Quality Assurance Manual

AWS Entry Welder Training Program

Revision 1
October 2012
 College of Western Idaho

Quality Assurance Manual

FOREWORD
Note: “At the option of the applicant Participating Organization, the detailed directions
which are included in this sample Quality Manual may be administered as either Exhibits or
Procedures. Regardless of what these detailed instructions are named, it is important that
they be controlled documents and that they be implemented and followed.” ~ AWS

To which point, the current revision number of the manual is available and checked for
conformity on a regular basis. All outdated pages will be removed from the manual and
destroyed. No old copies are to be kept anywhere in the College of Western Idaho or by any
staff member past or present. Only officially issued and current revision Quality Manuals are
allowed to be used.

Copy and Revision Records:

Copy Person Holding Copy Location Date Checked

1 Senior Official Assistant Dean Office

2 Quality Assurance Manager As Appointed Ex #

3 Test Supervisor As Appointed Ex #

1 As Submitted - -

Rev Changes Date of Update Updated by:

CONTENTS

Manual Sections

1. Policy Statement

2. Organizational Chart

3. Registration

4. Personnel
4.1 Qualification and Training
4.2 Test Supervisors and Instructors
4.3 Senior Official
4.4 Quality Assurance Manager

5 Purchase of Materials and Services

6 Material Control

7 Fabrication

8 Performance Qualification Testing

9 Documentation
9.1 Trainee Reports
9.2 Test Reports

10 References

11 Nonconformance

12 Quality Assurance Manual Review

13 Exhibits
1. Policy Statement. The Policy Statement of the College of Western Idaho
is that it will abide by all of the requirements of AWS Specifications governing
this program.
The Policy Statement is shown in Exhibit 1 and is as signed by the Senior Official of the
Facility. The Policy Statement shall be as a certification to AWS that the Facility has a
Quality program, which will be rigorously followed, and that the requirements of the
appropriate standard(s) (QC10 to QC12) will be met. For Participating Organizations that
are training and testing organizations, the letter shall also state that their curriculum follows
AWS EG2.0 to EG4.0 as applied for as Exhibit 1.0.

2. The Organization Chart. A suggested Organization Chart of the Participating

Organization is shown as Exhibit 2.0, and may be included as a part of the Quality
Manual.

3. Registration. The training organization shall apply to the American Welding

Society for registration as a SENSE Participating Organization.

3.1 The College of Western Idaho shall submit a checklist, Exhibit 3.1,
showing their review of their program. This shall be the checklist used during an
audit.

3.2 The College of Western Idaho shall prepare and submit a Quality
Assurance Manual indicative of how they operate.

3.2.1 This manual shall be an approved document as indicated by the

signature of some senior official of the organization.

3.2.2 This manual shall be a controlled document with procedures or

controlled exhibits included for its maintenance and operation.

4. Personnel

4.1 Qualification and Training:

4.1.1 All personnel of the College of Western Idaho involved with this
program to the extent that they are listed on the organization chart shall be
able to document their qualifications, including education and experience
for the position held.

4.1.2 The College of Western Idaho shall have a formal policy for the
maintenance of qualification of its personnel involved with this program.
4.2 Test Supervisors and Instructors. Test Supervisors and Instructors
may be either full-time employees or contract employees. It is recognized that
the same individual may do several job functions, but these duplicate jobs
shall not interfere with adequate performance of the tasks.

4.2.1 The Test Supervisor shall:

4.2.1.1 Be an AWS Certified Welding inspector (CWI) or justify that

they are qualified for the position.

4.2.1.2 Insure that materials and services are ordered as required,

following approved procedures.

4.2.1.3 Check base and filler metal materials before assembly.

4.2.2 Follow Procedure for Fitting Workmanship Sample Test Assemblies,

Exhibit 7.1, and complete Workmanship Sample Checklist, Exhibit 7.4.

4.2.2.1 Visually inspect workmanship samples to requirements of the

standard.

4.2.2.2 Conduct bend tests on test plates.

4.2.2.3 Prepare reports.

4.2.3 The Instructor shall:

4.2.3.1 Be an AWS Certified Welding Educator (CWE) or be

able to justify their qualifications as a welding instructor.

4.2.3.2 Complete the Training Achievement Record for

each trainee.

4.2.3.3 Ensure that all trainees are safety qualified before

any welding activities by allowing only those trainees with
adequate scores to perform any welding activities.

4.2.3.4 Administer and grade the written, closed book,

Practical Knowledge Test as required by the AWS QC10.

4.2.3.5 Develop and/or implement Lesson Plans as

required by the Entry Level Program.

4.2.3.6 Prepare reports as required by the QC10.

 4.3. Senior Official. The duties of the Senior Official are as follows:

4.3.1 Review and approve all documentation including:

4.3.1.1 The Quality Manual including Exhibits,

and Procedure.

4.3.1.2 Purchase Orders

4.3.1.3 Lesson Plans and other welding

teaching or instructional materials

4.3.2 Send the required documentation to AWS Certification Business

Unit.

4.4 Quality Assurance Manager. The duties of the Quality Assurance

Manager are as follows:

4.4.1 Prepare the Quality Assurance Manual.

4.4.2 Prepare the Quality Assurance Procedures.

4.4.3 Review the Quality Assurance manual and Procedures periodically.

4.4.4 Review reports before submission to AWS for accuracy and

completeness.

4.4.5 Resolve quality related conflicts when possible.

4.4.6 Prepare solutions to nonconformance’s.

5. Purchase of Materials and Services

5.1 The Test Supervisor shall prepare requisitions of base and filler metals
and services. All requirements such as material specification, grade or
classifications, documentation and delivery requirements of materials shall be
specified on the requisition and shall be included in the final purchase order.
Requirements for services shall include a thorough specification regarding the
required service and the necessary qualifications of the personnel providing the
service.

5.2 Purchase requisitions shall be reviewed and approved by the Senior

Official.

5.3 A purchase order shall be prepared by the Purchasing Agent.

5.4 The Quality Assurance Manager shall review and approve the purchase
order using the purchase requisition as a checklist.
 5.5 Receipt of materials will be checked by the Test Supervisor using the
purchase order as a checklist.

6. Material Control

6.1 Purchased material shall be identified by a purchase order, a unique

identification number, and will be stored in a secure area.

6.2 At the appropriate time, cutting tickets shall be prepared and issued for
the required materials by the Test Supervisor.

6.3 The identification numbers of the base material and the filler metal shall
be recorded on the cutting tickets. A sample cutting ticket is shown in
Exhibit 6.3.

7. Fabrication

7.1 The student shall assemble the workmanship sample or test plates by
using the fitting procedure shown in Exhibit 7.1

7.2 The student shall stencil the assigned identification on the metal, and
then position the test plates or workmanship sample in the welding positions for
inspection by the Test Supervisor.

7.3 After inspection by the Test Supervisor, the student may weld the
workmanship sample or test plates.

7.4 The Test Supervisor documents the workmanship sample activities on

the Workmanship Sample checklists, Exhibit 7.4.

8. Performance Qualification Testing

8.1 Upon completion of the performance qualification, the Test Supervisor

shall visually inspect the weldments. The Test Supervisor shall follow the criteria
in Exhibit 8.1.

8.2 After visual inspection, the SMAW qualification test plates shall be laid
out for saw cutting. The welder identification code shall be stenciled or stamped
on the bend specimens before their removal from the test plate(s).

8.3 The bend specimens shall be prepared following Exhibit 8.3, and they
shall be tested using the bend test procedures of AWS QC10.

8.4 The Test Supervisor documents the bend test activities on the Face-and
Root-Bend Test Results, Exhibit 8.4.

9. Documentation

9.1 A report shall be prepared by the College of Western Idaho for each
trainee as required by the Documentation Section of the QC10, QC11, or QC12
as appropriate.

9.1.1 The report shall be reviewed for accuracy and completeness by the
Quality Assurance Manager.

9.1.2 The report (Exhibit 9.0) shall be forwarded to the American Welding
Society with the appropriate processing fee for each trainee for:

9.1.2.1 Entry into the AWS SENSE database for Entry Level Welders.

9.1.2.2 Issuance of an AWS SENSE Completion

Certificate and an AWS SENSE Certification Card .

9.1.3 The file of the Entry Welder may be expunged after one year.

9.1.4 The College of Western Idaho shall keep and maintain all records
and original tests for one year after completion of the program by the
trainee. (Exhibit 9.1)

9.1.5 The Senior Official shall ensure that old test plates and bend bars
are destroyed when no longer necessary per paragraph 9.1.4 above.

9.1.6 All documents and records that are a part of this program shall be
stored so that they may be promptly retrieved, kept updated and secure
from unauthorized persons.

9.2 Test Reports. The instructor shall prepare an annual report for the
American Welding Society. The report shall be used to help maintain the validity
and relevance of SENSE. This report shall include:

9.2.1 The number of examinations administered.

9.2.2 Any questions that were missed by more than three students.

9.2.3 Any specific difficulties encountered in the administration of the

SENSE aligned welding program.
10. References. The College of Western Idaho shall maintain a library of all
standards referenced by the AWS QC10 and AWS EG2.0.

11. Nonconformance. All nonconformance’s shall be forwarded to AWS with

supporting documentation, and shall be processed following the SENSE qualification
document AWS QC10.

12. Quality Assurance Manual Review. The Quality Assurance Manager shall
review the Quality Assurance manual at least annually. The Senior Official shall
approve any revisions to the manual as a result of such annual review. A full
documentation of all reviews shall be made available for any audit of the SENSE
aligned welding program by AWS.