control- checking the quality of raw materials and auxiliary materials entering production. Constant analysis of the quality of supplied raw materials allows us to influence the production of supplier enterprises, achieving improved quality.
Interoperational control covers the entire technological process. This control is sometimes called technological or current control. The purpose of interoperational control is to verify compliance with technological regimes, rules of storage and packaging of products between operations.
Output (acceptance) control- quality control of finished products. The purpose of final inspection is to establish compliance of the quality of finished products with the requirements of standards or technical specifications, and to identify possible defects. If all conditions are met, delivery of the product is permitted.
The quality control department also checks the quality of packaging and the correct labeling of finished products.
Input, interoperational and output control can be selective, continuous and statistical.
Selective- control of a part of the product, the inspection results of which apply to the entire batch.
Continuous All products are subject to control (with untested technological conditions).
Statistical control is preventive. It is carried out throughout the entire technological process in order to prevent defects.
A conditional measure of the quality of goods is their grade.
Variety- this is a qualitative gradation of a product according to one or more indicators established by regulatory documentation.
During acceptance quality control, products are divided into grades, designated by numbers (1, 2, 3, etc.) or words (highest, selected, extra, etc.). Some goods (complex technical goods, furniture, plastic products, etc.) are not divided into grades, but are distinguished as good and bad.
Graduation of goods by grade is carried out according to defects appearance, less often by deviations from other properties. All appearance defects are divided into acceptable and unacceptable. Products with unacceptable defects are rejected.
Defects that determine the grade of a product are divided according to the following criteria: origin, size and location, possibility of detection, possibility of correction, degree of significance.
By origin - defects in raw materials, technological defects that arise during storage and transportation.
By size and location - defects are small, large; local, widespread.
If possible, detect defects, visible (explicit) and hidden.
If possible, corrections include correctable and irreparable defects.
By degree of significance - defects are critical, significant and minor.
If there are critical defects, the use of the goods is impossible or unacceptable.
The degree of reduction in product quality depends on the significance, size, location and number of defects.
The number, size and location of acceptable defects are specified in the standards.
Determination of a variety is carried out using a point and restrictive system. The product grade is determined by quality control inspectors at an industrial enterprise. The higher the grade, the higher the quality of the product.
With a point system, each defect or deviation from the nominal value of a property indicator is assessed with a certain number of points, taking into account their significance and size. The grade is determined by the sum of points.
With a restrictive system, a list of permissible defects, their number, size, and location is established for each grade.
If there is a discrepancy with the standards for a given grade by type, quantity and location of defects, the goods are transferred to a lower grade or defective.
Failure of a product to comply with standards for at least one defect or deviation provides grounds for transferring it to a lower grade or defective.
Quality assurance during product control and testing
The purpose of establishing quality protection systems is to protect the consumer from unintentionally receiving products that do not meet established requirements and to avoid unnecessary costs associated with reworking such products. Actions related to non-conforming products must be identified and documented.
Control- an activity that involves carrying out measurements, examination, testing or evaluation of one or more characteristics of an object and comparing the results obtained with established requirements to determine whether compliance has been achieved for each of these characteristics.
Product quality control plays an important role in the production of high-quality goods and quality management.
Product quality control is a procedure for checking the compliance of their quality indicators with the requirements of regulatory and technical documentation and supply contracts. The main task of quality control is to identify product defects, which include each individual product non-compliance with established requirements. At the same time, product defects can be detected both during organoleptic and measurement control; but can only be identified during operation.
Depending on the possibility of detection defects can be obvious or hidden.
Obvious product defect- a defect for the detection of which in the regulatory documentation mandatory for this type of control, there are appropriate rules, methods and means. Many obvious defects are detected already during visual inspection of products.
Hidden product defect- a defect for the detection of which the regulatory documentation required for this type of control does not provide appropriate rules, methods and means. Hidden defects are discovered during the operation of the product (product).
By origin, defects can be production or non-production.
Manufacturing defect occurs during the production process of a product, due to a violation of the technological regime for manufacturing the product.
Non-manufacturing defect arises after the completion of the production process of a product - during transportation, storage, sale, operation, etc. consumption.
If it is possible to eliminate defects, they are divided into removable and irreparable.
Removable defects- defects, the elimination of which is technically possible and economically feasible.
Fatal defects- defects, the elimination of which is technically impossible and (or) economically impractical.
When studying defects, it is necessary to determine its significance - a relative value determined by the type, size, location of the defect and characterized by the degree of its influence on the quality level of the product compared to other defects. Depending on the degree of impact on quality, defects can be: critical, significant, insignificant.
Critical defect- a defect, the existence of which makes it practically impossible or unacceptable to use the product for its intended purpose.
Significant product defects significantly affect the possibility of using the product for its intended purpose, its quality and service life.
Minor (minor) defects do not significantly affect the intended use of the product and its durability.
In the process of continuous or selective product quality control, suitable products and defects are detected.
Good products- a product that meets all established requirements.
Marriage- products, the transfer of which to the consumer is not allowed due to the presence of defects that are not allowed by regulatory documents.
It must be remembered that for some groups and types of products it is provided division by variety. It depends on the presence of defects and deviations in certain indicators of consumer properties.
The procedure for establishing varieties:
1) varieties are established according to a point or restrictive system. The most common point system, in which regulatory documents for each from grades limit the type of defects, their number, size, location on the product;
2) with a point system, deviations from the standard according to controlled indicators and defect parameters are assessed in conventional units - points;
3) by comparing the amount of points acquired by the product during control with the regulatory requirements of the standards, which provide for an acceptable amount of points for each grade, the product is assigned to one or another grade.
But in recent years there has been a tendency to reduce the number of varieties or even to refuse to divide goods into varieties.
There is the following classification of types of control:
For control purposes:
■ product control;
■ process control.
By stage of the production process:
■ incoming control;
■ transportation control;
■ operational control;
■ acceptance control (control of finished products);
■ storage control.
The nature:
■ inspection control;
■ volatile control.
Based on the decisions made:
■ active control;
■ passive control.
By product coverage:
■ complete control;
■ selective control.
If further use of the product is possible:
■ destructive testing;
■ non-destructive testing.
By means of control:
■ visual control;
■ organoleptic control;
■ instrumental control.
In general, quality control should confirm that specified product requirements are met. It includes:
■ incoming control. It is used to ensure the quality of purchased materials, components and assemblies that arrive at the production plant. Incoming inspection depends on the information coming from the subcontractor and their impact on costs.
■ intermediate (operational) control. It is carried out at certain points in the production process to confirm compliance. The locations of inspections and their frequency depend on the significance of the characteristics and the convenience of inspection during the process. The following types of checks exist: automatic control or automatic tests; checking the installation
(and the first sample; control checks or tests carried out by the machine operator; control at established points of the technological process at certain intervals; periodic control of specific operations carried out by special controllers.
■ acceptance control. Such control is the resulting stage that sums up the entire production process. It can be used to assess the effectiveness of the quality system in force at the enterprise. It is he who has the most complete information to improve the quality management system at the enterprise. In this case, two forms of checking finished products can be used, which can be used both together and separately:
a) acceptance control or acceptance tests to confirm that the finished product meets the established requirements. Reference may be made to the purchase order to verify the conformity of the type and quantity of goods supplied. This includes continuous control of all units of goods, selective control of batches of goods and continuous sampling;
b) checking the quality of goods, carried out on sample units representative of completed lots, on a continuous or periodic basis.
In general, acceptance inspection and product quality testing can be used to provide prompt feedback for corrective action on products, a process or a quality system. Goods that do not meet the established requirements must be recorded and analyzed, imported or analyzed, repaired, accepted with or without permission to deviate from the requirements, remade, re-sorted or turned into scrap. Repaired and/or remanufactured goods must be re-inspected or re-tested.
■ permission to ship products, inspection and test reports (data registration). Products may only be shipped once all activities specified in the quality program or documented procedures have been successfully completed and relevant information and documentation have been received and approved.
Control of control and measuring equipment. Achieving confidence in the correctness of decisions made or actions based on measurement results requires continuous management of all measurement systems used in product development, production, installation and servicing. Measuring instruments, sensors, special test equipment and the necessary software for testing are subject to management. It is also recommended, as necessary, to extend control procedures to technological equipment and various devices that may affect the specified characteristics of a product or process. Needs to be developed documented procedures to manage and maintain the measurement process itself in a state of statistical regulation, including equipment, methods and professional training of operators. Documented procedures require the use of appropriate instrumentation and test equipment, including test software, to ensure accurate measurement uncertainty data that is consistent with the required measurement capabilities. Appropriate measures must be taken when the accuracy of the equipment does not allow proper measurement of process and product characteristics.
In this case, it is necessary to pay attention to the following points:
■ establish range, accuracy, precision and stability parameters under specified environmental conditions;
■ carry out an initial check before initial use to assess the required accuracy;
■ ensure periodic return for adjustment, repair and re-verification, taking into account
manufacturer's technical requirements, results of previous verification, order and intensity of use to ensure the necessary accuracy during operation; “carry out documentary evidence of the unambiguous designation of measuring instruments, the frequency of re-verification, the state of affairs with the verification and the procedure for recall, transportation, preservation and storage, adjustment, repair, verification, installation and operation;
■ ensure the connection of measuring instruments with reference standards of known accuracy and stability, preferably with standards recognized at the national and international level; in the absence of such standards, it is necessary to document the basis for verification.
■ evaluate software and control procedures for automated test equipment.
Verification of measuring instruments is a set of operations performed by bodies of the State Metrological Service or other accredited organizations in order to determine and confirm the compliance of measuring instruments with established technical requirements.
The Law of the Russian Federation “On Ensuring the Uniformity of Measurements” introduced the term “calibration of measuring instruments”. Calibration of measuring instruments is a set of operations performed to determine and confirm the actual values of metrological characteristics and (or) suitability for use of a measuring instrument that is not subject to state metrological control and supervision. Only those measuring instruments that are not subject to state metrological control and supervision, i.e., verification, are subject to calibration. Verification is a mandatory operation performed by state metrological service bodies, and calibration is performed by any metrological service or individual who has all the necessary conditions to carry out this activity. Calibration is an additional function that is performed either by the metrological service of the enterprise or, at its request, by any other organization capable of performing the work.
Management of non-conforming products. Such activities are carried out in order to protect the consumer from unintentionally receiving products that do not meet established requirements and to avoid unnecessary costs associated with the modification of such products. Actions to be taken regarding nonconforming products must be defined and documented in procedures. Such actions usually include:
■ Identification. This is a process whereby units or lots of products suspected of not conforming to specified requirements must be immediately identified and their occurrence recorded. Where necessary, conditions for carrying out
inspection or re-examination of previous batches.
■ Isolation. A process by which non-conforming items are isolated from compliant items and appropriately identified to prevent their further unintended use before a decision is made to dispose of them.
■ Return of products. Sometimes it may be necessary to return finished products that are in the finished goods warehouse, on the way to distribution organizations, in warehouses or already in service. Return decisions are based on safety, product liability, and consumer satisfaction considerations. But ending with the disposal of identified non-conforming products, the quality management process would appear, to say the least, incomplete. All identified inconsistencies, after systematization and careful analysis, should become a solid information base for the development of measures to reduce the level of product defects to a minimum. Therefore, the development of corrective and preventive measures is an integral element of quality management.
■ Examination. Non-conforming products are subject to inspection by specially designated personnel to determine the possibility of their acceptance after or without repair with permission to deviate from the requirements, the feasibility of its repair, alteration or rejection. Reviewers must be competent to evaluate the impact of decisions on interchangeability, post-processing, performance, reliability, safety and aesthetics.
■ Taking various measures. Typically, this includes measures to prevent the misuse or installation of non-conforming products. Such measures may include examination of other products designed or processed under the same procedures as the product found to be nonconforming and/or previous batches of the same product.
For unfinished work, corrective action should be taken as soon as possible to save the cost of repair, rework or discard. Repaired, remanufactured and/or modified products are subject to re-inspection or re-testing to ensure compliance with specified requirements.
■ Disposal. Disposal of non-conforming products must be carried out as soon as necessary. The decision to accept such products must be documented (along with justification) in the authorized waivers, specifying appropriate precautions.
■ Corrective actions. Taking corrective action begins with identifying quality problems. Corrective actions involve repairing, reworking, returning or rejecting unsatisfactory products. The need to take action to eliminate the cause of nonconformities may be determined by the following factors:
a) consumer requirements;
b) information about the operation of the product;
c) audits carried out by management;
d) reports on non-compliance of the technological process;
e) audits (internal and/or external);
Measures to eliminate the causes of existing or potential nonconformities include:
■ Assessing the importance of an existing problem affecting quality. This assessment should be based on the potential impact of the problem on such aspects as quality costs, processing and manufacturing costs, performance, reliability, safety and customer satisfaction.
■ Study of possible causes contributing to the problem. It is recommended to identify important parameters that influence the process's ability to meet specified requirements. It is necessary to establish the relationship between cause and effect, taking into account all possible causes. The results of the study must be documented.
■ Problem analysis. In this case, it is necessary to establish the root cause of the problem. Very often, the root cause is not obvious, requiring a thorough analysis of the product specifications and all relevant processes, operations, quality records, service reports and customer feedback. Statistical methods can be used to analyze problems. At the same time, it is recommended to create a file of inconsistencies, from which general problems, individual problems, as well as ways to solve them would be indicated.
■ Eliminate the causes of actual or potential nonconformities. Identification of the cause or potential causes may lead to changes in product specifications and/or revisions to the quality system, manufacturing, packaging, servicing, transportation or storage processes. When eliminating the causes, it is necessary to do everything possible to prevent their recurrence in the future.
■ Process management. Appropriate measures must be taken to manage processes and procedures to avoid recurrence of problems. If corrective action is taken, its consequences must be monitored to ensure that the objectives are achieved.
■ Changes being made. Changes that are made as a result of corrective actions must be recorded in work instructions, documentation for production processes, technical requirements for products and/or documentation for the quality system.