L6-TGN-096

INSPECTION IN MANUFACTURING GUIDELINE

Contents

1) PURPOSE ................................................................................................................ 1
2) INTRODUCTION ...................................................................................................... 1
3) THIRD PARTY INSPECTION ...................................................................................... 4
4) INTERNATIONAL STANDARDS .................................................................................. 5
5) APPLICABLE DOCUMENTS ........................................................................................ 5
6) GUIDELINE HISTORY ............................................................................................... 6

1) PURPOSE

The purpose of this guideline is to assist with the Third Party Inspection of Materials or Equipment at
manufacturing locations, in order to determine if the Materials or Equipment meets the clients
expressed need, expectations, purchase order, call off, etc. placed on the manufacturer.

This guideline shall be read in conjunction with, the specified revisions of applicable national or
international Codes and standards; the Client specifications; the Manufacturers’ procedures; the
quality plan and/or any other related documents pertinent to the order.

This document assists Inspectors in completing the inspection in accordance with the clients
prescribed scope, it does not determine the minimum or maximum range or scope of the inspection
to be carried out. Hence elements of the guide may not be applicable in all cases

It is also intended to ensure that all relevant information is included in the inspection report in such a
way that all the issues relating to the purchase order, contract, manufacturing and client
requirements are correctly addressed and documented.

Inspection reports will serve as the principle record of information relating to Quality, Status of the
Purchase Order/Contract/ Material and Equipment.

2) INTRODUCTION

Mandatory Requirement
This procedure has been prepared as a general guide for Inspection/Third Party Inspection in
Manufacturing in conjunction with Inspection Test Plan/Quality and Industry guidelines.

Inspection in Manufacturing
Inspection in manufacturing is conducting inspection during the production process. This approach of
inspection helps to control the quality of products by helping to fix the sources of defects immediately
after they are detected, and it is useful for any factory that wants to improve productivity, reduce
defect rates, and reduce re-work and waste.

This document is considered CONTROLLED when obtained directly from the IMS section of the Applus Velosi SharePoint.
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Positive Impact
 Reduces end-line defects
 Saves time and efforts of final inspection
 Helps to fix the problems at the outset, and prevents common mistakes being made
repeatedly
 Helps to ensure quality of the products of a production line.

Steps in Implementation
1. The purpose of in-line inspection is to identify problems with the system that need correction
and also to identify errors earlier in the production process.
2. In-line inspection can be implemented by line workers under the supervision of QC staff.
3. Set up pre-determined in-line inspection points to help the workers to implement the in-line
inspection. Samples of the range of defects should be displayed so that QC staff can see and
access them easily. These samples serve as in-line inspection aids and should be clearly
visible, easy to understand and made available at each production line.
4. Develop and use an in-line inspection checklist or report to record the frequency of each type
of mistake
5. Conduct training for line workers on how to conduct in-line inspection and use the in-line
inspection points and samples
6. The workers should perform their own in-line inspections before they start their normal tasks.
7. A reject ticket should be filled in when a defect is detected to identify the rejected product.
8. Defective product should be sorted into different types, e.g. easy to fix the errors or
substantial re-work required.
9. Products with minor defects that can be easily repaired should be returned to the previous
operators in the line for rapid repair, together with their reject ticket detailing the defects.
This also helps workers to learn from their mistakes and avoid them in the future. Once the
error is fixed by the previous operator and the corrective action is annotated on the reject
ticket, the corrected items are re-inspected.
10. If there are any significant mistakes in line, use devices such as lights marks or flags to
highlight the problems in line for a quick response.
11. Random examinations of the in-line inspection can be conducted by QC staff. QC staff can
select a random number of products in the production line inspected by line workers to check
for certain types of defects. Any defects detected should be recorded and feedback should be
provided to the line managers to conduct instant repairs or to alert the workers.
12. In-line inspection QC staff should wear a special uniform, shirt or hat to distinguish them
from the workers and other QC staff.
13. QC staff should be provided with sample defects and in-line inspection checklists to record
the defects
14. Data on the defects detected during in-line inspection should be stored and used for
statistical quality control by the QC division

Resources Required
 Training of workers to conduct in-line inspection.
 At least one in-line QC staff member per line

Types of Inspection

Pre-Production Inspection - It focus on kind of material to be used, process to be followed in the

proceedings of production, inspection of material prior to production to decrease the quality risks.

This document is considered CONTROLLED when obtained directly from the IMS section of the Applus Velosi SharePoint.
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This area will also involve the client or client’s Third party nominated inspector.

During Production Inspection - This type of inspection gives clear idea to the buyer about the
shipment schedule and from where the goods are produced.

Final Random Inspection - It involves the checking of pre-specified quality and quantity
parameters of the shipment and is called as "pre-shipment inspection"

Inspection Locations
There are three general areas where inspection activities can be located:

Input Inspection - This aims at preventing the already defective material to enter a process.

Process Inspection - This aims at detecting the defective materials and parts between processing
stages and prevents them from entering a subsequent process. The four most common locations for
process inspection are:
 after having set-up a new process and before starting production;
 before materials/parts enter a subsequent process;
 during processing, especially before a series of processes in between which inspection is not
possible.

Output Inspection - This aims at preventing any defective products going into store or reaching the
consumers.

Inspection Methods
The inspection methods mainly depend on the inspection location. However, they are classified as:

Hundred Per Cent Inspection - It involves the inspection of every single unit in a batch. It
guarantees the identification of all defects. It is always used on critical parts where safety is vital.
However, it is more prone to errors because of its time consuming nature which may lead to
reduction in the concentration of operator. The errors can be as high as 15%.It is usually used for
output inspection.

Gate Sample Inspection - It involves dividing the production output into inspection lots. The lots
depend upon:
 the uniformity of the process;
 the ability to have truly random samples.

After each lot is finished, it is sampled. Any part of the lot can be sampled and has to wait at the
'gate' until the sampling inspection is complete. The lot is then approved or rejected depending upon
the results. The hundred per cent inspection follows this method. This inspection method is used for
output inspection.

Patrol Inspection - In this method, samples are taken at fixed times. It is useful at the beginning
and end of a shift and when machine set-up has changed. It is ideal for process inspection. The only
drawback is that problems may occur between inspection sampling.

First-off Inspection - This method inspects the first part produced after a new set-up, ensuring
that the set-up is correct. The production commences if the set-up is satisfactory. It is suitable for
process inspection.

This document is considered CONTROLLED when obtained directly from the IMS section of the Applus Velosi SharePoint.
Any copies which are saved, exported or printed are deemed UNCONTROLLED and as such due care should be taken during their use.

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Statistical Process Control - It provides the means of controlling the process and not just the
product.

Statistical Sampling - This method of inspection relies on there being a specified quality level
known as an Acceptable Quality Level (AQL).This can be defined as the worst level of quality for a
process considered acceptable by a customer and specified as a process mean. Using a sound
statistical sampling method can be an effective means of monitoring the AQL

3) THIRD PARTY INSPECTION

Third Party Inspection is used to verify material and equipment is being manufactured to approved
standards, specifications, procedures etc.

Third Party Inspection usually follows the requirements of an approved Inspection Test plan in which
Hold, Witness, Monitor and Review points are agreed by the purchaser (Client) against the
manufacturing process.

Wherever a component, product or installation is being fabricated, TPI to make sure that it meets the
right code, standard or specification required by the Clients purchase order.

Vendor Inspection & Mill Surveillance (in conjunction with IP-009)

Mill surveillance includes provision of experienced and competent quality assurance inspectors on site,
and overseeing all stages of production involving:
 Monitoring the manufacturing, inspection and/or testing of materials
 Assuring compliance to manufacturer’s and client’s requirements

Inspection activities at vendor location includes:

1. Review of Purchase Order (PO) to verify completeness
2. Verify acknowledgement of P.O.
3. Review of exceptions and deviations to P.O.
4. Effective Reporting / inspection time schedule
5. Major Sub-order schedule
6. Production schedule / PO Delivery Date (Expediting)
7. Finalising Inspection & Test Plan (Criticality Rating)
8. Identification of special Test & Inspection Procedures
9. Traceability of materials and certification

This document is considered CONTROLLED when obtained directly from the IMS section of the Applus Velosi SharePoint.
Any copies which are saved, exported or printed are deemed UNCONTROLLED and as such due care should be taken during their use.

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10. Non-Conformance and Concession Request Procedure.
11. Notification procedure for inspection
12. Manufacturer QC Data Report preparation
13. Qualification of personnel (welders, NDT)
14. Visit of Vendor’s site (QC facilities, Calibration, Safety)
15. Shipping and Transportation Procedure
16. Inspection Release Note Issuance
17. Correspondence (focal points)
18. Provision of all necessary QA/QC forms

Third party inspection is independent from the manufacture and reports directly to the client on
Material/equipment being manufactured.

4) INTERNATIONAL STANDARDS

General
This list of standards is provided for guidance only and is not intended to be comprehensive. It is
included to assist the Inspector in selecting suitable sources of information where clients’ specific
requirements do not exist.

Technical Standards

 BS EN 10204 Metallic products - types of inspection documents

 ISO 10474 Steel and steel products - inspection documents
 Din EN 10204 Metallic products - types of inspection documents

Packaging and Marking Standards

a) BS 1133 Packaging code.

b) BS 4672:1, 2 Guide to hazards in the transport and storage of packages.
c) BS 4826:P1-P14 Methods of test for complete filled transport packages.

5) APPLICABLE DOCUMENTS

Sr. No. Document No. Name of Document Retention Period

1 L5-FMT-008 Stamp Register 6 years
2 L5-FMT-045 IRC 6 years
3 L5-FMT-046 Inspection Report 6 years
4 L5-FMT-049 NCR 6 years
5 L5-FMT-054 Assignment Nomination Form 6 years
6 L5-FMT-058 PIM Report 6 years
7 L5-FMT-060 Flash Report 6 years
8 L5-FMT-062 PIM Checklist 6 years
9 L5-FMT-075 PIM Agenda 6 years
11 L5-FMT-080 AMIS Inspection Assignment 6 years
12 L5-FMT-082 Client Kick-off Meeting Report Form 6 years

This document is considered CONTROLLED when obtained directly from the IMS section of the Applus Velosi SharePoint.
Any copies which are saved, exported or printed are deemed UNCONTROLLED and as such due care should be taken during their use.

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6) GUIDELINE HISTORY

Rev. Date Section Outline of Change Generated By Authorisation

00 24-Sep-13 All First Issue C. J. Bandick M. Coles

Note: The above is for information only.

The Clients, Purchase order/procedures/Specifications has precedence over this

procedure.

This document is considered CONTROLLED when obtained directly from the IMS section of the Applus Velosi SharePoint.
Any copies which are saved, exported or printed are deemed UNCONTROLLED and as such due care should be taken during their use.

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