Vendor Assessment AUDIT REPORT
Document Sample


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Vendor Assessment Audit Report
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Date: Mar 23, 07
Vendor Assessment AUDIT REPORT
SGS Reference No.: IN07039QD
Requested by: Free Flow Pipe Systems
Evaluated Company HuoDa Pipe Fittings CO.,LTD
Office Adress: Room 812,8th floor,Yin hai heng ji Building, Dongfeng
East Street, Weifang city, Shandong Province, China
Factory Adress: DaZhuangZi Village, Weicheng district, Weifang city,
Shandong Province, China
Purpose of 1. Evaluation of company’s capacities and
Assessment: capabilities for production and test of steel pipe
fittings.
2. Evaluation of company’s quality system
Audit Date: Mar 20-22, 2007
Auditor: Mr. Lester Deng and Jeremiah Yu
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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Contents
A. General Information
B. Products
C. Sales Organisation
D. Procurement
E. Engineering Control
F. Inspection Procedures
G. Quality Assurance
H. Non-destructive Examination and Destructive Testing
I. Tool and Gauge Control
J. Welding Standards
K. Material Handling and Storage
L. Non-confirming Material
M. Corrective Action
N. On site inspection
O. Summary
Annex 1: The relation of Shengtian and Huoda and Xin Xiang
Annex 2: Machinery list
Annex 3: Reference Photos
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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A. General Information
COMPANY NAME: HuoDa Pipe Fittings CO.,LTD
Contact: Mr. Huo Qingguang ( his another name is Huoda), the
Managing Director
Office Adress: Room 812,8th floor,Yin hai heng ji Building, Dongfeng
East Street, Weifang city, Shandong Province, China
Factory Adress: DaZhuangZi Village, Weicheng district, Weifang city,
Shandong Province, China
TELEPHONE NO.: 0086-536-8199769
FAX NO.: 0086-536-8199759
E - MAIL: Shengtian@cnshengtian.com
LEGAL STATUS: Limited Company
REGISTER N°: 3707002806255
REGISTRY The Administration of Industry and Commerce of Weifang
OFFICE: City, China
VAT IDENT N°: 37070277971927X
FOUNDED ON: Aug 2, 2005
Note: the following information was based on:
- interviews with management and quality control inspectors
- reviewing all kinds of documents provided by the factory
- On site production process audit
- On site finished product inspection.
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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1. Is the company a part of a group? NO
(If yes, which one and since when?)
2. Has the company any subsidiaries? NO
(If yes, indicate their names, addresses and
percentage holding.)
3. Has the company foreign agents? YES
(If yes, which one?)
Shandong ocean chemical imp & exp co., ltd
4. Has the company agreements with
other firms? NO
(If yes, which firms?)
5. Does the company belong to an
intercompany partnership? NO
(If yes, which companies?)
6. Main shareholders: Mr. Huoda and Ms Li Junzhen (they are one couple)
7. Is there a holding company? YES
8. State any modifications envisaged to legal status or
affiliation (i.e. merging, change of owner): NO
9. PAID-UP CAPITAL: RMB 2,000, 000
10. TURNOVER:
10a. Annual turnover during last three financial years:
Year:2006 Turnover:78376632.00 (RMB)
10b. Export turnover: 100%
10c. Turnover percentage:
- In the client's field of activity: fittings: 90%
- In the other fields of activity: flanges: 10%
11. COMPANY WORKFORCE:
11a. Total: .....45..
- Executives or comparable category ....2....
- Supervisors, technicians and engineers .....4..
- Workers .....33.
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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- Office employees .....6...
11b. Workforce in the following functions:
- Marketing & sales: ... .7....
- Design/development: .....5..
- Logistics: .....1...
- Methods/industrialisation: ......4.
- Accounts, administration, .....2..
- Production: . ...20...
- Purchasing: .. .1...
- Quality control: . . ..2....
11c. Average age of employees: 35 year old
11d. - Average length of employment: ...2 years.....
11e. - Temporary or seasonally
employed staff: ......10..
11f. Average length these of contracts: ......No contract for workers..
11g. Does the current organisation enable
sudden fluctuations to be handled? YES
12. ASSOCIATIONS
(Names of the associations to Machinery
which the company belongs)
13. ORGANISATION OF THE COMPANY
General Manager
representative of managing
Production Dep. Tech. Dep. Office Purchase & Sales Dep.
Workshop Warehouse
14. IDENTIFICATION OF ACTIVITIES
14a. Main sectors of activities during the past
three financial years
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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(e.g.: aerospace, nuclear engineering, chemical
engineering etc.)
Water supply, gas, petrochemistry.
14b. Main customers during last year
(If necessary, attach a list of clients)
THE COMPANY OF THE
DATE Country TYPE OF STEEL PRODUCT SUPPLIED
CLIENTS
FITTINGS FORM 2" TO 48";UP TO
2006 STEEL TRADE S.R.L ITALY WP91/P22/347H/321/304L
54MM
INDUSTRIAL PROJECT WPB/WPHY65/ FITTINGS FORM 2" TO 24";UP TO
2006 IRAN
MANAGMENT OF IRAN A420WPL6 27MM
ASTM A234 WPB /P12/P FITTINGS FORM 1/2" TO 36";UP TO
2006 WILH.SCHULZ GMBH GERMANY
22 50MM
FITTINGS FORM 1" TO 24";UP
2006 PW "METKOM" s.c. POLAND Ste360.7/Ste290.7
TO 17.48MM
15, PRINCIPLE ITEMS PRODUCED BY THE COMPANY
(briefly description of items produced by the company)
Elbow (seamless and welded), tee (seamless and welded), reducer.
16. Has the company an own design and development
department for new products: NO
(If no, which company is for design and development
responsible?)
17. PATENTS, LICENCES
Are any patents or licences registered? NO
(If so, which?)
18. Are investment funds allocated to increase
the production capacity? NO
19. DOES THE FIRM OWN:
- the land NO
- the buildings NO
- the office YES
20. FLOOR SPACE OF THE COMPANY BEING EVALUATED:
- total: ...13000.... m²
- covered: .....5524. m²
- offices: .....137.. m²
- workshops: ......4800. m²
- storerooms: ......700. m²
21. Is there room for expansion? YES
33000 m² is planning for new factory
22. Is there a good road connection? YES
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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23. Is there a railway siding? NO
24. Is there an airport close by? YES
City/Distance: Qingdao city, 150KM
25. Working times:
office: 9:30-20:30 5days/week
factory: two shift per day .
26. Production work organisation
(continuous, shifts) .....shift.
27. Is a relocation of the production
facilities planed? NO
28. MACHINERY list
Pls see Annex 2.
29. Is a corrective maintenance performed? NO
30. Exist a formal preventive maintenance program? NO
31. What ratios is used for evaluating the capacity
and performance of the machines? Factory declared: 1/3
B. Products
1. Which products are planned for supply? fittings
2. Is the product listed in a catalogue? YES
3. For how many years has the given product been manufactured? From 2001
4. Is the product manufactured acc. to a national
or international standard?
(If yes, which?) YES
e.g.: ASME B16.9
5. Is the product type approved acc. to a national
or international standard?
(If yes, by which institution? Annex a copy of the
certificate.) NO
6. Which measures are initiated in case one piece
of the products fails during the before mentioned test? Dimension check
7. Are additional test carried out? NO
(If yes, which one and in which intervals?)
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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8. Are the final products marked? YES
(If yes, in which form?)
Painted mark or mould mark
9. How many days of production are covered by stocks?
30-40days
10. How long are spare parts available for the product?
No spare parts
11. Are the insurance risks due to the product
covered by an insurance policy? NO
12. List of suppliers, type and origin of raw material NO
(No relative documents provided to SGS audit)
13. ACTIVITY For the product, Do any In which
procedure or activity establishment(s)
service under be sub- does sub-con-
consideration, contracted? tracting take
does the com- place?
pany have this
activity
13a. Marketing YES NO
13b. Design/research NO NO
13c. Procurement/purchasing YES NO
13d. Brought-in products and
services verification NO NO
13e. Methods YES NO
13f. Production YES NO
13g. Verification and testing
during production YES NO
13h. End of production
verification and testing YES NO
13i. Dispatch/delivery YES NO
13j. Transport YES NO
13k. Assembly/installation NO NO
13l. Start-up NO NO
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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13m. After-sales/maintenance YES NO
C. Sales Organisation
1. Which of the following does the sales force comprise:
- Commercial or technical agents? Commercial
- Exclusive or non-exclusive representatives? non-exclusive representatives
- Authorised agents or travelling salesmen? Authorised agents
2. Are there any branch offices or agents? YES
3. Does the sales force inform clients of the intention
to cease production of certain lines? NO
4. What is the reaction when a schedule is likely to be
overrun due to unforeseen circumstances
(e.g. production or procurement incidents,
client's instructions, waiver requests etc.)?
Consult with client
5. Is a leaflet provided with general instructions and drawings
for the product delivered (assembling, use, maintenance)? NO
6. Are these instructions written in the native language
of the client? NO
7. What procedure is to be followed by the client in the event
of dispute arising from product faults or service failures
after delivery?
Claim for compensation.
D. Procurement
1. Are there procedures for the evaluation and
approval of new material and/or fabrication
sources? YES
2. Is there a written approved sources list? YES
3. Does Quality Assurance review all
purchase orders? YES
4. Does Quality Assurance audit approved
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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sources on a regular basis? YES
5. Are inspection records used to evaluate
suppliers? YES
E. Engineering Control
1. Are procedures and controls adequate to
ensure that the latest drawings, order
changes and specifications are used by
the Production and Inspection Depart-
ments? NO
(No documents provided for SGS auditor review)
2. Are records maintained which reflect a
history of the changes? NO
3. Are obsolete or inappropriate drawings or
specifications in use by Production or
Inspection Department personnel? NO
4. Are NDE symbols reflected on the
fabrication drawings? YES
5. If NDE symbols are not reflected on the
fabrication drawings, is a NDE symbol
map or general note provided for
reference? NO
6. Are "approved for construction" drawings
being reviewed by proper inspection
authorities? YES
F. Inspection Procedures
1. Are inspection operations performed in
accordance with approved written
instructions? YES
2. Does the Receiving Inspector check
incoming material to the purchase order,
specification and/or drawing requirements? YES
3. Are mill reports, NDE reports or certificates
reviewed for compliance? YES
4. Are reports, certificates and other material
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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documents retrievable by customer order
number? YES
5. Are discrepancies reflected in receiving
records? NO
6. Are materials tagged and identified as
Accept, Reject or Non-conforming? NO
7. Are non-conforming and rejected materials
adequately controlled? YES
8. Are written instructions available to in-
process inspectors at their work station? NO
9. Are in-progress inspections documented to
give the inspection status of the material? YES
10. Are process or routing sheets,
or "travellers" used? NO
11. Are the adequate and properly filled out? NO
12. Are records maintained attesting to the
results of final inspection and/or testing? YES
G. Quality Assurance
1. Manager of Quality Assurance
Name: Ms Li Junzhen Title: QA manager
2. The Quality Assurance Organisation reports to:
Name: Ms Li Junzhen Title: QA manager
3. Are taken measures to handle the management
of standards and regulation documents YES
4. Does the company has a Quality
Assurance Manual and/or Inspection
Manual? YES
5. Are quality assurance procedures
implemented which meets the require-
ment of one of the following standards:
ISO 9001 YES
Others NO
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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6. Is the manual approved by the Top
Management? YES
7. Are the records of the QA Department
reviewed periodically by Top Manage-
ment? YES
8. Are the system and the manual both
audited periodically by Top Management? YES
9. Does this manual contain procedures for
the following:
9a. - Quality Planning YES
9b. - Manufacturing Operation Control YES
9c. - Drawing, Documentation & Engineering
Control YES
9d. - Vendor Quality Assurance Surveillance YES
9e. - Procurement Control YES
9f. - Receiving Inspection YES
9g. - In Process and Final Inspection YES
9h. - Non Destructive Testing YES
9i. - Verification and Identification of Materials YES
9j. - Non-Conforming Materials YES
9k. - Internal Quality Audits YES
9l. - Corrective Action YES
9m. - Calibration of Measuring and Testing
Equipment YES
9n. - Welding Control, Welder & Welding
Operator Control YES
9o. - Heat Treatment and Heat Treatment
Record Chart YES
9p. - Storage, Cleaning, Packaging and
Shipping YES
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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9q - Storage of welding consumables: Are
adequate facilities available with
temperature controlled ovens NO
10. Who is responsible for analysis of
complaints and Non-Conformities?
Ms Li Junzhen
11. Does the manufacturer or supplier hold
any ASME certificates of authorisation
for Code Work? If so, attach copies NO
12. Client performed quality audits? YES
(If yes, list the main clients who have
performed quality audits):
IPS: SGS
ABB: TUEV
TOOSPADY: ITS
13. Qualifications and Certifications obtained
(national and international)
(Provide evidence of certificates obtained)
13a. For quality system:
- by third party (independent organisation):
ISO9001 by CQM
AD-2000/WO by TUEV (without certificate)
PED by TUEV (without certificate)
- by main clients (specify): NIGC, BHEL, etc.,
13b. For products not mentioned by this MCC Audit:
- Have any of the products obtained or are being
attributed by a national standard organization
(or other) mark? NO
14. For other items (qualified personnel etc.)
RT, PT, MT: one personnel
Qualified welder: 11 personnels
15. Are these workers periodically trained? YES
H. Non-destructive Examination and Destructive Testing
1. What testing capabilities are available?
- Ultrasonic YES
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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- Magnetic particle NO
- Liquid penetrate NO
- Gamma-ray NO
- X-ray YES
- Eddy current NO
- Others (specify) NO
2. Are written and approved procedures
available to operators? NO
3. In accordance with what specifications?
The user’s manual.
4. Are operators trained and qualified to the
Recommended Practice of the Society for
Non-destructive Testing, SNT-TC-1A or
equivalent programs? (Enter name) YES
one personnel: Dong Xianming
5. What inspector level are operators qualified
for?
- Level 1 NO
- Level 2 YES
- Level 3 NO
6. Are the following destructive test methods
conducted at the plant?
- Tensile NO
- Bends NO
- Charpy Y Notch YES
- Hardness (specify type) YES
- Others (specify) NO
7. Are the required test standards for
destructive tests current and available
for reference? NO
I. Tool and Gauge Control
1. Are tools and gauges permanently
identified? YES
2. Are they calibrated on a regular basis? YES
3. Are adequate calibration records
maintained? YES
4. Is there a management schedule for test and
measuring equipment? YES
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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5. Exist for the measuring equipment a:
- air conditioned rooms? NO
- clean rooms? YES
- special areas? NO
J. Welding Standards
1. Is welding performed at the facility? YES
2. To what standard or standards is
welding performed?
Welding procedure of factory.
3. Are welding procedures and welder
qualifications available? YES
4. Are welders or welding operators
qualified in accordance with the
ASME Section IX? NO
Other? (Specify) YES
GTAW-II: 6 personnel
SMAW-II: 5 personnel
K. Material Handling and Storage
1. Is material segregated by alloy or grade?
Grade.
2. Is material adequate identified and
segregated to preclude mixing of
different heat or lot numbers? YES
3. Are heat numbers and/or lot numbers
traceable to all documentations? YES
4. Are adequate precautions maintained to
prevent damage, contamination or loss
identity? NO
5. Are stored materials monitored for
deterioration? NO
6. Is "good housekeeping" maintained in
manufacturing areas? NO
L. Non-conforming Material
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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1. Are there adequate written procedures to
cover non-confirming materials? YES
2. Do the procedures provide for:
- Record maintenance YES
- Corrective action YES
- Repetitive discrepancy review YES
- Control of scrap YES
3. Is an adequate system in effect to
investigate, control and correct
customer complaints and materials
returned for non-conformance or
defective quality? NO
M. Corrective Action
1. Does an adequate corrective action
system exist? NO
2. Is corrective action initiated when an
unsatisfactory trend is indicated? NO
3. Are defective products and related
documents analysed to determine the
cause and extent of the condition? NO
4. Is there a follow-up system of control
and management review on corrective
action taken? NO
N. On site inspection
We performed on site inspection during audit, we selected randomly a few elbows (36“, 90°) and
tees (36“ x 36“) for visual quality and dimension check, and found the visual quality and dimension
were in sound condition.
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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Date: Mar 23, 07
O. Summary
In general, the production facilities as well as testing facilities are found
suitable for the production of buttwelding fitting (to ASME B16.9-2003), and
the size that they can manufacture as following:
Elbow (seamless): ½“ -36“
Elbow (welded): 16“-56“ (Auto-welding machine can apply for 96“ )
Tee (welded): 24“-56“
Reducer: 16“-96“
But one point must be mentioned: the area of workshop is too small, and
some of pressure equipment and welding machine and some moulds were
placed in the oper air, and they had not some necessary maintenance.
And for the quality control system of ISO 9001:2000, though the factory had
gotten the ISO9001: 2000 certificate from the CQM, and it still was found
some non-condormities, and the factory promised that they would improve it
Regarding to the traceability, from the raw material to cut to form to weld to
product, it was found sufficient.
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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Date: Mar 23, 07
Annex 1: The relation of Shengtian and Huoda and Xin Xiang
Shengtian: Shengtian pipe fitting Co., Ltd.
Adress: Room 812,8th floor,Yin hai heng ji Building, Dongfeng East Street,
Weifang, China
Huoda: Huoda pipe fitting Co., Ltd.
Office Adress: Room 812,8th floor,Yin hai heng ji Building, Dongfeng East Street,
Weifang city, Shandong Province, China
Factory DaZhuangZi Village, Weicheng district, Weifang city, Shandong
Adress: Province, China
Xin Xiang: Xin Xiang Forging Co., Ltd
Adress: Zhuang Li Village, Ding Xiang county, Shan Xi Province, China
The Shengtian and Huoda company both belonged to Mr. HuoDa’s company,
and they had the same office adress. On Mar 19, 2007, the Shengtian company
was logged out. Before this the main work of Shengtian is export all kinds of
fittings, and Huoda is manufacture all kinds of fittings. And Huoda company did not
manufacure any flanges.
And Xin Xiang Forging Co., Ltd is a flanges-manufactured company, it is located in
Shanxi Province, China, and it is about 1000KM away from Huoda company.
Before logging out, Shengtian company purchase some flanges from Xin Xiang
for his other foreign clients.
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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Date: Mar 23, 07
Annex 2: Machinery list
Item Equipment name Type Characteristica Remark
data
1 mandrel G1 TO 78 78 PC Used for elbow and tee
2 sandblasting G4025 2 set /
equipment
3 welding machine C620 350KW /
4 welding machine CAK6150 500KW /
5 Automatic Z5140 1250KW welding 96” elbow
welding center (OD6500MM)
for pipe fittings
6 Heat treatment Self-made Temperature /
furnace ≤1300°C
Size:
4500x2500x2000
7 Heat treatment RT2 2000Kg,950°C, /
furnace 120KW
Size:
2500x900x800
8 press machines HT033 1 set of 315Tons Used for fitting forming
and <12” tee
9 press machines Y-1500 1 set of 1500Tons Effective height: 2.4m,
effective area: 1.8*1.8m,
and used for elbow
forming and <56” tee
10 press machines Y-1000 1 set of 1000Tons Effective height: 2.8m,
effective area: 3.2*2.4m,
and used for elbow
forming and <96” tee
11 press machines Y-500 1 set of 500Tons Effective height: 2.2m,
effective area: 1.4*1.4m,
and used for elbow
forming and <16” tee
12 press machines Y-100 1 set of 100Tons Forming fitting (<6”)
13 Elbow & Bend- E36-1600 Sets /
machine Max.914.4mm, min.
273mm
14 Elbow & Bend- E16-600 Sets /
machine Max.406.4mm, min.
21.3mm
15 Bevel machine DT1003A 5sets of max. /
89mm, min.21.3mm
16 Bevel machine DT4008A 5sets of max. /
219.1mm,
min.114.3mm
17 Bevel machine DT1016A 5sets of max. /
406.4mm,
min.273mm
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
Doc No.: IN07039QD
Rev.: 0
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Date: Mar 23, 07
18 Bevel machine DT2442A 5sets of /
max.610mm,
min.1067mm
19 Bevel machine DT1096A 5sets of /
max.610mm,
min.2438mm
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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Rev.: 0
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Date: Mar 23, 07
Annex 3 : Reference photos
Office profile ISO9001 certificate
the gate of factory Factory's office
machining workshop Cutting material
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
Doc No.: IN07039QD
Rev.: 0
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Page: 22 of 25
Date: Mar 23, 07
forming elbow elbow mould
elbow moulds bevel machine placed in the open air
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
Doc No.: IN07039QD
Rev.: 0
Vendor Assessment Audit Report
Page: 23 of 25
Date: Mar 23, 07
Auto-welding center (Max fot 96 inch Auto-welding center (Max fot 96 inch
elbow ) elbow )
Heat treatment equipment Another big heat treatment
equipment
pressure equipment placed in the pressure equipment placed in the
open air open air
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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Rev.: 0
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Date: Mar 23, 07
RT instrument. UT instrument
chemical composition analysis Sharp impact machine
instrument
Tee mould Finished product-tee
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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Date: Mar 23, 07
semi-finished products warehouse
Important Note
All orders are accepted and all reports and certificates issued subject to the General Conditions
of Service.
(copy available upon request).
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