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Updated: October 19, 2012

Inspection & Test Plan (ITP)


presentation for suppliers to FMC Technologies, Norway

QRL-0010001 FMC Standard Administration Requirements: - Revision P, released August 19, 2011 - Appendix F Quality Requirements, section 1.5 & 1.6

10/29/2012

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Learning Objectives
Why and when FMC require an Inspection & Test Plan (ITP). 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.

Purpose
Inspection & Test 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, FMCs customer and/or Third Party Intervention points allow the parties to go into different steps in the production process to assure the quality.

When is ITP applicable


The requirement for ITP is listed in the Document Requirement List (DRL), Supplier Document Requirements (SDR) / Manufacturing Information Requirements (MIR). Typically for Products with Special Processes (e.g. bending, welding, nondestructive examination (NDE), forging, castings) There will be Intervention points on all ITPs Product-, Project-, and Supplier Criticality decides the level of intervention

What
ITP is listing the sequence of activities, and shall as a minimum include: All important production processes in all phases of production. All examinations, inspections and tests to be performed with reference to applicable inspection and test procedures, and type of verifying document. Location of activity. Suppliers Intervention activities (witness, hold, etc). Interventions columns for FMC, 3rd party and Customer. Health, Safety & Environment (HSE) intervention point prior to critical tests, if any. Pre-Production Meeting (PPM) to preferably be an activity in the ITP.

Kick Off vs. Pre-Production Meeting (PPM)


Kick Off Meeting (Pre-Award Meeting): To ensure that the Supplier base their work on the correct input and that the commercial and technical requirements are understood.
FMC procurement responsible for meeting, without FMC customer.

Pre-Production Meeting (PPM): To determine whether the Supplier is ready to start production.
Supplier to call for meeting, FMC responsible for documenting the findings, often with FMC customer. All clarifications between FMC and supplier shall be done prior to PPM.

Responsibilities; issue & handling


ITP shall be uniquely identified and revision controlled documents to ensure proper communication of the latest requirements. Supplier shall issue ITP 2WAO (weeks after order) for FMC review and approval
FMC responsible to forward to FMC Customer for review if required Subcontractors ITPs:
The level of review and approval of subcontractors ITPs shall be based on the product and Supplier complexity, and communicated to the Supplier, by either;
Kick off or PPM (ref also PPM check list LST60069359) other written instructions from FMC

ITPs shall be listed on the SMDR (Supplier Master Document Register) If any change in manufacturing process on an ongoing ITP, the ITP shall be revised and resubmitted to FMC for review and approval.
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Responsibilities; Review
FMC responsible Quality personnel shall review
FMC to review and return document to Supplier within twenty (20) Business Days, or longer if the document shall be reviewed by FMC Customer as the case may be.

For every review cycle (revision) the supplier will receive a DR-4 document (Design Review) from FMC. The DR-4 document will have an Approval Status Code and may have comments for action or information. If comments, Supplier shall re-submit updated document within 10 Business Days. (if not otherwise agreed in the contract)

Responsibilities; Review
The Approval Status Code and the DR reference shall immediately 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 customer's final approval/comments. Hold next revision of the document until receipt of FMC final comments, or document is given approval status code 1. 3 Rejected 4 Information

Example (non complex part, page 1 of 1)

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Example (complex part, page 1 of 2)

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Example (complex part, page 2 of 2)

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Intervention Codes
R = Review:
Documentation and records shall be available for verification at any time by

FMC/Customer representative.

M = Monitor:
Activity will proceed as scheduled, without advance notification, but is subject to FMC/Customer witness as and when required. Monitor activities

are intended for process verification, not product inspection.

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Intervention Codes
W = Witness:
A critical step in manufacturing or testing where it is desirable that FMC and/or Customer 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. The step can proceed with or without the presence of FMC and/or Customer representative after the designated time has passed.

H = Hold:
A critical step in manufacturing and testing where it is essential that FMC
and/or Customer 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 . The step shall not proceed without the presence of FMC and/or Customer representative, or without a written statement giving a waiver. 14

Notification of Witness/Hold points - Content


Supplier may use their own format, but it shall as a minimum include:
FMC Purchase Order ref, Part Number & Serial Number (quantity) Part description Date & Time for activity Duration Supplier ITP doc number with reference to activity Procedure document number and revision Location for activity Contact persons

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Notification Format

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Notify
All notifications to FMC Kongsberg (including updates) shall be sent to: FKSnotifications@fmcti.com
E-mail subject: FMC Project code & name, PO number (but not limited to) Copy relevant personnel, such as Commercial point of contact and Quality resource

Notification time shall be minimum 10 business days unless otherwise formally agreed.

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ITP Notification Process (1 of 2)

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ITP Notification Process (2 of 2)

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Be aware
Recurring problems: Documentation is a bottle neck
Internally in FMC FMC Customer Contact FMC purchaser if delay in documents

ITPs and notifications


wrong / misspelled Purchase Order Number or Part Number several cases of copy-paste

If several Part Numbers (PN) are included in one ITP Be very clear on which procedure belongs to which PN Multiple ITPs for one PO if the manufacturing steps are different

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Be aware continue
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. Any special agreements with FMC or Customer (shorter notification time, document approvals etc) shall be clearly stated in the notification. An email shall only contain notifications for one project.

Notifications

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Summary
Where to find out if we require an ITP for the Part? Where to find out the required content of an ITP? When shall the ITP intervention points be agreed? When do the supplier need to update and resubmit ITP? When shall the notifications be sent to FMC? To whom shall the notifications be sent?

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