0.1 duties of the senior welding inspector
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CSWIP 3.2 Senior Welding Inspection
TWI Training & Examination
Services
Duties of the
Senior Welding Inspector
Course Reference WIS 10
Course notes section reference 11
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Visual Inspection Procedures
Important things to consider: When do I carry out inspections
How do I carry out inspections?
What do I look for?
What equipment do I need? How do I interpret the code or standard requirements?
What is the nature of the product?
What operating conditions will be present?
What is the quality of welding required?
Is there a code or standard available to inspect the welds against
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Duties of the Senior W.I.
What attributes does a Senior Welding Inspector need ?
Technical skillsLeadership skills
Compassion
Good communicator
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Duties of the Senior W.I.
What Technical skills are required:
1. Knowledge of Technology
2. Knowledge of Codes & Standards
3. Knowledge of Planning
4. Knowledge of Organization
5. Knowledge of Auditing
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Duties of the Senior W.I.
What Leadership skills are required:
1. Ability to do so if required
2. Willingness to direct
3. Acceptance of responsibility
4. Ability to delegate (trust staff)
5. Commitment to ones staff
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Duties of the Senior W.I.
What Compassion skills are required:
1. Understanding of problems
2. Willingness to help
3. Compromise if possible.
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Motivation
What Motivates You?
MONEY
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What motivates you ?
Money
Appreciation
Flexibility Job Satisfaction
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Lack of motivation
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Lack of motivation
Late for work
Sickness
Poor productivity
Lack of job satisfaction
Signing off poor quality documents
Arguments
No enthusiasm
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Supervisory Skills
MotivationAbraham Maslows Hierarchy of needsPHYSIOLOGICAL SAFETY
SOCIALSELF ESTEEM
SELF ACTUALIZATION
Hunger
ThirstSleep
Warmth
Protection
Security
Shelter
Acceptance
Affiliation
Belonging
Socialising
Friendship
PowerStatusRespectAppreciationRecognition
AchievementAttainment
Creativity
Developmen
Fulfilment
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Supervisory Skills
MotivationIntrinsic Motivation Extrinsic Motivation
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Supervisory Skills
MotivationTheory's (1)
People inherently dislike work and will avoid it ifthey can.
Because they dislike work they have to be offeredrewards to work, and threatened withpunishments if they dont.
They prefer to be controlled and directed, want toavoid responsibility, have little ambition anddesire security more than anything else.
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Supervisory Skills
MotivationTheory's (2)People do not dislike work; under the right conditionsthey can enjoy it.
If they are committed to the objectives of the group,they will direct and control themselves, rather than
having to be controlled from above.
People will be committed to objectives if they aregetting enough personal satisfaction from the job.
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Supervisory Skills
MotivationThe average human being learns to accept andto seek responsibility, if conditions are right.
Ingenuity and creativity are widely distributedand generally under-utilized
Continuo
usimprov
ements
Newid
eas
Suggestions
Thinkinginvolvement
Wanting
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Supervisory Skills
Herzberg,sTheory
Motivational or growth factors
Sense ofachievement
Recognition
Responsibility
Nature of work
Personal growth
Maintenancefactors
Salary
Job security
Working conditions
Supervision level &quality
Company policy and
administration
Interpersonal relations
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Supervisory Skills
Motivational Needs
Motivation needs change with each person, situation & time.
You must know your people well enough to provide the bestmotivational factors in the work place
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What does it mean to really listen?
Hearing.
Understanding.
Judging.
Supervisory Skills
Listening Skills
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Supervisory Skills
SENDER MESSAGE RECEIVER
FILTERSEMOTIONS/ATTITUDESROLE EXPECTATIONSNON VERBAL CUES
FILTERSEMOTIONS/ATTITUDESROLE EXPECTATIONS
NON VERBAL CUES
FEEDBACK
BARRIERS BARRIERS
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Supervisory Skills
Listening Skills
When we listen attentively
We empower the speaker
Receive all the message
Use facial and body language to encourage thespeaker
Read facial and body language coming from the
speaker
The speaker becomes motivated
We let the speaker finish his message
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SUPERVISORY SKILLS
LISTENING SKILLS ARE A VITAL PART OF
COMMUNIVATIONS
TUNING IN - SHORT VERBAL SIGNALS THAT ENCOURAGE THESPEAKER TO CONTINUE UH-HUH, I SEE, MMHMMM ETC.
PARAPHRASING - HELPING THE SPEAKER ORGANISEINFORMATION & CHECK UNDERSTANDING BY: PULLING OUT ACENTRAL IDEA OR COMBINING SEVERAL POINTS INTO ONEYOU THINK THAT ADDITIONAL PEOPLE WILL BE REQUIRED TOMAINTAIN THE SCHEDULE.
REPHRASING - REPEATING THE INFORMATION IN YOUR OWNWORDS WHAT YOU ARE SAYING THEN IS THAT BECAUSE OFLACK OF TRAINED PEOPLE, YOUR GROUP IS FALLING BEHINDSCHEDULE.
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SUPERVISORY SKILLS
LISTENING SKILLS ARE A VITAL PART OFCOMMUNIVATIONS
ACKNOWLEDGING - INDICATING THAT YOU ACCEPT THE SPEAKERSRIGHT TO FEEL OR THINK THAT WAY, OR THAT YOU MAY EVEN
AGREE WITH CERTAIN POINTS
I CAN UNDERSTAND YOUR FRUSTRATION
YOU A RE REALLY UPSET ABOUT THISTHATS A GOOD POINT
I KNOW YOU HAVE HAD A HARD TIME FINDING TRAINED PEOPLE
LISTINING - ENCOURAGING THE LOGIC, ORDER & FLOW OFINFORMATION
OK, SO FAR YOU HAVE MENTIONED THAT MANY OF YOUR PEOPLELACK SUFFICIENT TRAINING TO DO THE WORK, & SECONDLY, THESCHEDULE DEADLINES ARE IN JEOPARDY
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SUPERVISORY SKILLS
Barriers to listening
Time
Importance of the subject
Importance of the speaker
Attention
Distractions
Defensive
Discarding the feelings of the speaker
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Supervisory Skills
Types of communications
VERBAL - MOST COMMUNICATIONS
NON - VERBAL: WRITTEN - LETTER, ADVERTISING
VISUAL - BODY LANGUAGE, ACTIONS
YOUR ACTIONS SPEAK LOUDLY, I CANNOT HEAR A WORDYOU ARE SAYING
People believe visual communications more than verbal. whenvisual and verbal messages conflict, people believe the visualmessage
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Supervisory Skills
Planning and Organization
What?
Where?
When?
Who?
How?
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Supervisory Skills
Maintenance Factors
Moral Regular Meetings with your Team
Quality Conduct Mini Audits
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Duties of the Senior W.I.
Exam Compulsory question:
Signing off a product
What does this consist of?
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Signing off a product
Quality Plan:All stages signed off
Weld History Sheet (weld map? Materials):
All stages signed off
Materials:
All certificates checked and signed off (welding consumables Parent
materials)
Procedures:
Approved for cutting, welding, repair, NDT, PWHT, Testing Coating
Qualification of:Welders NDT Personnel Inspectors (All approved and up to date)
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Signing off a product
Inspection Reports for:Visual NDT Dimensional, ensure they cover all appropriate
joints
Calibration Reports:
For those items of equipment deemed necessary gauges etc
PWHT Charts:
Ensure all necessary information is on the chart speed data
etc
Hydro Tests:
Reports are complete and signed off etcAs built drawings:
Are completed and are marked as As built
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Signing off a product
Nameplate Rubbings:When applicable
Concessions:
Engineering Query's, Deviations etc
Permits:
Degas certificates, hot work etc
Coatings:
Final painting or coating certificates signed off
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Signing off a product
QA Procedures
DrawingsSpecifications
Material test certificates (Mill sheets, chemical analysis & mechanical
properties)
Transfer of cast numbers markings etc
Welding procedures
Welder approvals
Production welds (weld history)
Any problems with interruptions of the welding cycle
Documentation (welding consumables)
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Signing off a product
Non Conforming items
Pre & post weld heat treatment
Visual inspection report
NDT Done in accordance with procedure
NDT Reports
Repairs & repair proceduresPressure test reports
Dimensional reports (random check carried out)
Visual checks on welding
Concessions
Inspectors Qualifications
Q lit k t t
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Quality pack content
Documents supplied before
manufacture certificate of conformance
with different codes/standards
design calculations (optional)
manufacturing drawings
WPS with supporting WPQR(copies)
welder qualifications
qualification of NDT personnel
NDT procedures PWHT oven calibration record
(optional)
Documents supplied after
manufacture material test certificates (list!)
welding production tests (if
required)
PWHT record (if required)
NDT test reports: dimensional,pressure test and coating
thickness are included
quality plan and weld map
as-built drawings
non-conformity reports
operating/mounting
instructions
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Reference to the specification
As Built Weld Maps Weld Traceability log
Weld Numbers
Welder Numbers Material Classification & Certification
Welding Procedure Numbers (WPS PQR's) and Documentation
Material Traceability & Material Certificates
Consumable Control Procedures & Consumable Certificates
Welder's register and all approval Certificates
Weld Visual Inspection Procedures & Visual Inspection Reports
List of NDT Operators & Approval Certificates
NDT Procedures
NDT Reports
R/T Report Numbers
U/T Report Numbers
MPI Report Numbers
Dye/Pen Report Numbers
Dimensional Control Procedures & Dimensional Control Reports
PWHT Procedures & PWHT Reports + Calibration Cert.'s
Hydro-test Procedures & Hydrotest Reports + Calibration Cert.'s
Painting Procedures & Painting Conformance Reports
Non-Conformance Reports
Load Out Procedure
Engineering Queries
As Built Drawings
Quality pack content
Q
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Quality pack content
See Appendix 1
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Any QuestionsAny Questions
??