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This paper provides a real case study in regard to controlling the welding repair rate and NDT backlog in a company mega-project assigned to a new contractor. This case study shows the improvements in both KPIs, through the utilization of various quality and improvement tools, such as root cause analysis (Fishbone and Pareto chart), brainstorming, and PDCA cycle. The collaborative efforts between the client and contractor, including the welding and NDT subcontractors, resulted in reducing the WRR from 11.04% to below 5% (the set KPI). The NDT backlog was also controlled and reduced from 2500 joints to below 600 joints (less than one week production).
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Besides economic considerations, ecological and regulatory factors play an increasingly decisive role nowadays in the formulation of innovative coating systems. It is therefore no surprise that the call for zinc-free anti-corrosive pigments or those that do not require labeling has steadily increased in recent years. Zinc-free technology is not new. Numerous pigments based on calcium, strontium, aluminum, and magnesium phosphate have been available on the market for a long time.
The study objective was to evaluate the cost effectiveness and feasibility of a paint system warranty from a coatings manufacturer for a specified coating to be applied over steel with minimum surface preparation (without removing completely the existing coating or tightly adhering rust) and to evaluate the coating performance at the conclusion of the warranty period.