Shipyard’s Quality System involvement in the classification process at the new construction phase

The Quality Management System (QMS) of a shipyard is considered as a dynamic system which ameliorates in parallel with the evolution of the shipyard, having as purpose to optimize construction performance, to reduce risks, costs and time. The interaction and participation with external organizations play an important role in the cycle processes of maintenance and improvement of the Shipyard QMS. Bureau Veritas (BV) being a Ship Classification Society, contributes to the certification process through compliance with regard to BV technical rules and statutory requirements for each ship configuration. This paper illustrates the importance of the interaction between shipyard and class society starting at early design phase until delivery of the ship. Process described is based on specifics BV rules and New Building procedures which are continuously updated based on new international regulations, experiences, researches and developments. The pre-project process is founded on the definition of the scope of work, a thorough review of the contract, familiarization with the shipyard’s facilities, and the definition and agreement of all activities to be addressed throughout the entire construction. The construction process unfolds according to the agreements outlined during the pre-project phase. This part is specifically concentrated on Design Review (drawings and documents), Documentation System (procedures and methods), the Verification System (monitoring, control & reporting, witnessing, inspection & test), and the Management System (but not limited to); all of which are managed under a specific BV IT Tool. The result of all this is an efficient classification process that ensures ships remain safe, compliant, efficient, and environmentally friendly throughout their operating life.

The Quality Management System in a shipyard has the primary objective of achieving a zero-defect rate through the definition of processes, including controls, records, validations, measurements, analysis, monitoring, and improvements.This makes the QMS an integral part of a strategy to enhance market position and customer satisfaction.
The quality process must be established using standard procedures and methods, which need to be consistently followed throughout the entire process of the physical product, such as the construction of the ship.Such a process must include targets related to the limits of acceptance for each specific process.The system's control involves documentation such as construction procedures, fabrication drawings, technical analysis reports, weight control reports, subcontractor documents, and as-built documentation, among others.
Quality records encompass contract reviews, drawings, procedures, inspection and test records, verification records, pre-commissioning, calibration records, material and equipment certificates, non-conformities, commissioning dossiers, among others.
The validation process in production includes monitoring or verification of welder certification, welding procedures, welding machines, welding consumables, NDT operator certification, NDT plan, and NDT reports, among others.
Measurement analysis and improvement aim to demonstrate the conformity of the quality management system and the quality of the product.This involves a quality audit plan, control of non-conformities, management reporting, corrective actions necessary to improve the system, and client feedback.This article aims to emphasize the importance of defining, planning, and reaching agreements at an early stage by integrating all the mentioned activities and ensuring continuous follow-up within cross-functional processes during construction.This approach is based on the extensive knowledge and experience in high-quality standards gained since 1828 in the shipping industry.
The classification process involves the definition of rules, guidance notes, and other relevant documents for a ship, taking into account its structure, material, machinery, equipment, and other components contributing to its definition.This process includes the review of plans/ documents, calculations, surveys, checks, verification, validations, witnessing, and tests intended to demonstrate that the ship complies with the BV rules and applicable statutory requirements.
For Bureau Veritas, the key to achieving the classification process in new construction is to identify and agree with the client on the scope of work.It is essential to possess a comprehensive understanding of the shipyard's capacities and to reach consensus on every activity to be followed during the construction, as illustrated in Fig. 1.

Definition of marks and notations
The class notations establish the framework upon which the ship's classification is founded.They reference specific rule requirements that must be adhered to for their assignment.Class notations are specifically allocated based on the ship's type, service, operating area, and other criteria outlined by the interested party when applying for classification.
The types of class notations to be assigned to a ship are as follows: • Class Symbol: Indicates the degree of compliance of the ship with the rule requirements concerning its construction and maintenance.The second part contains specific activities of the hull construction survey.The purpose is to discuss in detail with the Shipyard QA-QC team, requirements and the principle of Patrol surveys performance.Each item mentioned below need to be discussed including survey requirement and survey method, BV rules, statutory requirements (if any), relevant references, documentation available to the surveyor during the construction, documentation for the ship construction file, specific activities and BV proposals for the project as far as applicable.All VPM users are provided with general information about the project, stakeholders, the follow-up of plan approval assessments, the follow-up of equipment and material certifi cation processes, the follow-up of construction surveys, submission of drawings, and the option to reply online to comments issued during the plan approval process or construction survey, as illustrated in Fig. 2.
Th e tool it is divided in four main parts: Additionally, some parallel projects are created in the same VPM tool based on material and equipment certifi cations as identifi ed at the Kickoff Meeting (KoM).Th ese projects are linked to the main ship project to provide a complete overview of the certifi cation process.Th e tool allows users to see the status of the process and whether any comments need to be addressed by plan approval surveyors, BVN surveyors, yard surveyors, or from the client side.
Regarding inspections at the yard, a tree is created in VPM based on the marks and notations defi ned, and data input available in the system at the signature of Classifi cation Request.It can be modifi ed if needed based on the complexity of the project or other factors.Th is tree lists every scheduled and unscheduled item to be inspected, trials to be performed, and quality documentation to be recorded.
VPM includes diff erent spaces to maintain traceability of the main items to be monitored, verifi ed, validated, witnessed, inspected and tested as far as agreed during the pre-project process at KoM.Moreover, VPM inform BV NC Team when quality documentation is missing prior to specifi c milestone dates.Missing documentation may be linked but not limited to shipyard review record, Kick off meeting, welding procedures specifi cation, welding qualifi cations, NDT records, patrol plan agreed, sea/river quay trials procedure, reminders to client about pending comments, etc.
Prior to delivery of the project, two last process are performed by the BV Project Leader and validated by the new Construction local manager.Process consist to review that all required drawings have been received and reviewed, all material and equipment certifi cates are received, all quality documentation is received and none pending comments.
In case of outstanding point remains, agreed solution between client and BV is to be specifi ed.Such process allow to go through the following phase, Issuance of Classifi cation Certifi cate.
With proper recommendation or memoranda (if applicable) in accordance with those agreement indicated during the fi rst phase.

Shipyard control of qualified welders for shipyard workers and/or subcontracted workers
4. Annexes (as applicable):a.Listof statutory attestations/ certificates b.List of statutory documents without survey (Stability examination, attestations) 1. Construction facilities: identification a. Building Berth or Dock (name, dimensions, capacity (GT), cranes) b.Outfitting quays (name, dimensions, berthing capacity (GT), cranes) c.Main fabrication and erection facilities i. Marking and cutting of steel plates ii.Marking and cutting of section bar iii.One-side automatic welding machine iv.Fillet welding machine gravity or automatic and percentage of automatization for this last one v.Painting equipment vi.Vertical automatic welding machine vii.Other main fabrication facilities 2. 6.Control system of Non-Destructive Examinations (NDE) a. Number of NDE supervisor in shipyard Ship Science & Technology -Vol.17 -n.°34 -(9-16) January 2024 -Cartagena (Colombia) Ship Science & Technology -Vol.17 -n.°34 -(9-16) January 2024 -Cartagena (Colombia) Shipyard's Quality System involvement in the classification process at the new construction phase Suárez Ship Science & Technology -Vol.17 -n.°34 -(9-16) January 2024 -Cartagena (Colombia)