Course on Quality Assurance & Quality Control for Mechanical Engineers

 

Course Title: Quality Assurance & Quality Control for Mechanical Engineers

Duration: 6–8 weeks
Mode: Self-paced / Classroom / Industrial Training Compatible
Level: Beginner to Advanced
Industry Focus: Manufacturing, Oil & Gas, Construction, Automotive, Fabrication, Power Plants

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📚 Course Structure

Chapter 1: Introduction to QA/QC

• Difference between QA and QC

• Importance in Mechanical Industry

• Standards: ISO 9001, ASME, API, ASTM

• Real-World Application: Why a failed weld in a pressure vessel costs millions

Chapter 2: Quality Management Systems (QMS)

• ISO 9001 Structure & Clauses

• Documentation: Quality Manual, SOPs, Work Instructions

• Control of Documents and Records

• Field Example: QMS in a fabrication shop – real forms and checklists

Chapter 3: Inspection and Testing Techniques

• Dimensional Inspection (Vernier, Micrometer, CMM)

• Visual Testing (VT), Radiographic (RT), Ultrasonic (UT), Magnetic Particle (MT), Dye Penetrant (PT)

• Destructive vs. Non-Destructive Testing (NDT)

• Practical: Interpreting RT film of a weld joint

Chapter 4: Welding Quality Control

• Welding Symbols and Procedures (WPS, PQR, WPQ)

• Weld Defects and Inspection

• Welding Codes: ASME Section IX, API 1104

• Real-World: Welding of pipeline in oil & gas project – NDT plan and welder qualification

Chapter 5: Material Traceability & MTC

• Heat Numbers, Batch Numbers

• Review of Mill Test Certificates (MTCs)

• Incoming Material Inspection Procedures

• Field Application: Checking MTC of stainless steel for pharmaceutical equipment

Chapter 6: Calibration and Control of Measuring Instruments

• Calibration Requirements

• Gauges and Instrument Traceability

• Calibration Logbook Maintenance

• Workshop Example: Calibrating pressure gauge before testing

Chapter 7: QA/QC in Manufacturing Processes

• Machining, Casting, Forging, Sheet Metal – QA/QC Points

• In-Process Quality Checks

• Final Inspection and Approval

• Real-World: Dimensional inspection of turbine blades in aerospace component plant

Chapter 8: QA/QC in Fabrication and Erection

• Fit-Up Inspection

• Weld Visual Inspection Checklist

• Pre-Commissioning and Commissioning Tests

• Field Case Study: Fabrication and erection of steel structures in a thermal power plant

Chapter 9: Non-Conformance, Root Cause Analysis & CAPA

• Identifying Defects and Non-Conformities

• 5 Whys, Fishbone (Ishikawa) Diagram

• Corrective & Preventive Actions (CAPA)

• Industrial Case: Repeated leaks in a pressure line – RCA and solution plan

Chapter 10: Quality Audits and Reports

• Internal and External Audits

• Audit Checklist Preparation

• Sample Audit Report Writing

• Field Activity: Conducting internal audit of a workshop

Chapter 11: QA/QC in Procurement and Vendor Inspection

• Vendor Qualification

• Third-Party Inspection Agencies (TPIA)

• Field Visit: Vendor Inspection of pump and valves in EPC project

Chapter 12: Health, Safety, and Environmental Considerations

• HSE and Quality Correlation

• Risk Assessment in Quality Control

• Job Safety Analysis (JSA) & Permit to Work

• Case: Quality-related accident in boiler maintenance – Lessons learned

Chapter 13: Digital QA/QC Tools and Software

• ERP Integration in QA/QC

• Quality Control Software (SAP QM, SmartSheet, etc.)

• Real Data Entry: Recording weld data and inspection status digitally

Chapter 14: Quality Metrics & Continuous Improvement

• KPIs: Rejection Rate, First Pass Yield, Rework %

• Lean Tools: 5S, Kaizen, PDCA, Six Sigma Basics

• Industry Practice: Implementing 5S in a machine shop

Chapter 15: Final Project & Field Application

• Real-Life QA/QC Project (Choose Industry: Welding/Fabrication/Inspection)

• Prepare QA Plan, ITP, Checklists

• Conduct Simulated or Real Inspections

• Report Submission and Presentation

• Example: QA/QC Plan for Pressure Vessel Fabrication

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🧠 How to Apply QA/QC Knowledge in the Field

1. Join Inspection Projects – Fabrication yards, manufacturing plants, EPC sites

2. Use Actual Templates – ITPs, NCRs, Inspection Reports

3. Practice NDT Interpretation – Partner with local NDT agencies

4. Observe Experienced QA/QC Engineers – Learn documentation and communication

5. Carry a QA/QC Toolkit – Calipers, gauges, inspection mirror, camera

6. Follow Codes & Client Specs – Always refer to ASME/API standards

7. Communicate Issues Professionally – Prepare proper CAPA plans

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🧰 Assignments & Practical Work

• Fill a real ITP form for a job

• Simulate a dimensional inspection in the lab

• Prepare a welding procedure document

• Conduct a mock root cause analysis

• Visit a local fabrication unit for an audit

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📄 Certification and Career Path

• Final Exam + Practical Evaluation

• Certification: "QA/QC Engineer for Mechanical Applications"

• Career Options:

  • QA/QC Engineer (Manufacturing/Fabrication/Oil & Gas)

  • NDT Inspector

  • Quality Analyst in EPC Projects

  • Vendor Inspector

  • ISO Auditor