Case Study 1

You are assigned to handle a project that is already gained a tender from a client (JAKSA PERMAI (M) SDN BHD). The project worth RM30 millions and must be completed within 2 years. Your team consist of several Sub-Contractors, Welding Coordinators and Welders. The inspectors include Welding Inspector, NDT Inspectors (RT, UT, MT, PT, and Visual) will assist you in the project given. As a QA Manager, you need to plan, implement and control the project economically without compromise with the quality aspects. The economic aspects must be taken into account so that the wastage or loss can be avoided and the maximum of profits can be gained.

One of task that should be implemented is to ensure the cost calculated can be minimised. You also need to ensure that costs of each welding processes, tests and inspections in detailed by comparison each of them. Besides, the suitability of the types of joints or joint design should also be carefully identified. Therefore, it is crucial to implement to following tasks for ensuring that the required project may achieve the objectives of your company which are minimizing the cost and maximizing the profits of the respective project.

From the above case study, answer the following questions by hand writing.

1. Compare briefly the radiographic testing (RT) and ultrasonic testing (UT) in terms of their flaw (defect) detectability, economy and safety.

(10 marks, C3)

2. Compare the Cost of Manual Shielded Metal Arc Welding vs. Semiautomatic and Automatic Gas Metal Arc Welding for Making a 1/4 in. (6.4 mm) Fillet Weld.

(20 marks, C3)

3. Compare the cost of the SMAW, GMAW, FCAW, and Submerged Arc Welding of 1/2 in. (12.7 mm) Fillet Weld in the Horizontal Position.