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FMC Training Program on Inspection & Test Plans (ITP) and Manufacturing Process Quality Plans (MPQP)

Comprehensive training for suppliers to FMC Technologies emphasizing ITP and MPQP requirements, interventions, and quality control.

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FMC Training Program on Inspection & Test Plans (ITP) and Manufacturing Process Quality Plans (MPQP)

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  1. Inspection & Test Plan (ITP) / Manufacturing Process Quality Plan (MPQP)- training of suppliers to FMC Technologies, Norway QRL-0010001 FMC Standard Administration Requirements - Revision Q, released June, 2013- Appendix 3 - Quality Requirements, section 11.1.1 & 11.1.2 - Appendix 4 - Technical Correspondence and Doc. Administration, section 5 Q00392 – Supplier Inspection & Test Plan Q00394 – Product MPQP Q00398 – Process MPQP

  2. Learning Objectives • Why and when FMC require an Inspection & Test Plan (ITP) or Manufacturing Process Quality Plan (MPQP). • What the requirements are. • The responsibilities of issue, review and handling. • Why and when FMC require intervention points. • The different types of intervention codes. • Notification requirements – content & communication.

  3. Purpose • Inspection & Test Plan / Manufacturing Process Quality Plan is a basis for verifying conformity with specified contractual requirements. • For FMC and the Supplier to establish and agree upon the following prior to production start; • Quality Control activities • Interventions for the Supplier, FMC, FMC’s Client and/or Third Party • Intervention points allow theparties to go into different steps in the production process to assure the quality. (mitigating risk)

  4. Requirement for ITP and/or MPQP • The requirement for ITP / MPQP can be found on the Part Report either by: • Throught DRLs (to be phased out) • Quality specification (Q00392, Q00394, Q00398) • There will be Intervention points on all ITPs / MPQPs • Product-, Project-, and Supplier Criticality decides the level of intervention

  5. ITP requirement driven through DRLs • Listed in the Part Report referencing a Document Requirement List (DRL). • Requirement will be from QRL-0010001

  6. ITP requirement driven through Qspec • Q00392 • FMC Required ITP template in section 6 • Listing the sequence of inspection and test activities required by Agreement as applicable for the Parts covered by the ITP • Part Description for the part / group of parts covered by the ITP • No Part Numbers listed, but all Parts covered shall follow the same production process, procedures and intervention points • ITP may be reused when there are no changes to the above • "Yes" or "No" drop down menu for ‘Do the subcomponent (lower level) Part Reports (DBIs) require Q00392? If so, are the lower level Part Report requirements included in this ITP? ‘ • Note: The ITP may contain subcomponent Part Report (DBI) requirements in one single ITP, only if the subcomponent Part Reports (DBIs) require Q00392 • Note: If Q00394 (for Product MPQP) is on the Part Report for Raw Material, subcontractor of the Raw Material shall provide an MPQP acc to Q00394 to the Supplier that will ensure FMC approval.

  7. FMC required ITP template – Q00392

  8. MPQP requirement driven through Qspec • Q00398 FMC Required ITP template in section 7 • Applicable to many parts following the same manufacturing process. • For example, welding cladding operation on parts of the same base material may use identical manufacturing processes and procedures. • Supplier performing the actual process is accountable for generating the MPQP and obtaining FMC (and FMC’s Client through FMC, when required) approval. • Supplier may list alternative subcontractors and approved alternate special process procedure numbers. • NOTE Q00398 shall only be used by suppliers executing document approval through eSMDR/SMDR, otherwise Q00394 shall be used to maintain traceability.

  9. FMC required Process MPQP template - Q00398

  10. MPQP requirement driven through Qspec • Q00394 FMC Required ITP template in section 7 • Manufacturing process is unique to a specific part. • FMC part number is required on the MPQP document. one PN per MPQP. • Three Types: • Standard (any supplier commodity other than forging) • Forging MPQ (Qualification) • Forging MPQP • Supplier performing the actual process is accountable for generating the MPQP and obtaining FMC (and FMC’s Client through FMC, when required) approval.

  11. Q00394 continued • Forging Template (MPQ & MPQP): • Process Parameters: • Section does not apply to induction bends. • Process Parameters G, H, I, L, M, and Ndo not apply to Forged Bar. Supplier shall state “N/A” for these cells. • All other forging suppliers shall complete all Process Parameters.

  12. Q00394 continued • MPQ (Manufacturing Process Qualification): Supplier shall state the mill, starting ingot/billet size, NDE supplier/procedure and heat treatment vendor that will be used. • MPQP (Manufacturing Process Quality Plan): Supplier may list alternative mills, alternative starting ingot/billet sizes, alternative special process suppliers/procedures, and alternative heat treatment vendors. If alternatives are not approved by FMC or FMC’s Client, then the supplier shall be notified through the MPQP review process. Note: Alternative subcontractors may not be allowed for forgings that required qualification. The Qualification test report (QTR) will document any restrictions on alternatives.

  13. Responsibilities; issue & handling • ITPs / MPQPs shall be uniquely identified and revision controlled documents to ensure proper communication of the latest requirements. • Supplier shall submit an ITP, MPQ and/or MPQP (regardless of type) no longer than two weeks after receipt of FMC PO. • FMC responsible to forward to FMC Client for review if required • ITPs /MPQPs shall be listed on the SMDR (Supplier Master Document Register) /eSMDR • If any change in manufacturing process on an ITP/MPQP still in use, the ITP shall be revised and resubmitted to FMC for review and approval. (provided that change is applicable for all parts it’s used for, unless issue a new document)

  14. Responsibilities; Review • Cycle Times • FMC to review and return document to Supplier within twenty (20) Business Days. • Supplier shall re-submit updated document within five (5) Business Days. • For every review cycle (revision) the supplier will receive a DR-4 document (Document Review) from FMC. • The DR-4 document will have an Approval Status Code and may have comments for action or information. • The procedure for submitting, reviewing and approving a supplier’s MPQP (Q00398 or Q00394) is described in Q00399.

  15. Responsibilities; Review • The Approval Status Code and the DR reference shall be recorded in the SMDR – by the Supplier. Approval Status Codes: 1 Accepted with no comments 2 Accepted with comments incorporated. Revise and resubmit. 2x Document returned before the Company's final approval/comments. Hold next revision of the document until receipt of FMCs final comments, or document is given approval status code 1. 3 Not accepted. Revise and resubmit 4 Information

  16. Intervention Codes • The following definitions apply unless otherwise specified by the Part Report (DBI) • R = Review: • Verification of a step in manufacturing or testing by FMC and/or Company by review of objective evidence. • M = Monitor: • A step in manufacturing and testing that proceeds as scheduled, and may be subject to FMC and/or Company observation at FMC and/or Company discretion. Advance notification is not required. Monitor activities are intended for process verification, not product inspection.

  17. Intervention Codes • W = Witness: • A critical step in manufacturing or testing where it is desirable that FMC and/or Company representative participates in the inspection / process activity of the material / equipment in order to ascertain that the product for delivery complies with the specified requirements. Formal advance notification shall be given in accordance with appendix 4. The step can proceed with or without the presence of FMC and/or Company representative after the designated time has passed. • H = Hold: • A critical step in manufacturing and testing where it is essential that FMC and/or Company representative participates in the inspection /process activity of the material / equipment in order to ascertain that the product for delivery complies with the specified requirements. Formal advance notification shall be given in accordance with appendix 4. The step shall not proceed without the presence of FMC and/or Company representative, or without a written statement giving a waiver.

  18. Notification of Witness/Hold points • Supplier shall notify FMC in writing prior to any hold/witness activities as specified in the ITP or MPQP. • Notification time - minimum ten (10) Business Days unless otherwise is stated in the PO/Agreement. • Submitted by Supplier latest 14:00 GMT+1 (2 PM). • All notifications related to POs from Kongsberg (first issue, postponements and updates) shall be sent to: FKSnotifications@fmcti.com • E-mail subject: FMC PO number and project number & name (not limited to) • One e-mail shall only contain notification(s) for one project. • Copy Commercial point of contact • Copy Quality resource, if known

  19. Notification of Witness/Hold points - Content Shall as a minimum include (as applicable): • FMC project number and name. • FMC Purchase Order ref, Part Number & Serial Number (quantity) • Part description • Start-up date & time for activity • Duration • Supplier approved ITP/MPQP doc number/rev with reference to activity • Procedure document number and revision • Location for activity • Contact persons • Other information needed (e.g. required personal protection equipment) Global Notification of Intervention Point Form: • http://www.fmctechnologies.com/en/SupplyChain/SubseaSystems/Subsea%20Requirements/Global.aspx

  20. Notification Format

  21. If not ok, state actions and ask Supplier to reschedule

  22. Be aware • Recurring problems: • Documentation is a bottle neck • Internally in FMC • FMC Customer • Contact FMC purchaser if delay in documents • Typing errors • wrong / misspelled Purchase Order Number or Part Number • several cases of ”copy-paste” • FMC is working on methods to inform about required intervention points at PO award. • For BP projects requirements for intervention will be included in the Part Report (DBI). Include those on first revision of ITP /MPQP • Notifications • Any special agreements with FMC or FMC’s Client (shorter notification time, document approvals etc) shall be clearly stated in the notification.

  23. QUIZ

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