Quality Assurance in the Amusement Industry CLARK WESTERFIELD

Transcription

1 Quality Assurance in the Amusement Industry 1 CLARK WESTERFIELD

2 General Overview Steps to building a successful QA Program Put Someone in Charge with Authority to Act Understand the Basic Requirements Adopt Industry Standard Requirements Be Aware of All Codes and Regulations Affecting Ride Maintenance Document Your Policies and Procedures Train Your Inspectors Define Your Inspection Criteria Understand the Checks and Balances of the Program Make a Decision to Fully Support the Program 2

3 QA Inspection Program Questions Why Do You Need to Inspect? What Do You Need to Inspect? Who Will Do Your Inspections? What Techniques Will They Use? What Equipment Will They Need? What Training is Needed? How Often Are Inspections Performed? What Needs to be Documented? 3

4 Inspection Requirements State Amusement Laws and Regulations Provides for Inspection of Rides 42 States Reference ASTM F24 Standards ASTM F24 Committee Standards Covers Amusement Rides and Devices 500 Members from Around the World 17 Currently Released Standards F770 Covers Owner Inspection Requirements F1193 Defines Inspection Requirements 4

5 ASTM F770 Overview Title: Standard Practice for Ownership, Operation, Maintenance, and Inspection of Amusement Rides and Devices Current Revision: 2011 Covers: Owner/Operator s Responsibility Maintenance Program Requirements Inspection Program Requirements 5

6 Owner/Operator s Responsibility Conduct Daily Pre-Opening Inspections Visual Check of Vehicles, Including Restraints and Latches Note: Although Not Required by the Standard, a Daily Track Walk Should be Considered Visual inspection of Entrances, Exits, Stairways, and Ramps Ride Communication Equipment Testing Ride Vehicle Operation Check Through One Complete Cycle Without Passengers 6

7 Maintenance Program Requirements Follow the Manufacturer s Recommendations Create Inspection Checklists to Include: Inspection Descriptions Training Requirements Pre-Opening Inspection Requirements Re-Opening Inspection Requirements 7

8 Inspection Program Requirements Owner/Operator Inspection Program to be Consistent with Requirements found in F770 and F1193 Inspection Documents to be Maintained in Accordance with the Procedures found in F770 and F1193 Prompt Notification to Manufacturer Required for any Incident, Failure, or Malfunction which Seriously Affects Continued Proper Operation 8

9 ASTM F1193 Overview Title: Standard Practice for Quality, Manufacture, and Construction of Amusement Rides and Devices Current Revision: 2006 Covers: Quality Assurance Program Inspections (Welding, NDT, Procedures, Bulletins) Inspection Requirements 9

10 Quality Assurance Program A Formal QA Program (e.g. ISO 9001) is Not Required for Owner/Operators A Formal Inspection Program is Required and Includes: Inspection of Purchased Ride Parts Inspection of Ride Parts and Structural Elements Inspection of Used Parts Prior to Re-Use Proper Disposition of Nonconforming Parts 10

11 Quality Assurance Program (cont) Formal Process and Procedure Documentation Documentation (Configuration Management and Record Retention Policy) Formal Inspector Training Program Dimensional Visual Nondestructive Testing (MT, UT, PT, AT, RT, etc.) Documentation (Reports and Training Records) 11

12 Inspection Receiving Inspection of Purchased Parts Inspection Procedure Required Parts Meet Drawing Requirements/Specifications Assembly Inspection Inspection Procedure Required Nonconforming Parts Segregated Properly Dispositioned, Reworked, or Destroyed 12

13 Welding Process Checks Inspection (cont) 13 Processes in Conformance with the American Welding Society (AWS) Standards Performed by Certified or Qualified Welders Documentation Maintained Operational Requirements Operator Safety Checks Documented Performed Prior to Each Ride Cycle

14 Nondestructive Testing Inspection (cont) Qualified Inspector Required Conforms to Manufacturer s Requirements Documented Scheduled NDT Type Specified Acceptance Criteria Defined Manufacturer s Maintenance Manual Follow All Recommended Inspections 14

15 Manufacturer s Bulletins Inspection (cont) Follow All Inspection Requirements Inspection Procedures Provided by the Manufacturer 15 Must Normally Provide an Acceptable Result During the Expected Life of the Part Must be Practical and Reasonably Able to be Performed by a Trained and Competent Inspector

16 Documenting Policies and Procedures Internal Development Document Your Procedures As Is Improve Them Later Use Manufacturer s Documentation as much as Possible Keep Documentation Secure and Under Control External Development Bring in a Third-Party Use or Modify Canned Documentation 16

17 Inspector Training Training Internal and External Training Records Inspector Types Mechanical Inspectors Electrical Inspectors Certified Weld Inspectors NDT Technicians ASQ Certifications 17 Quality Inspectors, Quality Technicians, Quality Calibration Technicians

18 Inspection Equipment Match the Tools to the Inspections Provide for Equipment Maintenance Account for Calibration Requirements Set Up a Calibration System Check Non-Inspector -Used Calibrated Equipment (Torque Wrenches, Go/No-Go Gages, Pressure Gages, etc.) Track All Tools by Asset Number 18 Recheck Suspect Equipment Immediately and Re-Inspect Any Parts Checked By This Equipment (Especially Torque Wrenches)

19 Inspection Reporting 19 Use Standardized and Numbered Paper or Electronic Forms Review All Nonconforming Parts Reports Provide Parts Traceability (S/Ns or Tagging) Require Disposition Log All Reports Manually or Electronically Analyze Inspection Reports on a Periodic Basis to Uncover Trends Keep Copies According to Record Retention Policy

20 Inspection Criteria Established by the Manufacturer or Industry Standards Includes: Drawing Specifications and Wear Limits Industry Standards (ANSI, AWS, ASNT, etc.) 20 Acceptance Sampling Plans Used Mainly for Receiving Inspection Standards Include ANSI Z1.4 or MIL-STD-105E

21 Checks and Balances You Can t Inspect In Quality 100% Inspection is Not 100% Effective Lack of Documentation Brings Inconsistency Poor Training Ensures Poor Performance Prevention is Cheaper Than Failure 21 Learn From Your Failures to Develop Added or More Effective Inspections and Procedures Consider Instituting a Process Audit Program It All Comes Down to Management

22 Conclusion An Effective Inspection Program is a Vital Component of Ensuring Attraction Safety Even if It was Not Required by Law, a Properly Set Up and Maintained Inspection Program Pays for Itself A Good Inspection Program Keeps You in Control of Your Future It Just Makes Good Sense 22

23 23 Questions?