Factory and Fabrication Inspection in Malaysia
itmad provides third-party factory and fabrication inspection in Malaysia: ITP witness and hold points, resident inspection, certificates.
itmad provides third-party factory and fabrication inspection for buyers in Malaysia: vendor audit, ITP witness and hold point attendance, resident shop inspection and factory inspection certificates, carried out as the representative of the buyer at the manufacturer's works. itmad inspects with both Malaysia-based inspectors and a travelling team, and has worked in Malaysia for more than 10 years. itmad acts for the buyer and holds no commercial interest in the manufacturer, the equipment or the outcome of inspection.
Why inspect at the manufacturer
When equipment is manufactured against a buyer's specification at a supplier's works, the quality of what arrives is decided long before delivery. itmad acts as the representative of the buyer at the manufacturer, verifying that the work is being done to the specification that the buyer purchased, before the equipment ships and while non-conformity can still be corrected at the maker's cost.
Factory audit
A factory audit is an assessment of the capability of the manufacturer, carried out before contract award or before production begins.
- Welding control system audit against EN ISO 3834 or ASME requirements
- Qualification and certification audit: welder and procedure qualifications, NDT personnel and operator certifications
- Production capability and capacity assessment
- Product quality control system review
- Experience with, and correct application of, the standards that the order is placed against
Document review before manufacture
Errors caught in procedures cost nothing to correct. The same errors found in finished product mean rework, rejection or a delivered defect. The review covers:
- Inspection and test plan (ITP), including agreement of witness (W) and hold (H) points
- Welding documentation (WPS, PQR and welding instructions), verified against the applicable code
- Welder and NDT personnel qualifications, and the validity of the qualifications for the work involved
- Heat treatment procedures and instructions
- NDT procedures and instructions
- Painting and coating procedures
- Pressure test and routine test procedures
- Packing and preservation procedures
Raw material inspection
- Material certificate review against the specification and the applicable standard
- Witness of chemical composition and mechanical property testing
- Material dimensional inspection
- Verification of traceability from certificate to the material actually in the shop, a step that is often skipped
Witness and hold point inspection
itmad attends the witness (W) and hold (H) points defined in the agreed ITP. A hold point means production does not proceed past that stage until the inspector has attended, examined and issued release. Enforcing that discipline is a core part of the value of inspection, because hold points are the mechanism by which a buyer retains control of quality in someone else's factory. itmad attends to agreed notification periods and confirms release or raises a non-conformance report (NCR) at each point.
Resident shop inspection
Where order value, schedule risk or fabrication complexity justifies continuous presence, itmad places a resident engineer at the works to act as the representative of the buyer through the full build.
- Daily inspection against process documents agreed between buyer and supplier
- Daily or weekly progress and quality reporting at the frequency required
- Immediate escalation and management of each non-conformity when the non-conformity arises, not at final inspection
- Ongoing review and verification of manufacturing quality records as produced
- Visibility of schedule slippage while there is still time to react
Performance and commissioning test witness
- Attendance at performance, functional and commissioning tests to the requirements of the buyer
- Review of manufacturing and test documentation before the test is permitted to start
- Verification that test conditions and instrumentation match the approved procedure
- Comprehensive final inspection of overall product condition and appearance
- Confirmation of preservation, marking and packing before release for shipment
Where factory inspection is used
- Capital equipment purchased from overseas manufacturers
- Pressure vessels, heat exchangers, tanks and fabricated structures
- Piping, valves, fittings and pipeline materials
- Electrical and rotating equipment packages
- Structural steelwork and modular fabrication
- Any order where the buyer cannot maintain a presence at the manufacturer's works
How itmad delivers factory inspection in Malaysia
itmad delivers factory and fabrication inspection in Malaysia through Malaysia-based inspectors and a travelling team. itmad acts for the buyer and holds no commercial interest in the manufacturer, the equipment or the outcome of inspection. Engineers are experienced in the international codes (ASME, AWS, EN ISO and client-specific requirements) and with the practical realities of enforcing the codes in a working fabrication shop.
What itmad provides
- Inspection reports at each attendance, referenced to the ITP stage
- Non-conformance reports (NCRs) with objective evidence and photographs
- Release notes or factory inspection certificates at hold and witness points
- Progress reporting at the agreed frequency for resident assignments
- Final inspection report before shipment release
- A complete documentation dossier where required for handover or client acceptance
Frequently asked questions
What is factory and fabrication inspection?
Factory and fabrication inspection is third-party inspection carried out at the manufacturer's works while equipment is being made against the buyer's specification. itmad acts as the representative of the buyer, verifying that the work meets the specification before the equipment ships.
What is a hold point in an inspection and test plan?
A hold point is a stage in the agreed inspection and test plan (ITP) at which production does not proceed until the inspector has attended, examined and issued release. Enforcing hold points is the mechanism by which a buyer retains control of quality in someone else's factory.
Which documents does itmad review before manufacture?
itmad reviews the inspection and test plan, welding documentation (WPS, PQR and welding instructions), welder and NDT personnel qualifications, and the heat treatment, NDT, painting and coating, pressure test and packing procedures. Errors caught in procedures cost nothing to correct, while the same errors found in finished product mean rework, rejection or a delivered defect.
When is a resident shop inspector used?
Where order value, schedule risk or fabrication complexity justifies continuous presence, itmad places a resident engineer at the works to act as the representative of the buyer through the full build. The resident engineer reports progress and quality daily or weekly, and escalates each non-conformity when the non-conformity arises.
What does a factory audit assess?
A factory audit assesses the capability of the manufacturer before contract award or before production begins. The audit covers the welding control system against EN ISO 3834 or ASME requirements, welder and NDT personnel qualifications, production capability and capacity, the product quality control system, and the application of the standards that the order is placed against.
Does itmad use inspectors based in Malaysia?
itmad uses both Malaysia-based inspectors and a travelling team for inspection in Malaysia. itmad has worked in Malaysia for more than 10 years.