Quality Control Planning for Successful Project Execution

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Understanding Your Supplier's Quality Control Practices

When it comes to manufacturing process equipment, quality assurance is a crucial factor to consider when selecting a supplier for your project. Your process supplier’s commitment to quality control planning is essential to ensuring that quality is maintained throughout the entire project. It’s important to ask the right questions when evaluating their quality control standards. Consider the following:

  1. Is there a quality control team dedicated to my process project?
  2. What documentation, inspection procedures, and practices does the equipment supplier follow?
  3. Which industry-governing bodies do they adhere to?
  4. What is the depth of testing performed on the equipment?
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is there A Quality control Team dedicated to my process project?

Having a skilled Quality Control department is the basis for maintaining a high quality standard. An effective Quality Control team should be comprised of testing specialists, inspectors, technicians, and a manager to oversee the team. When the team is well versed in employing quality control procedures that follow company and industry requirements, they are able to ensure standards are always met. 

 A team experienced in stringent regulatory compliance has the foresight that helps avoid quality control issues, consequently avoiding potential project delays. Among their other responsibilities, the team inspects components, audits reports, conducts tests, secures certifications, monitors processes, collaborates with authorized inspectors, aids validation teams during commissioning, and generates documentation that adheres to Good Documentation Practices (GDP). 

What documentation, inspection procedures, and practices should the equipment supplier follow?

Documentation quality is essential when it comes to process projects. An effective documentation system has to offer qualities like consistency, readability, accessibility, and accuracy. A Documentation Turnover Package (TOP) refers to a comprehensive set of documents, certifications, drawings, and information that is compiled, organized, and handed over to the client as part of the project closeout process. The specific content of a TOP may vary from one project to another, and it is typically established prior to the project’s commencement. A comprehensive Documentation Turnover Package (TOP) for a process project will usually include:

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What is the depth of testing performed on the equipment?

Testing following equipment build includes Factory Acceptance Test (FAT), Site Acceptance Test (SAT), and IQ/OQ. An overview of the requirements for the project, including post-fabrication testing and in-process inspections, is determined in the early stages of the project.

Testing performed should verify conformance to:

Factory Acceptance Testing (FAT) is conducted at the manufacturer’s facility following the assembly of equipment to evaluate and verify that all systems and components are functioning correctly. A successful FAT runs, usually with the client present, following pre-established protocols. Any deviations discovered during testing are rectified before the equipment or system is shipped to the facility. Some suppliers’ facilities offer dedicated and properly equipped testing areas or zones to simulate a production environment. The manufacturer may choose to take additional measures to make the FAT process more efficient and seamless, such as running a Pre-FAT.

Site Acceptance Test (SAT) which takes place after the equipment is transported to the client’s facility, verifies that the physical condition of the system or equipment has not been compromised during shipping. It also ensures that the design specifications have been met and are acceptable to the client.

Installation Qualification (IQ) verifies that the process system and equipment are installed according to the pre-determined specifications and functional requirements.

Operational Qualification (OQ) verifies that the process equipment and ancillary systems are capable of continuously operating within limits and tolerances according to the pre-defined specifications and functional requirements.

Selecting the Right process equipment supplier

Understanding the scope of quality control efforts and the best practices outlined in this blog should guide the selection of the right partner to handle your process project. When searching for a supplier to complete your project, it is imperative to confirm that they have a dedicated quality control department, as quality control planning is essential for executing a successful project. While an industry regulatory body, such as ASME, sets the minimum standard of requirements needed to build a piece of equipment, a supplier who prioritizes quality will adopt additional measures and enhanced quality standards to not only meet but exceed these requirements. A Quality Control Technician at Prosysco states, “Documentation allows our clients access to traceability, whether it be materials of construction (MOC), welding machines and instrument calibration records, welders and their qualifications, or internal procedures. With strong attention to detail and consistency in internal standard operating procedures, Prosysco provides clients with all documentation pertaining to their project, giving them comfort in the quality provided.” Prosysco complies with the rigorous equipment specifications of our clients while also adhering to the mandatory regulatory requirements of each industry. Our Quality Control department will ensure quality testing is completed on components and equipment, as well as compile detailed documentation throughout the fabrication process, so you can rest assured that your project will have the craftsmanship that you expect.

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