Manufacturing Surveillance

What Is Surveillance?

Manufacturing surveillance is the on-site monitoring that the production stages of the product are carried out in accordance with the specification and the inspection and test plan (ITP). The surveyor attends the hold and witness points, observes process parameters and verifies the records.

Why Is It Done?

The aim is to observe, as they happen, those process steps that cannot be verified once the product is finished. For special processes such as welding, heat treatment and coating, this is the only real assurance of quality.

Who Requests It?

EPC contractors and project owners
Buyers of pressure equipment and pipelines
Energy and petrochemical investors
Purchasers of critical structural fabrication
Industrial organizations sourcing internationally

Scope of Surveillance

Presence at ITP hold and witness points
Material acceptance control and traceability marking
Welding parameters, preheat, and interpass temperature
Records of heat treatment cycles
Dimensional control and assembly tolerances
Witnessing of non-destructive testing and its reports
Witnessing of pressure tests and functional tests
Surface preparation and coating application
Nonconformity records and corrective action tracking
Final inspection and documentation package review

Related Standards

ISO/IEC 17020
ISO 10005
EN 10204
ISO 3834
ISO 9712

Method and Equipment

Dimensional measurement instruments
Access to contact thermometer and temperature records
Coating-thickness gauge
Photographic recording equipment
Weld seam gauges

Surveillance Process

1Defining Scope and CriteriaThe order specification, the inspection and test plan (ITP), the delivery schedule and the reporting frequency are agreed with the buyer.
2Supplier AssessmentThe supplier's quality system, capacity, subcontractors and past performance are reviewed; a risk level is assigned.
3Surveillance PlanBased on the risk level, the frequency of site visits, the hold and witness points and the reporting calendar are planned.
4On-site SurveillanceThe surveyor attends the works during manufacturing, performing document checks, process observation and witnessing of inspections.
5Progress and Schedule MonitoringProgress against the plan is monitored; the risk of delay is identified early and reported to the buyer.
6Managing NonconformitiesDeviations found are reported, corrective action is requested and its close-out is followed up.
7Shipment Release and Close-outThe final inspection and the documentation package are checked; release for shipment is granted and a close-out report is issued.

Surveillance Report

Details of the survey company, the surveyor and the buyer
References to the order, the specification and the ITP
Date of the visit and scope of the surveillance
Findings of the document check
Stage of manufacture and progress status
Inspections and tests witnessed
Nonconformities found and the status of corrective action
Assessment of the schedule and the risk of delay
Photographic records
Recommendations for the next surveillance visit
Specification and ITP references
Hold/witness points visited
Witnessed tests and their results
Process parameter observations
Nonconformities and closure status
Shipping release statement

Limits of the Report

Surveillance does not remove the supplier's responsibility and does not assume liability for the quality of manufacture. The surveyor reports what was observed during the periods spent on site; production during the periods of absence falls outside the report. A surveillance report is neither an acceptance statement nor a guarantee; the inspection and acceptance provisions of the contract remain in force.

Accreditation

Surveillance activities are carried out under ISO/IEC 17020, which requires the impartiality of the survey body, the competence of its personnel and the validity of the survey methods. The impartiality rule is decisive: a survey body may not be a party to the trade in, or the manufacture of, the goods it surveys. EUROLAB holds internationally recognised accreditation under ISO/IEC 17020, granted by accreditation bodies that are signatories to the ILAC mutual recognition arrangement; because accredited scope is defined per type of surveillance, it is confirmed in writing at the quotation stage.

Scope and authorisations

Related Surveillance Services

Frequently Asked Questions

What is a special process, and why does it require surveillance?

These are processes whose outcome cannot be fully verified by subsequent inspection: welding, heat treatment, coating, bonding, and the like. Looking at the finished product does not reveal whether the process was performed correctly; therefore, the process itself must be observed while it is being carried out.

Does surveillance reduce the supplier's responsibility?

No, it does not. The surveyor observes and reports on behalf of the buyer; the supplier remains responsible for the quality of manufacturing and compliance with the contract. A surveillance report is not a statement of acceptance.

Is the surveyor present on site continuously?

This depends on the level of surveillance. On critical projects, continuous (resident) surveillance is applied; on others, visits are made at specific hold points. Manufacturing carried out while the surveyor is not present falls outside the scope of the report, and this is clearly stated in the report.

How is the independence of the surveillance body ensured?

Surveillance is carried out under ISO/IEC 17020, which requires impartiality and the prevention of conflicts of interest. The surveillance body cannot be a party to the design or production of the manufacturing it surveys.