When a tube bundle does not fit and seat on the tube sheet of a Heat Exchanger during an urgent shutdown maintenance work that has to be finished in a week, when an Emergency Shutdown valve leaks during commissioning or there is a crack of an RTR pipe at the time of final hydrostatic testing,  you realize what a disaster it is! This is when you feel it is an unpardonable mistake committed by the inspector engaged by a TPI which grossly failed the trust and confidence the customer placed on them. What a serious disruption! The entire purpose of a third-party inspection is lost which was meant to prevent these surprises. The client wants the piece of item fit for its intended purpose and works fine. This is the value they want for the cost they pay in the form of service charges. This is when you realize what is the importance of a credible body and reliable inspection. The cost paid by the customer is really negligible for the value the client could get but great money for a service company offering the inspection. What could be the cost of this disruption? could be a few hundred thousand or over a million dollars? what could be the cost of the inspection? What could be the ratio? Could be 0.000X %  or less . It could be a trivial cost considering the cost of the critical items or the overall project in most cases

How did it start?

The need for Safer Transport and reliable shipment of Goods by Ships lead to demand for Safer and reliable ships. Safer ships are better quality ships. Better Quality ships are of better design, controlled manufacturing process, and better machinery, equipment, and material that are continuously monitored during the entire life cycle. This led to the emergence of Ship Classification societies and their need to serve ships globally  as the ship sails needed them to have a global presence. There is no doubt these ship classification societies and their classification rules help develop better standards even for engineering and industrial products that ship builders needed to build the ship. ultimately a ship is a complex industrial product of great technology. This led to the development of better quality industrial products.

On the other hand, the need for precious and accurate arms and weapons was growing among powerful militaries in the world. This created demand for reliable products of superior quality- MIL standards were developed.  with the advancement in science and technology, with the industrial development, National international standards were being developed for industries.  BSI, ANSI, ASME, and API standards were established and started becoming industry standards for products and services and management standards. International Organization for Standardization, ISO was formed to develop international standards by consensus of global communities and nations to ease trade barriers and develop common standards as the nations were getting more globally connected with trade and business

What Values Could TPI offer?

The joy of cheaper price vanishes the moment you discover a problem with what you have purchased ! It’s all about the value that we gain that matters for the cost we pay.  Do we want a surprise when the items or products you buy arrive with a Fault or a Non-conformity? Remember Cheaper products may be attractive but can not be the best. We really need cost-effective reliable products and services. The global Presence of TPIs, their knowledge base, and their reliable network can be utilized to the best advantage of the Customers to offer a value-added cost-effective service to the advantage of buyers worldwide. The TPIs can add this great value and this is a multi-billion dollar business. Many TPIs served international clients for more than centuries

What is going wrong? Where did things start to decline?

Let us look at the root cause/s

Market Competition and Gradual decline in Price hit the bottom line. Customers on many occasions demand the cheapest offer however expecting the most reliable and credible service possibly downplaying the fact that Cheapest can not be the Best. however, the competition, solely based on price forced the TPIs to look for cheaper personnel. Qualified, competent, and capable Inspection People found it less attractive and gradually changed professions and were replaced by less qualified personnel.  technicians at many instances-This led to a gradual decline in the Quality of Inspection Personnel and the quality of services offered by the TPIs

Lack of Training. Competence-building measures were abandoned by most TPIs,  including the most leading ones as they found it was more economical to hire nonexclusive freelance resources than retain own exclusive resources those could be trained to build competence, indoctrinate with organizational policies, code of ethics, and greater organizational attachment and belonging.

Use of Self employed Freelance inspection People with a Lack of Commitment to a particular organization or familiarity with TPIs procedures led to several errors and omissions, With the growing need to use freelance resources, organizations started sourcing cheaper inspection people, in many instances without a true assessment of their knowledge skill, commitment, and experience. Again a Cheaper Freelance resource can not be expected to be the most reliable one and this is where the problem aggravated to a worse level. I do not want to mean that freelance inspection people are less capable and less committed. There are great guys around and we need to identify them, train them if needed, and pay them decently and on time. This gives a win-win situation for all. This is where all gains- The customers, The TPIs, the Inspection resources who are self-employed. The problem started when there is a lack of capable self-employed freelance resources in the market, and TPIs now do not have their own resources and they need to engage whoever is available on short notice, Cheaper, make him or her travel a long distance at a short notice who is not prepared well for the scope work, at many instances unaware of their clients, clients’ clients, the manufacturer. All of these make a favorable condition for mistakes and the sufferers are the TPIs and the client and gradually the inspectors because of their performance. All looses!

What can Customers do to save the TPIs for their own benefit? 

Demand the best quality service and pay a decent and fair price. Let the TPIs make some profit  as service providers to attract capable and competent professionals , develop Capabilities locally, grow globally to serve the custmers better with loyalty and greater commitment

Evaluate and re-evaluate fairly and objectively. Develop a long-term relationship for mutual benefit. Help the suppliers /TPIs improve their quality of service

Communicate problems and encourage improvement

The reward for good work-appreciate good performance

Held the TPI management accountable for negligence, and poor quality services. willful or otherwise

What can TCB offer? 

Institute an organization-wide Training program to develop Capable Inspection People. We developed program that industry needs worldwide. Our Certificated Quality Verification Professional course is the response to most problems  to develop competent  inspection personnel for reliable inspection with consistent level of repeatability and reproducibility

We recommend the following training programs offered by TCB:

QMS Foundation course

CQI/IRCA Approved QMS ISO 9001:2015 Lead Auditor Course

Certificated Quality Verification Professionals -CQVP Part 1 and Part 2

Awarness Program on ISO 17025:2017 Standard, a standard assessing competence of Test and Calibration laboratory

Awarness Program on ISO 17020:2012 Standard, a standard assessing competence of Bodies performing of Inspection

Awareness on Six Sigma

Awareness on Measurement Uncertainty