Manufacturing
With a strong focus on quality, Uttam Industrial and Engineering Group has detailed Quality Assurance Plan that includes thorough inspections at every stage.
The qualifications of welders, like PQR, WPQ, and WPS, are carefully documented to show high standards in welding. A thorough check of incoming materials and inspection of welding setups is conducted to ensure precision.
While welding, Non Destructive Testing is conducted as per ASME / ISO / EN / BS standards. This testing, including ‘Penetrant and Radiography Testing,’ is checked by trusted Third-Party Inspection Agencies such as SGS, Lloyds, Bureau Veritas, Intertek, TUV, LIRIS, Lurgi, BAX, MN Dastur, JPMA, ensuring reliability and compliance with industry standards.
Additional manufacturing steps are also closely monitored. Nozzle cutting is examined for elevation and orientation, while NDT after final welding undergoes scrutiny by Third-Party Inspection Agencies.
Final dimension checks, assembly, and mock-ups are vetted by these agencies, as are hydrostatic and pneumatic tests.
For stainless steel jobs, pickling and passivation are employed, and for carbon steel jobs, surface blasting and painting are utilized.
Inspection and Testing
PROCEDURE
After receipt of work order/job order and relevant technical specification, a Quality Assurance Plan (QAP) shall be prepared. The QAP shall detail out the required checks as per contract/product requirements along-with acceptance criteria. The QAP shall be issued to concerned shop engineers and issue record shall be maintained. Any revision in QAP shall be communicated to all concerned through revised QAP/suitably.
The material received from vendor/sub-contractors shall be offered for inspection by stores to QA Deptt. through entering in incoming inspection register. The stores deptt. shall provide the party bill/ challans along-with P.O. copy, drawings to QA Deptt. for carrying out inspection. The QA Deptt shall carry out the inspection & testing as per documented “Incoming Material Inspection Plan”.
The inspection observations and accepted/rejected status of the items shall be entered in the register, In case of any non conformity the Head QA/Project Head/GM (Works) or jointly, will be the authority for acceptance after evaluating that non- conformity does not have adverse effect on the product quality. If required such non-conformity either related to customer supplied product or contract requirements is communicated to client through marketing deptt. The records of customer approval for non- conformity are recorded. Any rejection observed is communicated to Purchase Deptt. /Subcontract Deptt., through stores deptt for their further necessary action.
Where material quality of the product e.g. Castings, Forgings etc., can not be verified at incoming stage, such products are cleared for further processing after carrying out necessary visual and dimensional checks and close monitoring is done by Shop Engineer/QA Deptt., for its material quality e.g., material soundness in castings, cracks in forgings etc. After observing such defects same is recorded and communicated by QA Deptt. to Purchase, Stores and PPC Deptt., for their further necessary action.
The products / items during processing are offered by production deptt to QA deptt for inspection at the stages identified in the QAP, by entering in the Inspection Call Register. The concerned shop engineer shall provide necessary assistance required for carrying out inspection.
After carrying out inspection, inspection reports (I.R) are made and issued to concerned persons clearly showing the status of the product (Accepted/Rejected/Rectification required). In case of any rectification required, a re-inspection is to be carried out after rectification is done to check the conformity.
Final Inspection/Testing of the equipment is carried out as per QAP/Specified Test method by Head QA and the observations are recorded. The Head QA shall again review the contract quality requirements and other requirements and ensure its conformance at the final stage inspection.
If any major non-conformity is observed waival shall be taken from Project Head or client where required. The final inspection report is issued to concerned person with information to PPC. The PPC Deptt., shall ensure that no equipment has been dispatched without inspection clearance.
Where decided, inspection call letter shall be sent by PPC Deptt., to third party/client with information to QA Deptt. The QA Deptt., will carry out joint inspection with third party/client representative. The inspection report showing acceptance status shall be taken from third party/client representative and recorded.
MEASUREMENTS
RECORD
PROCESS FLOW CHART
Order, Technical
Specifications Drawings from
Marketing & PPC
Department
Assurance Plan &
Issue to Production
& related Department
/ In-process Inspection
at offered / specified
stage or need
based as per QAP
Welding Quality,
Casting & Forging
material soundness
after any
rework / rectification
or Pre-dispatch
Inspection