FPC manual
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BS EN 1090-1
FPC-manual
This FPC manual contains a description of our company's FPC
system. The FPC system has been built in accordance with the
standard BS EN 1090-1.
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BS EN 1090-1
FPC-Manual
XXXX Ltd.
The address of the production facility
BS EN 1090-1+A1
Version 1.0
_________________________________________________
xxx xxx, managing director
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BS EN 1090-1
Content
1. Introduction.................................................................4
1.1. Scope..............................................................................4
1.2. Product families..............................................................5
2. Structure of FPC system...............................................6
2.1.
2.2.
2.3.
2.4.
2.5.
Structure of documentation.............................................6
Document management...................................................7
Managerial audits............................................................8
Conformity to relevant standards.....................................9
Standards in the FPC system............................................9
3. Resource management...............................................10
3.1. Human resources...........................................................10
3.2. Machines and testing equipment....................................11
4. Manufacture of structural steel products.....................13
4.1.
4.2.
4.3.
4.4.
4.5.
4.6.
Specification of requirements.........................................13
Structural design process...............................................13
Purchasing....................................................................13
Verification of a purchased product................................13
Product planning and execution.....................................14
Initial type testing and calculation, and testing as a part of FPC
15
4.7. CE marking and preparation of declaration of performance16
4.8. Handling and storage.....................................................16
5. Welding FPC...............................................................17
5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
Welding personnel.........................................................18
Reviews........................................................................18
Welding procedure specifications...................................19
Welding plan.................................................................20
Subcontracting..............................................................20
Inspection and testing...................................................20
6. Measuring, analysis and improvement.........................21
6.1. Non-conforming products...............................................21
6.2. Traceability and marking................................................22
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BS EN 1090-1
1.Introduction
We maintain a factory production control (FPC) system to ensure
that all structural steel products released in the market meet the
required quality standards and conform to the declaration of
performance delivered with the steel product.
The person responsible for the maintenance of our FPC system is
[FIRST NAME] [SURNAME] and s/he is responsible for it in terms
of:
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 products understand their individual responsibilities and
duties and that the subcontractors meet our quality standards.
Internal communication in terms of responsibilities, authorizations
and changes related to the FPC system takes place in meetings, via
e-mail and via personal communication.
1.1.
Scope
Our FPC system encompasses the manufacture of structural steel
products only and it has been prepared so that it conforms to the
relevant requirements of standards BS EN 1090-1 and BS EN 10902 and includes a non-certified quality management system for
fusion welding (BS EN ISO 3834-3).
Production is done in-house and subcontracted. Tasks are divided
according to the Table below:
Table 1. In-house and subcontracted production
Inhouse
Subcontrac
ted
Notes
Structural
design
Cutting
Shaping
Holing
Mechanical
fastening
Assembly
Welding
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Surface
treatment
In addition to structural steel products, we manufacture
other steel products, but the manufacturing of these
products is not included in this FPC system.
1.2.
Product families
Structural steel products are manufactured in series or bespoke
production with constituent materials and working methods
compliant with standard BS EN 1090-2.
All structural steel products have been divided into product families
according to the parent material and welding process:
Product family 1
EXAMPLE. Structural steel products manufactured according
to the requirements of EXC2 with welding process 135.
Constituent products are according to BS EN 1090-2 and with
same or lower yield strength and better weldability as S355.
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2.Structure of FPC system
This FPC manual contains the descriptions of inspections and
assessments that we apply to
Structural steel products manufactured by us,
Intermediate products of steel products,
Constituent products used in production,
Inspection and testing equipment.
With the help of the written procedure descriptions and working
instructions, it is possible to demonstrate to relevant stakeholders
that our steel products are manufactured under controlled
conditions, and our testing and measuring equipment have been
subjected to appropriate maintenance and inspection.
In addition, our FPC system documentation contains descriptions of
actions and procedures for handling products that are not
compliant with the requirements.
To ensure proper functioning of our FPC system, we continuously
update our documentation and retain quality records for ten (10)
years after their creation.
1 Structure of documentation
FPCman
ual
Execution
documentation and
working instructions
Quality records
Figure 1. The documentation hierarchy of the FPC system
The FPC manual, meaning this document, provides a general
description of our FPC system and its scope.
Execution documentation contains written instructions related to
and descriptions of, for example, the control of raw materials,
production machines and the manufacture of products. The
execution documentation also includes the most relevant standards
used in manufacture.
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Quality records contain the objective documentation and proof of
product conformity. These documents include, for example,
component specifications, test results and complaints.
2.1.
Document management
Documents belonging to the FPC system are stored in a secure
place that can only be accessed by people authorized by us.
All amendments in the FPC system documentation have been
prepared by our FPC responsible or by a person authorized by
him/her. Whoever revises the FPC documentation is also
responsible for the
Verification of the new information,
Communication of the change to other employees and,
Organizing training.
For all documents in the FPC system, we try to use a ready-made
document form Document template which makes it easy to
identify the files as belonging to the FPC system.
Our FPC system also includes documents that have not been
prepared in a ready-made document form like essential standards.
Updated documents and quality documentation
There are two kinds of documents in our FPC system: updated
documents and quality documentation.
Updated documents are guiding documents that exist already at
the beginning of the work. The updated documents include
guidelines, process descriptions, internal policies etc. The updated
documents are updated where necessary and they come with a
consecutive version number that identifies the amendments.
Quality documentation refers to the documents, which are
prepared as the work proceeds. Quality documentation contains
test reports etc. In addition to these, quality documentation also
includes the employees' qualification certificates, material
certificates, inspection slips and other quality documentation.
Naming of documents
Where possible, the naming of the documents follows a general
naming policy so that each file contains the plain text name,
identification code, date, and a version number.
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The documents in the FPC system follow the naming and
numbering system as follows:
Figure 2. FPC system documentation
2.2.
Managerial audits
Once a year, our companys management team performs an
internal audit on the FPC system to ensure that the system is
suitable and functional.
The managerial audit includes the assessment of the following
aspects where applicable:
Findings from previous managerial audits
External audit reports
Flaws and defects detected internally and from customer feedback
Implementation and effects of corrective actions
Surveillance of suppliers
Sufficiency of the production process surveillance
Sufficiency of resources
Effectiveness and sufficiency of preventive actions
Overall assessment of the effectiveness and suitability of the FPC
system for the requirements of the quality policy and quality goals
given the potentially changed customer needs
Based on the managerial audits, a separate document
Managerial audit is prepared and saved as a part of quality
documentation.
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2.3.
BS EN 1090-1
Conformity to relevant standards
The conformity of the standard BS EN 1090-1 to our FPC is
presented in the table below:
Table 2. FPC and BS EN 1090-1.
BS EN 1090-1+A1
Personnel
Equipment
Products used in manufacture
Assembly specification
Product evaluation
Non-conforming products
FPCmanual
3.1
3.2
4.3
4.1
4.6
6.1
Docume
nt
P
M
W
W
D
W, D
2.4.
2.4.
2.4.
2.4.
2.4.
2.4.
Standards in the FPC system
The following standards related to the manufacturing of structural
steel products are part of the FPC system.
Table 3. Standards we own
Standard
code
BS EN 1090-1
Description / contents
Execution of steel and aluminium
structures. Part 1: Requirements for
conformity assessment of structural
components.
BS EN 1090-2
Execution of steel and aluminium
structures.Part
2:
technical
requirements for steel structures.
ISO 3834-3
Part 3. Quality requirements for fusion
welding of metallic materials
EN 14731
Welding
coordination.
Tasks
and
responsibilities
EN 1011-1, -2, Welding.
Recommendations
for
-3
welding of metallic materials
These standards are available to all employees to read and the
company management is responsible for the accessibility and
validity of the standards.
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3.Resource management
3.1.
Human resources
Deleted text
3.2.
Machines and testing equipment
Deleted text
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4.Manufacture of structural steel products
4.1.
Specification of requirements
Deleted text
4.2.
Structural design process
Deleted text
4.3.
Purchasing
Deleted text
4.4.
Verification of a purchased product
Deleted text
4.5.
Product planning and execution
Deleted text
4.6.
Initial type testing and calculation, and testing as
a part of FPC
Deleted text
4.7.
CE marking and preparation of declaration of
performance
Deleted text
4.8.
Handling and storage
Deleted text
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5.Welding FPC
Deleted text
5.1.
Welding personnel
Deleted text
5.2.
Reviews
Deleted text
5.3.
Welding procedure specifications
Deleted text
5.4.
Welding plan
Deleted text
5.5.
Subcontracting
Deleted text
5.6.
Inspection and testing
Deleted text
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6.Measuring, analysis and improvement
Deleted text
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Version history
DATE
Reason for update
XX
Implementation of FPC [Name]
system
Version 1.0
Approved
by
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Requires
training
Yes
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FPC
documentation
instructions)
Type
Quality
documen
ts
Document id
Final Inspection
Inspection report
for welds
Structural design
review
Approved WPS
CEmark
Checklist
Complaint form
Document
template
DoP
DoP-Flowchart
Humidity and air
temperature
Internal training
ITT&ITC
Maintenance
records
Managerial audit
Parameter control
Procedure test
Holing
Procedure test
Thermal cutting
Control
of
Training
document
Visual NDT
Personnel
qualifications and
Version 1.0
BS EN 1090-1
(no
What is it used for?
Collect and record the inspections related to the
manufacturing
process.
Very
important
document.
Record the visual NDT of welds. Very important
document.
Verify that structural design has been performed
appropriately. Very important document.
Approval process for the new WPSs used in
production.
Blank template for CE mark. Use this to develop
CE mark for each new structural steel product.
Double check to make sure you have done
everything to back up your CE mark. This is
especially beneficial as a double check when
you're still learning how to use the FPC system.
Record all complaints from customers and major
internal complaints.
Blank document to make new FPC files
Blank template for Declaration of performance
Flowchart to help you determine the appropriate
Method to use when preparing the CE mark
and DoP
Record the storage conditions of welding
consumables and wet painting if you do it.
Record trainings that you organize for your
employees that relate to the FPC system
Record the Initial type testing and initial type
calculation where you assess your manufacturing
and design processes and make sure they
conform to the requirements of EN 1090-1.
Record the maintenance of your manufacturing
machinery
Record the managerial audit where you check
that the FPC system is functional
Control the appropriate use of WPSs during the
manufacturing
Approval of your holing processes and methods
Approval of your thermal cutting processes and
methods
Record the training where you teach your new
(or old) employee everything they need to know
about their new job.
Qualify your visual weld inspectors
Listing of employees and subcontractors. Define
tasks and responsibilities for employees.
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working
FPC manual
resource
s
organization
Qualification
requirements
Machinery and
testing equipment
Use and
maintenance of
measuring
equipment
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Listing of all minimum qualification requirements
from the standards
Listing of all manufacturing machinery and
testing equipment
Instructions for use and calibration of common
measuring equipment
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