User Manual QMS - Quality Control

Process Manual QMS
USER MANUAL
Quality Management System (QMS) Part II
Quality Control
Prepared by:
Sadashiv Salunkhe
Customer
L & T, Heavy Engineering Division
Process Manual - QMS
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Process Manual QMS
DOCUMENT CONTROL
DOCUMENT TITLE:
User Manual Quality Control - Quality Control
DOCUMENT PURPOSE
To guide QMS users through BaaN QMS Module.
VERSION:
0.01
RELEASE STATUS:
Draft
FILE LOCATION:
AUTHOR (S):
Sadashiv Salunkhe
REVISION HISTORY
VERSION
DATE
DESCRIPTION / ACTIVITY
AUTHOR (S)
0.01
2nd May 2008
Draft
Sadashiv Salunkhe
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Table of Contents
1.
Introduction..............................................................................................................................4
2.
Overview..................................................................................................................................4
3.
Quality Control (QC)................................................................................................................6
3.1 Introduction..............................................................................................................................6
3.2 Receipt Inspection....................................................................................................................6
3.2.1
3.2.2
Maintain Approval....................................................................................................................................6
Provisional Approval................................................................................................................................8
3.3 In Process Inspection..............................................................................................................10

3.3.1 Test Plan (TP).........................................................................................................................................10
3.3.2 Inspection Checklist (ICL)......................................................................................................................11
3.3.2.1
Copy Test plan Stages into Checklist.............................................................................................11
3.3.2.2
Preparation of Vertical Check List.................................................................................................12
3.3.2.3
Maintain Parts for Inspection by Project........................................................................................14
3.3.2.4
Maintain / Update ICL...................................................................................................................15
3.3.2.5
Approve ICL..................................................................................................................................20
3.3.2.6
Update ICL Status..........................................................................................................................20
3.3.3 Maintain Offers for Inspection................................................................................................................21
3.3.4 Enter Test Results....................................................................................................................................26
3.3.4.1
Maintain test results for Inspection................................................................................................28
3.3.4.2
Maintain test results for Inspection Details.................................................................................28
3.3.5 Non Destructive Test (NDT)...................................................................................................................30
3.3.5.1
Generate NDT Request..................................................................................................................30
3.3.5.2
Maintain NDT Request lines..........................................................................................................31
3.3.5.3
Maintain NDT Request Details......................................................................................................34
3.3.5.4
Enter NDT Test Results..................................................................................................................37
3.3.5.5
Maintain Test Results for NDT - SPOT.........................................................................................39
3.4 Final Inspection......................................................................................................................42

3.5 Third Party Inspection (TPI)..................................................................................................43
3.5.1
3.5.2
3.5.3
4.
Maintain Employee Authorization.........................................................................................48

4.1.1
5.
Generate Third Party Inspection Plan.....................................................................................................43

Maintain Third Party Inspection Agencies by Stages.............................................................................44
Maintain Third Party Inspection Results................................................................................................46
Maintain NDT Personal Master..............................................................................................................49
Exercise..................................................................................................................................50
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1. Introduction
The Quality Management System helps industries perform regular inspection procedures to
attain the required quality. QMS uses logistical flow of products to schedule inspections. In
every company, products, including raw materials, end products, and products in between
manufacturing steps, are regularly inspected to make sure the procedure runs smoothly, to
review what went wrong, or to determine what could go wrong during production, distribution,
or in the time that products are in inventory.
This document provides detailed QMS procedure adopted by L&T - HED to monitor and
improve the quality of their products.
2.
Overview
HED has customized the standard Infor ERP QMS module to suite its Quality Control
requirements. Its a standalone module which is not integrated with other BaaN modules.
It mainly covers three areas of operation.
Receipt Inspection
In process Inspection
Final inspection
Receipt Inspection is applicable for purchased parts like raw materials, components, sub
assemblies etc. materials cannot be used issued for production unless it is cleared by
inspection. However provisional clearance (approval) is possible to allow material issue
for production.
In process Inspection is done on the parts during manufacturing process. Welding
process is extensively used in manufacturing of HED products. Hence QMS is largely
focused on welding process & its associated Quality Control procedures. Once the
product design is frozen & drawings are released, Seams are identified to prepare the
Test Plan. Master data like Parameters (Characteristics), Inspection Stages (aspects),
default Tests are defined in BaaN. Based on Test Plan Inspection Checklist is prepared.
Stages are offered in a predefined sequence to ensure Quality compliance at each stage
of manufacturing. Inspection method depends on the type of stage, e.g. NDT (RT/UT),
Others & Inspection. Test results are entered against each parameter & status is
updated as Cleared / Rejected.
Final Inspection ensures the completion of all Tests & Inspection activities for the final
deliverables before posting to FG. (Stores Crediting). L&T Test Certificate is prepared &
delivered to customer. It comprises details like Applicable Standards, Inspection
Agencies involved, etc.
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Followings are the three process owners of QMS in BaaN.
Welding Engineer - Welding Engineering

Inspector - Quality Control (QC)
Supervisor - Production Centre (PC)
Each one of them (BaaN user) has been assigned a specific role & authorization to
perform set of activities.
This document is subdivided into two parts to facilitate BaaN Users to understand their
role specific activities in BaaN.
1) Welding Engineering Part I
2) Quality Control Part II
3.
Quality Control (QC)
4. Introduction
The QMS execution part is largely done by Quality Control department. QC users are
given the role of Inspector to perform transactions in BaaN. The transactions like
Maintain Approval, Prepare Inspection Check List (ICL), Approve ICL, Enter Test
Results, Generate NDT request, etc. Receipt Inspection & In process Inspection is
handled by QC. The BaaN procedural aspects have been explained in details below.
5. Receipt Inspection
Process Flow
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5.1.1 Maintain Approval

Receipt Inspection is done for purchased items like raw materials, parts, components,
sub assemblies, etc. it is applicable for the items only if Inspection flag is Yes in Item
Data & Supplier data along with Maintain Approval step is part of Order type. If the item
is received (IMR) & Inspection flag is Yes, then received quantity is kept on hold for
inspection activity. It is blocked for further transaction till it is cleared by inspection.
Inspector can use BaaN utility Print / Display sessions to know the IMRs (receipts)
pending for Inspection. After physical inspection is completed, inspector can maintain
test result as Approved / rejected for the quantity inspected. Following Baan session is
used to maintain Approval for receipt Inspection.
Session Name - Maintain Approval (tdpur4121m000)
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Once the IMRs (receipt no) are retrieved from BaaN using utility sessions, selected IMR
no is searched in the above session to enter Approved /Rejected Quantities.
Form No 1
Field
Data
Receipt No
IMR no. awaiting for inspection
Packing Slip No
Defaults from the IMR
Supplier
Defaults from the IMR
Order lines
Approved
Back Order
Defaults from the IMR, Order No, Pos No, Item Received,
Delivered Qty (Received Qty), Unit of Measure
Accepted Qty - Enter OK Qty in the sub session invoked by the
system (tdilc4123s000).
System calculates Back order Qty depending on accepted Qty
(Order Qty Cumulative Accepted Qty)
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Form No. 2
Field
Rejected Qty
Reason For
Rejection
Data
Displays Rejected Qty which is entered in the sub session
(tdilc4123s000).
Displays Reason for rejection when reason code is selected in
the sub session - maintains approval extension. This session is
invoked by clicking on Zoom button.
Item inventory appearing On Hold is cleared after the approval is maintained in the
system. It is now available for further transaction such as Inbound to warehouse, etc.
5.1.2 Provisional Approval

Sometimes item cannot be approved for the want of test certificate, Certification from
TPI agencies, etc. In such scenarios item can be provisionally cleared for the immediate
production requirement. The approval status remains as provisional clearance (PRV) till
supplier fulfills the stated requirements. Supplier payment is not released till it is finally
cleared (FIN).
The provisional clearance is given by using same session as used for Maintain approval.
Session Name - Maintain Approval (tdpur4121m000)
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Click on Zoom button on the right hand side, to open the sub session Maintain
Approval Extension (tdpurc135s000).
Inspection status is changed to PRV to maintain provisional clearance.

The appropriate reason code is selected on form no.2.
Item can be finally cleared by changing the status to FIN.
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6. In Process Inspection
Process Flow
6.1.1 Test Plan (TP)

Welding engineer identifies critical seams for the product & creates seam wise Test Plan
in BaaN. Based on the Quality IDs linked to seams, system populates all the stages
linked to quality ID in the Test plan. These stages appear in a predefined sequence to
facilitate stage wise inspection of Seam. Test Plan is approved by concerned authority &
is finally copied into Inspection Checklist by QC Inspector.
(Please refer Part I - Welding Engineering for further details of Test Plan).
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6.1.2 Inspection Checklist (ICL)
6.1.2.1
Copy Test plan Stages into Checklist
When Quality IDs are linked to project Seams by welding engineer, system populates
only Inspection stages in the Inspection Checklist & stages of type NDT (RT/UT) & Other
in the Test Plan. Once the Test Plan is approved, Inspector copies all the stages from
Test plan to prepare Inspection Checklist.
Following BaaN session is used to copy Test Plan stages into ICL.
BaaN session - Maintain test plan (tclnt0123m000)
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Inspection Checklist is prepared by clicking on the button ICL Preparation

This populates all the test plan stages into ICL & user ID is captured by the system.
(Note: - Test Plan status must be Approved Yes before this action)
6.1.2.2
Preparation of Vertical Check List
Inspector identifies stages which are not part of Test Plan but necessarily to be part of
inspection. These stages are defined as default stages for the entire Project. They can
be seam specific, part specific, applicable to both seam & parts, and miscellaneous
types. Seam & part specific stages are added for the specific seam / part whereas
miscellaneous types are added directly into ICL. The vertical check list is primarily used
to add stages other than seams & which are common for all.
Following BaaN session is used to maintain default stages by project.
BaaN session - Maintain Default Stages by project (tclnt0112m000)
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Field
Data
Project
Enter project no. by clicking group insert key from the tool bar.
Default Stage
Zoom to stage master & select the appropriate stage.

Select the type from drop down list
Type
Miscellaneous
These stages will be added in the ICL for the project i.e. only
once for the project when saved here.
Seam only
These stages are added in ICL for seam only for the project
under consideration whenever seam is saved in Seams/ Parts
by project.
Part only
Seam & Part only
6.1.2.3
These stages will be added in the ICL for parts only for the
project under consideration whenever part is saved in Seams/
Parts by project.
These stages will be added in the ICL for seam & Part for the
project whenever Seam/ Part is saved.
Maintain Parts for Inspection by Project
Part number is unique for a project & is directly loaded from customized BOM
maintained for the project. Part number has one to one relationship with item code. Part
number is same as position number in customized BOM for the final item of the project
instead of item number itself.
However Inspector can create new parts for the sections of the end product to carry out
overall inspection. These sections are defined as parts in the system. e.g. Shell assly,
channel assly, etc
Following BaaN session is used to maintain parts for Inspection by Project.
BaaN Session Maintain Parts for Inspection by Project (tclnt0111m001)
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Field
Data
Project
Enter project no. by clicking insert key from the tool bar.
Part
Enter the part no & description for the section of assembly
Insp Quantity
Default is 0 (not relevant)
Field
Data
Quality ID
Zoom & select the Quality ID. Stages & parameters linked to this
ID are populated in ICL under the part created
Prepared By
Login id is captured by the system when the record is saved.
6.1.2.4
Maintain / Update ICL
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Inspector identifies stages which need to be added before or after stages in ICL that are
copied from Test Plan. These stages are added in ICL of all applicable seams / parts for
the project. The sequencing of stages is critical while adding new stages in ICL. Revision
no. is incremented by one each time the ICL is modified & approved. Text can be added
for the ICL/stage.
Following Baan session is used to maintain / update ICL.
BaaN Session Maintain ICL Lines (tclnt0123m001).
Form No.1
Field
Data
Project
Enter project no. by clicking insert key from the tool bar.
Part
Enter the part no to update the Part ICL
Seam
Enter the Seam no to update the Seam ICL
TP Rev
Test plan revision no. New Rev no is updated whenever TP is

modified & approved by Welding Engineer.
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Field
Data
ICL Rev
ICL revision no. New Rev no is updated whenever ICL is

modified & approved by Inspector.
TP Text
Yes if text is present for the TP revision.
ICL Text
Yes if text is present for the ICL revision.
Stage
Populated from the Test plan. New stages can be added by

Inspector.
Sequence
Sequence number by default is imported from the extension to

stage master. Two stages with same sequence number can be
saved for a seam or part. Sequence number defines the path of
inspection stages.
Description
Description of the stage
Status
Prepared By
Status indicates whether stage is added, deleted by Inspector.

Approver may or may not approve it.
Login code is displayed against record (stage) created /
modified by the user. If user has no authority to maintain this
session as per employee authorization master, a record cannot
be saved.
Approved By
Login code is displayed against record (stage) approved by the

user. Only authorized person can approve the ICL.
Appr.
When approver approves ICL, this flag is set to Yes. Initially it is

set to No
ICL Date
When approver approves ICL, system date is recorded here.
ICL Time
When approver approves ICL , system time is recorded here.
Field
Data
Inspection Status
Ready To Offer
Inspection status indicates actions taken by various authorities

like shop supervisor, Inspector, NDT operator, etc. It also shows
with whom stage is pending.
By default stage carrying smallest sequence number will be set
to Ready to offer, while all other stages under that seam/part
will have inspection status ( Blank)
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Field
Data
When supervisor offers it for inspection in this session , the
inspection status changes to Under Inspection. This will remain
so until any of the parameters under stage is Rejected or
Cleared in case of non-NDT stage as per result in Test results.
When inspector runs the session Generate NDT request,
Inspection status changes to Offered to NDT. It is done only for
NDT type Stages i.e. RT/UT & had inspection status Under
Inspection
When all parameters under stage are cleared as per result in
Test results, inspection status changes to Cleared.
Under Inspection
Offered to NDT
Cleared
When any of the parameters under stage is rejected, inspection

status changes to Rework. Supervisor has to re offer stage in
Enter Test Result & then status changes to Under Inspection
When any of the parameter under stage is remake, as per
result in Test results, the inspection status changes to Remake
for all the stages under that seam. This means that a new seam
has to be entered.
When NDT person deletes a record in the request, the status
becomes Deleted by NDT. It will again change to Offered to
NDT when request is regenerated by the supervisor
Insp. Center
Rework
Ok
Zoom & select place from master list of Inspection centers
Cancel
Remake
Reseq. Stages
It is used to quit the session without saving any record.
App Seam/ Part
This button is used for approving the seam or part individually.
Deleted
Approveby
all NDT
This button is used for approving all seams/ parts
Field
Data
Update Rev No
This action button is used for updating the revision number
Project Extn
This button is used for maintaining the text for the revision
This action button is used for registering the

addition/modification of stage in Inspection check list.
Re sequencing of the stages is to be done when the ICL is
frozen. Re sequencing is not possible if any stage of seam or
part is offered for inspection
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Field
Data
Update status
This option sets inspection status of un offered stage with lowest

sequence number to Ready to Offer. Also it blanks the records
which have disappeared from ICL due to modification/ change in
Test Plan. User authorized to prepare & approve ICL can
operate this user option.
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(All are display fields only, updated by the system on actions done by the users.)
Form No.2
Field
Data
Insp. Offer
This field indicates whether the part or seam is offered to

inspection or not. Once a stage is offered to inspection,
subsequent changes to the related part or seam are not
accepted.
Field
Data
Shop
Location
This value is entered by the supervisor when a stage of part or

seam is offered for inspection.
This value is entered by the supervisor when a stage of part or
seam is offered for inspection.
Insp. Extent
Inspection extent determines whether this stage inspection

needs to be performed fully or partially.
Insp. Qty
Qty defaulted from the field BOM quantity entered in Maintain

Parts for inspection by projects.
Offer Qty
Total offered quantity
Cleared Qty
Quantity cleared & entered by Inspector in test results.
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(All are display fields only, updated by the system on actions done by the users.)
Form No.3
Field
Data
L & T Result
Defaults the test results entered by the Inspector (cleared)
Date
Date on which inspection result entered by Inspector or NDT

person.
Time
Time registered by the system when results are entered.
Final result
If all agencies clear the stage, the final result is cleared. If Third
party inspection is not required, this result is cleared
immediately after internal inspection is cleared.
Date
Date on which final results entred.
Text
Indicates yes f text is present
6.1.2.5
Approve ICL
Inspection Checklist List is approved by QC authorized person only. This activity ensures
ICL enlist all stages essentially to be covered under inspection. Any modification done in
ICL needs approval before it is made available for inspection. Approver has options to
approve ICL individually for seam / part or all ICLs for the project by single click of
button. The date & time of approval is registered & displayed against each stage.
System also captures the approvers user ID & displays on the screen.
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Following BaaN session is used to approve ICL.

BaaN session maintain ICL lines (tclnt0123m001)
6.1.2.6
Update ICL Status
Inspector updates the ICL status to make stages available for inspection. This action
changes the status of un offered stage with lowest sequence number to Ready to Offer.
All deleted stages are also removed from ICL. User authorized to prepare & approve ICL
can perform this activity.
6.1.3 Maintain Offers for Inspection

Inspection activity is triggered by the inspection offer made by Production Center (PC).
All the stages are offered for inspection in a chronological order. It means no succeeding
stage can be offered for inspection unless preceding stage is cleared.
Stage with status Ready to Offer can be offered for inspection. It is mandatory to enter
shop, location & welders for the stages of non NDT type. The status changes to Under
Inspection immediately after the stage is offered for inspection. Thus stage becomes
available for QC inspector to perform required parameter checks & enter test results in
the system. If the stage type is NDT, Inspector generates NDT request with required
details & offer to NDT. Stages with blank status are not visible to Supervisor.
In case of rejection, the status is changed to either Rework or Remake. Accordingly PC
needs to take corrective action on the seam or part before reoffering the stage for
inspection. Iteration No. is updated each time re offer is made. Supervisor can enter
his/her remarks if any.
Following BaaN session is used to maintain offer for inspection.
BaaN session Maintain Offer for inspection (tclnt0123m004)
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Form - Common
Field
Data
Project
Project No.
Stage
Part
Seam
Seq
Itrn
Stage may appear with different statuses for different seams.

e.g. Ready to offer, under inspection / cleared, Rework. Stage
with status Ready to offer or rework can be offered for
inspection.
Part No in the absence of seam
Seam no. to which this stage belongs. One stage can be part of
many ICL in the same project.
Sequence No. defaulted from the extension to stage master
Iteration No. initial value is set to 0. The no. is incremented by
one each time re offer is made by PC.
Inspection Status
Stage with status Ready to Offer can be offered for Inspection.
Prov /Final
System updates this field as Pro if TPI is involved. By default it

is kept blank till the time final inspection results are entered. It is
changed to Final after results are entered in the system.
Offer
Yes indicates offer is made.
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Field
Data
Shop
This field can be used when no. of seams are inspected in one
go & results to be entered are same. In such case data is
entered for single singe seam called Source Seam & copied to
others.
Results entered by internal inspection (QC). If TPI is involved in
inspection, stage cannot be cleared unless both results are
maintained in the system.
Its the place where inspection needs to be carried out.
Location
Location in the shop where inspection needs to carried out.
Supervisor
Supervisor user id is captured who has offered the stage
Date & Time
Date & time on which the offer is made

Select the stage & click on Offer button on RHS to offer the
stage for inspection.
Supervisor can access the Test Data to re offer stage & enter
his/her remarks.
Test data such required value, measured value, checked value,
parameter results can be copied from one seam to other.
New Stages can be added & offered to Inspection by
Supervisor.
Source Seam
L&T Results
Offer
Test Data
Copy Test Data
Non ICL stages
Form Part offer
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Field
Data
Part
Part No if the stage belongs to the part (Vertical check list)
Seam
Seam no. to which this stage belongs. One stage can be part of
many ICL in the same project.
Seq
Sequence No. defaulted from the extension to stage master
Insp Qty
Qty defaulted from the field BOM quantity entered in Maintain

Parts for inspection by projects.
Current offer Qty

Cleared Qty
Total offered quantity (not applicable in the existing process)

Quantity cleared & entered by Inspector in test results. (not
Total Offer Qty
Total cumulative offered Qty (not applicable in the existing process)
applicable in the existing process)
Form - Welders
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Field
Data
Welder
It is mandatory to input welders for the seam inspection.

Welders can be entered by using session Maintain Welding
Processes by project/seam/welder (tclnt0124m000).
Inspection Status
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How inspection status of stage changes by user actions is given below.
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Action
Action
By
By default stage with lower most sequence

OR After earlier sequence stage is cleared
by L&T Inspection
Inspection Status
After action
Ready to offer
Stage is offered for Inspection.
PC
Under Inspection
Results not accepted by L&T Insp.

Stage is re offered for Inspection after
rectification.
QC
Rework
PC
Under Inspection
Results accepted by L&T Inspection but

Awaiting TPI inspection
QC
Under Inspection
Results Accepted by L&T & TPI
QC
Cleared.
NDT Stages
Ready to offer
After earlier stage is cleared by L&T

Stage is offered for Inspection.
PC
Under Inspection
NDT Request is generated.
QC
Offered to NDT
Result entered by NDT(Seam not fully

cleared ).
NDT
Rework
Re-generate of NDT request
PC
Offered to NDT
Results Entered (All spots Cleared).
NDT
Cleared.
6.1.4 Enter Test Results

Test results are entered for the stages with status Under Inspection / Offered to NDT.
Inspector is authorized to enter results for Inspection stages whereas NDT test results
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are entered by NDT person only. Parameters are checked against the acceptance
criteria & the results are entered accordingly.
Cleared
Rejected (Rework / Remake)
If all the parameters are cleared, stage status in ICL changes to Cleared. In case of
any rejected parameter, the stage status changes to Rework. Supervisor has to take
corrective action based on inspection remarks & Re offer the stage for inspection.
System captures Inspection date, time & inspector user id when the record is saved.
Following BaaN session is used to enter test results.
BaaN session - Enter Test Results (tclnt0123m005)
Form no. 1
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Field
Data
Project
Project No
Stage
Select the Stage for inspection.

All the seams are displayed having this stage part of their
inspection check list.
Stage sequence no.
Seam
Seq. No.
Req. No.
Itrn
Source Seam
Inspection Status
NDT request no. if the stage is NDT type

Iteration No. initial value is set to 0. The no. is incremented by
one each time re offer is made by PC.
This field can be used when no. of seams are inspected in one
go & results to be entered are same. In such case data is
entered for single singe seam called Source Seam & copied to
others.
It indicates inspection status of the stage against various seams.
(please refer section 4.3.2.4 for further details)
Shop
System updates this field as Pro if TPI is involved. By default it

is kept blank till the time final inspection results are entered. It is
changed to Final after results are entered in the system.
Its the place where inspection needs to be carried out.
Location
Location in the shop where inspection needs to carried out.
Supervisor
Supervisor user id is captured who has offered the stage
Offer Date
Inspection offer date
Offer Time
Inspection offer time

This option is used to enter the test results.
Select the record & click on Test Data button, following sessions
will invoke depending upon the type of stage, seam/part
combination.
If the selected record is if part or seam is selected & stage type
is NDT system zooms to session Maintain test results for NDT
(tclnt1124s000).
If part is selected & stage type is non NDT system zooms to
session Maintain test results for parts (tclnt1122s000).
Prov /Final
Test data
If seam is selected & stage is non NDT system zooms to

session Maintain test results for Inspection (tclnt1120s001)
Copy Test Data
Test data can be copied from source seam. Values, results, etc
Form no.2 & 3 are display forms, shows quantity & welder details.
If the seam is selected & stage is non NDT type, following session invokes after pressing
the Test Data button.
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Maintain test results for Inspection (tclnt1120s001)
6.1.4.1
Maintain test results for Inspection
This session can be called only by Inspector or Supervisor and when the stage is nonNDT for a seam. Supervisor can re offer a seam for inspection from here; a new iteration
number is generated. When re offering is made, offer date & time is captured. Test
instruments & Remarks can be entered at header level.
6.1.4.2
Maintain test results for Inspection Details
After clicking on the button Details in the above session; system will open the following
screen. This session is used to maintain the parameter results of non-NDT stages of a
seam. The required value & measured value is filled in by the supervisor whereas the
checked value is to be filled by the inspector. Results only for the last iteration number
can be filled up as only these are visible here.
The result here can be maintained by inspector only. If all the parameters of a seam are
cleared then field L & T Result is set to Cleared in table ICL line. If any of the
parameter is made as Remake then facility to make results of all the parameters as
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Remake is available. If this is done then in the table ICL lines, L & T Result, Final Result
& status are set to Rejected are updated in ICL lines.
Field
Data
Parameter
Parameter is a particular quality or distinctive mark of an item
Description
Description of the parameter.
Req. Value
It is filled based on the requirement of standard.
Measured value
Here value measured by shop person is entered.
Checked value
Here checked value by inspector is entered.
Result
Select the result either Cleared or Rejected depending on the

acceptance criteria.
6.1.5 Non Destructive Test (NDT)
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Welding process is categorized as a special process & needs stringent process control
to ensure quality output & compliance with applicable standards. This is validated by
inspection & test on the welded seam. NDT is one of the special tests. e.g. Radiography
Test (RT), Ultrasonic Test (UT). NDT is carried out by separate NDT cell which is part of
Quality Control.
If the stage type NDT is offered for inspection by supervisor, Qc Inspector has to raise a
NDT request in BaaN by providing required details to NDT cell. Only authorized person
(NDT person) is allowed to process the NDT request in BaaN.
Please find below the details of NDT procedure.
6.1.5.1
Generate NDT Request
When NDT stage is offered for inspection by PC, NDT request is raised by Inspector.
System generates request only for the NDT stages Under inspection. All further
processing can be tracked by NDT request no. The request no. appears on the ICL lines,
NDT request header & lines & stage status changes to Offered to NDT.
Following BaaN session is used for generating NDT request for all applicable
parts/seams having NDT stages Under Inspection.
BaaN Session Generate NDT Request (tclnt0223m001)
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Process Manual QMS
Field
Data
Project
Project No.
Part
Range of parts belonging to the Project
Seq.
Series for
NDT request
Print
Stage Sequence no if one seam /part is selected
6.1.5.2
Zoom & select the appropriate series for the request no.
Click Print to generate request no.
Maintain NDT Request lines
When the request is made for NDT, related data is entered by the requesting person.
The data like spot length, seam length, seam type, etc. Spot is a part of total seam which
is inspected in one go. Length determines the no. of spots generated by the system.
Spot no. identifies a particular location on the seam under consideration.
e.g. Spot length -300mm, seam length is 1500mm
No. of spots shall be generated as follows.
Spot No.
Seam type
Straight (long)
Circular (Circ)
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Process Manual QMS
1
2
3
4
5
1-2
2-3
3-4
4-5
5-6
1-2
2-3
3-4
4-5
5-1
Following BaaN session is used to maintain NDT request lines.

BaaN session Maintain NDT Request Lines (tclnt0162m000)
Field
Data
Request No
Request Generated
By
Part
Request No. generated for NDT by project/seam/stage
Seam No.
Offr
Seam no. is displayed under the request no.

Iteration No. initial value is 0, incremented by one for
subsequent regenerations.
Offer indicates test type, i.e. RT/UT
Shop
Shop where the testing is to be carried out.
Field
Data
Location
Location on the shop
Itr
It displays User id of requester.

Not applicable
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Process Manual QMS
Field
Data
Status
Status of the NDT request. By default it is set to Not attended

when new request is generated. Only NDT person can change
the status to Attended, Pending or Deleted.
Attended
Pending
Deleted
It indicates the NDT has been done

Request is put under pending status if NDT person is unable to
perform the test for the reasons beyond the scope of NDT as
well as shop.
If reason for postponing of the test is with shop then the record
is deleted by NDT person with remarks for deletion. Supervisor
has to take corrective actions & regenerate the request. In this
case no new iteration no is generated as test is yet to be done.
Supervisor
User id of the supervisor who has regenerated the NDT request.
Insp Ext.
Extent of inspection in percentage, generally 100 %
No. Of Spots
Enter th spot length in mm which determines the no. of spots

generated for the NDT. It also depends on the seam length.
Seam Length
Length of the seam under consideration (in mm)
Type
Seam type Straight / Circular
Radiation
Thickness of the radiation.
Confm
Indicates confirmation date Yes /No
Option Set
NDT Test Results
This option is available only with NDT person. HE/She can enter
test result by clicking on this option.
This option is used to edit the spot information like spot no.,
description ,length, etc
Requester uses this option to update the request details. It has
been discussed in the next section.
NDT Spots
Req. Details
Print Results
6.1.5.3
To print test results entered by NDT person
Maintain NDT Request Details
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Process Manual QMS
Requester provides NDT details for the seam under consideration. Some of the details
are updated by the system if they are maintained in other BaaN sessions.
e.g. Materials, thickness, applicable standards
Following BaaN Session is invoked through session Maintain NDT Request Lines.
Maintain NDT Request - Details (tclnt0162s101)
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Process Manual QMS
Form No.1
Field
Data
Material
Thickness
Condition of the seam / part surface is entered here by

supervisor /inspector through popup master
Part number is a unique for a project and is directly loaded from
customized BOM maintained for the project. Part number has
one to one relationship with item code. However part number is
same as position number in customized BOM for the final item
of the project instead of item number itself
This is the material of a part attached to a seam.
Thickness of material specified before.
Field
Data
Approx. dia
Approximate diameter of the specimen
Seam/ Part Length
Approximate length of the specimen
Welders Remark
Welders remark if any
Shop
Issuing shop number in which the part/ seam exists.
Location
Location of the shop at which part/ seam exists.
Supervisor
User ID of supervisor.
Conf Date
The date of the confirmation of NDT request.
Conf Time
Del Date
The time of confirmation of NDT request.

The date of deletion of NDT request.
Del Time
The time of deletion NDT request.
Regen Dt
System date when the request is generated.
Regen Tm
System time when request is generated.
Off. Dt
The NDT offer Date
Off Tm
The NDT offer Time
Surface Condition
Part
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Process Manual QMS
Form No.2
Field
Seam Thickness
Total Thk with Reinf
Joint Type
Inspection Extent
Applicable Spec
Acceptance
Standard
Welding Remarks
Manufacturing code
Agency
Consumable Mt
Type
Heat/ Plate No:
Data
Thickness of the seam (defaults from the data entered in
session maintain seam by project)
Total thickness
Defaults from the data entered in session maintain seam by
project.
Inspection extent determines whether this stage inspection need
to be performed fully or partially
Defaults from the data entered in session maintain acceptance
standard by stage of the project. It can be edited.
Defaults from the data entered in session maintain acceptance
standard by stage of the project. It can be edited.
Welding remarks if any.
Manufacturing code if any
Third party Inspection agency that has to be attached to the
range of stages maintained.
Consumable material type.
Material category
Heat /Plate number for identification.

It indicates the status of the request made by the inspector to
the NDT
Category of the material. It is entered through master.
Remark for deletion
Remark for deletion if any.
Request status
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Process Manual QMS
6.1.5.4
Enter NDT Test Results
NDT test results are entered by spots which decide inspection result for the stage.
Unlike non NDT stage (inspection stage), NDT inspection results include various other
details pertaining to type of NDT is used i.e. RT/UT. The details like, recordable
indications, parameter, RT/UT technique, search unit, etc. Only NDT person is
authorized to enter the NDT test results in the system.
Following test results can be entered for the spots according to the type of NDT (RT/UT).
Cleared
Remake
Rejected
Re shoot
Check Surface
If one of the spots are marked other than cleared, supervisor has to take corrective
action & regenerate the NDT request with new iteration no. Every time request is
regenerated, status of inspection changes to Offer to NDT & request status changes to
Not Attended. When all spots are marked cleared, the status for stage is change to
cleared.
Following sub session can be invoked to enter the NDT test results by clicking on NDT
test result option in the session Maintain NDT Request Lines ( tclnt0162m000)
OR
By clicking on Test Data option in the session Enter test results (tclnt0123m005)
BaaN Session Maintain Test Results for NDT tclnt1124s000
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Process Manual QMS
Form - Common
Field
Data
Test Instrument
This flag can be set to No if inspection of all the spots of the

seam is not completed within a shift. This results in creation of
new sample no. for the seam.
Zoom & select the Test instrument used for inspection
Duration From
Duration To
Enter the start date of inspection

Enter the end date of inspection
Remark
Enter the remarks if any.
Cleared Qty
Enter the quantity cleared.
Allocation
Option set
Parameters
Enter the allocation of Hours by Job, shop, RT/UT or sub-con
Details
Click on Details to enter the test results by spot.
Generate New
Samples
Display Results
This option can be used to generate to new sample if inspection

of the seam is not completed in one shift.
Displays test results for the seam.
Insp Complete
Click on Parameters option to enter required NDT parameters.

(Please refer 3.3.5.5 for further details.)
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Process Manual QMS
6.1.5.5
Maintain Test Results for NDT - SPOT
The sub session Maintain Test Results for NDT SPOT (tclnt1121s000) is invoked by
pressing Details option in the session discussed above. This session is used to enter
Recordable indications & inspection results for the spots. UT parameters can be entered
for each spot, e.g. probe angle, length, depth, etc.
In case of Third Party Inspection, results are entered for the agencies involved. Seam
can be finally cleared after entering internal (L&T) & external (TPI) inspection results for
all the spots of seam under inspection.
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Process Manual QMS
Form -Results
Field
Data
Result
Select inspection result from the list. The result entered for spots
determines the status of stage.
Spot is cleared by NDT. If all the spots are cleared along with
TPI results, stage status changes to cleared.
If result of any single spot is to Remake, entire seam is rejected
& stage status changes to Rejected in ICL.
Cleared
Remake
Rejected
The spot is rejected by NDT, supervisor needs to take corrective

action & regenerate the NDT request. Every time request is
regenerated, status of inspection changes to Offer to NDT &
request status changes to Not Attended.
Re shoot
NDT person re shoots the spots with result Re shoot. There is

no new request is generated by the supervisor, instead iteration
no. is incremented by one, e.g Itr. No. 1, 2....
Check surface
Supervisor needs to take corrective action & regenerate the

NDT request.
UT length
Length in mm
Recordable
Indications
Inspection
Remarks
Zoom & select the appropriate recordable indications. Not

applicable for UT
Reject
Set reject flag to YES if spot is rejected.
Enter UT details of indications, applicable for UT.
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Process Manual QMS
The other two forms are Data & TPI. The details of indications & reason code are
entered in DATA form whereas TPI results are entered in TPI form.
I
Page 45 of 58
Process Manual QMS
7. Final Inspection
Final Inspection ensures the completion of all Tests & Inspection activities for the final
deliverables before posting to FG. (Stores Crediting).
QC prepares the L&T Test Certificate in BaaN with details like Project No, Customer PO
No, Inspection Agencies, Applicable Standards, Signing Authorities, etc.
Following baaN sesseion is used to enter & print L&T Test Certificate
BaaN Session Maintain L&T Test Certificate (ltltc0101m000)
Page 46 of 58
Process Manual QMS
8. Third Party Inspection (TPI)

Sometimes inspection is required to be done by external inspection agencies to fulfill
mandatory requirement or demand by customer. External Agencies conduct various
types of checks & certify the product conformance to the stated requirements.
Third Party Inspection procedure has been mapped in L&T QMS module. User may use
following sessions to maintain data related to TPI. Results of TPI affect the final
clearance of the stage. Unless TPI is cleared, stage cannot be cleared even if internal
(L&T) inspection is cleared.
Activity Flow Chart
8.1.1 Generate Third Party Inspection Plan

This session is used to generate TPI for the entire project. Inspection agencies are
identified & inspection check type is maintained in the system. e.g. IBR, ABS, etc.
Inspection Check Types are review, witness, monitoring, verification, etc.
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Process Manual QMS
Field
Data
Project No.
Project No.
Stage
Select the stage/s to generate TPI
Agency 1..3
Zoom & select Inspection Agencies identified

Select check type applied for the agency. This determines the
role of inspection agency in final inspection.
Click on print button to generate TPI.
Check type
Print
8.1.2 Maintain Third Party Inspection Agencies by Stages

This session is used to maintain or edit Inspection Agencies and their check types
attached to their various stages of the project. It can be updated by selecting a record &
clicking on special to open session Maintain check type of Inspection Agencies
Update ICL button on this session links TPI with standard inspection & updates the same
in ICL for the stages selected.
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Process Manual QMS
Field
Data
Project No.
Project No.
Part
Part no. (not applicable)
Seam from __To
Select range of seams for the project

It displays stage under the seam selected. Each stage can be
selected individually to maintain Inspection Agency & Check
type.
Click on this button to update TPI data in ICL for the respective
stages.
Stage
Update ICL Line
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Process Manual QMS
Following sessions can be accessed by clicking on the special menu. Inspection

Agencies & Check types are maintained for the stages selected in earlier sessin.
8.1.3 Maintain Third Party Inspection Results

When Stage is subject to both type of inspection, i.e. Internal (L&T) & TPI, internal
inspection results are entered first in the system. the status changes to Provisionally
Cleared. TPI results are entered in the system with the details of inspection & status is
updated Cleared under final results of ICL lines.
Following session is used to Maintain Third Party Inspection Results
Select the record & click on zoom to maintain third party inspection details.
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Process Manual QMS
Select the record & click on zoom to maintain third party inspection details.
TPI inspection details are maintained in the session below.
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Process Manual QMS
9. Maintain Employee Authorization

Roles have been defined in QMS environment to perform specific tasks. These roles are
attached to employees (users) to assign the specific responsibility in their area of work.
The QMS role holders are mainly from three departments.
Welding Engineering
Quality Control
Production Center
This session is used to maintain user authorizations for the various sessions. The
authorities here for the users have to be maintained by super user so as to maintain
sanctity in the use of various sessions. Maintain & Approval sessions have been given to
different users for the effective process monitor & control.
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Process Manual QMS
9.1.1 Maintain NDT Personal Master

This session is used to maintain NDT persons & their details . Only persons maintained
here can be maintained as NDT Person= Yes in employee authorization
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Process Manual QMS
10. Exercise
1) Define new project in the system. Give project code as <your initials123>
Session Maintain Project with Sketch (tipcs2101m000)
2) Activate the project
Session Maintain Project Status (tipcs2102m000)
3) Maintain Extension to Project. (Accept the default final item).
Session Maintain Extension to Project (tclnt0110m000)
4) Define one Quality ID for the project. Define code as your <project code/1>
Session Maintain Extension to Quality ID (tclnt0150m000)
5) Maintain stages & parameters for the Quality ID defined earlier.
Session - Maintain Stages & Parameters by Quality ID (tclnt0154m000)
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Process Manual QMS
Select following type of stages & save the record. If no parameter is maintained for
stage, insert minimum 2 parameters from the list.
i) Inspection type 2 nos. (Select the stage with seq. no. 10 & 20)
ii) Others type -3 nos.
iii) RT or UT 3 nos.
6) Maintain acceptance standards & specification for the selected stages.
Session - Maintain Acceptance Std by Stage of the Project (tclnt0148m000)
7) Define Seams for the project. Create Seam code as <your project code/001>
Session Maintain Seam by Project (tclnt0111m000)
Define minimum 3 seams for your project & link them to your Quality ID.
8) Review the test plan for the seams.
Session Maintain Test plan (tclnt0123m000)
Observe stages appear in the test plan. (All the stages linked to Quality ID do not
populate in Test plan).
Add any one new stage in the test plan of each seam.
Observe the changes taking place in some of the fields.
9) Approve the Test Plan.
10) Add any one new stage in the test plan of each seam & observe the changes taking
place in some of the fields.
Approve the test plan & update the revision no.
11) Copy test plan stages into ICL. Observe stages that are copied into ICL.
12) Add new stages in ICL before or after the stages exist in ICL.
Session Maintain ICL Lines (tclnt0123m001)
13) Prepare Vertical Checklist by adding default stages for the project.
Add minimum 5 default stages & select stage type as miscellaneous.
Observe the change in ICL after creating default stages.
Session Maintain Default stages by Project (tclnt0112m000)
14) Define new parts of the project (end product) for overall inspection.
Session Maintain Parts for Inspection by Project (tclnt0111m001)
15) Add inspection stages in ICL for the parts defined earlier.
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Process Manual QMS
16) Approve ICLs prepared for all the seams & parts.
17) Add new stages in one of the stage & observe change in ICL. Approve ICL & update
revision no. & status. Observe change in status for the stage with lowest sequence no.
18) Offer stage for inspection after filling all required details & observe the change in
status.
Session Maintain offers for Inspection (tclnt0123m004)
Session Maintain Welding process by project/seam/welder (tclnt0124m000)
19) Enter test results for the stage under inspection & observe changes in ICL.
Session - Enter Test Results (tclnt0123m005)
If the stage type is NDT then follow below steps
20) Generate NDT request & note the request no. Observe change in ICL.
Session Generate NDT Request (tclnt0223m001)
21) Maintain NDT Request lines & details for the request generated.
Session Maintain NDT Request Lines (tclnt0162m000)
22) Enter NDT results & observe changes in ICL
Session - Maintain NDT Request Lines (tclnt0162m000)
Scenarios
1) Reject one of the stages & re offer for Inspection. Observe various changes taking
place in ICL.
2) Reject few spots in NDT & regenerate NDT request.
Page 56 of 58
Process Manual QMS
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Process Manual QMS
END OF USER MANUAL
Page 58 of 58

User Manual QMS - Quality Control

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Process Manual QMS

L & T, Heavy Engineering Division

Process Manual - QMS

Process Manual QMS

User Manual Quality Control - Quality Control

To guide QMS users through BaaN QMS Module.

2nd May 2008

Process Manual - QMS

Process Manual QMS

Quality Control (QC)................................................................................................................6

3.3 In Process Inspection..............................................................................................................10

3.4 Final Inspection......................................................................................................................42

Maintain Employee Authorization.........................................................................................48

Generate Third Party Inspection Plan.....................................................................................................43

Process Manual - QMS

Process Manual QMS

Process Manual - QMS

Process Manual QMS

Process Manual - QMS

Process Manual QMS

Followings are the three process owners of QMS in BaaN.

Welding Engineer - Welding Engineering

Quality Control (QC)

Process Manual - QMS

Process Manual QMS

5.1.1 Maintain Approval

Process Manual - QMS

Process Manual QMS

IMR no. awaiting for inspection

Defaults from the IMR

Defaults from the IMR

Process Manual - QMS

Process Manual QMS

5.1.2 Provisional Approval

Process Manual - QMS

Process Manual QMS

Inspection status is changed to PRV to maintain provisional clearance.

Process Manual - QMS

Process Manual QMS

6.1.1 Test Plan (TP)

Process Manual - QMS

Process Manual QMS

6.1.2 Inspection Checklist (ICL)

Copy Test plan Stages into Checklist

Process Manual - QMS

Process Manual QMS

Inspection Checklist is prepared by clicking on the button ICL Preparation

Preparation of Vertical Check List

Process Manual - QMS

Process Manual QMS

Process Manual - QMS

Process Manual QMS

Zoom to stage master & select the appropriate stage.

Seam & Part only

Maintain Parts for Inspection by Project

Process Manual - QMS

Process Manual QMS

Enter the part no & description for the section of assembly

Default is 0 (not relevant)

Login id is captured by the system when the record is saved.

Maintain / Update ICL

Process Manual - QMS

Process Manual QMS

Enter the part no to update the Part ICL