Fastening, Joining & Assembly

The root cause can be complex, and somewhat different for each case in the various industries. We are all well aware , for example , that highway and bridge construction has far surpassed our ability to keep-up with inspections on same. And we keep building more every year ... more-often-than-not, without plans in-place for the inspection and maintenance thereof.

Pipelines do not get better/younger/stronger as they age. They deteriorate, sometimes gradually, and (infrequently) at alarming rates. And, for a combination of reasons (including costs, and qualified inspector availability), pipeline companies adopt "Risk based inspection" plans, that focus the routine inspections at points where disaster would supposedly cause the greatest harm.

Fancy words will oftentimes feed-the-need for "cozy, warm, fuzzy feelings of safety".

But, fundamentally, a severe worldwide shortage of properly trained/skilled inspection personnel exists: in the airlines, shipping, pipelining, automotive, railroad, highway and bridge construction, etc. etc. Too many employers for TOO long have staunchly believed that inspection is merely a "necessary evil", for the purpose of "appearances" (..."Yes, we have a certified staff of quality control inspectors"...)

But they refuse to supply their inspectors with the right tools for the job. Technologies for inspection have advanced remarkably in the past few decades, but many companies hang onto 15-yr old gear because: "If it was good enough back then, it is good enough for you guys to use NOW."

Legislation that has been passed (49CFR), requiring pipeline personnel to be "Properly Qualified" to perform the tasks to which they are assigned left GIANT GAPING LOOPHOLES, which most every company jumps-through on a daily basis with glee... "We been doin' it this-a-way for 40 years, and the feds ain't gonna stop us now from doin as we see fit."

The almighty dollar wins at EVERY single solitary turn. PERIOD. And greed, arrogance, and passing the buck are now staples of the corporate diet, such that change can only occur in fractional increments with respect-to the cube of deaths that occur as a result of irresponsibility.

Be very afraid next time you fly or take a cruise.......

Re:

" I think quality is "made" not "controlled". That is: The main issues are in design and manufacturing. If both are properly done, controls are just necessary because..."

...[the above should be followed by:] ... because of things like fatigue, corrosion, vibration, creep, and all the other things that cause failures while something (like a pipeline) is IN SERVICE ... thus, even greater degrees of inspection are required while in-service than during manufacture / fabrication.

I have known a few QC guys. And they are all very 'properly' schooled to remain focused on "Make sure it's right when it goes out the door", or "...when the customer takes delivery"...

Any time LATER, the old "Pass-the-buck" philosophy takes precedent.

I am the quality Control Manger where I work and have been fooling with some form of welding or it's inspection for all of my working life. One thing I would like to add to this conversation is something that I have found more of in the last few years. It is not the problem of the inspector not finding, or reporting the problems but more the problem of managers not seeing that the problems are repaired corectly or even at all when they are found. I have been always told (and believe) that quality control inspector has only 3 main duties. These are:

1)to inspect the weld or item correctly according the criteria of the code or standard he is charged with following.

2) Report any problems he may find to the appropriate managers for remedy.

3) Document the problem, remedy and repair exactly as it is.

In no circumstance should it be the quality control inspector's responsibility to force or police a person or company to make the appropriate repair. Many people think that it is the inspector's duty to see to it that the proper repairs are made and although I have meet inspectors and managers both that do think this it is just not correct. It is and always will be the managers job to see to it that things are repaired correctly when the inspector finds a problem and that he is notified to re-inspect and/or document that the repair has been made. An inspector is worthless if he does not have all of a company's managers complete cooperation and respect and dedication to have things repaired as he may find them. I speak from experience in saying that being a weld inspector without having the complete cooperation from the entire company managing team is truly a crappy job.