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Manufacturing Record Book

Manufacturing record book review for QA/QC teams: each weld followed from plate heat to hydrotest, its dates read together, and a release held until two people sign.

See the demo Book a demo

Follow weld C3 from the drawing to the hold ↓

The problem

A ticked inspection plan line proves a page exists, and nothing more

The fabricator's record book arrives as one file of thousands of pages: certificates, weld maps, procedures, welder qualifications, continuity logs, NDE reports, heat treatment charts, the hydrotest. The QA/QC engineer works down the inspection and test plan and ticks each line when its pages are there.

What the tick cannot show is whether one weld's records match across those pages. The weld map gives a date and a welder. The continuity log gives that welder's last use of the process. Read apart, both pages pass. Read together, the welder's qualification had lapsed before the weld was made.

Built forQA/QC engineersLead inspectorsInspection coordinatorsProject engineers

The Problem Today

A ticked inspection plan line proves a page exists. It does not prove each weld's records agree.

6 months: without a process, and a welder's qualification for it lapses published
129 h: to read 3,870 pages once, at an assumed 2 minutes a page our estimate

Checked by hand today

Certs
Weld maps
Welder logs
NDE

Each page passes aloneDates on different pages are never read together
Lapses hide in logsA welder's last use of a process sits in a long log

The Solution

Split by sectionOne file placed into the supplier's own index sections
Walk every weldHeat, certificate, weld map, procedure, welder, test: eight links a weld
Read the dates togetherEach weld date against the welder's last use of that process
Query, then two peopleA cited supplier query; the engineer proposes, the inspector signs

Built-in controls

Inspector opens the pages before signing
Nobody signs what they proposed
A clean test never closes a qualification gap

What You Get

A vessel ships on a book whose welds were each followed through their records, with the pages behind every ruling.

Queries that cite pagesWhat differs, on which page, and what would close it
A release that waitsHolding takes one person; releasing takes two
Records ready to hand overWeld records and indexed pages staged for the data systems

Day two of the review clock

One manufacturing record book, 58 welds, and a welder whose window had closed

A replacement high-pressure separator for a hydrocracker sits finished at the fabricator. Its record book came in through the supplier portal two days ago, and the release note is due on the tenth working day.

demoVessel, fabricator, welders, people and dates are sample data.

01First night, 02:10 to 02:52
464 links walked in one night: 54 welds complete, 3 missing a record, 1 broken
Weld walker
Step by step, the replay shows the overnight walk. First, 3,870 pages went into 17 sections, with two faint pages held. Next, 17 of 24 ITP lines were matched to their pages. Then 14 heats were followed, six welders' logs were read in full, and each weld was walked across eight records. Five supplier queries came out of it, drafted for people to rule on.
02Day two, morning
Five findings stop the release, and C3 is the one broken chain
QA/QC engineer
All 58 welds appear as beads on the vessel drawing: long seams, circumferential seams, boot, nozzles and attachments, colored by what the agents found. The banner says plainly that five findings stop the release, and points to C3 first. The screen also says why a running vessel is being built again: it waits in storage in case inspection finds cracking beyond repair.
0310:02
C3 is broken at the welder link, and the dates say why
QA/QC engineer
Opening C3 lays out its eight links: plate heat, certificate, weld map, procedure, welder, NDE, heat treatment, hydrotest. Seven hold. The welder link reads broken: WD-117 is qualified for submerged arc welding, but his last use of it came more than six months before C3, so the window closed 15 days before the weld. Each cited page is a click away.
0410:03
The welder continuity log: after the last submerged arc entry, only stick
QA/QC engineer
He reads the log page himself. It is carried forward from earlier sheets, one line per use of a process with the job number. The last submerged arc entry is highlighted. Every entry after it, up to the weld, is shielded metal arc. Later welding in another process does not keep the first one alive.
0510:04
The weld map puts C3 on that welder, with that process, on that date
QA/QC engineer
Sheet 3 of the as-built weld map lists the circumferential seams with members, heat numbers, process, procedure, welder and date. C3's welder and date are highlighted. On its own the page is correct. It only becomes a finding when its date is read beside the log on page 1,447 and the qualification on page 1,402.
0610:06
He agrees with the finding only after opening its three pages
QA/QC engineer
The finding card shows what the agents found overnight, the three pages they read together, and the draft query to the fabricator. Agreeing is refused until the engineer has opened the cited pages; he has, and the card now reads ruled, with his name. The query asks for a dated production weld record that shows the process in use inside the window.
0710:07
One voice to the supplier: the query goes out with a five-day clock
Vendor inspection coordinator
The vendor inspection coordinator is the only channel to suppliers. She sends the query through the supplier portal, and the card records who sent it and when the answer is due, five working days on. The engineer drafted nothing himself; he ruled, and the coordinator sent.
0810:09
The release note is held: nothing ships until a person lifts it
QA/QC engineer
He holds release note IRN-6118-01 with the reason that welder qualification is not shown, in his own words. The note lists what stops the release: five open findings, each with its query. One person can hold; a release needs two. The book moves from in review to held at release, and the queue counts change with it.
0910:15
Six welders on one timeline, and only one weld falls outside a window
QA/QC engineer
The welders screen draws each welder's processes as bars with every weld as a dot and the six-month window behind it. Five welders cover every weld they made on this vessel. One row carries a red mark: WD-117's submerged arc weld on C3, after the window closed. The lapse touches one weld on this vessel.

The other four findings in the same book

Each one passed its inspection plan line, and each has its own query.

A weld map with the wrong heat

The plate is right on its certificate and transfer record; the weld map gives another heat number

A repair after the furnace

A boot nozzle rewelded after heat treatment, with no later chart in the book

A report that lists one weld twice

An ultrasonic report covers one flange twice and its neighbor not at all

Pages too faint to read

Two hardness pages held, with a clean copy asked for

demoSample data, from the working solution.

Around the book

Sections, ITP review, heats and the queue behind one MRB review

Screens the engineer, the inspector and the auditor use on the same book.

Manufacturer data book intake: 17 index sections with page ranges and counts, and two unreadable pages held — **The record book as received**3,870 pages split by the supplier's own index into 17 sections, every page placed, none dropped or reordered, and two faint pages held.

Inspection and test plan review: ITP lines with evidence pages, matched or open with the query that holds them — **Inspection and test plan, line by line**24 ITP lines, each with the pages that prove it. A line is never ticked on a page that does not name the item.

Plates and forgings with certificate heat, transfer record, weld map heat, HIC result and the welds each feeds — **Materials and heat numbers**Plates and forgings with their certificate heat, transfer record and weld map. One plate's heat disagrees with the weld map.

Queue of record books in review by class, supplier, pages and clock, with what the agents found in each — **Books in review**63 in review, 11 held at release, 58 returned, 286 accepted. Each with its class, supplier, pages, clock and what the agents found.

Audit trail of a record book review: pages opened, the finding agreed, the query sent and the release note held — **Audit trail**Each act by a person or an agent, and each page a person opened, in order. An auditor exports the evidence pack here.

Settings for record book review: welder continuity window, sample sizes, confidence line and release punch category — **Settings**The continuity window, release sample sizes, the reading line and the punch category that stops a release. Changes are proposed and then signed.

demoSample data, from the working solution.

The agents

Book splitter to query writer: what each one leaves to people

They split, match, trace, check and draft.

Book splitter

Splits the book by section against the supplier's index.

Keeps each page in its place and order
Holds a faint page rather than guess

ITP matcher

Matches each plan line to the pages that prove it.

Never ticks a line on a page that does not name the item

Heat tracer

Follows each heat from certificate to transfer record to weld map.

Never assumes a heat number

Qualification checker

Reads each welder's whole log against each weld date.

Never treats later welding as reviving a lapse

Weld walker

Walks every weld across its eight records.

Never marks a chain complete with a link missing

Query writer

Drafts each supplier query with the pages it rests on.

Sends nothing; the coordinator sends

What only the engineer and the lead inspector decide

Agents find and cite. People rule, hold and sign.

Whether a finding standsThe QA/QC engineer opens its pages and agrees or disagrees with a reason.

Closing a findingThe engineer proposes; the lead inspector opens the pages herself and signs, and a proposer cannot be the signer.

Releasing the vesselTwo people, after a sample of chains the agents passed is drawn and opened.

Whether a clean hydrotest covers a lapseIt does not. A qualification gap needs its own record.

What QA/QC engineers ask about manufacturing record book review

What is a manufacturing record book?

A manufacturing record book, or MRB, is the fabricator's file of records for a piece of equipment: material certificates, weld maps, procedures, welder qualifications, NDE, heat treatment and test records. This solution reads the manufacturing record book weld by weld, reads the dates together and drafts cited queries before release.

Is this the same as a manufacturer data book or final documentation dossier?

Yes, those are other names for the same file. The book is split by the supplier's own index, so it works with whatever layout the fabricator uses.

How does it check welder qualification?

The qualification checker reads each welder's whole continuity log and every gap between uses of a process, then lays each weld date against the window. A lapse is a finding with the three pages that show it.

Does it replace the inspection and test plan review?

No. The ITP matcher ties each plan line to the pages that prove it, and the weld walk adds what the plan cannot: whether each weld's records agree.

Who talks to the fabricator?

Only the vendor inspection coordinator. Agents draft each query with its pages; she sends it and logs the reply.

Can an agent release a vessel?

No. Holding takes one person, and releasing takes two: the engineer proposes and the lead inspector signs after opening a sample of the chains the agents passed.

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