<h2>Why Use Management of Change Templates?</h2>
<p><a href="https://safetyculture.com/topics/management-of-change/"><span style="font-weight: 400;">Management of change</span></a><span style="font-weight: 400;"> templates provide a standardized format and structure for documenting changes. This ensures that all necessary information is captured consistently across different types of changes. They also help organizations comply with industry requirements by following a systematic process for demonstrating </span><a href="https://www.trade.gov/perform-due-diligence"><span style="font-weight: 400;">due diligence</span></a><span style="font-weight: 400;">.</span></p>
<p><span style="font-weight: 400;">Additionally, ready-to-use templates such as this prompt decision-makers to consider all the risks associated with any change before they are implemented.</span></p>
<h2>What to Include in a Management of Change Template</h2>
<p><span style="font-weight: 400;">Aside from the primary details like the name of the facility, location of the site, name of the change initiator, description and area of the proposed change, and targetted date and time of implementation, a good management of change template should ideally include a review of  following items:</span></p>
<ul>
<li style="font-weight: 400;"><span style="font-weight: 400;">Engineering</span></li>
<li style="font-weight: 400;"><span style="font-weight: 400;">Operating and Design</span></li>
<li style="font-weight: 400;"><span style="font-weight: 400;">Quality</span></li>
<li style="font-weight: 400;"><span style="font-weight: 400;">Operating Personnel</span></li>
<li style="font-weight: 400;"><span style="font-weight: 400;">External Personnel</span></li>
<li style="font-weight: 400;"><span style="font-weight: 400;">Regulations, Standards, or Code of Practice</span></li>
<li style="font-weight: 400;"><span style="font-weight: 400;">Suppliers, Community, and/or Client/User</span></li>
<li style="font-weight: 400;"><span style="font-weight: 400;">Other</span></li>
<li style="font-weight: 400;"><span style="font-weight: 400;">Completion</span></li>
</ul>
<p><span style="font-weight: 400;">Since a management of change initiative is not limited to the above aspects, businesses can further customize their own templates according to their needs.</span></p>


Free Management of Change Templates

||Management of Change Template|Management of Change Template2023

Business Processes

Operations

Management of Change (MOC) Template

<h2>What is a PPAP Checklist?</h2>
<p>A <a href="https://safetyculture.com/topics/ppap/">PPAP</a> checklist is used by quality managers to easily detect mismatched process flows, <a href="#3" rel="noopener">FMEAs</a>, and control plans; ensure the complete, accurate, and timely submission of <a href="#featured-block-2">PPAP documents</a> such as Design Records, <a href="#featured-block-4" rel="noopener">Appearance Approval Report (AAR)</a>, and <a href="#featured-block-5" rel="noopener">Initial Sample Inspection Report (ISIR)</a>; and gain full approval for production and shipment of parts.</p>
<h2>3 Common PPAP Mistakes and How to Avoid Them</h2>
<p><img loading="lazy" decoding="async" class="aligncenter wp-image-145236 size-full" src="https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2023/12/3-Common-PPAP-Mistakes_2022.png" alt="3 Common PPAP Mistakes" width="700" height="400" /></p>
<p>Due to the methodical and comprehensive nature of the production part approval process, quality managers often overlook some customer-specific requirements. When PPAPs get rejected, OEMs and suppliers inevitably waste time and resources to implement corrections for resubmission. Here are 3 common mistakes during the PPAP and how to avoid them:</p>
<h3>1. Ineffective Communication Between Supplier and Customer</h3>
<p>Quality managers should work closely with the PPAP evaluator to provide exactly what the customers are looking for, especially when there are engineering changes and the master sample needs sign-off from both parties. During the contract review, clarify <a href="https://safetyculture.com/topics/iatf-16949/customer-specific-requirements/">customer specifications</a> with FMEA teams, design engineers, and manufacturing personnel to facilitate effective communication in the manufacturing facility as well.</p>
<h3>2. Mismatched Process Flows, FMEAs, and Control Plans</h3>
<p>There should be a clear link from the Design FMEA and <a href="https://safetyculture.com/checklists/pfmea/">Process FMEA</a> to the Process Flow Diagram and Control Plans. Quality managers should consider all known special characteristics and address all high-risk failure modes with executable action plans to accurately demonstrate all manufacturing operations, handling techniques, inspection steps, and alternate/backup processes. Detailed and complete process control plans should be in place and include all print, specification, attribute, and purchase order requirements.</p>
<h3>3. Mismanaged PPAP Documents</h3>
<p>Most PPAP revisions get rejected because of avoidable clerical shortcomings. Quality managers should provide evidence that the FMEA is a living document, a special characteristics deviation waiver is available, and non-conformance in any of the PPAP documents is resolved before submission. All PPAP documents should be legible, updated, and reviewed for completeness.</p>
<h2>Understanding your <span data-sheets-value="{&quot;1&quot;:2,&quot;2&quot;:&quot;Production Part Approval Process&quot;}" data-sheets-userformat="{&quot;2&quot;:4289,&quot;3&quot;:{&quot;1&quot;:0},&quot;9&quot;:1,&quot;10&quot;:2,&quot;15&quot;:&quot;Arial&quot;}">Production Part Approval Process</span> Status and What to Do Next</h2>
<p><img loading="lazy" decoding="async" class="aligncenter size-full wp-image-123802" src="https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2023/12/Understanding-your-PPAP-Status-and-What-to-Do-Next.jpg" alt="Team planning whats next after getting PPAP result" width="700" height="400" /></p>
<p>The PPAP evaluator may take some time reviewing the PPAP documents, but quality managers can use the lead time to create fixtures and adjust a few operating parameters. Upon receipt of the PPAP status, here is what OEMs or suppliers should do to move forward:</p>
<h3>Fully Approved</h3>
<p>Since the part and its PPAP documents have proven that the manufacturing process can consistently produce conforming output, the parts can now be shipped to the customer as scheduled. OEMs and suppliers prevent costly production delays when they meet or even exceed customer expectations.</p>
<h3>Interim Approval</h3>
<p>If customers see nonconformance in any of the PPAP documents, containment measures should be undertaken by the quality manager. Even when the OEM or supplier is authorized to ship for a defined period of time and/or a limited number of parts only, corrective actions should be implemented and reflected in the resubmission of PPAP documents to gain full approval within 90 days.</p>
<h3>Rejected</h3>
<p>When the part fails to meet customer-specific requirements or when the PPAP shows inconsistencies in the documentation, the OEM or supplier is not authorized to ship the rejected product. Quality managers should execute corrective actions based on what the customer established as the reason for rejection, and revise PPAP documents accordingly before resubmission.</p>
<p>&nbsp;</p>


Digital PPAP Checklists & PDF Reports

ppap|3 Common PPAP Mistakes|Team planning whats next after getting PPAP result|Lista de comprobación del PPAP

Quality

Quality Management

Production Part Approval Process (PPAP)

<h2>Scope of a PSSR</h2>
<p>A PSSR covers <a href="https://www.aiche.org/ccps/introduction-operational-readiness" rel="noopener">multiple aspects of the workplace</a> as a whole and ensures the existence of procedures that promote a safe working environment. Here is the scope of a PSSR divided into the 3 main workplace factors:</p>
<h3>Facility</h3>
<p>A PSSR aims to confirm that the facility is both safe for and conducive to work. It checks the facility’s <a href="https://safetyculture.com/topics/electrical-hazards/" rel="noopener">electrical safety</a>, ergonomics, control of noise and fire hazards, existing confined spaces, waste management, and environmental management.</p>
<h3>Equipment</h3>
<p>PSSR checks for procedures such as lockout/tagout and the existence of machine guarding or <a href="https://safetyculture.com/topics/fall-protection/" rel="noopener">fall protection</a> measures to control workplace risks. It also helps verify if the training was provided on the proper use of new or modified equipment and if potential risks that may arise from the use of new equipment are mitigated.</p>
<h3>Staff</h3>
<p>PSSR checks if the organization provides employee training on safe operating procedures such as using <a href="https://safetyculture.com/topics/ppe-safety/" rel="noopener">PPE</a>, handling of chemicals and hazardous substances, as well as food safety practices.</p>
<h2>How to Conduct a PSSR</h2>
<p>PSSR procedures will vary depending on the facility and industry. In order to conduct one that is relevant and effective for a new or modified facility, the following steps should be followed:</p>
<h3>Build a team and select a leader</h3>
<p>A multidisciplinary team composed of staff with authority on engineering, operations, quality, safety, and security can help identify areas for improvement in the facility and assist in carrying out an effective PSSR. The PSSR team should be led by an authority in the organization who can delay the commissioning of a facility should the team discover sufficient risks that can compromise workplace safety.</p>
<h3>Create a PSSR checklist</h3>
<p>Creating a PSSR checklist will need the collaborative effort of the PSSR team members who will specify which aspects of the workplace should be checked, with particular consideration to the facility, equipment, employees, and operational processes.</p>
<h3>Use the right tools</h3>
<p>The PSSR team should be able to capture data on any areas for improvement identified during a PSSR and be able to quickly implement corrective actions. Delays in addressing safety issues will not only expose employees to potential <a href="https://safetyculture.com/topics/workplace-hazards/" rel="noopener">workplace hazards</a> but can also lead to costly delays in the commissioning of a facility.</p>


PSSR Checklists

|Ingenieurin bei der Durchführung einer PSSR||pssr-checklist

Safety

Safety Management

PSSR

<h2>What is an Incoming Inspection Checklist?</h2>
<p>An incoming inspection checklist details exactly what <a href="https://safetyculture.com/topics/quality-assurance-and-quality-control/">quality assurance</a> personnel should be validating—size, color, shape, markings, and packaging of sample material from the entire batch. With this checklist, you should be able to:</p>
<ul>
<li aria-level="1">Specify manufacturer details</li>
<li aria-level="1">Provide supplier name and address</li>
<li aria-level="1">Add purchase order number, material name, &amp; description</li>
<li aria-level="1">Validate quantity and sample size</li>
<li aria-level="1">Determine inspection results if accepted, conditionally accepted, or rejected</li>
<li aria-level="1">Implement required actions based on the tagging system</li>
<li aria-level="1">Capture photos for evidence</li>
</ul>
<h2>Why Use Incoming Inspection Checklists?</h2>
<p>Taking advantage of a mobile-ready incoming inspection checklist helps ensure the conformity of raw materials to purchase order specifications, reduce production costs, and manufacture high-quality products that meet or even exceed quality standards, customer expectations, and safety regulations.</p>
<h2>Understanding the Identification Tagging System</h2>
<p>The identification tagging system is used during the process of incoming quality control to express the acceptance criteria specified in the purchase order.</p>
<p>Each inspection result corresponds to the following actions:</p>
<div id="attachment_167574" style="width: 710px" class="wp-caption aligncenter"><img aria-describedby="caption-attachment-167574" loading="lazy" decoding="async" class="wp-image-167574 size-full" src="https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2023/12/Incoming-Inspection-Identification-Tagging-System-3.png" alt="Incoming Inspection Identification Tagging System" width="700" height="400" /><p id="caption-attachment-167574" class="wp-caption-text">Incoming Inspection Identification Tagging System</p></div>
<h3>Accepted</h3>
<p>Place the accepted materials in stock or forward them to the next operation. When all raw materials or purchased components meet quality standards, manufacturers usually proceed with the first production run and perform a <a href="https://safetyculture.com/checklists/first-article-inspection/" rel="noopener">First Article Inspection (FAI)</a> to confirm that the manufacturing process produces output that meets design requirements.</p>
<h3>Conditionally Accepted</h3>
<p>Quality inspectors should keep an eye out for minor or major defects such as functional and dimensional deviations, shipping damages, and improper markings to determine if the raw materials can be conditionally accepted. Specify the <a href="https://www.qualitymag.com/articles/92832-eliminate-waste-in-incoming-inspection" target="_blank" rel="noopener">conditions for acceptance</a> such as rework or replacement by the supplier and ascertain that the quality manager and a supplier representative sign in agreement.</p>
<h3>Rejected</h3>
<p>Quality inspectors should issue a <a href="https://safetyculture.com/checklists/non-conformance-report/" rel="noopener">Non-Conformance Report (NCR)</a> for rejected materials and indicate if they will be scrapped, sorted, or reassessed against more specific acceptance criteria. Rejecting materials may cause shortages and destabilize the production schedule, but it prevents costly manufacturing problems such as mass-producing unsafe and defective products.</p>


Incoming Inspection Checklists

Quality Assurance

Incoming Inspection Checklist

<h2><strong>Why Conduct Air Compressor Maintenance?</strong></h2>
<p><span style="font-weight: 400;">All air compressors need preventative maintenance to facilitate efficient energy distribution. Failing to conduct air compressor maintenance can result in unusable equipment and unnecessary delays. Additionally, faulty air compressors are not safe to use and may even cause harm or injury to workers.</span></p>
<h3>1. Maintain efficiency</h3>
<p><span style="font-weight: 400;">Air compressors are expected to operate at optimum levels within the expected run time. Scheduled air compressor maintenance by engineers can help catch issues that lead to inefficiencies, such as prolonged run time or lower compressor capacity caused by possible leakage from safety relief valves or suction valves.</span></p>
<h3>2. Ensure safety</h3>
<p><span style="font-weight: 400;">Depending on the air compressor type, unchecked air compressors can have condensed water buildup which can lead to internal corrosion and cause equipment to weaken and explode unexpectedly. Overheating of air compressors can be caused by clogged components or lack of ventilation. Conducting air compressor preventive maintenance checks can help safety officers proactively catch problems to avoid compromising the safety of workers.</span></p>
<h3>3. Ensure compliance</h3>
<p><a href="https://www.iso.org/standard/63787.html"><span style="font-weight: 400;">International standards</span></a><span style="font-weight: 400;"> such as </span><a href="https://safetyculture.com/topics/iso-45001/"><span style="font-weight: 400;">ISO 45001</span></a><span style="font-weight: 400;"> for </span><a href="https://safetyculture.com/topics/occupational-health-and-safety/"><span style="font-weight: 400;">occupational health and safety</span></a><span style="font-weight: 400;">, and </span><a href="https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.430"><span style="font-weight: 400;">OSHA standards for equipment</span></a><span style="font-weight: 400;"> require maintenance to ensure the safety of employees. Conducting regular preventive equipment maintenance inspections of air compressors and having proof through </span><a href="https://safetyculture.com/topics/recordkeeping/"><span style="font-weight: 400;">recordkeeping</span></a><span style="font-weight: 400;"> can help organizations stay compliant with international safety standards.</span></p>
<p>Perform maintenance inspections with this Air Compressor Maintenance Checklist. Download and customize for free:</p>
<div id="attachment_47638" style="width: 610px" class="wp-caption aligncenter"><a href="https://public-library.safetyculture.io/products/compressor-preventive-maintenance-checklist"><img aria-describedby="caption-attachment-47638" loading="lazy" decoding="async" class="wp-image-47638" src="https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2023/12/Air-Compressor-Maintenance-Checklist-729x1024.png" alt="Air Compressor Maintenance Checklist" width="600" height="843" srcset="https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2023/12/Air-Compressor-Maintenance-Checklist-729x1024.png 729w, https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2023/12/Air-Compressor-Maintenance-Checklist-213x300.png 213w, https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2023/12/Air-Compressor-Maintenance-Checklist-768x1079.png 768w, https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2023/12/Air-Compressor-Maintenance-Checklist-1093x1536.png 1093w, https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2023/12/Air-Compressor-Maintenance-Checklist-1457x2048.png 1457w, https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2023/12/Air-Compressor-Maintenance-Checklist.png 1587w" sizes="auto, (max-width: 600px) 100vw, 600px" /></a><p id="caption-attachment-47638" class="wp-caption-text"><a href="https://public-library.safetyculture.io/products/compressor-preventive-maintenance-checklist">Air Compressor Maintenance Checklist | SafetyCulture</a></p></div>
<h2><strong>3 Air Compressor Maintenance Tips</strong></h2>
<p><span style="font-weight: 400;">Conducting air compressor maintenance and <a href="https://safetyculture.com/checklists/compressed-air-audit/">audits</a>, however, have some challenges, and not doing them consistently will lead to costly breakdowns. The reliability of these tasks usually falls on the safety officers and technicians. Perform routine air compressor preventive maintenance or necessary predictive maintenance by following the tips below.</span></p>
<h3><span style="font-weight: 400;">1. Read the air compressor manual</span></h3>
<p><span style="font-weight: 400;">It’s important to read the air compressor manual first before doing anything to the machinery because it may have additional tips that can help solve the issue and can guide the maintenance process. Even if the air compressor will be serviced by someone else, it still helps to browse through the manual to get the most use out of the air compressor and retain its warranty.</span></p>
<h3><span style="font-weight: 400;">2. Check and change the oil </span></h3>
<p><span style="font-weight: 400;">For air compressors that use oil, make sure that there’s adequate lubrication before operating the device. This has to be performed daily since “fresh” oil is needed for the air compressor to work. Start by turning off the air compressor. Next, remove the fill cap and the drain plug. Place a container underneath to drain the oil. Attach the new drain plug and add in the new oil. Finally, attach the new fill cap.</span></p>
<h3><span style="font-weight: 400;">3. Check and change the air filter</span></h3>
<p><span style="font-weight: 400;">A clean air filter is crucial to the functioning of the air compressor e.g. a clean air conditioning system. While the air filter is designed to trap and hold impurities, if not inspected, it could cause the air compressor to produce less air, and the <a href="https://safetyculture.com/checklists/compressed-air-system-maintenance/">compressed air</a> that it does produce may even be contaminated. To make sure the filtration process is clean, allow the compressor to get cooled off, check the air filter, loosen the top screw,  and remove the filter element. If it is full of dirt, put in a new one.</span></p>
<p><strong>Other air compressor routine maintenance tips to follow:</strong></p>
<ul>
<li style="font-weight: 400;"><span style="font-weight: 400;">Clean intake vents and heat exchangers</span></li>
<li style="font-weight: 400;"><span style="font-weight: 400;">Drain tanks of moisture or condensate</span></li>
<li style="font-weight: 400;"><span style="font-weight: 400;">Inspect the safety shutdown system</span></li>
<li style="font-weight: 400;"><span style="font-weight: 400;">Check belts, hoses, and bolts</span></li>
<li>Condition monitoring and set up regular preventive maintenance checks</li>
</ul>


Air Compressor Maintenance Checklists

Equipment Maintenance

Maintenance

Air Compressor Maintenance

<h2>What is a PDI Checklist?</h2>
<p><span style="font-weight: 400">A PDI checklist is a tool used by vehicle inspectors to assess vehicles’ operating conditions and compliance with safety regulatory standards before selling to customers.</span> <span style="font-weight: 400">Using a PDI checklist can help proactively repair identified issues,</span><span style="font-weight: 400"> lessen vehicles that come back to the dealership with problems, prevent costly recalls, and gain a high reputation of consistent quality for the dealership.</span></p>
<h2>Risks of Inefficient Pre-delivery Inspections</h2>
<p><span style="font-weight: 400">Striking the right balance between efficiency and satisfactory work has been a challenge in doing pre-delivery inspections. Vehicle inspectors either waste too much time and energy using paper-based PDI checklists or conduct pre-delivery inspections based on fallible human memory. </span><span style="font-weight: 400">Here are risks that dealers expose themselves to when they perform inefficient PDI inspection:</span></p>
<h3>Recurring Issues</h3>
<p><span style="font-weight: 400">Technicians might miss common issues that should have been detected during an effective pre delivery inspection.</span><span style="font-weight: 400"> Defective vehicles returned to the dealership entail repairs or modifications that could have been accomplished prior to delivery and spending costly man-hours of duplicated work.</span></p>
<h3>Missed Delivery Commitments</h3>
<p>Dealers inevitably struggle with delays in the delivery schedule as sold vehicles in the service bay increase. Expect low customer satisfaction when business processes such as customer service and <a href="https://safetyculture.com/topics/transport-and-logistics/">logistics</a> slow down due to inefficient inspections.</p>
<h3>Automotive Recalls</h3>
<p>At least 24 people have died and hundreds more have been injured because of airbag inflators that hurl shrapnel into drivers and passengers. Automakers have recalled 50.36 million inflators and replaced 27.2 million of them as part of the largest series of automotive recalls in U.S. history, involving as many as 70 million to be recalled by the end of 2020. Pre-delivery inspections can help find major recall issues before a single unit is sold or delivered.<a id="PDIchecks"></a></p>
<h2>Basic PDI Car Checks</h2>
<p>Pre-delivery inspection is a crucial task because it helps secure the safety of your customers. It is performed to prevent car manufacturing product recalls and <a href="https://safetyculture.com/checklists/vehicle-damage-reports/" rel="noopener">accidents due to factory defects or damage</a>. The following are the basic checks performed during the pre-delivery inspection of a light vehicle.</p>
<h3>Engine Compartment</h3>
<ul>
<li>The engine should not produce any growling sounds</li>
<li>All fluids such as washer, coolant, brake, power steering, transmission, and oil are free from leaks and at their normal levels</li>
<li>Hood latch should be lubricated to ensure smooth operation</li>
<li>The battery is tested and fully operational</li>
</ul>
<h3>Underside</h3>
<ul>
<li>There are no visual defects such as tears or holes on hoses, electrical lines, exhaust systems, and suspension components</li>
<li>Brakes should be tested and checked for damage indicators such as brake lights on, squeaking noises, vibration, and soft brake pedal</li>
</ul>
<h3>Interior</h3>
<ul>
<li>The steering wheel should be aligned</li>
<li>Locks, latches, and hinges are lubricated and functional</li>
<li>Fuses are installed for electronic accessories</li>
<li>No evident damage on car seats</li>
<li>Seat belt, wheel covers, wheel locks, and airbags are installed properly</li>
</ul>
<h3>Exterior</h3>
<ul>
<li>All lighting should be checked if operational</li>
<li>Headlights are aligned</li>
<li>Tire pressure is set to manufacturer-suggested specifications, including the spare tires</li>
<li>All mirrors should be fixed and clear</li>
<li>Windshield wipers and washer fluid level are examined</li>
<li>Paint condition and emblems are damage free</li>
</ul>
<p>PDI also includes checking of owner’s manual, service passport, warranty booklet, and guides before handing vehicle over to customers. It is also necessary to perform the recommended 10-kilometer road test both on city roads and the highway to check overall car performance.</p>


Pre-delivery Inspection (PDI) Checklists & PDF Reports

|||Pre-delivery Inspection Checklist|Pre-delivery Inspection (PDI) Checklist sample report|Pre-delivery Inspection Checklist

Logistics

Pre-delivery Inspection

<h2><b>What is the Purpose of the SPCC Plan?</b></h2>
<p><span style="font-weight: 400;">According to the U.S. Environmental Protection Agency (EPA), the purpose of an </span><span style="font-weight: 400;">SPCC plan is to help prevent oil spills and control a spill should one occur. SPCC rules require the implementation of certified SPCC plans by owners or operators of </span><span style="font-weight: 400;">qualified facilities</span><span style="font-weight: 400;"> containing storage for petroleum and oil products. An SPCC plan can also be self-certified upon following specific requirements.</span></p>
<h2><b>What is an SPCC Plan Template?</b></h2>
<p><span style="font-weight: 400;">An SPCC plan template is a guidance tool used to develop a spill prevention, control, and countermeasure plan that addresses the necessary SPCC rule requirements. SPCC plan templates can be completed electronically and customized accordingly to meet facility-specific needs. Using mobile-ready </span><a href="#featured-block"><span style="font-weight: 400;">spill prevention plan templates</span></a><span style="font-weight: 400;"> can help owners and operators to not only create an SPCC plan, but also implement it in compliance with regulations.</span></p>
<h2><b>What is an SPCC Plan Checklist?</b></h2>
<p><span style="font-weight: 400;">An SPCC plan checklist, or spill response plan checklist, is a supporting attachment to an SPCC plan. For example, this </span><a href="https://public-library.safetyculture.io/products/spcc-plan-template-tier-2"><span style="font-weight: 400;">SPCC plan checklist</span></a><span style="font-weight: 400;"> based on </span><a href="https://www.epa.gov/oil-spills-prevention-and-preparedness-regulations/spcc-guidance-regional-inspectors"><span style="font-weight: 400;">USEPA SPCC Guidance for Regional Inspectors</span></a><span style="font-weight: 400;"> features the following items for onshore oil drilling, production, and workover facilities:</span></p>
<ul>
<li style="list-style-type: none;">
<ul>
<li><span style="font-weight: 400;">Dikes, berms, or retaining walls sufficiently impervious to contain oil,</span></li>
<li><span style="font-weight: 400;">Curbing or drip pans,</span></li>
<li><span style="font-weight: 400;">Sumps and collection systems,</span></li>
<li><span style="font-weight: 400;">Culverting, gutters or other drainage systems,</span></li>
<li><span style="font-weight: 400;">Weirs, booms or other barriers,</span></li>
<li><span style="font-weight: 400;">Spill diversion ponds,</span></li>
<li><span style="font-weight: 400;">Retention ponds, or</span></li>
<li><span style="font-weight: 400;">Sorbent materials.</span></li>
</ul>
</li>
</ul>
<p><span style="font-weight: 400;">The SPCC plan checklist referred to above is for tier 2 qualified facilities and can also be used as a template for the primary SPCC plan. For tier 1 qualified facilities, this </span><a href="https://public-library.safetyculture.io/products/oil-spill-contingency-plan-and-checklist-spcc-tier-1-attachment-2"><span style="font-weight: 400;">SPCC plan checklist</span></a><span style="font-weight: 400;"> can help owners or operators develop and implement criteria for state, local, and regional oil removal contingency plans.</span></p>
<h2><b>What is the Goal of the <span data-sheets-value="{&quot;1&quot;:2,&quot;2&quot;:&quot;Spill Prevention Countermeasures and Control&quot;}" data-sheets-userformat="{&quot;2&quot;:4289,&quot;3&quot;:{&quot;1&quot;:0},&quot;9&quot;:1,&quot;10&quot;:2,&quot;15&quot;:&quot;Arial&quot;}">Spill Prevention Countermeasures and Control</span> Plan?</b></h2>
<p><span style="font-weight: 400;">The U.S. EPA states that the </span><span style="font-weight: 400;">SPCC plan must be maintained at the location of the facility that is normally attended at least four hours per day. </span><span style="font-weight: 400;">Regardless of the tier, SPCC plans aim to provide procedures that can help qualified facilities achieve these 3 goals in compliance with SPCC rules:</span></p>
<h3>SPCC Goal #1. Prevent oil spills</h3>
<p>Personnel in the facility should be trained on the proper handling of oil and the correct use of equipment in order to prevent oil discharge. Aboveground storage tanks and equipment should be periodically inspected using the <a href="https://public-library.safetyculture.io/products/oil-spill-contingency-plan-and-checklist-spcc-tier-1-attachment-2" rel="noopener">corresponding checklist</a> to ensure that they are in good working condition to handle oil and oil products.</p>
<h3>SPCC Goal #2. Prevent a spill from reaching navigable waters</h3>
<p>The facility should be able to prevent a discharge from reaching nearby water through equipment or structures such as dikes, retention ponds, booms, or an equivalent containment system that can hold oil in the event of a spill. Proactively inspect equipment and structures to ensure that they are able to prevent spills from reaching navigable waters and that immediate action is taken if a spill is found.</p>
<h3>SPCC Goal #3. Mitigating the effects of a spill in navigable waters</h3>
<p>The facility’s communication system should be able to immediately notify the national response center (<a href="https://www.nrt.org/" rel="noopener noreferrer">1-800-424-8802 or 1-202-426-2675</a>) and other parties such as cleanup contractors in the event of a spill reaching nearby water. Use an oil containment checklist to make sure procedure is followed for the containment and cleanup of an oil spill.</p>


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What is a Tier 1 facility?

What is a Tier 2 facility?

How to be qualified for either Tier 1 or Tier 2?

SPCC Plan

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Environmental Safety

<h2>5 Critical Checkpoints of ISO Container Inspections</h2>
<p><span style="font-weight: 400;">While easily avoidable, container fires may occur on a weekly basis, and a major container ship fire can happen at sea roughly every 60 days. On the maiden voyage of the </span><a href="https://www.iims.org.uk/cause-of-maersk-honam-fire-is-inconclusive-reveals-report/" target="_blank" rel="noopener"><span style="font-weight: 400;">Maersk Honam</span></a><span style="font-weight: 400;">, a fire broke out in one of 7,860 containers which caused the death of 5 crew members and an estimated total loss of $1 billion. </span></p>
<p><span style="font-weight: 400;">Here are 5 critical checkpoints that safety officers should watch out for in ISO container inspections to prevent similar incidents from occurring:</span></p>
<h3>1. ISO Identification</h3>
<p><a href="https://www.iso.org/standard/20453.html" target="_blank" rel="noopener"><span style="font-weight: 400;">ISO 6346:1995</span></a><span style="font-weight: 400;"> is the international standard for coding, identification, and marking of freight containers. It specifies a physical presentation of marks on the ISO container to identify its size and type and verify the accuracy of its use. The ISO mark should be clearly displayed on the upper right corner and roof of the shipping container.</span></p>
<h3>2. CSC Plate</h3>
<p><span style="font-weight: 400;">An ISO container should undergo static longitudinal restraint, concentrated loads, and stacking tests to be approved for transport under customs seal and gain CSC safety approval. Usually located on the exterior doors, the combined data plate should be a permanent, non-corrosive, fireproof rectangular plate with alphanumeric characters of proportionate width and thickness stamped into, embossed on, or indicated on its surface.</span></p>
<h3>3. 7-Point Technique</h3>
<p><span style="font-weight: 400;">Safety officers should follow the 7-point visual inspection method in checking the condition of shipping containers before transit. Keep an eye out for the condition of these <a href="https://safetyculture.com/topics/transport-and-logistics/intermodal-transportation/">intermodal</a> container parts: </span></p>
<p><img loading="lazy" decoding="async" class="aligncenter size-full wp-image-153966" src="https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2023/12/7-point-iso-container-inspection.png" alt="7-Point Technique" width="1024" height="512" /></p>
<h3>4. Cargo</h3>
<p><span style="font-weight: 400;">Improper cargo lashing, especially for dangerous goods, can lead to container fires as cargo moves or is damaged inside the ISO container during transit. Safety officers should inspect the cargo before and after packing and the cargo holds before and after loading.</span></p>
<h3>5. Shipping Documents</h3>
<p><span style="font-weight: 400;">One of the leading causes of container fires is misdeclared cargo. Safety officers should examine shipping documents and confirm the consistency of the commercial invoice, packing list, and bills of lading to the actual cargo inside the ISO container.</span></p>
<h2>How to Efficiently Inspect ISO Containers</h2>
<p><span style="font-weight: 400;">When transporting products, businesses and shipping companies—may they be internal or third-party, aim to ensure that products will safely arrive from their origin to their final destination. To assist with that, regular inspections should be conducted, particularly on the containers of the products. </span></p>
<p><span style="font-weight: 400;">Take note of the following instructions to perform a comprehensive and reliable container inspection procedure:</span></p>
<h3>Preparation</h3>
<p><span style="font-weight: 400;">Before anything else, establish which specific container is to be inspected. Then mention other important information such as the name of the inspector, date and location of inspection, and country or place of origin of the shipment. </span></p>
<p><span style="font-weight: 400;">Make sure that the container is empty before starting the actual inspection.</span></p>
<h3>Exterior</h3>
<p><span style="font-weight: 400;">Next, examine the container from the outside. Things to look out for include defects, damages, alarming stages of rust, and other signs of deterioration. Go through each external aspect of the container and assess if it’s a pass or fail. Add necessary notes or create immediate actions for failed ones. </span></p>
<h3>Interior</h3>
<p><span style="font-weight: 400;">Lastly, do a comprehensive review of the inside of the container. Similar to the exterior inspection, keep an eye out for damages, leaks, and cracks, as well as suspicious odors that might be caused by cleaning materials or other chemical residues. For reefer containers or those that need their temperatures regulated, check the temperature controls and make sure that they are working properly.</span></p>
<p><span style="font-weight: 400;">Record all these using a pre-existing </span><a href="https://public-library.safetyculture.io/products/iso-container-inspection-checklist" target="_blank" rel="noopener"><span style="font-weight: 400;">ISO container inspection checklist</span></a><span style="font-weight: 400;"> or template so that it’s properly documented, efficient, and easy to track for future reference.</span></p>
<h2>What is an ISO Container Inspection Checklist?</h2>
<p><span style="font-weight: 400;">An ISO container inspection checklist is a pre-made document that businesses, safety officers, and third-party shipping services can use when assessing a container. Not only does it provide all the important information you need, but it also guides you through the entire process of the inspection—preventing you from missing any critical areas and aspects while inspecting.</span></p>
<p><span style="font-weight: 400;">Through the use of ISO container inspection checklists, businesses can determine whether a shipping container is durable and safe for product transportation.</span></p>
<h2>What to Include</h2>
<p><span style="font-weight: 400;">The format of an ISO container inspection checklist can vary depending on the business, but its contents are generally very similar. It mainly consists of the following items:</span></p>
<ul>
<li style="font-weight: 400;" aria-level="1"><span style="font-weight: 400;">Container number</span></li>
<li style="font-weight: 400;" aria-level="1"><span style="font-weight: 400;">Shipper</span></li>
<li style="font-weight: 400;" aria-level="1"><span style="font-weight: 400;">Name of inspector</span></li>
<li style="font-weight: 400;" aria-level="1"><span style="font-weight: 400;">Date of inspection</span></li>
<li style="font-weight: 400;" aria-level="1"><span style="font-weight: 400;">Country/place of origin</span></li>
<li style="font-weight: 400;" aria-level="1"><span style="font-weight: 400;">Undercarriage</span></li>
<li style="font-weight: 400;" aria-level="1"><span style="font-weight: 400;">Doors</span></li>
<li style="font-weight: 400;" aria-level="1"><span style="font-weight: 400;">Left side</span></li>
<li style="font-weight: 400;" aria-level="1"><span style="font-weight: 400;">Right side</span></li>
<li style="font-weight: 400;" aria-level="1"><span style="font-weight: 400;">Front wall</span></li>
<li style="font-weight: 400;" aria-level="1"><span style="font-weight: 400;">Floor</span></li>
<li style="font-weight: 400;" aria-level="1"><span style="font-weight: 400;">Roof</span></li>
</ul>
<div id="attachment_104730" style="width: 610px" class="wp-caption aligncenter"><img aria-describedby="caption-attachment-104730" loading="lazy" decoding="async" class="size-full wp-image-104730" src="https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2019/04/ISO-Container-Inspection-Checklist-Sample-Report.png" alt="ISO Container Inspection Checklist Sample Report" width="600" height="800" srcset="https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2019/04/ISO-Container-Inspection-Checklist-Sample-Report.png 600w, https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2019/04/ISO-Container-Inspection-Checklist-Sample-Report-225x300.png 225w" sizes="auto, (max-width: 600px) 100vw, 600px" /><p id="caption-attachment-104730" class="wp-caption-text"><a href="https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2023/11/ISO-Container-Inspection-Checklist-Sample-PDF-Report.pdf">ISO Container Inspection Checklist Sample Report | SafetyCulture</a></p></div>


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ISO Container Inspection Checklists

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<h2><b>Why Use Pressure Vessel Inspection Checklists?</b></h2>
<p><span style="font-weight: 400;">Boilers and <a href="https://safetyculture.com/topics/pressure-vessel/">pressure vessels</a> vary by shape, construction materials, working pressure, vessel threads, safety features, and maintenance features. Engineers, safety officers, or boiler inspectors use pressure vessel inspection checklists to help maintain the good working condition of pressure vessels and their safety accessories which keep liquid and gas pressure in check. Boilers are common devices for industrial heating and humidification applications, and pressure vessels are used to hold liquids, vapors, or gases at high pressures.</span></p>
<h2>What to Include in a Pressure Vessel Inspection Checklist?</h2>
<p><span style="font-weight: 400;">Below are the general items to check during pressure vessel inspections: </span></p>
<p><strong>External Inspection</strong></p>
<ul>
<li><span style="font-weight: 400;">Coverings</span></li>
<li><span style="font-weight: 400;">Leakage</span></li>
<li><span style="font-weight: 400;">Vessel mountings</span></li>
<li><span style="font-weight: 400;">Check for defects, cracks, or deformations</span></li>
<li><span style="font-weight: 400;">Corrosions</span></li>
</ul>
<p><strong>Internal Inspection</strong></p>
<ul>
<li><span style="font-weight: 400;">Threads and threaded connections</span></li>
<li><span style="font-weight: 400;">Openings</span></li>
<li><span style="font-weight: 400;">Special closures</span></li>
<li><span style="font-weight: 400;">Free from cracks, deterioration, and corrosion</span></li>
</ul>
<p><strong>Safety Devices</strong></p>
<ul>
<li><span style="font-weight: 400;">Proper seal</span></li>
<li><span style="font-weight: 400;">Intact bolts</span></li>
<li><span style="font-weight: 400;">Check for rust, corrosion, and damage</span></li>
<li><span style="font-weight: 400;">Rupture disks</span></li>
</ul>
<p><strong>Piping Systems</strong></p>
<ul>
<li><span style="font-weight: 400;">Provision of expansion and support</span></li>
<li><span style="font-weight: 400;">Free from leakage, corrosion, erosion, cracking</span></li>
</ul>
<h2><a id="how-often-should-pressure-vessels-be-inspected"></a>How Often Should Pressure Vessels be Inspected?</h2>
<p><span style="font-weight: 400;">Generally, pressure vessels should be inspected at least once every two years and tested at least once every five years. Visual examinations of pressure vessels, or storage tanks/vessels that operate at pressures above 15 psig (pound-force per square inch gauge), should also be conducted after installation, before operation, and during maintenance to detect potential cracks and ensure boiler and pressure vessel safety. This also applies to high-pressure vessels that will require regular inspections and monitoring.</span></p>
<h2><b><a id="requirements"></a>Pressure Vessel Inspection Requirements</b></h2>
<p><span style="font-weight: 400;">Inspection requirements for pressure vessels depend on country-specific regulations such as the Pressure Systems Safety Regulations of 2000 (</span><a href="https://www.hse.gov.uk/pubns/books/l122.htm"><span style="font-weight: 400;">PSSR</span></a><span style="font-weight: 400;">) in the UK, regional guidelines such as the Pressure Equipment Directive of 2014 (</span><a href="https://ec.europa.eu/growth/sectors/pressure-gas/pressure-equipment/directive_en"><span style="font-weight: 400;">PED</span></a><span style="font-weight: 400;">) from the European Commission, and applicable industry standards such as the Boiler and Pressure Vessel Code of the American Society of Mechanical Engineers (</span><a href="https://www.asme.org/shop/certification-accreditation/boiler-and-pressure-vessel-certification"><span style="font-weight: 400;">ASME</span></a><span style="font-weight: 400;">).</span></p>
<h2><a id="causesfailure"></a>3 Main Causes of Pressure Vessel Failure</h2>
<p>There are several causes of pressure vessel failure that can have dangerous consequences if not caught early and immediately corrected during routine inspections. Consider these common reasons why pressure vessels become unfit for use and watch out for them during routine inspections.</p>
<h3><strong>1. Hardware issues</strong></h3>
<p>Error in vessel design, plate material used, construction, or installation can cause cracks and erosion on boilers and pressure vessels that could lead to leakage or rupture. Compliance with industry standards for the manufacture of boiler pressure vessel valves can help prevent failures and other hardware issues.</p>
<h3><strong>2. Errors in repair</strong></h3>
<p>Welding, coating, and other methods of pressure vessel repair that do not conform with standards may not properly address issues and render the vessel unsafe for use. Periodic inspections should be conducted by engineers or boiler inspectors to proactively determine if boilers, pressure vessels, and safety devices are still in good working condition or already in need of repair or replacement.</p>
<h3><strong>3. Lack of monitoring </strong></h3>
<p>Prolonged use of pressure vessels without periodic maintenance or routine inspections can lead to catastrophic accidents. Whether inspections are done annually or every 4 hours, they can help keep the vessels at optimal condition and prevent unforeseen accidents if they are conducted by competent personnel.</p>
<p>Wrong material used and lack of internal audits contributed to the rupture of a pressure vessel in 2009 that caused injury, damage to nearby businesses, and loss of life in the state of Illinois.</p>
<p><iframe loading="lazy" title="Falling Through the Cracks" width="500" height="281" src="https://www.youtube.com/embed/uo7H_ILs1qc?feature=oembed" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share" referrerpolicy="strict-origin-when-cross-origin" allowfullscreen></iframe></p>


Pressure Vessel Inspection Checklists

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Pressure Vessel Inspection

<h2>What is Advanced Product Quality Planning (APQP)?</h2>
<p><a href="https://safetyculture.com/topics/apqp/">Advanced Product Quality Planning (APQP)</a> is a structured process employed when introducing a new product in the market or incorporating changes in the product after its release. This method helps detect defects during production and ensures that there is proper documentation of the processes involved when manufacturing new products.</p>
<p>A Cross-Functional Team (CFT) composed of engineering, manufacturing, quality, procurement, and distribution professionals performs an APQP to ensure that products meet or even exceed customer requirements. Primarily practiced in the automotive industry, it has been adopted by other manufacturing sectors such as aerospace, defense, medical, and pharmaceutical since this method is proven effective.</p>
<h2>What’s Included in an APQP Checklist?</h2>
<p>An APQP checklist ensures that all aspects of product development and production meet quality standards. The checklist should typically include:</p>
<ul>
<li aria-level="1"><strong>Planning and Management</strong>: Define project scope, goals, timelines, and resources. Establish quality objectives and risk management strategies.</li>
<li aria-level="1"><strong>Product Design and Development</strong>: Ensure design specifications meet customer and regulatory requirements. Validate designs through testing and analysis.</li>
<li aria-level="1"><strong>Process Design and Development</strong>: Document production processes and identify potential failures using FMEA. Validate processes to ensure consistent quality.</li>
<li aria-level="1"><strong>Validation and Verification</strong>: Validate both design and process to meet specifications. Conduct thorough testing and maintain detailed records.</li>
<li aria-level="1"><strong>Production and Post-Delivery</strong>: Implement production controls and plan for customer support. Ensure consistent quality during production.</li>
</ul>
<p>By following these steps, there is an increased chance that an APQP checklist will be a valuable asset to your company.</p>
<div id="attachment_107210" style="width: 610px" class="wp-caption aligncenter"><a href="https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2023/11/APQP-Checklist-Sample-PDF-Report.pdf"><img aria-describedby="caption-attachment-107210" loading="lazy" decoding="async" class="wp-image-107210 size-full" src="https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2019/04/APQP-Checklist-Sample-Report.png" alt="apqp checklist sample report" width="600" height="800" srcset="https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2019/04/APQP-Checklist-Sample-Report.png 600w, https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2019/04/APQP-Checklist-Sample-Report-225x300.png 225w" sizes="auto, (max-width: 600px) 100vw, 600px" /></a><p id="caption-attachment-107210" class="wp-caption-text"><a href="https://wp-website.safetyculture.com/wp-content/uploads/sites/3/2023/11/APQP-Checklist-Sample-PDF-Report.pdf">APQP Checklist Sample Report</a></p></div>
<h2>What is the Difference Between APQP and PPAP?</h2>
<p><a href="https://safetyculture.com/topics/ppap/">PPAP</a>, which stands for Production Part Approval Process is one of the components and output of an APQP. But what really is the main difference between the two?</p>
<div class="table">
<table style="border-collapse: collapse; width: 100%;">
<tbody>
<tr>
<td style="width: 50%;"><strong>APQP</strong></td>
<td style="width: 50%;"><strong>PPAP</strong></td>
</tr>
<tr>
<td style="width: 50%;">Advanced Product Quality Planning</td>
<td style="width: 50%;"><a href="https://safetyculture.com/checklists/ppap-production-part-approval-process/" rel="noopener">Production Part Approval Process</a></td>
</tr>
<tr>
<td style="width: 50%;"><strong>What are the 5 phases of implementing APQP?</strong></p>
<p><strong>Phase 1:</strong> Plan and Define Program<br />
<strong>Phase 2:</strong> Product Design and Development Verification<br />
<strong>Phase 3:</strong> Process Design and Development Verification<br />
<strong>Phase 4:</strong> Product &amp; <a href="https://safetyculture.com/topics/process-validation/">Process Validation</a> and Production Feedback<br />
<strong style="font-family: inherit; font-size: inherit;">Phase 5:</strong> Launch, Assessment &amp; <a style="font-family: inherit; font-size: inherit;" href="https://safetyculture.com/topics/corrective-action/">Corrective Action</a></td>
<td style="width: 50%;">PPAP belongs to the 4th phase of APQP: Product &amp; Process Validation and Production Feedback</td>
</tr>
<tr>
<td style="width: 50%;">APQP is a process for introducing a new product in the market or for incorporating changes in the product after its release.</td>
<td style="width: 50%;">The goal of PPAP is to provide evidence that the manufacturer and supplier have understood the customer’s specifications and that they can produce products that consistently meet those specifications.</td>
</tr>
</tbody>
</table>
</div>
<p>APQP and PPAP both have essential importance, especially to the aerospace and automotive manufacturing industry. They help ensure that quality materials and products are created, released, and continually improved.</p>
<h2>5 Common APQP Challenges and Cost-efficient Solutions</h2>
<p>Manufacturing products based on APQP requirements can be challenging, but it enables Original Equipment Manufacturers (OEMs) and the entire supply chain to gain long-term, high yields. Here is how CFTs can proactively solve the 5 common challenges of advanced product quality planning:</p>
<h3>1. IATF 16949:2016 Compliance</h3>
<p>IATF 16949:2016 is an international standard for automotive quality management systems. Compliance with the IATF standard requires the proper documentation of processes implemented, inspections conducted, and actions taken for nonconformance. Perform regular <a href="https://safetyculture.com/checklists/iatf-audit/" rel="noopener">IATF audits</a> using a digital <a href="#5">IATF 16949:2016 Audit Checklist</a> to schedule routine compliance checks, assign corrective actions, and secure records in the cloud.</p>
<h3>2. Clear Direction and Responsibilities<strong><br />
</strong></h3>
<p>Management should oversee the advanced product quality planning process based on the quality policy of the company. Project managers should facilitate communication and collaboration among cross-functional teams to remove the guesswork and address unresolved issues. Take advantage of a mobile-ready APQP documents checklist to easily manage priorities and ensure the completion of all deliverables from pre-planning to production.</p>
<h3>3. Adequate Knowledge and Resources</h3>
<p>Engineering, manufacturing, and quality personnel should understand what APQP requirements entail and how to deliver them. Here are some of the most widely used APQP tools for designing, developing, and validating products and processes:</p>
<ul>
<li style="list-style-type: none;">
<ul>
<li><strong><a href="https://safetyculture.com/checklists/fmea-template/" rel="noopener">Failure Modes and Effects Analysis</a> (FMEA)</strong> is a systematic method of anticipating potential failures in manufacturing processes and mitigating their impact on customers. In conducting Design and <a href="https://safetyculture.com/checklists/pfmea/">Process FMEAs</a>, utilizing an easy-to-use <a href="https://public-library.safetyculture.io/products/fmea-template-machinery" rel="noopener">FMEA template</a> can help properly identify the mechanism of failure, accurately compute the Risk Priority Number (RPN), and regularly monitor corrective actions.</li>
<li><strong><a href="https://safetyculture.com/checklists/first-article-inspection/" rel="noopener">First Article Inspection</a> (FAI)</strong> is the process of verifying design requirements of a product from the first production run, including part number accountability, materials/processes, special processes, functional tests, and design characteristics. An <a href="https://public-library.safetyculture.io/products/first-article-inspection-fai-report" rel="noopener">FAI report form</a> converted into a <a href="https://safetyculture.com/platform/">SafetyCulture (formerly iAuditor)</a> mobile app empowers quality inspectors to automatically generate a shareable report from the moment an FAI is completed.</li>
<li><strong><a href="https://safetyculture.com/checklists/factory-acceptance-test/" rel="noopener">Factory Acceptance Test</a> (FAT)</strong> is used to verify that newly produced equipment works according to its construction code and customer purchase order specifications. It is performed in the manufacturing facility before delivery and installation at the customer’s site. Immediately resolve equipment nonconformities and keep the project on track and within its budget by using an intuitive <a href="https://public-library.safetyculture.io/products/factory-acceptance-test-checklist-UGEOo" rel="noopener">FAT checklist</a>.</li>
</ul>
</li>
</ul>
<h3>4. Time Management</h3>
<p>As a strategy for actionable data, ascertain all inspections/tests are recorded and analyzed to develop and implement corrective and preventive actions. To save time and effort, project managers should create <a href="https://safetyculture.com/platform-workflows/" rel="noopener">automated workflows</a> and easily manage reporting procedures, especially for visual inspections and risk assessments.</p>
<h3>5. Discipline and Team Accountabilit<strong>y<br />
</strong></h3>
<p>CFTs should meet on a regular basis to review APQP priorities and check the status of the entire advanced product quality planning process. Together with a record of open issues, risk and opportunity lists should also be maintained and presented to management.<a id="FAQs"></a></p>


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Advanced Product Quality Planning (APQP)

<h2><strong>First Article Inspection Process</strong></h2>
<p>First article inspections assure product conformance at the start of series production and after design changes. Generally, here are the steps taken by quality inspectors when performing first article inspections:</p>
<h3>Step 1: Prepare the engineering design and specification requirements</h3>
<p>Quality managers should regularly coordinate with design engineers and fabrication managers to ascertain that the as-built technical drawings (electrical, mechanical, pneumatic, and process schemes) are followed. Before the first article inspection, prepare the instruments calibration certificates and refer to the equipment and materials data sheets to deliver high-quality machines with performance that clients can trust.</p>
<h3>Step 2: Determine the part or assembly to inspect</h3>
<p>The “first article” to be inspected is neither the prototype model nor the first product from a production run. Quality inspectors should randomly select a representative item from the first production run and document part number accountability which includes the part number, part name, and manufacturing process reference.</p>
<h3>Step 3: Conduct raw materials, special processes, and functional testing</h3>
<p>Quality inspectors measure and verify design characteristics through product-specific tests with required design tooling. For product accountability, each material and process used to manufacture the product is listed and certificates of conformance for special processes are added. Functional test procedures should also be cited with corresponding acceptance reports as supporting documents.</p>
<h3>Step 4: Evaluate characteristics of accountability and compatibility</h3>
<p>Inspection results can ascertain the necessity of a delta FAI or a full re-accomplishment of the first article inspection. In the case of non-conforming characteristics, design revisions should be implemented. Quality inspectors should review the manufacturing process and non-conformance documentation to improve the performance of a delta FAI.</p>
<h3>Step 5: Report the first article inspection with proper documentation</h3>
<p>Upon the completion of the first article inspection, quality inspectors validate the FAI report with their signatures, indicating that all characteristics are accounted for; meet drawing requirements; or are properly documented for disposition.</p>
<h2>What is an FAI Report?</h2>
<p>An FAI report, or FAIR, is a document completed by quality inspectors that usually includes part number accountability, product accountability, and characteristic accountability. Generally, electronic signatures are acceptable in an FAI, as long as their usage and control are clearly defined in the organization’s quality management system (<a href="https://safetyculture.com/app/qms-software/">QMS</a>).</p>
<h2>What to Include in a First Article Inspection Checklist</h2>
<p>A FAI report should contain the steps or processes that could help verify the integrity of the product made. A First Article Inspection Checklist checklist and FAI report ideally includes the following:</p>
<ul>
<li aria-level="1"><strong>Drawing and specification review</strong> &#8211; product is at par with the specified design</li>
<li aria-level="1"><strong>Dimensional inspection</strong> &#8211; product has the correct dimensions (length, width, diameter, etc.)</li>
<li aria-level="1"><strong>Material/process assessment</strong> &#8211; product has the correct parts and materials</li>
<li aria-level="1"><strong>Functional test</strong> &#8211; product works as intended in the design</li>
<li aria-level="1"><strong>Packaging</strong> &#8211; product meets packaging requirements</li>
<li aria-level="1"><strong>Safety</strong> &#8211; product is safe to consume/use</li>
</ul>
<h2>How to Write a First Article Inspection Reports</h2>
<p>This is what your how to create FAI reports with SafetyCulture as a first article inspection app:</p>
<ol>
<li aria-level="1"><strong>Streamine inspection process</strong> &#8211; Easily convert an existing first article inspection template to digital format. This ensures that the same best practices are being followed across all branches of your operation so FAI standards are maintained.</li>
<li aria-level="1"><strong>Automate generating and sharing FAI reports </strong>&#8211; After completing the inspection, immediately generate a report. Set automatic sharing so they are regularly sent to relevant stakeholders.</li>
<li aria-level="1"><strong>Assign corrective actions</strong> &#8211; The SafetyCulture FAI app enables teams to assign corrective actions to appropriate personnel. Through the web dashboard, managers can check which actions have been assigned, are in progress, or have been completed.</li>
<li aria-level="1"><strong>Make sense of your data </strong>&#8211; With all of your inspection data flowing back to SafetyCulture’s powerful analytics tool, you can immediately gain actionable insights from the web app. Have the ability to filter data by inspection, department, personnel, and site so you can pinpoint the root of the issue instead of trying to fix the symptoms.</li>
</ol>


What is a 9102 FAI?

What is a Delta FAI?

How often should a first article inspection be performed?

FAQs About First Article Inspections

First Article Inspection Checklists & FAI Reports

Manufacturing Safety

First Article Inspection Checklist

<h2>Common Plant Workplace Hazards</h2>
<p>While it is important to proactively perform scheduled pump inspections and keep pumps in good working condition to maintain uninterrupted operation, it is vital to first ensure that the inspectors are safe. Here are the vital items to check during a plant risk assessment and the common questions inspectors ask.</p>
<h3>Work environment</h3>
<ul>
<li>Is the ventilation poor?</li>
<li>Are there confined spaces where workers cannot move properly?</li>
<li>How is the lighting in the plant?</li>
<li>Are workers exposed to constant loud noise?</li>
<li>Is the floor clean and dry?</li>
<li>Are ladders secure and do elevated spaces have guardrails?</li>
<li>Is the workplace ergonomically designed? Are workers exposed to extreme temperatures?</li>
</ul>
<h3>Equipment, tools, and substances</h3>
<ul>
<li>Is there appropriate machine guarding?</li>
<li>Are chemicals labeled correctly, in their recommended containers, and properly stored?</li>
<li>Are all tools in the working area in good working condition?</li>
</ul>
<h3>Performance of tasks</h3>
<ul>
<li>Do workers have prolonged exposure to vibration?</li>
<li>Is everybody wearing proper PPE?</li>
<li>Is Lockout Tagout being followed?</li>
<li>Are workers trained not only in the execution of tasks but also in safe working practices?</li>
</ul>
<h2>Optimize Inspections with a Plant Inspection Software</h2>
<p>A plant inspection software is a digital tool used by plant inspectors when performing safety checks and risk assessments in fixed industrial facilities such as power plants, chemical plants, and factories.</p>
<p>The purpose of a plant inspection is to identify risk hazards that may result in worker injury and/or fatality, as well as prevent unexpected downtimes that may result in the interruption of operations.</p>
<p>With SafetyCulture as your plant inspection software, you can make safety inspections more efficient while automating reporting, and documentation. Perform different plant inspections with the help of a highly customizable mobile platform, and get a comprehensive look at your plant’s performance so you can make necessary adjustments to improve safety and quality.</p>


Digital Plant Risk Assessment Templates

Risk Assessment

Plant Risk Assessment

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