STANDARD OPERATION PROCEDURE – QC DEPT

Document Department Document No

Standard Operation
Quality Control LBE-QC-SOP-01
Procedure

STANDARD OPERATION PROCEDURE

FOR
QUALITY CONTROL
(COLD ROLL FORMED SECTIONS)

Rev Date of Issue Status Prepared by Checked by Approved by

0 25-Jan-2022 Issue for Approval QC Dept

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 STANDARD OPERATION PROCEDURE – QC DEPT

TABLE OF CONTENTS

1. SCOPE

2. INSPECTION TEST PLAN (ITP)

3. RECEIVING OF IN-COMING MATERIALS

4. RAW MATERIAL INSPECTION

5. MATERIALS IDENTIFICATION AND TRACEABILITY

6. TESTING OF MATERIALS

7. PREPARATION FOR PRODUCTION

8. PRODUCTION PROCESS

8.1 INSPECTION

9. INSPECTION AND RELEASING OF FINISHED PRODUCT

10. DOCUMENTATION

11. ATTACHMENT

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 STANDARD OPERATION PROCEDURE – QC DEPT

1.0 SCOPE
Inspection and test of production material shall be based on approved drawing and approved
applicable procedures.

The quality control department shall responsible for the following but not be limited:

 Continuous check for all production process during the whole fabrication
periods.
 Conduct all required inspection and tests.
 Maintain the record for all the quality control document for review/reference at all times.

2.0 INSPECTION TEST PLAN (ITP)

1. QC is to prepare inspection test plan (ITP) shall be generated for main contractor /
consultant, review and acceptance. Reference No. LBE-QC-ITP-001

2. ITP shall be marked up with verification and inspection requirement and agreed with
contractor before start of the work. The “responsibilities” columns (s) of the ITP define the
responsibilities of the involved parties responsible personnel.

3. Approved Inspection and test plan shall be implemented during each and every stage of
fabrication, to ensure the work is carried out with full compliance drawings and
specification. The Inspection and approving parties as per ITP shall ensure the quality of
work at every level.

3.0 RECEIVING OF IN-COMING MATERIALS

1. Quality Controller (QC) or Production Supervisor (PS) is to check all in-coming materials
(eg coils, bars and plates) and products (eg galvanised ,semi-finished or finished products)
delivered to fabrication yard before unloading.

2. Before delivery to fabrication yard QC may visit the supplier’s yard, blasting yard &
galvanize yard to check the ordered materials.

3. They are visually checked against supporting documents eg. Delivery orders to ensure the
following:

 Correct description of the material / product

 Right quantity is delivered.

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 Right quality is delivered, ie. compliance with specifications / standards

 Material / product delivered are not damaged or spoilt

4. For materials / products in loose bulk form or of large quantity where it is not possible to
examine completely upon delivery, appropriate random visual checking to be carried out.

5. QC or PS is to:

 Identify any non-conforming materials / products delivered due to damages, deficiencies

in quantity, quality, lack of supporting documentation, etc

 Immediately reject the non-conforming materials / products in whole or in part.

 Record the nature of the non-conforming materials / products in the delivery order

 Report to Production Manager

6. The Production Manager is to follow-up on any non-conformance in delivery.

7. Where delivered materials / products did not pass the necessary inspection and / or test, QC
or PS to ensure that they are segregated and identified by tags or labels or other appropriate
means with the following information:

 Not for Issue

 Not for Use

 Not Inspected / Tested

 Rejected

 On Hold

8. All delivery orders to be duly signed by QC / PS or appointed staff receiving them before
forwarding to the Finance / Admin Dept for payment purpose.

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4.0 RAW MATERIAL INSPECTION

1. QC shall obtain a valid FPC certificate and manufacturer test certificate to verify the
compliance of the steel materials delivered to the specifications.

2. Before notifying main contractor / consultant, QC inspector shall visually inspect the raw
material and verify the heat number and material specification to be confirm whether it is
free from scale, rust, oil, grease and other deleterious foreign material shall be within the
project specification and standard requirements.

3. Any non-conforming materials shall be highlighted by QC inspector and replace with a new
one shall be carried out before Client Authorized Representative’s Inspection.

4. Coating Thickness Gauge can be used for measuring galvanizing thickness on raw material
steel.

5. Dry film thickness shall be checked prior to cutting.

6. After material inspection has been conducted and material been accepted, the production
shall store the material and issue to the fabrication upon instruction.

7. All inspection result shall be reported in material inspection report.

Reference No. LBE-QC-DOC-2 – Material Inspection Report

5.0 MATERIALS IDENTIFICATION AND TRACEABILITY

1. To provide adequate and effective control over the identification of material and parts
through all stages of manufacture, assembly and installation. The control system shall
prevent items of unknown origin being used or incorporated into the works.

2. Each item that is fabricated shall have a piece mark identifying it, preferably in a permanent
and standardized location. These identifying marks will facilitate identification and
traceability from the beginning of fabrication through to transporting, erection, repair or
modification

6.0 TESTING OF MATERIALS

1. QC is to prepare a Inspection Test Plan (ITP) Reference No. LBE-QC-DOC 1 – Inspection

Test Plan - Fabrication Process to record materials / products that required testing as
specified in the contract or by the customer.

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2. QC to arrange the materials / products for testing based on the Inspection Test Plan.(ITP)

3. QC shall raise the witness request to the main contractor / consultant for material test at 3 rd
party laboratory.

4. QC or Purchasing Manager is to review the test results.

5. In the event if test results do not meet the specified contract requirements, Purchasing
Manager or QC to evaluate and determine the necessary action needed for the materials /
products to comply with the acceptable test requirements.

7.0 PREPARATION FOR PRODUCTION

1. Production Manager to establish and maintain the overall layout of the production yard.

2. Production Manager or Production Supervisor to identify the Team Leader for each
production work.

3. Team Leader to consult Production Manager, Production Supervisor, or PM on matters

relating to progress and any problems encountered during production.

4. If available, Contract / Project Dept to provide Team Leader with relevant engineering /
shop drawings for manufacturing works through Production Dept.

5. Wherever possible, identities of the manufactured element parts to follow that shown in the
engineering / shop drawings.

8.0 MANUFACTURING PROCESS

8.1 INSPECTION

1. Production Supervisor or Team Leader to supervise manufacturing works to ensure that they
are carried out in accordance with appropriate engineering / shop drawings, specifications
and Works Quality Plan – Fabrication Process.

2. Production Supervisor shall raise the inspection request to the QC Dept for inspection.

3. Prior to production work, the materials shall be checked against the approved shop drawings
in terms of quality as well as identification / markings.

4. QC to inspect all production works carried out within the production yard using the QAQC
inspection report.

5. The material specification and dimensions shall be verified based on applicable drawing.

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6. Materials length shall be verified using steel ruler. Other final product dimension to check
including thickness, web ,flange and lip dimension.

7. QC is to highlight any minor defects / non-conforming works to the Team Leader and ensure
that they are rectified before allowing the work to proceed to the next work processes.

8. QC will record those defects / non-conforming works that are extensive or has a major
adverse effect on quality and productivity in the Corrective / Preventive Action Request
Form.

9.0 INSPECTION AND RELEASING OF FINISHED PRODUCT

1. QC will check all completed finished product, including dimensional inspection and any
non-destructive testing as may be required.

2. Non-destruction testing will be conducted by external independent agency approved by the

customer.

3. QC will record those defects / non-conforming works that are extensive or has a major
adverse effect on quality and productivity in the Corrective / Preventive Action Request
Form.

4. Production Manager or Production Supervisor is to confirm with QC to ensure that the

finished product could be released for any subsequent trade or to project site directly.

5. Upon confirmation, Production Manager and / or QC to endorse the company’s Delivery

Order or Material Delivery Form before forwarding to Transportation Supervisor, Sub-
Contractor or delegated staff for delivery.

10.0 DOCUMENTATION

Inspection report shall be maintained by QC department and approved by the involved parties.
The following final documents shall be recorded and maintained.

Attachment 1 - Inspection Test Plan

Attachment 2 - Material Inspection Report
Attachment 3 – Inspection Report Purlin C
Attachment 4 - Inspection Report Purlin Z
Attachment 5 - Inspection Report Pro Deck

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Attachment 6 - Inspection Report Pro Panel

11.0 ATTACHMENT

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