QC Check Sheets (overview) - QA/QC-Construction Ltd

THE QUALITY LIVES ON LONG AFTER THE PRICE

ISO 9001:2000 QUALITY MANAGEMENT SYSTEMS IN THE FAST TRACK (EPC) ENGINEEER, PROCUREMENT & CONSTRUCTION PROJECTS

QUALITY PLANNING PREVENTS PATHETIC PERFORMANCE

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QC Check Sheets (overview)

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and Inspect.

Using QC Inspection Checklist for As-built Verification and Mechanical Completion

A checklist is a structured form or questionnaire for collecting and analyzing data. This is a generic tool that can be adapted for a wide variety of purposes. Collecting and analyzing data is important for identifying and understanding problems and thus making appropriate changes to solve these problems.

Prospective Users
Inspection checklists are useful on construction projects that wants to improve quality and productivity, reduce defect rates, and reduce re-work.

Problem Addressed:

Increasing or high frequency of product faults.
High rates of defective products requiring repair or re-work.
High levels of waste materials.
Low productivity.
Verification documentation for as-building of the project for project turnover.

Process
This practice requires line managers and quality control staff to collect information about the number and sources of defects in the construction process. Information about the number, causes and frequency of the defects are recorded in the checklists and tallied to show totals. These totals can then be analyzed to see the times most defects are made, the types of defects and the most common causes of defects. This information can then be used to reduce defects.

Steps in implementation

Decide what construction activity will be observed or inspected.
Identify the period to be observed or inspected. This period should be relevant to the problem.
Develop a standard table or form for each type of construction activity based on criticality.
Name the columns and rows in the table.
The checklist form is usually an A4 sheet with a table with rows indicating types of defects and columns indicating the time the mistakes are detected. The QC inspector fills in the number of defects of each type in the cell of the relevant defect and time period. This checklist helps to identify the major types of defects.
Make standard format check sheets available each construction activity.
Discuss the results and draw conclusions.
Discuss possible actions for improvement.
The inspection checklists should be stored in a safe place.
The summary the inspection check sheet can be used as input for a quality improvement program. The checklist totals can be used to identify which errors are most common, and to try to prevent these errors in the future. Workers may need additional training or guidance in order to avoid making such errors.
Resources Required
- Line managers and QC quality inspectors' involvement.
- Check sheets.
- Document controller

Challenges and pitfalls

Staff may feel they have more work to do.
Difficulty in maintaining efforts to collect information.

Positive Impact

Helps to record all faults and sources of faults.
Saves money by helping to eliminate major sources of defects.
Bench mark best practices for quality improvement.
Transparent and honest reporting

Indicators for monitoring

QC Check sheets form created and made available.
QC Check sheets filled, summarized and discussed.

1. Application For Inspection	01 APPLICATION FOR INSPECTION
2. Material Control	01A MATERIAL RECEIVING REPORT 01B OVER SHORTAGE DAMAGE REPORT 002 MATERIAL INSPECTION REPORT 003 STORAGE REPORT 005 HANDLING REPORT 008 MATERIAL REQUEST ISSUE SLIP 009 STOCK CARD 010 MATERIAL RETURN SLIP 011 MATERIAL SURPLUS LIST 109 MATERIAL ACCEPTED LABEL 110 MATERIAL REJECTED LABEL 111 MATERIAL HOLD LABEL 112 CONDITIONAL RELEASE LABEL 113 MATERIAL RELEASED LABEL
3. Surveys	122 FINAL INSPECTION OF INTERSECTION POINTS, PIPE SUPPORT & CROSSFALLS 123 SURVEY REPORT PAD AND EQUIPMENT AREA 124 FINAL INSPECTION OF PIPE COLUMN 125 FINAL INSPECTION OF PIPE COLUMN, HEAD, SHOE 126 SURVEY REPORT 127 FINAL INSPECTION OF PIPE ANCHOR 128 FINAL INSPECTION OF ROAD CROSSING 129 FINAL INSPECTION OF ROAD 130 EQUIPMENT TEST
4. Building Installation	01 ASPHALT WATER PROOFING WORK 02 WATER PROOFING PROTECTION 03 DAMPPROOFING/WATER REPELLENT WORK 04 CAULKING AND JOINT FILLER INSTALLATION 05 TILE WORK 06 WOOD WORK 07 ROOFING INSULATION, ROOFING AND SIDING WORK 08 DOWN SPOUTS AND ROOF DRAIN WORK 09 STEEL FRAMING WORK 10 MISCELLANEOUS METALS INSTALLATION 11 INSPECTION OF PLASTER WALL & FLOOR FINISH 12 FIXTURES AND HARDWARE INSTALLATION 13 GLASS AND GLAZING INSTALLATION 14 VINYL FLOOR TILE WORK 15 GYPSUM BOARD INSTALLATION 16 ACOUSTICAL BOARD INSTALLATION 17 PIPING INSTALLATION (1 of 2) 18 PIPING INSTALLATION (2 of 2) 19 SANITARY EQUIPMENT INSTALLATION 20 MISCELLANEOUS EQUIPMENT INSTALLATION 21 PRESSURE TEST 22 LEAKAGE TEST 23/1 FIRE PROTECTION EQUIPMENT INSTALLATION 23/2 FIRE PROTECTION EQUIPMENT INSTALLATION CHECK 24 TEST RECORD OF PIPING & DUCTING 25 BUILDING INSPECTION RECORD 26 ACCEPTANCE OF BUILDING EXTERNAL 27 ACCEPTANCE OF BUILDING INTERNAL
5. H.V.A.C.	01 AIR HANDLING UNIT & FANS 02 HVAC SYSTEM FUNCTION CHECK 03 HVAC SYSTEM NOISE MEASUREMENT 04 ACCEPTANCE CERTIFICATE OF BUILDING EQUIPMENT 05 HVAC INSTALLATION CHECK LIST
6. Earthwork	01 SEWER PIPING WORK 02 OPEN DITCH 03 WATER LEAKAGE OF SEWER LINE 12 NEW ROADS FINISHING WORKS 13 COMPACTION OF STRUCTURAL FILL 14 CLEARING OF NEW LAND 15/1 COMPACTION TEST OF SAND BEDDING BY CLEGG HAMMER 15/2 COMPACTION TEST OF SAND BEDDING BY CLEGG HAMMER 16 INSPECTION OF LANDSCAPING 17 INSPECTION OF LANDSCAPE EQUIPMENT
7. Concrete Work	01 TRIAL MIX OF CONCRETE 02 COMPRESSIVE STRENGTH TEST OF CONCRETE 03 RECORD OF ANCHOR BOLT FOR STEEL STRUCTURE 04 CONTROL MIX OF CONCRETE 05 TANK FOUNDATION RECORD 06 EARTH & CONCRETE WORK FOUNDATION 06/1 PRE-CONCRETE INSPECTION RECORD 07 PROCTOR TEST 08 CONCRETE AGGREGATES 09 CABLE PULL PITS PRE POURING 10 CABLE PULL PITS POST POURING 11 INSPECTION OF REINFORCING BAR INSTALLATION
8. Piping Work	01 PIPE WORK PRETEST CHECK LIST 02 HYDROSTATIC TEST REPORT 02/2 HYDROSTATIC TEST REPORT 03 FLUSHING, BLOWING AND CHEMICAL CLEANING ACCEPTANCE CERTIFICATE 03/2 FLUSHING AND CLEANING REPORT 04 PIPE WORK POST TEST CHECK LIST 05 MECHANICAL COMPLETION OF PIPE WORK 06 PIPING WORKS INSTALLATION 07 BURIED FRP PIPE INSTALLATION
9. Structural	01 STEEL WORK FABRICATION CHECK LIST 02 STEEL WORK INSTALLATION CHECK LIST 03 STRUCTURE INSTALLATION
10. Structural Steel For Buildings	01 INSPECTION OF STRUCTURAL STEEL FABRICATION 02 INSPECTION OF STRUCTURAL STEEL ERECTION
11. Welding	01 WELDER QUALIFICATION TEST 2/1 PROCEDURE QUALIFICATION RECORD (PQR) 2/2 PROCEDURE QUALIFICATION RECORD (PQR) 03 WELDING PROCEDURE SPECIFICATION 04 WELDERS QUALIFICATION LOG 05 WELDERS PERFORMANCE CHART 06 DAILY FIELD WELD REPORT 07 WELDER B31.3 RANDOM RADIOGRAPHIC CONTR. LOG 8/1 WELD TRAVEL SHEET 09 HEAT TREATMENT INSTRUCTION SHEET 10 CONSUMEABLE CHECK LIST FOR WELDING WORK
12. New/Special Processes	01 RADIOGRAPHIC EXAMINATION LOG 02 MAGNETIC PARTICLE EXAMINATION LOG 03 LIQUID PENETRANT EXAMINATION LOG 04 ULTRASONIC EXAMINATION LOG 05 RADIOGRAPHIC EXAMINATION REPORT 06 LIQUID PENETRATION EXAMINATION REPORT 07 HARDNESS TESTING RECORD
13. Pipe Cleaning Blow Down	01 PIPEWORK PRETEST CHECK LIST 02 HYDROSTATIC TEST REPORT 03 FLUSHING, BLOWING AND CHEMICAL CLEANING ACCEPTANCE CERT 04 POST PIPE CLEANING/BLOW DOWN CHECK LIST 05 MECHANICAL COMPLETION OF PIPE WORK 06 PREPARATION CHECK FOR PIPE CLEANING /BLOW DOWN
14. Pressure Testing	01 PIPEWORK PRETEST CHECK LIST 02 HYDROSTATIC TEST REPORT 04 PIPEWORK POST TEST CHECK LIST
15. Coating	01 DAILY REPORT ON PAINT OPERATIONS 02 IN-PROCESS PAINT INSPECTION
16. Insulation	01 INSULATION INSPECTION RECORD 02 EQUIPMENT/PIPING RELEASE FOR INSULATION 03 FIELD LININGS INSPECTION RECORD
17. Static Equipment	01-STATIC EQUIPMENT INSTALLATION 02 HEAT EXCHANGER INSTALLTION INSPECTION 03 FINAL VESSEL CLOSURE 04 SPECIAL EQUIPMENT INSPECTION 05 AUXILIARY EQUIPMENT INDEX MISCELLANEOUS ITEMS 06 FIRED HEATER INSTALLATION INSPECTION 07 FIRED BOILER INSPECTION
18. Rotating Equipment	01 EQUIPMENT PROTECTION, PRESERVATION & EQUIPMENT 02 ALIGNMENT INSPECTION 03 EQUIPMENT FLANGE ALIGNMENT 04 COMPRESSOR INSPECTION 05 PUMP INSPECTION 06 FAN & BLOWER INSPECTION 07 ELECTRICAL MOTOR INSPECTION
19. Electrical	02 OIL DIELECTRIC STRENGTH TEST RECORD 03 CABLE TRAY INSPECTION CHECK LIST 04 CABLE PULLING INSPECTION CHECK LIST 05 MEGGER RADINGS (POWER, CONTROL WIRE & CABLE) 06 MEGGER READINGS (ELECTRICAL, EQUIPMENT INCLUDED MOTORS) 09 INSULATING RESISTANCE TEST RECORD (ROTATION) 10 GROUND WELL RESISTANCE READINGS 12 MEGGER READINGS (TRANSFORMER) 13/1 SWITCHGEAR, PANEL & CUBICLE INSPECTION RECORD 13/2 SWITCHGEAR, PANEL & CUBICLE INSPECTION RECORD 14-380V SWITCH GEAR INSPECTION RECORD 15/1 MOTOR CONTROL CENTER INSPECTION RECORD 15/2 MOTOR CONTROL CENTER INSPECTION RECORD 16 LIQUID FILLED TR. INSPECTION CHECK LIST 17/1 PRE-COMMISSIONING OF POWER TRANSFORMER 17/2 PRE-COMMISSIONING OF POWER TRANSFORMER 17/3 CHECK ON ARRIVAL FOR TRANSFORMER 20 NEUTRAL GROUNDING RESISTOR INSPECTION RECORD 21 BATTERY & BATTERY CHARGER INSPECTION RECORD 22 REPLACEMENT OF FIELD CONTROL STATION TEST R 23 CONNECTION OF EXISTING LOADS TO NEW MCC’S T 24 LIGHTING CHECK SHEET 25 SMALL POWER INSPECTION CHECK LIST 26 2DISTRIBUTION BOARDS PANEL INSPECTION CHECK LIST 27 TELEPHONE SYSTEM INSPECTION CHECK LIST 28 UNDERGROUND CONDUIT INSPECTION CHECK LIST 29 ABOVEGROUND CONDUIT INSPECTION CHECK LIST 30 IPB INSTALLATION CHECK LIST 31 DIESEL ENGINE GENERATOR INSTALLATION CHECK LIST 32 DCS/CONSOLE DESK CHECK LIST 33 CONTROL PANEL INSTALLATION CHECK LIST 34 LV BUS DUCT CONNECTION CHECK LIST 35 LOCAL PANEL & BOX INSTALLATION CHECK LIST 36 LIGHTING PROTECTION INSTALLATION 37 OA SYSTEM INSTALLATION 38 FIRE ALARM SYSTEM INSTALLATION CHECKLIST 01 OVERALL COMPLETION OF EARTHING GRID 02 EARTHING RISER LAYOUT 03 EARTHING WIRE LAYOUT 04 CADWELD CONNECTION OF EARTH GRID WIRE
20. Instrumentation	01 SITE INSPECTION CERTIFICATE FOR LOCAL MOUNTEDINSTT 02 INSTRUMENT POWER SUPPLY INSPECTION RECORD 03 ALARM ANNUNCIATOR TEST RECORD 04 CONTROL SYSTEMS PUNCHLIST RECORD 05 CONTROL SYSTEM TEST EQUIPMENT CALIBRATION LOG 06/1 CALIBRATION FORM ONE 06/2 CALIBRATION FORM TWO 07 INSTALLATION AND LOOP CHECK RECORD 08 MEGGER READINGS 10 INSTRUMENTS INSTALLATION
21. Gas Removal System	01 GAS REMOVAL SYSTEM CHECK LIST SUPPORT STRUCTURE INSTALLATION 02 GAS REMOVAL SYSTEM CHECK LIST EJECTOR, CONDENSER & SEPARATOR 03 GAS REMOVAL SYSTEM VACUUM PUMP INSTALLATION
22. Overhead Crane	01 O/H CRANE INSTALLATION CHECK LIST
23. Generator	01 GENERATOR INSTALLATION CHECK LIST 01/2 GENERATOR INSTALLATION CHECK LIST 01/3 GENERATOR INSTALLATION CHECK LIST
24. Hotwell Pump	01 HOTWELL PUMP INSTALLATION CHECK LIST
25. Cooling Tower	01/1 COOLING TOWER INSTALLATION CHECK LIST 01/2 COOLING TOWER INSTALLATION CHECK LIST
26. Turbine	01/1 TURBINE INSTALLATION CHECK LIST 01/2 TURBINE INSTALLATION CHECK LIST 01/3 TURBINE INSTALLATION CHECK LIST
27. Condenser	01/1 CONDENSER INSTALLATION CHECK LIST 01/2 CONDENSER INSTALLATION CHECK LIST
28. General Construction Punchlist Report	01/1 GENERAL CONSTRUCTION PUNCHLIST REPORT 01/2 GENERAL CONSTRUCTION PUNCHLIST REPORT