Planning inspection work

Enough of generalities how do we plan our inspection work on a real project Inspection activities should be classified according to the aims 

Group 1. These are critical items where the consequences of failure are severe. An exercise of due diligence is necessary that is, the intensity of inspection should at least equal customary practice for comparable work. Typically, all work should be carried out in accordance with an appropriate code or standard, with an independent inspector to certify compliance in accordance with an individual quality plan per item. Group 2. These are items where compliance is required by statute, for example pressure vessels. The applicable regulations dictate the minimum requirements. If these items are also group 1 items, above-statutory-minimum requirements may be needed. 

Group 3. These are items where conditions of contract or connnercial policy dictate the levels of inspection, for example, in case the inspection is linked to a final pa5onent. There are no short-cuts here. 

Group 4. These are the remaining items, where inspection is carried out on a basis of economic evaluation, considering the selected supplier s reputation and facilities, the availability and credibility of conformance certificates, the consequences of accepting non-compliant items, and the cost of inspection. 

For management purposes, the decisions on inspection intensity may be classified into a few standard levels , for example no shop inspection, random inspection of end product, and individual item quality plan. 

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In addition, a variety of cleaning, inspection, and planned maintenance work is also required, including boil outs, lay ups, protection of idle boilers and nondestructive testing. Some of these many ancillary tasks are discussed in the following sections. 

Occupational illness and injury187 cost 30-40 billion dollars/yr in the United States.188 In 1994 there were 6.8 million injuries and illnesses in private industry, amounting to 8.4 cases per 100 workers. Nearly two-thirds were disorders associated with repeated trauma, such as carpal tunnel syndrome.189 The Occupational Safety and Health Act of 1970 set up the National Institute Safety and Health (NIOSH) to study the problem and the Occupational Safety and Health Administration (OSHA) to deal with it through inspections and regulations. Both have received so much criticism of their effectiveness that they are struggling to find more effective ways to deal with the problem.190 NIOSH is searching for practical ways to protect workers, especially those in small businesses from methylene chloride, tetrachloroethylene, diesel exhaust in coal mines, isocyanates, 2-methoxyethanol, and others. OSHA is about to expand a plan that worked well in Maine, a state that used to have one of the worst accident and illness records in the United States.191 The 200 firms with the worst records were asked to look for deficiencies and to correct them. They were also inspected. These measures cut injuries and illnesses over a 2-year period. 

The Calder and Chapelcross reactors have now operated for up to 27 years with average load factors of around 85% and it is planned to continue operation to beyond 1990. The original design life of 20 years has been exceeded and it is therefore important that continuous revalidation of the reactors is carried out, and the in-service inspection described in this paper will play an Important part in this exercise. New developments in ISI are under review and where applicable will be used to improve the scope and quality of the direct inspection work. 

Controls One control for preventing slipping conditions involves inspection. Work planning should include inspection of working and walking surfaces to remove or prevent slip hazards. 

The U.S. Army Corps of Engineers requires contractors who perform construction work for the federal government to prepare a safety and occupational health plan (SOH). The idea is to analyze the potential work on a specific job or project and to plan accident prevention measures for each phase and component of the work. The plan includes work performed by subcontractors. It includes contractor hazard control measures. The plan must include frequent and regularly scheduled safety inspections of work sites, materials and equipment by competent persons. 

When work at the accident site is finished, have a plan for temporary storage of evidence that might be required later for additional examination. Determine when and where final disposal of evidence, damaged equipment, and materials should be. Make plans for the follow-on phases of the investigation. Conduct a planned inspection of the workplace or equipment before allowing full, normal activity to resume. 

These factors, along wifii company and government regulations, will set file schedules for inspection. Qualified persoimel should carry out the inspections. They must have the appropriate tools and protective equipment and be given time to prepare and plan their work. 

The inspection dates should be entered in a diary or call-forward system or planned preventive maintenance software package which is consulted by the supervisor when planning the work schedule. 

The "Plant Life Assessment Network" (PLAN), was started on the 1/12/1997, established around EU funded research projects working in the area of inspection, instrumentation, monitoring, structural mechanics and maintenance. 

This means that parts must be ordered in advance for the turnaround and other work must be planned so that the whole operation may proceed smoothly and without holdups that could have been foreseen. This usually means close collaboration with the manufacturer or consultant and the OEM (or specialty service shop) so that handling facilities, service men, parts, cleaning facilities, inspection facilities, chrome plating and/or metaliz-ing facilities, balancing facilities, and some cases even heat treatment facilities, are available and will be open for production at the proper time required. This is the planning, which must be done in detail before the shutdown with sufficient lead-time available in order to have replacement parts available at the job site. 

Quality plans are needed when the work you intend to carry out requires detailed planning beyond that already planned for by the quality system. The system will not specify everything you need to do for every job. It will usually specify only general provisions which apply in the majority of situations. You will need to define the specific documentation to be produced, tests, inspections, and reviews to be performed, and resources to be employed. The contract may specify particular standards or requirements that you must meet and these may require additional provisions to those in the quality system. Although ISO/TS 16949 requires the plan to include customers requirements, the intention is not that these requirements are reproduced if provided in a documented form by the customer, but that a cross reference is made in the plan together with any other relevant specifications referred to in the contract. However, when constructing the plan, it would make sense to refer to specific customer requirements and provide a response that indicates your intentions regarding those requirements. 

Any product that has had work done to it should be re-inspected prior to it being released to ensure the work has been carried out as planned and has not affected features that were previously found conforming. There may be cases where the amount of re-inspection is limited and this should be stated as part of the remedial action plan. However, after rework or repair the re-inspection should verify that the product meets the original requirement, otherwise it is not the same product and must be identified differently. 

The iiifornialioii from Tier II and on-site inspections should help the local fire department in the development of prefire plans. Tlie information submitted by facilities midcr Sections 311 and 312 must generally be made available to tlie public by state and local govermneiits during normal working hours. 

Planned maintenance programs are an essential weapon in a department s armory to ensure that the services it is called on in meeting its responsibilities are fully met. The traditional method of working from pieces of paper or individuals own notebooks as to when maintenance is to be carried out or when the insurance representative is due to visit to carry out an inspection are no longer satisfactory. This is especially the case when the skilled resources necessary to carry out the work are more difficult to obtain. 

In planning the quality dimension, include specifications for the quality and types of materials to be used, the performance standards to be met, and the means of verifying quality such as testing and inspection. Two techniques facilitate planning for quality a work breakdown structure and project specifications. Both are described on the next few pages. 

Maintenance embraces regular inspection, periodic examination by competent persons , and repairs. All maintenance on equipment used with chemicals should be properly planned and recorded. Maintenance operations, particularly those which are non-routine, require a sound system of work with strict administrative procedures, e.g. permit-to-work, to avoid risks arising from modifications to established safe practices. A permit-to-work should be used wherever the method by which a job is done is likely to be critical to the safety of the workers involved, nearby workers, or the public it is required whenever the safeguards provided in normal operations are no longer available. Examples include ... 

Inspections should be carried out as study-specific inspections for critical phases of the study or as a batch of process inspections relating to critical tasks which are performed regularly and although may not be inspected for a specific study are inspected on a regular basis (e.g., once per month). The coordination of inspections is perhaps more difficult to predict than actually conducting the critical event. The use of local QA staff close to the sites where the field work is being conducted helps to reduce the travel time to the field sites and also the down time if the critical event cannot be made at the specified time. The use of computer planning tools to schedule fieldwork is very helpful, not only to the field staff but also to QA. 

Team Biologics inspectors report to an ORA Washington, D.C., office for administrative purposes only. Although this office has a central budget, which differs from most inspection efforts, it does not exercise inspection or compliance oversight. Work plans are prepared quarterly and include decisions about which firms are due for inspections. 

Inspection and test plans or requirements (usually included in work instructions and quality plans)... 

If the development work is planned with the goal of passing the PAI and the work complies with CGMP quality principles, there should be only minimal preparations needed for the FDA in the weeks and months just prior to the inspection itself. A number of different methodologies have been developed to help with the short-term preparation efforts. Justice and co-workers at Eli Lilly and Company have described a 10-step process to help guide these preparation efforts [4], These steps can be found inTable 1. 

The planning group is responsible for ensuring that copies of sketches and any other pertinent instructions would be issued to the contractor doing the work and to the operating, maintenance, and inspection departments. 

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