1. Manufacturing Quality Gates
Quality Gates are shop-floor checkpoints designed to prevent defects from being buried downstream. A unit does not move to the next stage without QC sign-off (and Client / Class witness where required).
| Quality Gate | Control Focus | Typical Checks / Records |
| Gate 0 | Contract & Interface Review | Foundation dimensions, hazardous area, control architecture, cable routing, documentation deliverables. |
| Gate 1 | Raw Material Traceability | MTC review, identification marking, heat/batch record; storage & preservation. |
| Gate 2 | Fabrication & Welding Control | WPS/PQR compliance, welder qualification, fit-up inspection; NDT as per ITP. |
| Gate 3 | Machining & Assembly | Dimensional inspection, torque control, alignment with pre-installed foundation; functional checks. |
| Gate 4 | Surface Protection | Surface prep (Sa 2.5 or specified), DFT, holiday test (if required), coating cure log. |
| Gate 5 | Factory Acceptance Test (FAT) | 150% proof load / function test, sensor calibration, software/HMI checks, fail-safe & redundancy verification. |
| Gate 6 | Packing & Shipping Readiness | Preservation, packing list, spares, data book completeness, marking & lifting points. |
The gate structure above is typical; actual hold/witness points are tailored to the project scope and specifications.
2. Verification & Testing
Verification & Testing answers a different question: after we build it, does it meet the required performance and safety functions? We verify through calculations, inspection and FAT activities (e.g., proof load, functional release, interlocks, redundancy and calibration). Tests can be witnessed by the Client / EPC / Class / 3rd party inspectors when specified.
| Verification Item | Typical Method / Record |
| Structural verification | Design calculations, FEA (where applicable), safety factors, fatigue consideration for critical details. |
| Load & function test | Proof load test (e.g., 150% SWL where specified), functional release test, interlock / fail-safe checks. |
| Dimensional & interface | Foundation alignment, bolt pattern, hook throat /opening, actuator stroke, proximity & limit switch positioning. |
| Electrical & control | I/O check, HMI logic, redundancy verification, alarm tests, power-loss behavior, emergency release behavior. |
| Sensor calibration | Load cell / tension measurement calibration certificates and as-found/as-left records. |
| Protection & enclosure | IP rating checks, gland selection, cable routing inspection, condensation prevention measures. |
| Coating / corrosion | Surface preparation records, DFT report, adhesion test (if required), salt spray / material selection per environment. |
3. Supplier & Sub-supplier Control
Critical components and processes are managed through approved vendor evaluation, incoming inspection, and performance feedback. Where the project requires, we can provide an approved vendor list and certificates as part of the MDR package.
Project Quality Plan (PQP) and Inspection & Test Plan (ITP) with signed hold/witness points Material Test Certificates (MTC) and traceability list (heat numbers, serial numbers) Welding records: WPS/PQR, welder qualifications, NDT reports (UT/MT/PT/RT as specified) Dimensional inspection reports and interface check records Coating system specification, surface preparation reports, DFT & cure logs Load test certificate and functional test report (FAT), calibration certificates Electrical drawings, PLC I/O list, cable schedule, termination list and as-built schematics Software/HMI backup and configuration record (where applicable) Packing list, preservation record and shipping photos (when requested) O&M manual, spare parts list, recommended maintenance plan and service report template
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