FPC manualGET FULL VERSION ATHTTP://CEWIZARD.EUBS EN 1090-1

FPC-Manual

XXXX Ltd.The address of the production facilityBS EN 1090-1+A1Version 1.0

_________________________________________________xxx xxx, managing director

Content1.Introduction41.1.Scope41.2.Product families52.Structure of FPC system62.1.Structure of documentation62.2.Document management72.3.Managerial audits82.4.Conformity to relevant standards92.5.Standards in the FPC system93.Resource management103.1.Human resources103.2.Machines and testing equipment114.Manufacture of structural steel products134.1.Specification of requirements134.2.Structural design process134.3.Purchasing134.4.Verification of a purchased product134.5.Product planning and execution144.6.Initial type testing and calculation, and testing as a part of FPC154.7.CE marking and preparation of declaration of performance164.8.Handling and storage165.Welding FPC175.1.Welding personnel185.2.Reviews185.3.Welding procedure specifications195.4.Welding plan205.5.Subcontracting205.6.Inspection and testing206.Measuring, analysis and improvement216.1.Non-conforming products216.2.Traceability and marking22

IntroductionWe 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.ScopeOur 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 1090-2 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 productionIn-houseSubcontractedNotes

Structural design

Cutting

Shaping

Holing

Mechanical fastening

Assembly

Welding

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. Product familiesStructural 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 1EXAMPLE. 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.Structure of FPC systemThis 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.0. Structure of documentation

Figure 1. The documentation hierarchy of the FPC systemThe 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.Quality records contain the objective documentation and proof of product conformity. These documents include, for example, component specifications, test results and complaints.Document managementDocuments 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 documentationThere 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 documentsWhere 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.The documents in the FPC system follow the naming and numbering system as follows:

Figure 2. FPC system documentationManagerial auditsOnce 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 needsBased on the managerial audits, a separate document Managerial audit is prepared and saved as a part of quality documentation.

Conformity to relevant standardsThe 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+A1FPC-manualDocument

Personnel3.1P

Equipment3.2M

Products used in manufacture4.3W

Assembly specification4.1W

Product evaluation4.6D

Non-conforming products6.1W, D

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 ownStandard codeDescription / contents

BS EN 1090-1Execution of steel and aluminium structures. Part 1: Requirements for conformity assessment of structural components.

BS EN 1090-2Execution of steel and aluminium structures.Part 2: technical requirements for steel structures.

ISO 3834-3Part 3. Quality requirements for fusion welding of metallic materials

EN 14731Welding coordination. Tasks and responsibilities

EN 1011-1, -2, -3Welding. Recommendations for 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.Resource managementHuman resourcesDeleted textMachines and testing equipmentDeleted textManufacture of structural steel productsSpecification of requirementsDeleted textStructural design processDeleted textPurchasingDeleted textVerification of a purchased productDeleted textProduct planning and executionDeleted textInitial type testing and calculation, and testing as a part of FPCDeleted textCE marking and preparation of declaration of performanceDeleted textHandling and storageDeleted textWelding FPCDeleted textWelding personnelDeleted textReviewsDeleted textWelding procedure specificationsDeleted textWelding planDeleted textSubcontractingDeleted textInspection and testingDeleted textMeasuring, analysis and improvementDeleted text

Version history

DATEReason for updateApproved byRequires training

XXImplementation of FPC system[Name]Yes

FPC documentation (no working instructions)

TypeDocument idWhat is it used for?

Quality documentsFinal InspectionCollect and record the inspections related to the manufacturing process. Very important document.

Inspection report for weldsRecord the visual NDT of welds. Very important document.

Structural design reviewVerify that structural design has been performed appropriately. Very important document.

Approved WPSApproval process for the new WPSs used in production.

CEmarkBlank template for CE mark. Use this to develop CE mark for each new structural steel product.

ChecklistDouble 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.

Complaint formRecord all complaints from customers and major internal complaints.

Document templateBlank document to make new FPC files

DoPBlank template for Declaration of performance

DoP-FlowchartFlowchart to help you determine the appropriate Method to use when preparing the CE mark and DoP

Humidity and air temperatureRecord the storage conditions of welding consumables and wet painting if you do it.

Internal trainingRecord trainings that you organize for your employees that relate to the FPC system

ITT&ITCRecord 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.

Maintenance recordsRecord the maintenance of your manufacturing machinery

Managerial auditRecord the managerial audit where you check that the FPC system is functional

Parameter controlControl the appropriate use of WPSs during the manufacturing

Procedure test HolingApproval of your holing processes and methods

Procedure test Thermal cuttingApproval of your thermal cutting processes and methods

Training documentRecord the training where you teach your new (or old) employee everything they need to know about their new job.

Visual NDTQualify your visual weld inspectors

Control of resourcesPersonnel qualifications and organizationListing of employees and subcontractors. Define tasks and responsibilities for employees.

Qualification requirementsListing of all minimum qualification requirements from the standards

Machinery and testing equipmentListing of all manufacturing machinery and testing equipment

Use and maintenance of measuring equipmentInstructions for use and calibration of common measuring equipment

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