Low Voltage Switchboard Production Quality Plan

STANDARD ELECTRIC SDN. BHD. (KINGSGATE SDN. BHD.) Doc. No.: SOP/ 10-PQP Page No.: 1 of 5

Items to check  

Metal Paints



    

   Chemicals for  metal treatment



Bus Bars

Rev. No.: 1 Eff. Date: 1 Dec 2010

Monitoring

Materials

Metal and Fiber Sheet

Quality Plan: Incoming Material / electrical components

  

  Electrical  Components/ electronic gadgets & Parts



Thickness, mm Size: length &Width Physical appearance - Flatness - Rustiness - Cleanliness Quantity Colour code Packing label MSDS Physical appearances - Leakage - Breakage Quantity/ Volume Packing label MSDS Physical appearance - Leakage - Breakage Quantity/ Volume Width Thickness Appearance - Straight - Dented - Rust Quantity Product technical specification Physical appearances - Crack/ broken - Stains/ dirt - Safety label Quantity/ batches

Frequency Upon receipt from supplier & before use

Responsibility

Inspection/ Test method  Visual  Use Measuring tape

Reference Document  SOP 7.4  P.O. & D.O.

Store



Visual

 

SOP 7.4 P.O. & D.O.

Store



Visual

 

SOP 7.4 P.O. & D.O.

Visual Measuring Tape

 

SOP 7.4 P.O. & D.O.

Visual  Measuring  Tape Multimeter Insulation Meter

SOP 7.4 P.O. & D.O.

Location

Supervisor &

Metal sheet

Storekeeper

Storage Area

Upon receipt from supplier & Before Use

Supervisor &

Upon receipt from supplier & Before Use

Supervisor &

Upon receipt from supplier & Before Use

Supervisor & Storekeeper

Upon receipt from supplier & Before Use

Supervisor & Storekeeper

Storekeeper

Storekeeper

 Bus bar storage  area

Store

   

 Consumable  (Nuts, screws,  bolts,  connector, cable tag, etc.)



Product Specification Sizes Cleanliness Physical appearance - Crack - Damage Quantity/ Volume

Upon receipt from supplier or Before use

Supervisor & Storekeeper

Store

 

Visual Vanier caliper

 

SOP 7.4 P.O. & D. O.

STANDARD ELECTRIC SDN. BHD. (KINGSGATE SDN. BHD.) Doc. No.: SOP 7.3 QP Page No.: 2 of 5

Items to check     

Metal Grinding/ Welded Joints/ Edges

  

 Metal PreTreatment  Deruster Treatment

Rev. No.: 1 Eff. Date: 1 Dec. 2010

Monitoring

Materials

Cut & Bend Metal & Fiber Sheet

QC Plan Work In-Progress for Metal Fabrication

 

Frequency

Responsibility

Mark on the sheet Before & after Supervisor & Dimension cut or bend Modular (Tolerance ±2mm) Fabricators Thickness Quantity Calculation of required number of cut metal pieces Loose/ tightness After grinding / Supervisor & welded joint welded the cut/ Storekeeper Angle for welded bend metal structure pieces Quantity Smoothness of joint (after grinding/ welding) Dimension (Tolerance +/- 2mm Knock off welding Before deruster Treatment/ laxity treatment Painting/ Oven Wash off dirt, Operators welding laxity and Final check by oil using water supervisor After PreTreatment/ Dip in De-ruster treatment Painting/ Oven solution Operators Duration/ time of submerge of metal piece Concentration of chemical solution

Inspection/ Test method

Location At cutting machine/ Cutting/ bending area

Metal grinding area & welding Area

 

Visual  check  Measuring tape

-Visual - measuring tape

Treatment/  Painting/ Oven area

Visual

  

Visual Clock Litmus paper

Treatment/ Painting/ Oven area

Reference Document

 

SOP 7.3 WI-001Modular fabrication

SOP 7.3 W.I-002Carta aliran welding

 SOP 7.3 W.I-003- Carta aliran kerja rawatan besi dengan bahan kimia  SOP 7.3 W.I –003Carta aliran kerja rawatn besi dengan bahan kimia

Pre-Rust Inhibitor Treatment

   

After deruster Wash metal sheet treatment thoroughly after derust treatment Dip in rust inhibitor (duration/ After pre rust concentration) Inhibitor Duration of treatment chemical submerge Correct dilution factor

Treatment/ Painting/ Oven Operators

Treatment/ Painting/ Oven area



Visual



SOP 7.3

W.I –003Carta aliran kerja rawatn besi dengan bahan kimia

STANDARD ELECTRIC SDN. BHD. (KINGSGATE SDN. BHD.) Doc. No.: SOP 7.3-QP Page No.: 3 of 5

Items to check    

Paint Spraying





Ovening

Rev. No.: 1 Eff. Date: 1 Dec 2010

Monitoring

Materials

Pre-Painting Washing & Drying

Quality Plan: Work In-Progress for Metal Fabrication works



 

Frequency

Responsibility

Location

Inspection/ Test method  Visual

After Rust Wash metal plate of Inhibitor acid with water Treatment Dry water using air blower

Treatment/ Painting/ Oven Operators

Treatment/ Painting/ Oven area

After pre painting washing & Drying

Treatment/ Painting/ Oven Operators

Treatment/ Painting/ Oven area



Visual

After painting

Treatment/ Painting/ Oven Operators

Treatment/ Painting/ Oven area



Visual

Paint layers evenness and equal Edges/ welded/ joints/ sides must be fully covered by paints Paints stickiness

Set oven temperature and ovening time according to paint powder spec Arrangement of sprayed metal sheet (until it fully occupied oven) Baking of paints Visual paint & crack test

Reference Document SOP 7.3

Operating Instructions & spare Parts list Manual Powder system with powder gun W.I-004- Carta aliran bagi kerja-kerja mengecat dan ovening  SOP 7.3 W.I-004- Carta aliran kerja mengecat dan ovening

STANDARD ELECTRIC SDN. BHD. (KINGSGATE SDN. BHD.) Doc. No.: SOP 7.3- QP Page No.: 4 of 5

Items to check     

 Wiring Work       Components Fitting

Rev. No.: 1 Eff. Date: 1 Dec 2010

Monitoring

Materials

Modular Installation

Quality Plan: Work In-Progress for Modular Installation, components fitting & Wiring work

 

Dimension of modular Tightness nut/ bolts Right angle at corners Evenness of modular setting Firmness of frame structure Wire labelling Size of cables Correct wiring according to CAD drawing Continuity check by using multimeter Tightness of terminal Neatness of cable way Wash metal plate of acid with water Dry water using air blower

Frequency

Responsibility

Location

After Ovening & completion of metal modular box

Modular Installer/&

Modular area

Supervisor

Before, During & After wiring work

Wireman/ Technician

Wiring/ QC/ Packing area

During Wiring works

Supervisor/ Wireman/ Technician

Components Installation Areas

Inspection/ Test method  Visual  L-Shape ruler  Measuring Tape  Vernier callipers

 

Reference Document  SOP 7.3 W.I –005Carta aliran kerja pemasangan modular

Visual  SOP 7.3 Multimeter W.I –006Carta aliran kerja pendawaian

Visual

SOP 7.3 WI 007 Components Fitting works

STANDARD ELECTRIC SDN. BHD. (KINGSGATE SDN. BHD.) Doc. No.: SOP/ 10-PQP

Quality Plan: Final Inspection & Testing

Page No.: 5 of 5

Factory Acceptance Test (FAT)

Eff. Date: 1 Dec 2010

Monitoring

Materials QC Inspection & Testing & labelling &

Items to check             



Panel paints Panel physical dimension Label & Tag Cables lug/marking Wiring/nuts tightening Component physical condition /position Busbar mechanical condition and screw tightening Components functioning Wiring tighten Component screw tightening Control functional test Insulation test at 1000V (pre-pressure test). Above 5 MΩ Insulation test at 1000V (after pressure test). Above 5 MΩ Pressure test for 400A + switchboard. 2 kV for phase. 1 kV for neutral. Below 3 mA

Product Packing



Sealing of PVC plastic sheet

Delivery



Max. load limit for crane Handling method



Preliminary Commissioni ng & testing

Rev. No.: 1

   

Functioning test/ operation tests Component/ part check Joints termination Panel to panel corrections

Frequency Upon completion of switchboard assembly

Responsibility

Inspection/ Test method

Location

Electrical Wiring/ QC/ Supervisor & Packing area QA Technician

    

On completion Worker of inspection & testing

Packing area

Upon delivery from factory and client arrange own transport

Supervisor or Storekeeper

Wiring/ QC/ Packing area

Preliminary test

Factory On-side Manager or switchboard Supervisor Or installation QA Technician Or Wiremen

Visual Insulation tester Pressure tester Multitester Red paint marker pen

Reference Document SOP 7.3 WI-008 Carta Aliran Kerja pemeriksaan pengujian terakhir



Visual



Visual

SOP 7.5 handling, storage & delivery  SOP/ PRO 13.0  Delivery order/ invoice



Visual



SOP/ PRO 15.0