In the first part of our deep dive into quality management systems (QMS), which you can read here, we learned how a QMS helps to ensure products and services meet regulatory and customer requirements, while also providing a basis against which to assess and improve operational performance.
Ultimately by fostering a controlled and balanced relationship between workplace inputs and outputs, a QMS is a powerful tool for maximising quality, customer satisfaction and safety.
In this second part, we explore the remaining element of an OCTG QMS and conclude by exploring the benefits of a QMS in more detail.
Elements 6-10 of an OCTG quality management system
6. Product and service quality plans
With regard to the vendor purchasing and manufacturing process, the organisation will need to develop product and service quality plans that define all the required activities to deliver a product or service, a description of the product to be manufactured or supplied, required processes and documentation (including required inspections, tests, and records for conformance with requirements), as well as identification of each procedure, specification, or other document referenced or used in each activity.
The quality plans should also identify the resources and responsibilities of each relevant employee or group of employees, and identify the required infrastructure and equipment. They then need to identify the subcontractors or vendors and the level of control that’s being applied to them. Finally, Key Success Factors and criteria must be established and the execution of the service or product quality plan must be verified.
Verification of execution according to a product or service quality plan and analysis of performance against Key Success Factors or criteria serves to make sure that the operational effectiveness and efficiency of the service or product delivery can be measured and, if necessary, improved.
7. Preventative maintenance and control of testing and measurement devices
When it comes to preventive maintenance and the control of testing and measuring devices, a master list of equipment is needed to set maintenance and control requirements, as well as to determine what the acceptance criteria and tolerances are.
Procedures for the establishment of preventive maintenance for equipment and control of testing, monitoring, and measurement devices should be developed to identify the requirements for the type of equipment and devices, frequency of monitoring and testing, calibration status and verification method.
Equipment that is maintained, inspected, and calibrated regularly is less likely to fail in service and is typically safer to use. The results delivered by controlled testing devices can be more readily relied upon and used for verification and validation if they’re part of a calibration or maintenance program that is applied consistently and informed by relevant internal, external and regulatory requirements.
8. Control of nonconformities measurement
Controlling nonconformities, including corrective and preventive actions is the first step in identifying nonconforming products or services and immediately applying corrective actions to stop the problem from reccurring or, if possible, occurring in the first place. Having fewer and less severe nonconformities (which should be one of the outcomes of a well-established QMS) translates into increased efficiency, effectiveness, and financial performance, as well as customer and stakeholder satisfaction.
The opening of an investigation and undertaking of root cause analysis are important steps in developing corrective and preventative actions to make sure the issue does not reoccur, and that there is assurance that mitigation has been effective. Investigation of a non-conformity, root cause analysis and the related corrective actions should be conducted with the participation of cross-departmental teams or employees, ensuring subject-matter experts are involved and that decisions are informed by and communicated at the level of the organisation, rather than just the quality team.
9. Analysis and improvement of operational performance
Continual improvement is at the heart of every QMS. You can’t improve what you can’t measure, so clear, measurable quality objectives must be set. These quality objectives should be quantitative and derived from operational performance KPIs.
Quality objectives need to be tracked continuously and communicated throughout the organisation, at the required levels and via required means. These objectives and analysis of compliance with them will be used to determine continuous improvement initiatives and measures.
10. Review and assessment of compliance
Every QMS must be reviewed regularly to ensure it is implemented fully and continues to be effective in yielding the desired results. These reviews take place at the executive and senior leadership level, while certified organisations may also be subjected to external audits by ISO or API auditors, which will also form part of the annual QMS management review.
Internal audit and compliance assessments should also be conducted to verify that the QMS is effectively implemented and maintained and conforms to the requirements of the QMS.
Improvement initiatives should be developed based on the findings of these internal and external audits, reviewed, and the results should then be communicated at a high level throughout the organisation.
Benefits of a quality management system
A well-designed QMS ensures that quality standards remain consistent throughout the manufacturing process of OCTG products. This translates into enhanced product reliability and performance, reducing the risk of failures and operational disruptions in critical oil and gas operations and instilling confidence in customers.
At the organisational level, a solid QMS drives efficiency, streamlines processes, and minimises wastage, ultimately leading to cost savings and increased customer satisfaction. It also fosters an environment that encourages proactive identification and mitigation of potential risks, enhancing safety and reliability in OCTG applications, often deployed in high-risk environments.
Overall, implementing a robust quality management system ensures the delivery of high-quality products, elevates operational performance, builds trust with stakeholders, and ultimately bolsters the industry’s reputation for delivering safe and reliable solutions.
Are you looking for ready-made pipes that align with your QMS? At Pipesales, you can filter your product search by grade or condition to ensure the results meet your standards. You can also request further quality assurance before finalising your purchase. Start exploring our global marketplace today.
