Source Inspection and Quality Surveillance

Vendor QA/QC Audit & Mill Surveillance

A vendor QA/QC audit is intended to identify quality and procedural gaps that may lead to equipment failures or poor performance. The RPA auditor reviews product traceability, shipping and receiving procedures, personnel training records, inspection, assembly, and function test procedures, and equipment storage and handling.  Reviews of work in progress are often conducted to verify that the vendor’s employees are following their documented procedures for inspection, assembly, and testing of their equipment. The result is an understanding of the vendor’s quality management system and identification of any issues.  We can continue to work with the vendor, on behalf of our customer, to correct any issues and mitigate risk of equipment failure. RPA can conduct an audit to meet your operational objectives and provide specific recommendations to drive quality improvement.

The quality assurance and control processes commence well before manufacturing process begins.  We first provides a combination of Project Managers, Engineers and QA/QC Technicians to review the Process Control Points (PCPs) in order to identify witness, monitoring, and documentation review points for all stages of the manufacturing process. These are established in accordance with applicable client requirements in a pre-production meeting where the client’s concerns and choices are discussed and applicable standards agreed upon.

Check lists are then developed for review of the documentation, manufacturing processes and receiving inspections.  An Engineer reviews material specifications and establishes accept/reject criteria that are used to monitor manufacturing and inspection of all components.

Our Project Manager makes initial visits to evaluate systems specific to the client’s order, meet with manufacturing personnel and discuss RPA’s involvement in line with the PCPs. These processes are then monitored by the Technicians who will witness, review and document manufacturing and mill inspection and prepare weekly status reports for submittal to the client.

This closely monitored process is shared by the Project Manager in regular client meetings throughout the manufacturing process to ensure that the client’s requirements are met and the equipment delivered is fit for purpose.

Quality Management System Audit of Manufacturing & Service Supply Organizations 

RPA provides quality management system audit for organizations that manufacture products or provide manufacturing-related processes under a product specification and service supply organizations for use in the petroleum and natural gas industry based on API-Q1 & API-Q2 specification.

This Audit provides the requirements of a quality management system for an organization to demonstrate its ability to consistently provide reliable products and manufacturing-related processes that meet customer and legal requirements. We assess the organization‘s ability to meet customer, statutory, and regulatory requirements applicable to the product and the organization‘s own requirements.

For an organization to function effectively, it has to determine and manage numerous linked activities. An activity that transforms inputs into outputs can be considered a process. Process activities include determination of needs throughout the organization, provision of resources and product realization, identification of the proper sequence or order in a series of activities, monitoring and measuring the effectiveness of the activities performed, and applying changes or corrections to those activities as needed.

Source Inspection and Quality Surveillance of Fixed Equipment

We provide quality surveillance of materials, equipment and fabrications being supplied for use in the oil, petrochemical and gas Industry, including upstream, midstream and downstream segments.

RPA provides a systematic approach to risk-based source inspection in order to provide confidence that mechanical rotating equipment being purchased meet the minimum requirements as specified in the project documents and contractual agreements.

The purpose of source inspection is simply to verify that the suppliers/vendors quality process is working as it should and to verify that certain vital steps in the inspection and test plan (ITP) have been satisfactorily accomplished prior to manufacturing completion and/or shipping.

This department of  RPA focuses primarily on Pressure Containing and Structural Equipment including but not limited to: vessels, columns/towers, heat exchangers, piping, valves, pressure relief devices, tubulars and associated structural fabrications.

Like most business processes, the Source Inspection work process follows the PDCA circular process. The “Planning” part of source inspection involves the source inspection management systems, source inspection project plan and the Inspection and Test Plan (ITP). The “Doing” part involves implementing the ITP, participating in scheduled source inspection work process events, filing nonconformance reports and source inspection report writing. The “Checking” part involves looking back at all the source inspection activities that occurred in the Planning and Doing segments to see what went well and what should be improved based on the results of that look-back. And finally the “Act” part involves implementing all the needed improvements in the “Planning and Doing” process before they are implemented on the next source inspection project.

Source Inspection and Quality Surveillance of Rotating Equipment

We provide quality surveillance of materials, equipment and fabrications being supplied for use in the oil, petrochemical and gas Industry, including upstream, midstream and downstream segments.

RPA provides a systematic approach to risk-based source inspection in order to provide confidence that mechanical rotating equipment being purchased meet the minimum requirements as specified in the project documents and contractual agreements.

The purpose of source inspection is simply to verify that the suppliers/vendors quality process is working as it should and to verify that certain vital steps in the inspection and test plan (ITP) have been satisfactorily accomplished prior to manufacturing completion and/or shipping.

This department of  RPA focuses primarily on Mechanical Rotating Equipment including but not limited to: pumps, gears, compressors, turbines, etc. and associated appurtenances.

Like most business processes, the Source Inspection work process follows the PDCA circular process. The “Planning” part of source inspection involves the source inspection management systems, source inspection project plan and the Inspection and Test Plan (ITP). The “Doing” part involves implementing the ITP, participating in scheduled source inspection work process events, filing nonconformance reports and source inspection report writing. The “Checking” part involves looking back at all the source inspection activities that occurred in the Planning and Doing segments to see what went well and what should be improved based on the results of that look-back. And finally the “Act” part involves implementing all the needed improvements in the “Planning and Doing” process before they are implemented on the next source inspection project.