FPC

manual
XXXX Ltd.

FPC manual

XXXX Ltd.
Address

BS-EN 1090-1+A1
Version 1.0

_________________________________________________
xxx xxx, CEO

Table of contents
1. Introduction ................................................................................................................ 4
1.1. Scope ................................................................................................................................... 4
2. The structure of the quality control system ..................................................... 5
2.1. The structure of the documentation ........................................................................ 5
2.2. File management ............................................................................................................ 6
Updated documents and quality documentation ...................................................................... 6
Naming of the files .................................................................................................................................. 6
2.3. Managerial audits ....................................................... Error! Bookmark not defined.
2.4. Conformity to standards .............................................................................................. 8
2.5. Standards in the quality control system ................................................................. 8
3. Resource managemet ............................................................................................... 9
3.1. Human resources ............................................................................................................ 9
Trainings .................................................................................................................................................. 10
Identification of training needs ...................................................................................................... 11
Orientation of new employees ........................................................................................................ 11
3.2. Equipment ....................................................................................................................... 11
Production machines .......................................................................................................................... 11
Measuring and testing equipment ................................................................................................ 12
Inspection and maintenance ............................................................................................................ 12
4. Product realization ................................................................................................ 14
4.1. Component specifications ......................................................................................... 14
4.2. Structural design process .......................................................................................... 14
4.3. Purchasing ...................................................................................................................... 14
Verification of purchased product ................................................................................................ 15
4.4. Production provisions ................................................................................................ 15
4.5. Evaluation of conformity ........................................................................................... 15
4.6. Product evaluation and CE marking ...................................................................... 16
4.7. Handling and storage .................................................................................................. 16
Handling ................................................................................................................................................... 16
Storage ....................................................................................................................................................... 16
5. Welding ...................................................................................................................... 18
5.1. Welding personnel ....................................................................................................... 19
Welders ..................................................................................................................................................... 19
Responsible welding coordinator ................................................................................................. 19
Responsibly and authority ............................................................................................................... 19
5.2. Reviews ............................................................................................................................ 20
5.3. WPS and welding plan ................................................................................................. 21
5.4. Subcontracting .............................................................................................................. 21
5.5. Inspection and testing ................................................................................................. 21
5.6. Control of monitoring devices .................................................................................. 22
6. Measuremetn, analysis and improvemetn ..................................................... 23
6.1. Control of nonconforming products ....................................................................... 23
Small mistakes ....................................................................................................................................... 23
Serious mistakes ................................................................................................................................... 23
Handling of records ............................................................................................................................. 24
Corrective procedures ........................................................................................................................ 24
Preventive measures ........................................................................................................................... 24
6.2. Tracebility ....................................................................................................................... 24

1. Introduction

We maintain a quality management system to ensure that all

structural steel fabrications released in the market meet the
required quality standards and conform to the declaration of
performance delivered together with the assembly.
The person responsible for the maintenance of our quality
management system is [FIRST NAME] [SURNAME]. S/he is
responsible for the quality management system in regard to:

Documentation,
Maintenance and
Continuous verification of functionality.

In addition to this, [FIRST NAME] is responsible for ensuring that

all employees who are involved with manufacturing of structural
steel fabrications understand their individual responsibilities and
duties when manufacturing products that meet the requirements,
and that the subcontractors conform to our quality standards.
The informing and internal communication in regard to the
responsibilities, authorizations and changes related to the quality
management system in the production is conducted in meetings,
via e-mail and via personal communication.

1.1. Scope
This documented quality management system encompasses the
manufacturing of structural steel fabrications only. The quality
management system has been drafted so that it conforms to the
relevant requirements of standards BS-EN 1090-1 and BS-EN
1090-2 and it includes a non-certified quality management system
for welding compliant with standard BS-EN ISO 3834-3.
Our quality management system does not include structural design
process because we do not give declarations of characteristics
related to structural design.
In addition to structural steel fabrications, we also
manufacture other steel products, but the manufacturing of
these products is not included in this FPC system.
The structural steel fabrications are bespoke/series production
with base materials and working methods compliant with
standard BS-EN 1090-2, and the manufactured assemblies fall into
execution
classes
EXC
1
and
EXC
2.

2. The structure of the quality control system

This FPC manual includes the descriptions of intra-production

inspections and assessment that we apply to

The structural steel fabrications manufactured by us,

The intermediate products,
The raw materials and components used in the production,
Production machines and
Inspection and test apparatus.

With the help of the written descriptions that accompany the

quality management system, it is possible, where necessary, to
demonstrate to the interest groups that the assemblies are
manufactured in controlled conditions and the used appliances
have been subjected to appropriate maintenance and inspection.
FPC manual and the documentation of the quality control system
also include descriptions of measures and procedures for handling
products that are do not conform with the requirements.
To ensure the efficiency of the quality management system of the
production we update the documents continuously. The records
and other documents produced within the quality management
system are stored for five (5) years after their creation.

2.1. The structure of the documentation

FPC manual
Exectuion documentation
Quality documentation

Figure 1. The documentation hierarchy of the quality control system
The FPC manual, meaning this document, offers a general
description of the factory's production and quality control system
and its functions.
Execution documentation includes written instructions related
to and descriptions of for example the control of raw materials,
production machines and the manufacturing of products. The
execution documentation also include the most relevant standards
used in the manufacturing process.

FPC manual

X.X.2014

BS-EN 1090-1+A1

Quality documentation includes the objective documentation
based in the quality procedures. These documents include for
example the field books, assembly specifications, test results,
complaints and other quality documentation.

2.2. File management

Documents in the quality management system are stored in a

secure place that can only be accessed by people authorized by the
company.
A person assigned by the company, or an authorized person has
made all the changes in these documents. The person who makes
the change is responsible for the verification of the changed
information, communication of the change to other employees in
the company, and, where applicable, of organizing training.
For all documents in the quality management system, the aim is to
use a ready-made document template - L1 document template -
with which files can easily be identified as belonging to the quality
management system.
The quality management system also includes documents that
have not been drafted in a ready-made document template.
Essential standards are examples of this kind of documents.
Updated documents and quality documentation
The FPC system is comprised of two types of documents: updated
documents and quality documentation.
Updated documents are guiding documents that exist already in
the beginning of the work. The updated documents include
guidelines, process descriptions, internal policies etc. The updated
documents are updated when necessary and they come with a
consecutive version number that identifies the changes.
Quality documentation refers to documents that are drafted as
the work proceeds. The quality records contain informaton about
quality control, procedure entries, reports etc. In addition to these,
the quality records also include the employees' qualification
certificates, material certificates and other quality documentation.
Naming of the files
As to documents drafted in a ready-made document template, the
naming of the documents follows the general naming policy so that
each file contains the clear name, identification code, date and,
where applicable, a version number.

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FPC manual

BS-EN 1090-1+A1

X.X.2014

The folders in the FPC system follow the naming and numbering
system as follows:

Figure 2. Naming of FPC documents.

2.3. Management review

Once a year, the management team of our company performs an

internal audit on the quality management system to ensure that
the system is suitable and functional.
The management review is performed during the last quarter of
the year, or, alternatively, prior to a quality control system
assessment performed by an external auditor.
The managerial audit includes the assessment of the following
aspects where applicable:

The observations from previous managerial audits

External audit reports
The flaws and deficits that have arisen internally and in
the form of customer feedback
The implementation and effects of corrective measures
for these flaws and deficits
The monitoring of the suppliers
The assessment of the company's security of supply
The sufficiency of the production process monitoring
The assessment of the profitability
The sufficiency of resources
The effectiveness and sufficiency of preventive
measures
The overall assessment of the effectiveness and
suitability of the quality management system for the
requirements of the quality policy and quality goals
given the potentially changed customer needs
Follow-up goals

Based on the managerial reviews, a separate memo L3

managerial audit is drafted and saved as a part of quality
documentation.

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FPC manual

BS-EN 1090-1+A1

X.X.2014

2.4. Conformity to standards

The company's quality system and this FPC manual have been
drafted in accordance with standards BS-EN 1090-1, BS-EN 1090-
2, BS-EN ISO 3834-3 and their related reference standards.
The conformity of the standards to this FPC manual is presented in
the table below:
Table 1. Conformity of our quality management system to the
requirements of standar BS-EN 1090-1.

BS-EN
1090-1+A1
Personnell
Equipment
Constituent products
Component specification
Evaluation of conformity
Non conforming products

FPC manual
3.1
3.2
4.3
4.1
4.6
6.1

Document
H1
K1
T2-1
T1-2
T
T6-3

2.5. Standards in the quality control system

The following standards related to the manufacturing of struvtural

steel fabrications are part of the quality control system.
The standards are available to all employees to read and the
company management is responsible for the access and validity of
the standards.
Standard
BS-EN 1090-1
BS-EN 1090-2

Description / contents
Execution of steel structures and aluminium
structures. Part 1: Requirements for conformity
assessment of structural components.
Execution of steel structures and aluminium
structures. Part 2: Technical requirements for
steel structures.

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