Chris,
Maybe your company procedure requires inspection of every piece, but the COSP does not state that. It only states that the fabricator make visual inspection of material that is recieved from the mill. It does not state "for the fabricator to inspect any material they use to fab parts from", as you said in your post. That's why I asked you where that is stated in the COSP. It can be taken as implied, but it is not clearly stated as to the degree/frequency of visual inspection, (i.e. inspecting every single piece that is received). That was the point I wanted to make. Furthermore, if taken literally, 8.2 only addresses materials received from the mill, which could be taken to exclude materials received from a service center or warehouse. In one way or another any material received is received from the mill, whether it's received direct or via service center, it was produced by a mill. That's just me playing devils advocate, as I said in my post.
However, I totally agree with you that it's a good idea to check every piece. We do that too, at one point or another. We don't make a special effort to roll over every piece of material we recieve at any point during the receiving and fabrication process in order to verify that all surfaces are in compliance. It's not practical and I don't think anyone else actually does that either. We look at only what is visible when material is received, what is visible at the saws, shears, ironworkers, pressbrake, plasma, camber machine, etc., We may see more/other areas on the fabrication bucks, because many times the material is turned over for additional fitting, welding, etc., and QC is always walking around monitoring all areas, as well as the area supervisors monitoring the processes they are responsible for. I think we've got it covered pretty well, but we won't catch everything unless we take extra time to look at every inch of every piece received. I don't know about other fabricators, but I can't justify that. The mills and service centers have responsibilities too, but ultimately it all comes back to the fabricator if there's an issue later on.
It's been a while since I ran into any problems with raw materials, but when it last happened, the supplier told us that had the probelm been identified before we cut it, drilled it, or machined it, they would have replaced the material. However, because the lamination was discovered after the plate was cut, we owned it.
Just my past experience.
Best regards - Al
Al,
A couple of our suppliers tried that with me over the years, but they replaced the material anyway. On a couple other occasions, I took pictures of laminations, repaired them, and turned in the repair time to the supplier, who issued us a credit.
We had some custom size... 20 something by large rectangular tubing one time that came in with a backing strip down two sides(on the inside).....terrible fitup and welding of that seam on both sides. There were places where the backing had drooped down and the weld didn't even touch it. We were able to get replacements from the supplier. Also had several laminations like Scott stated and got compensated for our time repairing them.
I guess if you are a "good" customer the supplier will be more accommodating.
Best regards - Al
snorris, you bring up an interesting angle to look at this issue from. I see what your referring to because eventually all material came from a mill at some point or another. Additionally, when I spoke with one of our suppliers, they mentioned that they look at the material as well before they sell it.
I guess I automatically intrepeted the COSP and jumped ahead and figured at some point all material needs to be checked, which it is.
It seemed clear to me, but your take on it could add a twist, but I'm still sticking to how I intrepret it.
Thanks for the enlightening though, good job, There's two side to every story. Chris
" at some point all material needs to be checked, which it is."
Except when it isn't, and hence this thread.
Hg
Al,
You're exactly right. Good customers have more leverage on an issue like this as compared to the occasional customer. Good observation.