fabtrolruanjian & aiscrenzheng

8/11/2019 FabTrolruanjian & AISCrenzheng

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2010 FabTrol Systems, Inc. All rights reserved.

TABLE OF CONTENTS

BACKGROUND ...................................................................................................................................................... 1

Certification requirements: define and document ............................................................................................ 1

Applicability to quality standards for other certifying bodies ...................................................................... 1

How FabTrol MRP helps .............................................................................................................................................. 1

BENEFITS OF CERTIFICATION ............................................................................................................................... 2

To certify or not to certify? ......................................................................................................................................... 2

STANDARD-BY-STANDARD:HOW TO USE FABTROL MRP ............................................................................. 3

Where FabTrol MRP helps define and document ............................................................................................. 3

Standard 6: Contract and Project Specification Review and Communication ....................................... 4

Standard 7: Detailing .................................................................................................................................................... 5

Standard 8: Document and Data Control ............................................................................................................. 6

Standard 9: Control of Quality Records ................................................................................................................ 8

Standard 10: Purchasing................................................................................ .............................................................. 9

Standard 11: Material Identification ....................................................................................................................... 10

Standard 12: Fabrication Process Control ............................................................................................................ 12

Standard 13: Inspection and Testing ...................................................................................................................... 13

Standard 15: Control of Nonconformances ........................................................................................................ 14

Standard 17: Handling, Storage and Delivery of Product and Materials ................................................. 15

AISCCERTIFICATION RESOURCES ................................................................................................................... 16

American Institute of Steel Construction.............................................................................................................. 16

Quality Management Company ............................................................................................................................... 17


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How FabTrol MRP Supports AISC Certification 1 A Structural Steel

BACKGROUND

Certification requirements: define and document

Reduced to its most fundamental level, AISC certiication for steel building structures requires two key

activities:

De!ining a quality management system that includes written procedures for carrying out the

system.

Documenting that you are following your system on an ongoing basis.

Many fabricators "ind it challenging to set up a quality management system designed to support the AISC

certi#ication process. This is not surprising. A review of the table of contents of the AISC Certiication

Program for Structural Steel Fabricators Standard for Building Structures includes 15 work categoriesand 29 subcategories.

However, FabTrol MRP can help streamline and simplify the process.

Applicability to quality standards for other certifying bodiesstructural steel certi$ication standards to discuss how

FabTrol MRP can help fabricators obtain and maintain certi%ication. In most cases, there is a close

correlation, if not a one-to-one correspondence, between AISC standards and other certifying

organizations standards, whether U.S.-based, such as the Department of Transportation; international,

such as the International Organization for Standardization (ISO); or country-speci &ic, such as the

Canadian Institute of Steel Construction, The British Constructional Steelwork Association and the

Australian Steel Institute.

In all cases, structural steel fabrication standards require that fabricators have procedures in place and

can verify their use of the procedures for the following key fabrication activities:

Document/data/drawing management control

Material traceability from purchasing through to job site delivery

Fabrication process control and shipping management

Quality assurance procedures and nonconformance control

It will be a small leap, if any at all, for steel fabricators considering multiple certi 'ications to apply the

information in this handbook to a speci(ic certi)ication process.

How FabTrol MRP helps

FabTrol MRP can:

Help de*ine procedures related to fabrication activities.

Provide documentation that those procedures are being followed.

Define quality management system

If your company does not have a quality management system in place, your use of FabTrol MRP can

provide the basis for setting up those portions of a system relevant to typical project work+low, from

project setup to delivery to the job site.

For example, AISC Standard Six (Contract and Project Review and Communication) can be met by basing

your quality management procedures in this area on the steps involved in setting up and tracking a

project in FabTrol MRP.


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This involves:

Documenting project requirements in the Project

Speci!icationsand Project Detailsareas.

Tracking and attaching correspondence (e.g., quote

letters, change orders, contracts, bid-set drawing list,etc.) in the Project Managementregister.

Using the RFI Managementtool for project-related

communications and attachment of relevant

documents

Tracking design drawing questions and revisions with

the RFI and transmittal systems.

De,ining your quality management procedure for each

fabrication work-low activity described in the AISC standards

can be handled similarly, whether related to drawing

management, purchasing, stock and material traceability,

production control, QC inspection and testing, or job site

delivery.

Document that you are following your quality management system

All project data that has been entered in FabTrol MRP is readily available to provide veri .ication that you

are following the procedures de/ined in your quality management system. Carrying forward the example

of contract review and communications, all project speci0ications/details, RFIs, and project

correspondence created or stored in FabTrol MRP can be readily shared, archived and retrieved using the

These veri1ication methods can be similarly used for project data in all relevant work2low areas

addressed by AISC certi3ication standards (e.g., purchasing, drawing management, etc.).

Yes, the procedures have to "it within

Zac Parker, Project Manager

Dave Steel Co. Inc., Asheville, North Carolina

BENEFITS OF CERTIFICATION

To certify or not to certify?

companies have prospered without being AISC-certi4ied. Changing trends in the steel fabrication

environment in recent years, though, are making it more dif5icult for uncerti6ied fabricators to win

contracts.

In an increasingly global economy, fabricators often work with more project participants and more far-

7lung participants than in the past. AISC certi8ication provides an assurance to all members of the

supply chain, from owners, architects and engineers to building inspectors and construction company

owners, that the steel fabricator on the project is quali9ied to perform the work.

Note that some standards, such as

management roles and responsibilities orthe company training plan, fall outside

typical project work#low. As a result, their

de$inition and documentation will be

handled outside of FabTrol MRP. In the

second section of this handbook, we breakout the standards that can and cannot be

effectively addressed through your use of

FabTrol MRP.

TIP: Some FabTrol MRP users set up a job in

FabTrol MRP called Quality System and

attach all quality-related documents, (e.g.,

equipment inspections, completed trainings,

etc.) to the job. In this way, FabTrol MRPhelps them document and prove that they

are following quality procedures that fall

outside typical fabrication work%low.


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AISC certi:ication can also help during a down market. In lean times, more fabricators bid each job, and

many are willing to reduce pro;it margins to keep work ication can provide credibility and opportunities outside your company, but it can also

enhance your internal environment. As staff members participate in setting up and carrying out a quality

management system, employee morale and productivity often get a boost. These are common outcomeswhen people have an opportunity to contribute and to better understand their jobs and how to do them

well.

We chose to get certi&ied because almost all projects in our region, or service area, are

requiring that you be an AISC-certi'ied fabricator to even bid on the project, and not just

government projects, but across the board. The architects are even putting it in their specsthat you have to be AISC-certi(ied.

Stefanie Dehoyos, Asst. Project Manager

Rast Iron Works, San Antonio, Texas

STANDARD-BY-STANDARD:HOW TO USE FABTROL MRP

Where FabTrol MRP helps define and document

FabTrol MRP customers and fabricators who contact FabTrol Systems about purchasing FabTrol MRP

often report that certi?ication auditors have asked if their company uses FabTrol MRP.

There is good reason for this question. Certainly, some aspects of the AISC certi@ication standards, such as

management responsibilities, fall outside the fabrication management processes handled by FabTrol

MRP.

However, fabricators who use FabTrol MRP from project startup through to shipping end up with most of

the data needed to verify that they are following those portions of their quality management system

directly related to job and fabrication activities.

material management, production control, quality assurance and shipping data will be readily available.

The chart below identiAies those standards where the use of FabTrol MRP can help your organization

deBine and document a quality management system.

AISC Standard How FabTrol MRP Helps

Yes No

1. Purpose X

2. Scope X

3. References X

4. Definitions X

5. Management Responsibility X

6. Contract and Project Specification Review and Communication X

7. Detailing X

8. Document and Data Control X

9. Control of Quality Records X


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AISC Standard How FabTrol MRP Helps

Yes No

10. Purchasing X

11. Material Identification X

12. Fabrication Process Control X

13. Inspection and Testing X

14. Calibration of Inspection, Measuring, and Test Equipment X

15. Control of Nonconformances X

16. Corrective Action X

17. Handling, Storage and Delivery of Product and Materials X

18. Training X

19. Internal Audit X

Standard 6: Contract and Project Specification Review and Communication

Use of the Project Management module in FabTrol MRP provides a basis for deCining and documentingprocedures needed to meet this standard.

Standard6

requirements How FabTrol MRP supports Standard 6 requirements

Record and distribute project

requirements

Use the Project Specifications area to document project scope, material

requirements, coating and testing requirements.

Use the Project Details area to document and manage project details,

contacts and status updates.

Distribute project requirements by with reports from the Projects report tab.

Provide for review of original and

revised contract documents.

Use the RFI system to communicate about contract clarifications or changes.

Use the transmittal system to send and receive design drawing revisions.

Track bid-set revisions by transmittal and in the Contract drawing register.

Provide for evidence of contract

review

Use the Project Management register to document and track tasks, make

notes and review the project schedule. Attach all project correspondence,

change orders, and relevant documents to the register.

Relevant Reports

Projects reports > General Project Details; Project Specifications; Project Change Orders; Project Correspondence;

Project Notes; RFI Revs & Responses; RFI Log; Drawings with RFI; RFI Summary by Job.

Drawing reports > Contract Drawing Transmittal List; Contract Drawing List with Revisions; Contract Drawing

Issue Sheet

The Project Management module handles a signiDicant amount of the data needed to meet this

requirement. However, some data and procedures related to Standard 6 are generated in, and available

through, other areas of FabTrol MRP, speciE

ically:Detailing (Standard 7): Drawing Manager module

Purchasing (Standard 10): PurchaseMate and StockMiser modules.

Fabrication Process (Standard 12): Production modules.

Quality Assurance and Control (multiple standards apply): PurchaseMate, StockMiser, Drawing

Manager and Production modules.

Additional relevant information is covered in this handbook in the appropriate sections.


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STANDARD 6:CUSTOMER EXAMPLE

A fabricator specializing in industrial, power and commercial projects uses the Project Details area to

store notes from all project review meetings. Meeting notes and project data sheets, including answers to

questions provided to each project manager during the review of design drawings, are

added or attached in the Project Management module. Blankforms are also attached in the Project Management correspondence register, making them available to

everyone working on the project. As the job progresses, blank forms are copied, completed, given an

appropriate name, and then reattached to the register. This ensures that there is documentation

conFirming that quality assurance speciGications are being met. Detailing, engineering and other

departments have access to this information in FabTrol MRP at any time.

The information can also be readily updated by anyone authorized to login and make changes. Having

one reliable repository where technical, speciHication and drawing information for a project is

consolidated and easily accessible saves time and ensures accuracy. Project information can also be

readily shared with customers and subcontractors by running relevant reports in FabTrol MRP.

Standard 7: Detailing

Detailing standards include requirements for drawing management and detailing procedures. FabTrol

MRP provides full drawing management support. However, detailer management standards and

qualiIications are outside the fabrication-based workJlow handled by FabTrol MRP.

The chart below provides information about those aspects of the detailing standards addressed by

FabTrol MRP.

Standard 7 requirements How FabTrol MRP supports Standard 7 requirements

Preparation of Shop Drawings and Erection

Drawings (7.1.1): Document how information

is tracked and how information is maintained

with the customer.

Use of the Project Manager RFI system and the Drawing

Manager transmittal system document all drawing-related

questions between the fabricator and external partners (e.g.,

detailer, customer, engineer, etc.).

Detailing Standards (7.1.2):As mentioned

above, FabTrol MRP does not address

procedures related to detailer management

standards or qualifications, but it does readily

provide information about how the detailer

should identify material.

Use the Detailer Export in the Unit Price File Maintenance

functions to extract your material definitions and translation

tables. Detailers who run the FabTrol MRP Detailer Package can

use the exported data in their installation to provide model data

that will match your material definitions.

Checking of Shop and Erection Drawings

(7.1.3):The project manager checks and signs

off on drawings before they are released. A

record or log is maintained.

Use the Drawing Manager Fabrication and Erection drawing

registers to track to all drawing events and related statuses (e.g.,

sending out for approval, receiving approval, revision status,

release for production, etc.).

Customer Approval of Shop Drawings (7.1.4) Related to the description above for Standard 7.1.3, drawings

received back from approval as approved are logged in the

fabrication drawing register as approved. Electronic copies of the

approved drawings are attached to the relevant line in the

drawing register.

Customer-Supplied Shop Drawings (7.2.4):

Document the receipt, revision and control of

customer-supplied shop drawings.

Customer supplied drawings are added to the fabrication

drawing register, where they are documented and tracked

through to release for fabrication.


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Relevant Reports

7.1.1: Drawing reports > Drawing Transmittal List; Projects reports > RFI Log; RFI Summary by Job.

7.1.2: System Admin. reports > Material Type Codes. Unit Price file Maintenance reports > Unit Price File Export.

7.1.3 & 7.1.4: Drawing reports > Drawing List with Revisions; Drawing List with Actions; Drawing Register Event

Log.7.2.4: Drawing reports > Fabrication Drawing List filtered for Date Issued to Production; All reports previously

mentioned in this section.

control to keep track of drawings that are

out sent for approval,)ile copy that kind of thing. And track them when they

come back from the detailer, project manager, or customer.

Bruce Lanier, Quality Assurance Manager

SteelFab Inc., Charlotte, NC

Standard 8: Document and Data ControlThis standard deKines speciLic information and documents that must be available to meet document and

data control requirements. Before looking at which areas of FabTrol MRP support these requirements, it

is helpful to understand the bigger picture: all project data entered into FabTrol MRP can be reviewed,

stored and retrieved.

backup of a project that includes all project- s requirement for long-term

storage, this .zip Mile can be archived and stored off site. Should the need arise, a project backup can be

However, some important information is not automatically included in a project backup, speciNically:

Documents that were not created in FabTrol MRP (e.g., correspondence, inspection reports, etc.).

Data created in FabTrol MRP that is not project-speciOic (e.g., stock, purchasing or production

information), and is, therefore, not included automatically in a project backup Pile.

Fortunately, FabTrol MRP makes it easy to back up non-project speci Qic items by adding them to the

Project Management register:

For non-FabTrol MRP data, such as project communications that were sent outside of the

transmittal systems, create a descriptive line in the Project Management register

and attach an electronic copy of each communication. The same approach can be used for other

documents, such as MTRs and inspection reports.

For FabTrol MRP data that is not project-

generate the desired data. For example, you might want to track your stock usage on a particular

job during a speciRic time period. To do this and make sure the information is included in your

project backup, set a stock Silter by job and date range. Then generate a PDF version of the

resulting report and attach it to the Project Managementregister.

All items attached to the Project Management register will be included automatically in the projectbackup.

The chart below includes only those portions of the requirements addressed by FabTrol MRP. Be aware,

though, that Standard 8 also pertains to documentation of all procedures included

quality management system.


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Customer Requirements (8.2): Receive and

document customer requirements and

contract changes.

Maintain a log of shop detail drawingsreceipt, approval and distribution (including

distribution to subcontractors, if any).

Use the Project Specifications and Project Details areas to

document customer requirements.

Use of the Project Management RFI system and the Drawing

Manager transmittal system documents all project and drawing-related changes. The Drawing Manager drawing register tracks

drawing receipt and approval. Use of the transmittal system

tracks distribution of drawings outside the company.

Revision Control (8.3): Current job

specification and contract revision are readily

available.

Use of all areas in the Project Management module to keep

project information up to date ensures access to the most current

specifications and contracts.

Access (8.4): Appropriate personnel within

each department have access to current

contract revisions and job specifications.

User access rights and report distribution ensure access to current

data.

Obsolescence and Transmittal (8.5):

1. Maintain a list of current revisions for all

project documents, including drawings, and

follow procedures that prevent inadvertent

use of obsolete documents.

2. Obsolete drawing prints are removed from

the shop floor.

3. A transmittal will always accompany

quality-sensitive documents sent to outside

parties. The transmittal will be stored.

1. Use of the Project Management module to track contract

revision ensures identification of the most current contract

revision. Use of the Drawing Manager modules to track drawingsensures identification of the most current drawing revision. The

current revision is attached to the appropriate register line in

each case.

2. FabTrol MRP cannot remove the drawings from the shop floor,

but by maintaining the current revision in the drawing register

and attaching the associated image file, it is easy to determine

and print the most current revision for use on the shop floor.

3. Use of the transmittal system ensures that sensitive documents

will be accompanied by a transmittal, and that the transmittal

will be stored as part of the project data.

Relevant Reports

8.2 and 8.3: Project reports > General Project Details; Project Specifications; Project Change Orders; ProjectCorrespondence; Project Notes; RFI Revs & Responses; RFI log; Drawings with RFI; RFI Summary by Job. Drawing

reports > Drawing Transmittal List; Drawing Register Event Log.

8.4: System Admin. reports > Access Rights for Current User.

8.5: Drawing reports > Drawing Transmittal List; Drawing List with Revisions; Drawing List with Actions; Drawing

Register Event Log. 7.2.4: Drawings > Fabrication Drawing List filtered for Date Issued to Production.

I use the transmittal system in FabTrol MRP extensively. How does that tie into AISC

standards? Revision control. All our drawings are entered or imported into FabTrol MRP, so

we have the backbone for tracking revisions with transmittals. Right now, w

a big job w

manually. I jump into FabTrol, set a *ilter and track status changes based on the FabTrol

transmittal. I need to show I submitted Zone 17 as a whole to the shop on a speci+ic date.

A week later, I submitted drawings to the shop for the same

zone, but with different rev numbers. The transmittal system keeps track of activity. And that

tracking is key to a part of our AISC certi,ication.

Merle Brown, Project Manager

B & B Fabricators, Arlington, WA


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Standard 9: Control of Quality Records

This standard requires that your company use a documented procedure

storage, maintenance, retention and disp

include quality management records, such as internal and external audits of your quality management

system, as well as .The chart below provides information about how FabTrol MRP can support this standard for items

related to fabrication. Note that we have not included references to relevant report titles. Reports related

to the speciTic topic in the chart below are covered under the relevant standard in this handbook (e.g.,

Mill and consumable purchase orders > see Standard 10: Purchasing).

Standard 9 requirements How FabTrol MRP supports Standard9

requirements

Requests for Information Use of the RFI system in FabTrol Project Management module

allows you to create an RFI, attach documents, add the response and

resolve the RFI, or add a revision to an RFI if the response did not resolve

the question. All RFIs are included in a project backup to ensure

document retention.

Design Changes:

Project Management module: RFI

Management

Drawing Management module:

transmittal system; drawing registers

The RFI system (in the Project Management module) and the transmittal

system in the Drawing Manager module fully document design- and

drawing-related questions and their resolution through the project life

cycle.

The drawing registers for each drawing type in the Drawing Manager

maintain a record of drawings and their revisions.

All RFIs, transmittals and drawing register data on a job are included

automatically in a project backup.

Drawing logs The Drawing Manager module includes a drawing log for every drawing

of all drawing types whether drawing data is imported or manually

entered into FabTrol MRP. The log provides a full record of

history, including events, associated statuses and dates.

Drawing data in the Drawing Manager module is included automatically

in a project backup.

Mill and consumable purchase orders The PurchaseMate and StockMiser modules in FabTrol MRP provide the

traceability backbone for steel and non-steel items as their usage is

tracked from purchasing, receiving, allocation/nesting into production

and actual usage through to shipping. Information is preserved and

accessible for all purchases made through the PurchaseMate module

using a variety of tracking criteria (e.g., job, vendor, job and vendor, heat

certification numbers, etc.). All purchase orders and stock usage are

backed up automatically in an installation backup. Specific POs can be

printed to a PDF format and attached to the Project Management

register. (See Standard 8: Document and Data Control above for more

information about use of the Project Management module to retainpurchasing records.)

Material Testing:

Material Test Reports

Non-Destructive Testing Reports

Certificates of

Compliance/Conformance

All test-related documents can be scanned and attached in the Project

Management correspondence register. Once attached, they are included

automatically in a project backup.


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A structural steel fabricator who uses FabTrol MRP from purchasing through to production and shipping,

maintains Uingertip access to all drawing and material traceability data.

The Drawing Management module is used to record drawing receipt and status, allowing a log to be

reviewed at any time of each drawing s history and status.

is used to purchase all steel and

module. Once the material is received into stock, the company can trace all material back to its original

purchase order. As a result, every piece of material that moves through the shop and out the back door on

a load can be quickly traced back to the vendor, the test requirements and heat certi Vication numbers, the

job it was purchased for, and the job it was actually used on. Material is preposted to the StockMiser

before it is received so that cut lists generated in the OptiMiser module include purchase order numbers

and heat certiWications numbers for all parts on the list and for unused remnant lengths.

Standard 10: Purchasing

This standard requires that your company can ensure that purchases for a job conform to the project

requirements, including the purchase of professional and subcontractor services, and materials. FabTrolMRP fully supports this requirement when purchasing material, and provides partial support for thepurchase of services.


Purchasing Data (10.1)

This standard defines the information

purchasing documents must include (e.g.,

type of service, unique identification,

inspections requirements, etc.).

Use the Project Details area in the Project Management module to

document purchasing data requirements on each project, including

material, and testing requirements. Use the Project Manager

register to specify the project schedule and delivery dates.

Use the PurchaseMate module to specify material requirements and

shipping instructions. Use the Remarks area on a purchase order to

ensure that additional required information is included, such as

Use the PurchaseMate to purchases services (e.g., detailing,

galvanizing); specify requirements on the purchase order to ensure

conformance.

Verification of Purchased Product,

Materials and Services (10.3)

Incoming products and material are

checked to ensure conformance with the

purchase order and project requirements.

Test reports and other evidence of quality

control are received and retained.

Use the Receiving function in the PurchaseMate module to compare

what was ordered with what was delivered. Choose to accept or

reject receipt based on conformance to the purchase order

specifications. Include test reports and note their receipt and

identifiers (e.g., heat cert number) in the receiving record in FabTrol

MRP. Add receiving notes as necessary for each item received.

Once formally received (material, services or supplies), the received

items can be traced back to the original purchase order at any time.

After being formally received, item usage can be traced back to thestock system.

Customer Verification of Fabricated

Product (10.4)

The fabricator can provide the customer

with verification of conformance to the

project requirements.

Use the Project Management module as described above in 10.1 to

provide verification that project requirements are documented.

and shipping systems ensures that there is full material traceability

down to the part level.


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(cont.) Customer Verification of Fabricated

Product (10.4)

The fabricator can provide the customer

with verification of conformance to theproject requirements.

Full use of the drawing management system ensures that only the

appropriate revision is used for fabrication.

Use the Production modules to ensure that appropriate inspections

are carried out before items are released for the next operation.

Control of Customer-Supplied Material

(10.5)

Supplied material is verified for

conformance at the time of receipt and is

properly stored to avoid loss, damage or

misuse.

Use the PurchaseMate module to create a purchase order with no

cost assigned to the material. Formally receive the items in to the

stock system, identifying them as customer-owned. Verify

conformance with the purchase order before receipt. Assign a

storage location for the material that prevents it from comingling

with other material.

Run purchasing or stock reports at any time filtered against the

relevant job number.

Relevant Reports

10.1: Projects reports > General Project Details; Project Specifications. Purchasing reports > Review POs; Material

List.

10.3: Purchasing reports > Material Received; Delivery Note Listing. Stock reports > Stock List by PO #; Heat Cert

Usage by PO.

10.4: Projects reports > Project Specifications; Project Change Orders. Drawing reports > Drawing List with

Revisions; Fabrication Drawing List filtered for Date Issued to Production. Production Status reports > Quantity

complete; Summary by Status and Workshop; Production Completed Summary; Production tracking.

10.5: Purchasing reports > Material Received. Stock reports > Stock list by PO Number; Stock recap by [Storage]

Area; Stock Movements.

The role of the purchasing group, and their use of FabTrol MRP, is very clear. As a result, they

and

When we buy material, we put it into the StockMiser module, then we use the OptiMiser

module .

Bruce Lanier, Quality Assurance Manager

SteelFab Inc., Charlotte, NC

Standard 11: Material Identification

This standard requires that your company can identify all material origins and can provide material

traceability information as speciXied in the contract documents and AISC codes of standard practice.


Conformance to specifications:

Contract requirements

ASTM order information standards

Use the Project Specifications and Project Details areas in the Project

Management module to document contract requirements and ensurethey are available for reference.

Use the PurchaseMate to reflect material requirements on each PO:

Fill purchase orders from nests created in the OptiMiser and Plate

Manager modules. Material type, size and grade information is

carried forward automatically to the purchase order.

Specify ASTM standards on purchases orders using the ASTM

specs function.


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Conformance of base and consumable

materials:

Optionally retain test reports, etc. for one

year for base material, bolts, weldingconsumables and coatings.

Use the PurchaseMate module to purchase items, specifying test

requirements on the purchase order. Formally receive items through

the purchasing system, verifying conformance during receipt. Scan

and attach test reports in the Project Management correspondenceregister. All attached documents are included during a project backup.

Assign identifying number:

Job number to materials.

Part numbers during fabrication and

assembly.

Use the PurchaseMate module to purchase material, specifying the job

for which it is purchased on the purchase order. Formally receive

items through the purchasing system to carry forward the job

assignment number into the stock system.

Assign material or remnants to a different job before or after usage to

reflect changes in actual use.

Use the OptiMiser and Plate Manager modules to create cut lists that

include part numbers for all parts and show the material used to

create each part. Cut lists based on received and/or on-order stock tie

material traceability from POs and stock through production to

shipping loads that include heat cert information, country of origin,etc.

Use the Advanced Production, CNC and ADC modules to maintain full

traceability down to the part level.

Relevant Reports

Projects reports > General Project Details; Project Specifications; Project Correspondence.

Purchasing reports > Material Received; Material Received by Type, POs by Job.

Stock reports > Stock List by PO number; Stock Recap by Job; Stock Recap by Area; Allocation of Per-Each Stock;

Stock Movements; Cross Allocation from Job; Cross Allocation to Job; Heat Cert Usage by PO; Heat Cert Usage

with Nesting Info.

Nesting reports > Cut List; Pull List; Maintain Material Links.

Production reports > Production Cut List; Summary Part List.

Shipping reports > Bill of Lading by Country; Assembly List with Heat Certs; Part List with Heat Certs.


document material requirements, including test requirements, for all items on the job. All material is

purchased with FabTrol

are communicated to the vendor. Material is received into the StockMiser module, carrying forward

material requirement speciYications, as well as providing a link back to the PO for reference if necessary.

Receiving is set up to require that material test reports are provided at the time of material delivery to

ensure that heat certiZication numbers and test reports are provided by the vendor, and that their receipt

is documented by the fabricator.

The OptiMiser module is used to generate all cut lists from all received or due-in material in theStockMiser module. This ensures that material traceability by job and part number is carried forward

Production module, where bar coding is used to con[irm cuts as

they occur.


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Standard 12: Fabrication Process Control

This standard requires that your company has procedures in place to ensure that fabrication processes,

such as welding and coating application, conform to the quality requirements of relevant codes, project

speci\ications, and AISC requirements.

Standard 12 requires quality procedures that cover all fabrication processes, as well as equipmentmaintenance procedures (12.5). FabTrol MRP provides full support for all requirements in this standard,

except equipment maintenance procedures.

Standard 1

requirements How FabTrol MRP supports Standard 1

requirements

Welding (12.1):

Describe how welds are created and the

qualifications of the welders.

Use the Project Details area to document welding requirements and

identify appropriate staff.

Use the Advanced Production module to set up a Work Area and

assign employees by work qualification (as set up in the Choose an

Employee area) to the welding work area.

Use waypoint or progress tracking in the Basic or Advanced

Production modules to ensure that the appropriate operations areperformed by qualified staff.

Bolt Installation (12.2)

Describe inspection and testing that

verifies that product quality requirements

are met.

See preceding description for 12.1 and apply to bolt installation.

Material Preparation for Application of

Coatings (12.3)

Describe material inspection process

used in coating application to ensure

requirements are met.

Coating Application (12.4)

Describe how coating material is applied

in accordance with quality requirements.

Use the Paint Calculator to set up paint systems that define surface

preparation (e.g., sandblasting) and finish application (standard

prime, zinc primer, standard enamel. etc.).

Use the Project Specifications area to define required coatings on a

project, including material preparation, primer, and finish coat.

Use the Basic or Advanced Production modules to set up the paint

work area to ensure that items cannot move to the next work areabefore material coating requirements are met.

Cambering and special fabrication

processes (12.6)

Describe how cambering and other

special processes meet contract

requirements.

See description for 12.1 and apply to cambering or other special

fabrication processes. If subcontractors are used, set the subcontractor

up as a Workshop in Workshop Setup, rather than an internal Work

Area.

Relevant Reports

12.1, 12.2, 12.6: Production lists reports > Production Material Status by Operation Codes; by Employee Codes; by

Labor Waypoint Operations; by Work Area Summary. Production Status reports > Left-to-do & Production

Tracking; by Work Area; by Employee by Project

12.3: BOM reports > Coating Requirements. Production Status reports > Summary by Status & Workshop; Batches

Completed by Work Area


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I always use the FabTrol Coatings tab in Project Speci-ications. To meet AISC specs, we have

to use certi.ied paint gauges and check the paint to make sure it

got the mls all de/ined in FabTrol. For the standard coats, all we have to do is print out the

-

de0ine it in Project Speci1ications and attach that to the drawings. And of course,

available in FabTrol if anyone needs to check.

Stefanie Dehoyos, Asst. Project Manager

Rast Iron Works, San Antonio, Texas

Standard 13: Inspection and Testing

This standard requires that your company de]ine and use a documented procedure to test and inspect

material and work to ensure that both meet the project requirements. This procedure applies to

incoming material and to all products furnished on the project. Inspection records must be compiled and

maintained.

Standard 1


requirements

QC Assignment and Monitoring (13.1):

Inspectors are qualified to perform their

inspection responsibilities.

Set up employees based on their qualifications and use the Choose an

Employee area to identify and select employees qualified to perform

specific inspections.

Set up FabTrol MRP preferences to track worked performed by the

employee who performed it.

Inspection Procedure: Material Receipt

(13.2.1)

Incoming material is checked to ensure it

conforms to material requirements and is

not damaged.

Use the Receiving area in the PurchaseMate module to check

incoming material against the purchase order, including the

requirement that material test reports be delivered with the load.

Inspection Procedure: In-ProcessInspection (13.2.2)

Use the Basic or Advanced Production module setup to prevent itemsfrom moving to the next work area before being inspected.

Inspection Procedure: Final Inspection

(13.2.3)

Set up a final QC inspection in Waypoint Tracking.

Inspections Procedure: Inspection

Records (13.2.4)

All items that pass through an inspection work area will be tracked in

FabTrol MRP, including the date, person performing the inspection,

and the items inspected.

Relevant Reports

13.1, 13.2.2, 13.2.3, 13.2.4: Production Lists reports > Production Material Status by Operation Codes; by Employee

Codes; by Labor Waypoint Operations; by Work Area Summary.

Production Status reports > Left-To-Do & Production Tracking (by Work Area; by Employee by Project); Summary

by Status & Workshop; Batches Completed by Work Area.

Time Card reports > Time Card Posting (by Employee & Job; by Employee & Date; Reference Data by OperationCodes; by Employee Codes; by LaborMate Waypoint Operations).

13.2.1: Purchasing reports > Material Received.

Stock reports > Stock List; Stock List by PO Number; Heat Cert Usage by PO.


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it gives us the ability to keep up with who

welded an item, who inspected it, who cut it, who drilled it. All that information used to be

written on a drawing or checked off a list. Now we can do it, down to the piece mark, with the

and during the day different QC

people record who did the work. We

months we back up jobs that have closed out and we burn the .zip 2iles to a CD, then put themin the safe. For all intents and purposes, those quality records are kept forever. And that

tracking and storage are built into FabTrol MRP.



FabTrol provides a lot of the tracking data for quality assurance. We use a bar code system

for issuing to production to track the progress toward completion cutting, 3it up, welding,

4inal QC and then on to shipping. e got QA points set up in FabTrol and things are

scanned at each of those points. The scan log is becoming more and more useful as people

realize its value. For example, on our large hospital project, our company owner is looking at

FabTrol reports everyday to track how much material is going to the saw, and other work

areas. He can check all this without going out to look because everything is being recorded

his desk in real time. So this use of FabTrol has become an integral part of documenting

toward quality control. And the AISC is all about quality control, quality control.

Merle Brown, Project Manager

B & B Fabricators, Arlington, WA

Standard 15: Control of Nonconformances

Standard 15 requires that you have procedures in place to identify and control two types of

nonconformance, speci^ically:

Process nonconformances in which work activities are not carried out as described in your

Product nonconformances in which received material or fabrication processing does not

meet quality standards.

FabTrol MRP helps fabricators control for product nonconformances.

Standard 15requirements How FabTrol MRP supports Standard 15requirements

Nonconforming Product (15.2)

Control of nonconforming product

to prevent delivery to the customer

of items that do not meet

specification requirements.

Use the receiving function in the PurchaseMate to note material

nonconformances and the resulting action (e.g., delivery refusal,

acceptance with notes, etc.) During receiving, non-conforming material

can be posted to a storage area that segregates the item(s) from other

material. The receiving notes and storage area information carry forward

to the StockMiser, where the material can, optionally, be placed on hold.When using the linear or plate nesting modules (OptiMiser, Plate

Manager), which nest into existing stock and/or on-order items, segregated

material can be made unavailable to the nesting engines by setting a filter

that prevents material usage based on, for example, on-hold status or

specific words in the notes field.

Use the preferences set up in the Production modules to prevent loading of

uncompleted items. With this setup, FabTrol MRP will not allow items to be

loaded that have not been marked as complete in all relevant work areas.


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Relevant Reports

Purchasing reports > Material Received.

Stock reports > Stock List; Stock List by PO; Stock Recap by [Storage] Area; Stock Movements; Number; Heat Cert

Usage by PO.

Shipping reports >Bill of Lading (BOL) by Sequence & Lot; by Assembly. Heat Cert tracking on the BOL from theShipping Manager (BOL with Assembly List with Heat Certs; BOL with Parts List with Heat Certs; BOL with Heat

Cert Usage by PO).

CUSTOMER EXAMPLE

A structural fabricator who uses the full suite of integrated FabTrol MRP modules, from purchasing

through to shipping, is con_ident that only items meeting quality standards will arrive at the job site. To

control for nonconformances in incoming material, the company requires a visual inspection of every

item on incoming loads. Rejected material is documented in receiving area of the

purchasing system to ensure easy access to information about why it was rejected. Non-conforming

material that is an acceptable substitute is clearly identi ied as such during receiving. To control its use, if

necessary, it is placed in a storage area that segregates it from other material received for the job. Thisinformation is available in the stock system, and can be used to allow or disallow the nesting engines

from including the material on a speciaic nest. To ensure that all fabricated items meet quality standards,

the company uses the production systems progress tracking functions to require that all items are

marked complete in all work areas, including a binal QC work area, before they can be loaded for shipping.

Because every item, and the material it was fabricated from, has passed through the full suite of

integrated modules, the Bill of Lading load list provides con cirmation to the customer that specidications

have been met (e.g., assembly mark, assembly name, material T/S/G, item weight, heat number and

material country-of-origin are included).

Standard 17: Handling, Storage and Delivery of Product and Materials

Standard 17 requires that your company have procedures for handling, storing and delivering products

and materials in a way that avoids damage or deterioration. Material must also be marked in a way that

allows for easy identieication on shipping documents and for possible traceability needs. Additionally, if

you have a shipping agreement with your customer or subcontractor, you must have a system in place to

ensure that material is shipped in compliance with the shipping instruction (e.g., by sequence or phase)

according to the erection plan).

Standard 17


requirements

Product and Material Storage and Handling Use the PurchaseMate receiving function to receive material into

stock and identify a storage location. Received material is given a

stock ID number when received, and heat certification numbers

are linked to the material. Material can always be easily traced

back to these identifiers. When material is moved or fully or

material management, production and shipping modules.

Product and Material Delivery and

Traceability

Full use of the material management and production systems

ensures that shipping documents generated in FabTrol MRP

include material traceability for every item on a load.


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Standard 17requirements How FabTrol MRP supports Standard 17requirements

Shipping Agreement Compliance

function to establish completion dates (e.g., sequence or phase).

Use the Shipping Manager to plan loads based on a sequenced

erection schedule to ensure shipping documents fully identifyeach item included on the load.

Relevant Reports

Stock reports > Stock List; Stock recap by [storage] Area; Stock Movements.

Shipping reports > Bill of Lading (with optional inclusions: by sequence & lot; by assembly mark; by material type

& country; by assembly name & country; assembly list with heat certs; parts list with heat certs).

Accounting Export report > Shipping > tonnage shipped by date range (optionally include line item details and

sequence summaries).

MRP.

. The software

over- -

into the



AISCCERTIFICATION RESOURCES

American Institute of Steel Construction

Contact the institute for information about certification at:

866. ASK.AISC

[email protected]

www.aisc.org

Download relevant documents at www.aisc.org):

AISC Certiication for Structural Steel Fabricators: Standard for Steel Building Structures

(This document degines each certihication standard in detail.)

important.

(A brochure that provides information on certiiication issues and processes.)
mailto:[email protected]://www.aisc.org/http://www.aisc.org%29/http://www.aisc.org%29/http://www.aisc.org/mailto:[email protected]


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Quality Management Company

QMC conducts the AISC certijication audits. Contact them:

312.896.9202

[email protected]

http://www.qmconline.com

Download relevant sample documents at QMC

(http://www.qmconline.com/resources/sample-quality-manuals)including:

Quality Manual Sample

(This document delines the quality management system for the mictitious XYZ Corporation as

an example of what is required by the AISC.)

Quality Manual Sample Manual with instructive comments

(This document is an annotated XYZ Corporation manual that provides an explanation of the

goals and requirements for each quality management procedure.)

Sample procedures and guidelines for writing procedures
mailto:[email protected]://www.qmconline.com/http://www.qmconline.com/resources/sample-quality-manuals)includinghttp://www.qmconline.com/resources/sample-quality-manuals)includinghttp://www.qmconline.com/mailto:[email protected]


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