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Welding Program Quality Assurance Guide
Welding Program Quality Assurance Guide
Date Issued:_______________________________________________________________________
Location:__________________________________________________________________________
Classification:_____________________________________________________________________
Staff:______________________________________________________________________________
Outside Agency:__________________________________________________________________
Other:_____________________________________________________________________________
Purpose:___________________________________________________________________________
Issued By:_________________________________________________________________________
Title:_______________________________________________________________________________
This Welding Quality Assurance Manual is for the exclusive use of Mid-Plains Community College in
the operation of its Accredited Test Facility.
This manual may not be reproduced without consent of the appropriate Mid-Plains Community
College facility representative in writing.
Section: __________________________
Revision: ________________________
Approved: _______________________
Date: _____________________________
Section 1: Scope.................................................................................................................................................................. 2
Section 3: Organization.................................................................................................................................................... 4
Section 8: Applicants......................................................................................................................................................... 9
APPENDIX (A-BB): A list of items contained in the Appendix follows the Quality Assurance
Manual.
Section 1:
Policy Statement and General Requirements
1.1 Scope
This manual describes Mid-Plains Community College, North Campus Quality System
Policies and Procedures that will comply with the rules as required by AWS to establish
and operate an American Welding Society Accredited Test Facility. The policies and
procedures control all activities from Supplier procurement to the applicant’s final weld.
1.3 Application
The quality System described herein is mandatory for all activities performed at Mid-
Plains Community College, North Campus at North Platte, Nebraska.
1.4 Purpose
This Quality Assurance document shall establish the rules and guidelines to assure
compliance under the American Welding Society’s Standard for Accreditation of Test
Facilities (AWS QC4-89).
1.5 Safety
Safety precautions, regulations and rules shall conform to the latest edition of (ANSI
Z49.1:2012) “Safety in Welding, Cutting, and Allied Processes” published by the
American Welding Society. Supplemental safety regulations may also be required.
1.6 Responsibilities
This manual and supporting documents will be reviewed on an annual basis, and revised
as necessary to ensure conformance. Revisions will be issued by the FTest
Manageracility Representative and controlled in accordance with the applicable
procedures.
1.7 Definitions
ANSI/AWS A3.0-2010 Standard Welding Terms and Definitions shall be used as it
pertains to Mid-Plains Community College’s Quality Assurance Manual. In addition the
following terms will also apply.
Accredited facility: A facility that applies to the AWS designated third party agency and
received accreditation.
Assessor: A third party who is qualified for the task of performing assessments.
Facility representative: An individual designated by the Test Facility who can make
legally binding commitments and statements on behalf of the Test Facility. The Facility
Representative and Campus President, if applicable, have final authority concerning all
changes. The facility representative shall be an AWS Certified welding Inspector who has
been designated by the Test Facility. This person(s) shall be the Technical manager and
the Facility Manger.
Quality Control Manager (QCM): An AWS Certified Welding Inspector who has been
designated by the Test Facility. This person(s) shall be the Technical Manager and the
Facility Manager.
Test Facility: A facility that has met the qualification requirements of this specification
as verified by a designated third party assessor.
Test Supervisor: A current AWS Certified Welding Inspector (CWI) designated by the
accredited test facility.
Test Weldment: Work pieces joined by welding to qualify welding procedures, welders,
or welding operators.
Section 2:
Amendments and Revisions to the Quality Assurance Manual
2.2 Reviews
Management reviews of operations are continuous and any problems indicated with the
Quality Assurance Program or its implementation will be addressed and corrected as
directed by management. Management Reviews will be performed annually.
Section 3:
Organization
3.4 Responsibilities
The Quality Manager is responsible for:
a) Update and distribution control of the Quality Manual as required.
b) Directing inspection activities.
c) Surveillance of procurement documents.
d) Approval of Suppliers.
e) Maintaining a listing of approved suppliers.
f) Monitoring procedures to assure compliance.
g) Reviewing and maintaining Quality Records.
h) Calibration of Measuring and Test Equipment.
Section 4:
Control of Purchased Items
4.1 Purchasing
Purchasing shall be approved by the Facility Representative or designee. A separate
account for revenues designated by the Mid-Plains Community College Business Office
shall exist (Project Code: WELD ATF). Purchasing of materials shall be done by
Requisition and Purchase Order for traceability and shall follow all policies of the College
purchasing department.
4.3 Supplies
Supplies shall be subject to the Test Facility needs and evaluated for reliability by the
Quality Control Manager.
4.4 Inspection
Articles are inspected in accordance with the requirements of the receiving documents.
As a minimum, all articles are inspected for count, identification and damage. The
Quality Control Manager or a designate will sign for materials.
4.5 Certifications
Certifications and Certified Material Test Reports (CMTR’s) are reviewed for compliance
and accuracy of contents as required by procurement documents certified reports or
other proof.
4.7 Acceptance
Acceptance of the receipt will be documented on the Receiving Report as accepted and
the identity of the inspector will be included by initialing the document.
Section 5:
Control of Measuring and Welding Test Equipment
Section 6:
Welding
Section 7:
Control of Quality Records
7.4 Corrections
Corrections to documents shall be accomplished by completing the top left box
contained on each page of the manual and the front Manual Revision Status section.
7.6 Records
Records shall be labeled for easy identification and accessibility.
Records that document compliance typically include:
Inspection records
Mill and consumable purchase orders
Corrective action reports
Internal and external quality management audits
Section 8:
Qualification Testing
8.1 Applicants
Each applicant shall be assigned an identification number. It shall consist of the first
letter of their last name and the last four digits of their social security number.
8.2 Identification
Prior to initiation of welding, the applicant’s identification shall be checked by the Test
Supervisor against the photograph of the applicant’s driver’s license or similar identifying
documents.
8.3 Materials
Prior to welding, materials shall be checked by the Test Supervisor for fit-up
requirements and marked with the welder’s identification number as specified in Section
8 of this manual.
8.4 Preparation
8.6 Cleaning
All cleaning, grinding, chipping of slag, or other process operations, shall be performed
with the test assembly in the specified welding position unless removal for cleaning is
approved directly by the Test Supervisor. Evidence of removal of the test assembly or
movement from the original location, except by accidental means or supervisor approval
(subject to concurrence of the Test Supervisor) shall be cause for test termination.
8.7 Documentation
All welder performance qualification tests that have met the specified requirements shall
be documented on the welder performance qualification record (PQR) supplied by the
Quality Control Department.
8.10 Checklist
A checklist shall be used to insure a uniform process of testing. The Test Supervisor shall
check each listed item as the test progresses (see form MPCC-1).
8.11 Retests
Retests may be allowed by the Test Supervisor, under the provisions of QC-89 Section
9.9.1 and 9.9.2. The applicant must re-apply to the Test Facility if applicable.
Each welder candidate will receive and sign a form that they
have received and read the Mid-Plains Community College Welder Candidate Package.
Section 9:
Destructive and Non-Destructive Inspection
9.1 Inspection
All inspection including visual, destructive and non-destructive shall be done in
accordance with the latest ANSI/AWS, ASME, API Standards or as applicable to other
standards allowed.
9.2 Codes
All inspections shall conform to applicable welding codes, standards or procedures shall
be performed by a current Certified Welding Inspector.
Section 10:
Measuring and Testing Equipment
10.6 Records
Records of measuring and testing equipment shall be kept and made available to those
authorized when requested.
Section 11:
Handling and Storage of Test Specimens
Section 12:
Non-Conformance
12.1 Reporting
All nonconformances shall be reported to the test supervisor and the Quality Control
Manager. The Quality Control Manger shall then report the nonconformance to the
Facility Representative.
12.2 Investigation
The Quality Control Manager shall investigate the scope of the nonconformance, its
cause and repercussions.
12.7 Records
Records of all complaints filed shall be available for AWS review.
Section 13:
Quality Assurance Procedure Review
13.1 Review
The Quality Control Manager shall review the Quality Assurance Manual annually.
13.2 Management
The Quality Assurance System shall be reviewed annually by the management or their
designate.
13.3 Records
Records of the annual review shall indicate their findings or other actions taken.
13.4 Storage
Records of the annual review shall be kept on file for review by those authorized to do
so.
13.5 Approval
The Facility Representative shall approve and direct all changes found during the annual
audit.
Section 14:
Quality Records
Section 15:
Report Forms
15.2 Directions
Reports shall be completed clearly and accurately. Blanks and space that are “not
applicable” on test reports shall be marked “NA”.
15.3 Copies
Copies of reports shall be available to the Facility Representative for review
purposes and approval.
Section 16:
Safety
16.1 Standard
ANSI standard Z49.1: 2012 or later (Safety in Welding and Cutting) shall be used as
safety guidelines at Mid-Plains Community College, North Campus Welding.
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