Why this course?

Description

Aluminium, Facades & Glassworks Quality Control & Assurance Engineering, Documentation and Management Course

50 Emails Samples Plus 50 Checklists Included Extra !!

Module 1 – Fundamentals of Aluminium & Glass Facades QC

1. Aluminium & Glass Systems Overview

   • Types of aluminium profiles, glass units, curtain-wall systems

   • Key performance parameters (thermal, structural, acoustic)

   • Standards & codes (EN 1090, ASTM E2190, IS 14225)

   • Example: Comparison table of Glass IGU types

2. Quality Management Principles

   • QC vs QA: definitions and roles

   • Quality planning: QCP, Inspection Test Plans (ITP)

   • Document control (DCC) for specs, drawings, procedures

   • Template: ITP-FAC-01

3. End-to-End Workflow (“.material aane se jaane tak”)

   • Factory QC → Dispatch → Site receipt → Installation → Handover

   • Key touchpoints for inspection & sign-off

   • Flowchart diagram of process stages

   • Template: Process Flow – FAC-02

4. Key Documentation & Records

   • Material Inspection Report (MIR), Welding Inspection Report (WIR)

   • Non-Conformance Report (NCR), Non-Performance Observation (NPO)

   • Holding/Release Certificates (HC Certificate)

   • Example: MIR-01 sample with fields for dimensions, labels

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Module 2 – Factory QC I: Incoming Materials & Pre-Production Checks

1. Incoming Inspection Checklist

   • Visual defects, dimensional tolerances, surface finish

   • Sample size & acceptance criteria

   • Template: Incoming Checklist – FAC-IN-01

2. Chemical & Mechanical Testing

   • Alloy verification (spectro analysis)

   • Hardness, tensile tests for extrusions

   • Example: Lab Test Report form

3. Documentation Review

   • Mill Test Certificate (MTC), Packing List, LPO/NPO issuance

   • Verifying certificates against specs

   • Template: MTC Verification Log – FAC-DOC-01

4. Factory Calibration & Equipment QC

   • Calibration records for cutting, machining, welding machines

   • Preventive maintenance schedules

   • Template: Calibration Log – FAC-CAL-01

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Module 3 – Factory QC II: Fabrication & Welding

1. Welding Procedure Specification (WPS) & WPQR

   • Qualifying procedures for aluminium welding

   • Welding parameters, preheat, filler metal selection

   • Template: WPS-ALU-01

2. Welding Inspection & WIR

   • Visual, dye‐penetrant, ultrasonic inspections

   • Recording weld size, length, defects

   • Template: WIR-02 sample

3. Handling NCRs in Fabrication

   • Raising NCR/NPO for defects (cracks, porosity)

   • Root‐cause analysis & corrective action

   • Template: NCR-03 form

4. Factory Assembly Checks

   • Trial assembly of frames, door leaves, façade mock-ups

   • Gap & tolerance verification

   • Example: Assembly QC report

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Module 4 – Factory QC III: Pre-Shipment & Packaging

1. Pre-Shipment Inspection (PSI)

   • Final dimensional, functional checks (operation of doors, drains)

   • Sealant adhesion, hardware testing

   • Template: PSI-FAC-04

2. Packing, Labeling & Protection

   • Protective films, edge guards, crate marking

   • Label format for easy site identification

   • Example: Packing Label sample

3. Outgoing Checklist

   • Checklist for item count, accessories, spares

   • Verifying LPO closure before dispatch

   • Template: Outgoing Checklist – FAC-OUT-01

4. Shipping & Logistics Coordination

   • Handling instructions, moisture barriers

   • Documentation: BL, AWB, export declarations

   • Template: Shipping Log

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Module 5 – Site QC I: Receiving & Storage

1. Site Incoming Inspection

   • Unloading checks, damage assessment

   • MIR update upon receipt

   • Template: Site MIR – MIR-SITE-01

2. Storage & Handling Procedures

   • Rack layout, weather protection, segregation by project area

   • Handling heavy frames safely

   • Example: Site Storage Plan

3. Material Release & Holding

   • Issuing HC Certificates for released items

   • Managing on-hold tags for non-conforming items

   • Template: HC Certificate form

4. Site Document Control

   • Logbooks for MIR, WIR, NCR, NPO

   • Email tracking for approvals & clarifications

   • Template: Site Document Register

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Module 6 – Site QC II: Installation of Curtain Walls & Glazed Systems

1. Pre-Installation Checks

   • Plumb & level of mullions, base fixing verification

   • Substrate interface (insulation, waterproofing)

   • Template: Pre-Install Checklist

2. Mechanical & Sealant QC

   • Fastener torque, gasket seating, sealant bead dimensions

   • Water infiltration & air-leak tests

   • Example: Field Water Test Report

3. Alignment & Dimension Control

   • Diagonal measurements, unit-to-unit tolerances

   • Shim placement & gap consistency

   • Template: Alignment Log

4. Post-Installation Inspection

   • Functional tests of openings (vent panels, vents)

   • Final sign-off & punch-list generation

   • Template: Punch-List Report

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Module 7 – Site QC III: Doors, Windows, Shutters & Operable Elements

1. Sliding Doors & Windows

   • Track alignment, roller function, drift & smoothness

   • Brush seals, weatherstrip checks

   • Template: Sliding Door QC Form

2. Shutters, Louvers & Ventilators

   • Blade angle uniformity, free rotation, locking mechanism

   • Corrosion protection checks

   • Example: Louvers Inspection Report

3. Pergola, Canopy & Balcony Fans

   • Structural connections, bracket checks, load tests

   • Fan mounting, electrical safety inspection

   • Template: Structural Load Test Sheet

4. Safety & Access QC

   • Fall-protection anchor points, scaffolding interfaces

   • Safe access for maintenance

   • Template: Safety Compliance Checklist

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Module 8 – QC Documentation, Reporting & Communication

1. Material Inspection Reports (MIR)

   • Writing clear MIR emails, attaching photos & test certificates

   • Template: Email – MIR submission

2. Welding Inspection Reports (WIR)

   • Structuring WIR mail: findings, references to WPS/WPQR

   • Template: Email – WIR submission

3. Managing NCR/NPO

   • Communicating non-conformance, tracking closure

   • Template: NCR notification email

4. Release Orders (LPO) & Close-Out

   • Preparing LPO after corrective actions

   • HC certificate issuance email

   • Template: Email – LPO release

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Module 9 – Quality Management Systems & Audits

1. Implementing QMS for Facades

   • Key clauses (control of non-conforming outputs, corrective action)

   • Integration with ISO 9001 / EN 1090

2. Internal & Third-Party Audits

   • Audit checklists (factory & site), auditor roles

   • Reporting audit findings

3. Corrective & Preventive Actions (CAPA)

   • Root-cause analysis tools (5 Why, Fishbone)

   • CAPA plan templates

4. Continuous Improvement & Lessons Learned

   • KPIs (PPM, on-time delivery, rework rates)

   • Weekly QC review meetings

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Module 10 – Case Studies & Hands-On Workshops

1. Mock Factory QC Drill

   • Simulated incoming inspection, NCR generation

   • Group exercise using MIR-01 / NCR-03 templates

2. Site Installation Workshop

   • Curtain wall mock-up assembly, water-leak testing

   • Completion of site checklists

3. Root-Cause & CAPA Exercise

   • Analyze a real NCR case, propose corrective action

   • Fill CAPA template and present

4. Final Assessment & Certification

   • Written exam on key QC docs & procedures

   • Practical evaluation: write & submit MIR, WIR, NCR emails