INPLANT TRAINING REPORT

FUNCTIONS OF SUPERVISOR IN THE SHOP

WHILE EXECUTING A PROJECT.
 Deploy right man on right job.
 Distribute the work to the workmen.
 Study the job related documents and give proper written
instructions to workmen to ensure quality of products.
 Make an inspection entry at predetermined stage as per ICL.
 Proceed only if inspection clearance is ok.
 Hold non-conforming items till NCR is cleared.
 Maintain seam wise welder record.
 Maintain discipline on shop- floor.
 Issue consumable requisition.
 Welding parameters to welders.
 Use of calibrated m/c.
 Use of qualified welders from the list.
 Issued by shop welding engg.
 Maintain producton programme, job completion targets with
the help of continous monitoring of schedules.
 Offer completed jobs for inspection.
 Interact with maintenance to ensure proper working of
Machinery.
 Monitor productivity on shop-floor which will result in cost
reduction.
 Co-ordination with planning, prod.engg, maintenance,
inspection, nde departments.
 Maintain good & safe housekeeping on shop floor.
 Receive & maintain job related documents.
 Communicate problems faced & decisions taken to
Counterpart.
 Job study.

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WHAT A SUPERVISOR SHOULD KNOW?

 Estimated hours for shop scope of work.

 CDD/ latest promised delivery date.
 Target hours.
 Manufacturing procedure/ sequence of Manufacturing.
 Welding procedures.
 Stages of machining/ PWHT.
 Inspection check list.
 Weld plan.
 Applicable drgs, NCRS, DCRS.
 Test plan.
 RT/UT reports.
 Man-hours booked.

Knowledge of Welding Procedures

 Positions of welding
 Why preheat is necessary?
 Why post heat is necessary?
 What is interpass temperature
 Methods of recording temperature while welding
 Why PTC (production test coupon) is required?
 Permissible weld offset.
 Weld reinforcement tolerances.
 Type of weld defects.
 Positions of welding 1G,2G,3G,4G,5G,6G and
1F,2F,3F,4F,5F,6F.
 Why inert gas back purging is necessary in single
side full penetration welds?

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NDE

 Various NDE techniques.

 What is spot radiography? Can several seams be combined for
spot RT?
 What is the surface finish required for performing
NDE?
 What are the types of defects?
 How much clear space is required on either side of weld joint
for carrying out NDE?
 What are the acceptable defects?
 Various leak detection tests?
 Concept of zero defect- do it right the first time.

HYDROTEST

 Why venting is necessary during hydro test?

 What care is to be taken during de-pressurizing?
 What supporting arrangements are needed during hydro
test/pwht/ transportation?
 What care is to be taken during high pressure pneumatic test?
 What is the necessity of thoroughly drying
the vessel after hydro test?

ECONOMICS OF REWORK

 Increase in manufactuing cost.

 Increase in cycle time resulting in increase in WIP interest.
 Loss of shop capacity resulting in loss of production.
 Increase in material handling.
 Inferior job.

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 Repair/rework requires more attention of supervisor, welding

engineer.
 Delays on job ultimately result into levy of penalties by
customer.

SUPERVISOR SKILLS

 Distribution of work.
 Maintaining drawing folder, weld plan and test plan on shop
floor.
 Drawing materials from stores.
 Check the material received against material challan.
 Report material lost / spoilt / rejected on shop floor to planning
through foreman.
 Transfer of material from shop floor.
 Maintaining shift change list/request.
 Maintain records of RT/UT reports.
 Use reports for communicating with counterpart.
 Make proper inspection / maintenance entry giving all the
details.
 Issue consumable slip after entering all the details
 Obtain priority for RT/UT/wagon movement/machining/pwht
before positioning the job.
 Give requirement for indirect material/jigs and fixture /tools to
planning in advance.
 Check correctness of dimensions / feedback being given to
inspection, planning, welding engineering.

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SHOP WELDING PRACTICES
SL DO'S
NO
1 Fix the earthing clamp
directly to the job
2 Use properly baked
electrodes.
3 Always refer the weld plan
before issuing the electrode
to the welder.
4 Use qualified welder on the
job.
5 Issue a consumable slip for
the maximum of 15
electrodes at the time to the
welder or less as per the job
requirement.
6 Start the post heating
immediately after the welding start below the preheat
is completed.
7 Circumferential /Restraint
joints should be tacked with
tacks with more than 50mm
in length and minimum two
layers of welding should be
done.
8 Always weld on clean surface Don't weld on dirty surface to
only which are free from rust, avoid defects like porosity
grease, developer, oil paint
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INPLANT TRAINING REPORT
DON’T'S
Don't fix the earthing to the
roller body/positioner
Don't use fresh electrode
from the Packet
Don't issue electrode without
checking the weld plan for
preheating, interpass
temperature or post heat
temperature.
don't use unqualified
fabricator for tacking on the
Job
Don't issue more than 2-5
electrodes to the fabricator
for tacking.
Don't allow post heating to
temperature.
Don't tack less than 50mm
long. The tack may crack due
to restraint.
and crack.
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etc.

9 Always weld only the required Don’t over weld. It will

size of the fillet. increase material cost, labour
cost and other overheads. It
will also cause distortion.

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 INPLANT TRAINING REPORT

IMPORTANT DOCUMENTS RELATED TO PROJECT

1) ROUTE CARDS (RC):

Route cards are basically made for routing jobs, operation wise from
machine. Various things which are added on to the route card are:

Estimated hours for the job along with the machine on which the job
is loaded.

P.W.O. NO., Drg. No., Part description, Quantity.

Initiating dept., Reference, Inspection dept.

Special jigs & Fixtures if any.

Material description with size, type & location.

Required sketch if any is drawn or attached along with.

2) PURCHASE REQUEST (PR) :

Purchase Request is the basic document related to

material required for manufacturing the product. It is initiated &
prepared by the design dept.It gives the authority to purchase dept.
for procurement of material as per customer’s order, design &
drawings. It contains PR no. , Item no. , item description. It also
covers data & information regarding delivery schedule & transport.

3) PURCHASE ORDER :

Purchase order is prepared by purchase dept. after

receiving P. R. from the shop planning. Purchase dept. places the P.O.
with the concerned supplier after inquiring with various sub-
contractors/vendors & deciding on the factors like taxes, duties etc.

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4) MATERIAL REQUISITION (MR) :

Material requisition is a document prepared by the

product groups. It may also be prepared by planning & other dept. on
arising need of some material like jigs, fixtures, templates, gauges
etc. It mainly consists of MR No., job No., Material Code, Quantity,
Insp. Agency name etc.

5) PLATE CUTTING REQUISITION (PCR):

PCR is a document which is prepared by the fabrication

shop planning dept. who in turn releases it plate preparation shop.
PCR shows about the details of the edge preparation of the plates.
This document gives MR No., Drg No., & item No., description & size
of the plate.

6) JOB TICKET (JT):

Product Group after approval of the drgs. to the related

shop ,planning dept. will then prepare the job ticket which describes
the item or job to be manufactured in the shop.

7) OPERATION CARD:

Operation card is also a document prepared by the

planning dept. It gives details of operations such as rolling, pressing,
forming, nozzle fabrication, pipe fabrication etc. to be carried out in
the particular shop.

8) NON-CONFIRMATIIVE REPORT (NCR) :

It is not possible to maintain cent-percent accuracy or

perfection in the fabrication of a critical item. The fabricator
sometimes makes a mistake due to which the job suffers. Such a
mistake has to be rectified.

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A document called Non-confirmative report which is

prepared by the inspection dept. shows change in the dimensions of
the items which are different from actual dimensions of the job as
mentioned in the drawings.

9) DESIGN CHANGE REQUEST (DCR):

The design change is initiated by the shop planning people.

This document is forwarded with the rectification of some design, item,
material, welding, non-destructive testing etc. After the approval of
design dept., the rectification is mentioned in the revised drawing.

10) MANUFACTURING SCHEDULE:-

The Manufacturing Schedule depicts the sequence of

operation of the job and the time required to do each operation. This
schedule is prepared by the shop planning department.

11) PRODUCTION PROGRAMME:-

The production programme is made every month giving

the targets (CDD & EDD).Completion of jobs in the shop for a period of
three months, which should be met for effective control. It also gives a
list of MP jobs & TP.

12) SHOP LOADING STATEMENT:-

In this, the capacity of shop is distributed among the

various jobs depending upon the priority, CDD & schedules. It gives a
clear picture of monthly distribution of man-hours for each job, and the
Quarterly Man-hours Capacity report of the shop based on the
workmen data.

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13) STORES CREDIT NOTE:-

When the job gets over in all respects, progress

department makes this document & along with item list or supply list
attached, it is handed over to inspection department. After getting SCN
signed from inspection, it is handed over to product group which in
turn credits the amount of the job to the concerned shop.

14) MANHOURS PERFORMANCE REPORT:-

This shows whether a job is being executed by effectively

utilizing the man-hours. It shows the estimated man hour and the
actual man-hours during and up to a particular period, resulting in
under run or over run of the job.

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SHOP LOADING STATEMENT

 Capacity of shop in terms of man-hours, machine hours

available per month.

 List of all orders available in hand. details of CDD, estimated

man hours for each job.

 Likely shop estimated man hours booking for each job

depending on scope of work, past performance, urgency of
job, material availability etc.

 Possible man-hours booking for each job in each month

depending on material & engineering status and urgency of
job.

 Summary of total load available per month. compare the load

with available capacity per month to establish overload/ under
load.

 Shop loading statement is used for,

Generating master load which includes forecast orders.

 Deciding to augment existing capacity by either permanent or

temporary recruitment.

 Deciding need for sub-contracting.

 Deciding future order booking.

 Ensuring proper capacity utilization.

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