Module 1:

QA and QC Terminology
Ts. Mohamad Riza Bin Ismail

Module 1: QA and QC Terminology

What is Quality?
• Degree of excellence or superiority of a product, service, or process in meeting or
exceeding the expectations and requirements of its intended users or customers.
• It is a multidimensional concept that encompasses various attributes and
characteristics that contribute to the overall value and satisfaction experienced by the
end-users.
Key aspects of quality include:
1. Performance
2. Reliability
3. Durability
4. Safety
5. Features
6. Aesthetics
7. Service
8. Consistency
9. Customer Satisfaction
Module 1: QA and QC Terminology
Standards Related to Quality in Welding:

ISO 9000 Quality System

EN ISO 3834 - Quality

Requirements for
Fusion Welding of
Metallic Materials

EN ISO 17662 -
EN ISO 5817 - Welding
EN ISO 15614 - Welding - Calibration,
EN ISO 9606 - EN ISO 14731 - - Fusion-Welded Joints
Specification and Verification, and
Qualification Testing of Welding Coordination - in Steel, Nickel,
Qualification of Validation of
Welders - Fusion Tasks and Titanium, and Their
Welding Procedures Equipment Used for
Welding Responsibilities Alloys (Quality Levels
for Metallic Materials Welding, Including
for Imperfections)
Ancillary Activities

Module 1: QA and QC Terminology

Quality Assurance (QA) and Quality Control (QC):
Why are QA/QC Processes Needed?

Contracts for fabrications often require adherence to specific welding standards, which, in
turn, may outline the implementation of well-defined QA/QC processes. In some instances,
customers may demand a more stringent QA/QC framework than what the standard
requires.

Certain industries have regulatory requirement that necessitate compliance with particular
welding standards, making the use of designated QA/QC processes mandatory. These
industries encompass pressure vessels, structural steelwork, and lifting equipment.

QA/QC serves as a means to demonstrate the meticulousness exercised during the

fabrication process. It also captures the product's condition throughout its fabrication and
upon completion. This data can be utilized in the future to counter claims of product defects.
Module 1: QA and QC Terminology
What can happen if QA/QC Procedures are Not Followed?

Poor Quality Customer Rejections and

Safety Risks
Products Dissatisfaction Rework

Legal and
Loss of Market Safety Incidents
Increased Costs Contractual
Competitiveness and Liability
Issues

Damage to
Loss of Business
Brand
Opportunities
Reputation

Module 1: QA and QC Terminology

Quality Assurance (QA):
• Systematic and proactive approach to preventing defects and ensuring that the
final product or service meets specified requirements
• Establish processes and standards that guarantee the quality of the product or
service throughout the entire development or production lifecycle
• Focuses on prevention rather than detection

Typical activities;
1. Process Design and Implementation
2. Quality Planning
3. Auditing
4. Training
5. Document Control
6. Continuous Improvement
7. Risk Management
Module 1: QA and QC Terminology
Quality Assurance Documents:
Quality
• Records and written materials that Quality Policy Quality Manual
Procedures
outline the policies, procedures,
guidelines, and standards related to
Work Records and
the quality management system within Instructions
Quality Plans
Forms
an organization.
• These documents serve as a reference Corrective and
and guide for employees to follow Training Internal Audit
Preventive
Materials Reports
consistent practices that ensure Action Reports
product or service quality and
compliance with established Management Supplier Quality Change Control
Review Reports Agreements Documents
requirements.
• Some common QA documents include:
Risk Calibration and Customer
Management Maintenance Feedback and
Documents Records Complaints
Module 1: QA and QC Terminology
Sample of Quality Policy:
At XYZ, we are dedicated to delivering exceptional welding services and products that meet or exceed our customers' expectations. We are
committed to ensuring the highest level of quality, safety, and reliability in all our welding operations.

Our Welding Quality Policy is founded on the following principles:

1. We strive to understand our customers' welding requirements fully and deliver welding solutions that meet their needs with the highest
quality and value.
2. We comply with all relevant welding standards, industry codes, and regulatory requirements to ensure the integrity and safety of our
welding work.
3. We invest in the training and development of our welding personnel, ensuring they possess the necessary skills and knowledge to perform
their tasks proficiently.
4. We are committed to continuously enhancing our welding processes, techniques, and technologies to achieve greater efficiency and quality.
5. Our welding quality assurance program ensures that our welding processes and products consistently adhere to the highest quality
standards.
6. We implement environmentally responsible welding practices and strive to minimize the environmental impact of our operations.

Management and every employee of XYZ are responsible for adhering to this Welding Quality Policy. We will regularly review and improve our
welding processes to ensure ongoing compliance and customer satisfaction.

This policy shall be communicated to all employees, suppliers, and contractors involved in welding activities, and it will be made available to all
interested parties.

XYZ's commitment to welding quality reflects our dedication to becoming a leading provider of welding services and products in our industry.

Module 1: QA and QC Terminology

Contents of Quality Manual:
Introduction Quality Management System Welding Management Welding Processes and Procedures
•Purpose of the Manual •Quality Policy •Welding Coordinator's Role and •Welding Techniques and Best Practices
•Scope of the Manual •Organizational Structure and Responsibilities Responsibilities •Pre-Welding Preparations and Inspections
•Applicability and References •Management Commitment to Quality •Welding Process Qualification and Certification •In-Process Weld Inspections and Testing
•Document Control Procedures •Welder Qualification and Certification •Post-Weld Inspection and Non-Destructive
Records Management Procedures •Welding Procedure Specification (WPS) Testing (NDT)
Development and Approval •Weld Repair Procedures
•Welding Consumables Control and Storage

Welding Quality Assurance Health, Safety, and Environment Quality Training and Competence Customer Requirements
•Quality Audits and Reviews (HSE) •Welding Training Program and Requirements •Understanding Customer Needs and
•Corrective and Preventive Actions •Occupational Health and Safety Measures •Competence Assessment and Certification Expectations
•Non-Conformance Reporting and Management •Environmental Considerations in Welding •Customer Communication and Feedback
•Change Management and Control •Personal Protective Equipment (PPE)
Requirements

Suppliers and Subcontractors Quality Performance Metrics Continuous Improvement Appendices

•Supplier Evaluation and Approval Process •Key Performance Indicators (KPIs) •Continual Enhancement of Welding Processes •Glossary of Welding Terms
•Supplier Quality Requirements and •Monitoring and Measuring Welding Quality •Management Review and Improvement •List of Approved Welding Procedures and
Performance Initiatives Welders
•Relevant Industry Standards and Codes
•Records and Forms

Module 1: QA and QC Terminology

Contents of Quality Procedure: Approval and
Review
Quality procedures are a set of
Title and
documented instructions and guidelines References
Purpose
that provide step-by-step details on how
specific quality-related activities and
processes should be performed within
an organization. Forms and Quality Scope
Records Procedure
Each quality procedure should be
written in a consistent format to
facilitate easy comprehension and
navigation. Procedure
Definitions
Steps

Responsibilities

Module 1: QA and QC Terminology

Quality Assurance Principle:

What are you going to do

(by writing procedures)

Do it – in compliance with our own

procedures

Demonstrate that we have done it

By doing check audit By keeping proper records

Module 1: QA and QC Terminology

Quality Assurance in Welding:
Importance in welding processes to ensure the safety, reliability, and performance of welded components
and structures. QA in welding involves a systematic approach that encompasses various activities and
practices aimed at maintaining consistent and high-quality welds.

Welding Procedure Inspection and

Welder Qualification Material Control
Specification (WPS) Testing

Welding Equipment
Documentation and Welding Quality Training and
Calibration and
Record Keeping Metrics Certification
Maintenance

Welding Process Corrective and

Audits Preventive Actions

Module 1: QA and QC Terminology

Quality Control (QC):
• Quality Control (QC) is a reactive process that involves monitoring and testing the
final product or service to identify defects or deviations from the established quality
standards.
• Unlike QA, which focuses on preventing issues, QC is concerned with detecting and
correcting problems before the product is released to customers.

Key activities in QC include:

• Inspection
• Testing
• Corrective Action
• Sampling

Module 1: QA and QC Terminology

Quality Control in Welding:
• QC in welding is the process of inspecting, testing, and verifying welds to ensure that
they meet specified quality standards and requirements.
• QC focuses on detecting and correcting defects or deviations in welds before the final
product or structure is released to customers or put into service.
• It complements Quality Assurance (QA) practices by providing a reactive approach to
identify and address issues during or after the welding process.

Module 1: QA and QC Terminology

QC Prior to Welding

Before During After

In-process Post-Weld Inspection
Material Inspection
Monitoring
Mechanical Testing
WPS Development /
Visual Inspection
Selection Documentation and
Record-Keeping
Non-Destructive Final Acceptance
Welder Qualification
Testing (NDT) Inspection

Module 1: QA and QC Terminology

QA vs QC
In summary, Quality Assurance (QA) involves establishing processes and standards
to prevent defects and ensure quality throughout the development or production
process,

While;

Quality Control (QC) focuses on detecting and correcting defects in the final
product or service through inspection and testing.

Both, QA and QC are crucial elements of effective quality management systems and
work together to ensure the delivery of high-quality products or services to
customers.

Module 1: QA and QC Terminology

Welding Coordinator:
Leadership Technical
• Also known as a Welding Engineer skills skills
• Professional responsible for overseeing
and coordinating welding activities within
an organization or project.
• The role of a Welding Coordinator is Knowledge Knowledge of
crucial in ensuring that welding processes of normative
technology documents
are carried out in a safe, efficient and
quality-conscious manner.
• To ensure that Welding Coordinator are
able to perform their duties well, they Knowledge
Knowledge of
need to have various skills, including; planning
of
organisation

Module 1: QA and QC Terminology

Duties and Responsibilities of Welding Coordinator:
1. Developing and qualifying welding Procedures Specification (WPS)
2. Ensuring that welders are qualified and certified to perform specific welding tasks
3. Selecting welding process based on the materials, joint design and project requirements
4. Coordinating welding inspections and testing
5. Ensuring that welding equipment and tools are appropriately selected, calibrated and
maintained
6. Ensuring compliance with safety regulations and promoting a safe working environment
7. Maintaining accurate and up-to-date documentation
8. Providing training and guidance to welding personnel
9. Identifying opportunities for process improvement
10. Serving as a liaison between engineering teams, welding personnel and project
management

Module 1: QA and QC Terminology

1. Developing and Qualifying Welding
Identify Project Requirements
Procedures Specification (WPS):
Material Selection and Testing
• Developing and qualifying Welding Define Welding Parameters
Procedure Specifications (WPS) is a critical
Prepare Test Coupons
process in ensuring the quality and integrity
of welds in various applications. Conduct Welding Tests
• WPS documents outline the specific welding Non-Destructive Testing (NDT)
parameters and techniques required to Mechanical Testing
achieve sound and reliable welds.
Evaluate Test Results
• Here are the steps involved in developing
and qualifying a WPS: Documentation
WPS Review and Approval
Requalification and Revisions
Training and Implementation

Module 1: QA and QC Terminology

2. Ensuring that Welders are Qualified and Certified:
• Welder Qualification Test (WQT) / Welder Performance Qualification (WPQ) will carry
out to determine whether the welder or the weld operator can produce a sound weld
or not.
• Here are the steps involved in ensuring welder qualification and certification;

• Welder Training • Practical Welding • Written • WQT / WPQ • Review and

and Education Test Examinations Documentation

• Certification • Third-Party • Quality Control and • Continuous • Compliance with

Renewal Certification Oversight Education Industry Standards

Module 1: QA and QC Terminology

3. Selecting Welding Process Based on The Materials, Joint Design and
Project Requirements:
• Selecting the most suitable welding process based on the materials, joint design and
project requirements is essential to achieve high-quality and efficient welds.
• Each welding process has its advantages and limitations, so it's crucial to consider
several factors before making a decision.
• Here are the steps to select the appropriate welding process: Understand Material
Properties

Identify Project
Evaluate Joint Design
Requirements

Joint Accessibility Welding Speed and Productivity

Equipment Skills and

Environmental Considerations
Availability Qualifications

Module 1: QA and QC Terminology

4. Coordinating Welding Inspections and Testing:
• Welding Inspection and Test Plan (ITP) is key working documents for the QC
coordinator and inspection team
• Give direct instruction detailing the sequence of operations / activities to be carried
out in accordance with the specification requirements
• It specifying which procedures and associated resources shall be applied by whom and
when.
• A large contract can have several hundred ITPs, using different formats and containing
varying degrees of detail.
• Some contract specifications will often include in ITP to indicate the level of
information required.

Module 1: QA and QC Terminology

Simple Welding Inspection and Test Plan (ITP):
INSPECTION POINT

STEP REFERENCE CERTIFICATION RECORD

OPERATION M TPI C
NO. DOCUMENTS REQUIREMENT NO.
1 Pre-inspection meeting Spec. H H H - A
2 Drawing & Design - H R R - B
3 Weld procedures WPS R - - EN ISO 15614 C
4 Welder approvals EN ISO 9606 R - - EN ISO 9606 D
5 10% RT BS 2600 R R - Record sheet E
6 100% MPI BS 6072 R R - Record sheet F
7 Visual inspection BS 5289 R W W Record sheet G
8 Document review - R R R - H

M = Manufacturer; TPI = Third party (or clients) inspection organization; C = Clients

H = Hold point; W = Witness point; S = Surveillance; R = Review
Module 1: QA and QC Terminology
5. Ensuring that Welding Equipment and Tools are Appropriately Selected,
Calibrated and Maintained:
Calibration and
Equipment Selection Calibration Maintenance
Maintenance Records
• Identify the specific • Calibrate welding • Develop a preventive • Maintain
welding processes equipment to ensure maintenance program comprehensive records
required accuracy and reliability • Inspect and clean • Keep track of
• Choose welding • Maintain a calibration welding equipment maintenance activities
equipment schedule

Training and Skill Compliance with Replacement and

Safety Considerations
Development Standards Upgrades

• Provide training to • Promote a safety- • Ensure welding • Monitor the

welding operators and conscious culture equipment and tools performance of
maintenance • ensure all safety comply with relevant welding equipment
personnel measures are followed industry standards

Module 1: QA and QC Terminology

6. Ensuring Compliance with Safety Regulations and Promoting a Safe
Working Environment:

Familiarize with Safety Provide Safety Signage and Incident Investigation and
Regulations Communication Reporting

Establish Safety Policies and

Conduct Safety Audits Emergency Preparedness
Procedures

Inspect and Maintain Safety Engage in Safety Culture

Conduct Safety Training
Equipment Promotion

Promote Safe Working Hazard Identification and

Regular Safety Meetings
Practices Risk Assessment
Module 1: QA and QC Terminology
7. Maintaining Accurate and Up-to-date Documentation:
Maintaining accurate and up-to-date documentation is critical for ensuring welding quality,
safety, compliance, project management, and continuous improvement. It provides a
reliable source of information, helps mitigate risks, and enhances overall efficiency and
performance in welding operations.

Main welding documents to be maintained;

Equipment Maintenance /
WPS Welder Qualification Records
Calibration Records

Material Certificates Inspection and NDT Reports ITP

Consumables Records Safety Records Project Records

Module 1: QA and QC Terminology

8. Providing Training and Guidance to Welding Personnel:
• Conduct a comprehensive assessment to
identify the specific training needs of
Safety
welding personnel. Material and
Hands-on
• Consider factors such as their current Welding
Metallurgy
Practical
skills, experience and the welding
processes they will be involved in.
• Design and develop training programs Inspection, DT Project

that cover essential topics such as

& NDT Types of Management

welding techniques, safety practices, Training

welding codes and standards, welding Joint Design
Codes and
and
procedure qualifications and equipment Preparation
Standards

operation.
Welding
Automation WQT / WPQ
and Robotics

Module 1: QA and QC Terminology

9. Identifying Opportunities for Process Improvement:

Data Training and

Collection Skill
Development
Evaluate
Equipment Root Cause
and Analysis
Technology
Document Safety
Changes Enhancement

Identify
Cost Analysis
Opportunities Continuous Areas of
for Feedback Improvement
Improvement

Collaborative
Automation
Approach

Supplier Process
Evaluation Mapping

Standardization
Benchmarking

Module 1: QA and QC Terminology

10. Serving as a Liaison between Engineering Teams, Welding Personnel
and Project Management:
Understand the overall • Act as a bridge to • Develop and qualify • Incorporate welding
project scope, welding translate engineering WPS activities into the
requirements and specifications overall project plan and
specific objectives schedule

Project Scope Translating Coordination Project

and Engineering of Welding Planning and
Requirements Specifications Procedures Scheduling

• Allocate the necessary Ensure welding activities • Act as a problem solver • Establish a feedback
resources are compliance with • Mediate and find loop
safety regulations, resolutions for conflicts • Assess the
quality standards, and performance of
project specifications. welding activities

Problem Feedback
Safety and
Resource Solving & Loop &
Quality
Allocation Conflict Performance
Compliance
Resolution Evaluation
Quality Audit:
• QC coordinator may be required to assist in the audit process.
• Quality audits examine a quality system for adequacy and correct implementation and
defined as systematic and independent examinations to determine whether quality
activities and related results comply with planned arrangements and whether these
arrangements are implemented effectively and are suitable to achieve objectives.
• Auditing provides objective evidence that the system is working in accordance with
the procedures.
• When an audit is complete, the results are analyzed by management who must
ensure that the quality policy is satisfied and modify the quality system if necessary.

Depths of audit:
1. Systems audit
2. Compliance audit
3. Ongoing audit

Module 1: QA and QC Terminology

Auditing of Documentation:
The purpose of auditing a document is to ensure accuracy, completeness, consistency,
and compliance with specific requirements.

Items to check include:

• Is all the documentation available?
• Is the documentation schedule in accordance with contract or specification
requirements?
• Does the documentation comply with contract or specification requirements e.g. are
weld procedure and welders correctly qualified?
• Is it the correct material composition?
• Is the documentation legible?
• Have all interested parties, e.g. inspection department, independent third party
inspectors, client inspectors, signed off where required?
• Has provision been made for storage, including the capability to retrieve documents,
and are the storage conditions designed to prevent deterioration?
Module 1: QA and QC Terminology
Thank you…

Module 1: QA and QC Terminology