A piping fabrication company developed quality plans in Word documents customised for each project. Plans were rarely updated after initial creation, and inspection points were missed because there was no systematic tracking. When a client rejected a completed spool piece due to a missed hold point inspection, the rework cost exceeded the original fabrication value.
PMG QA Plans digitised quality planning with structured inspection and test plans linked to work packages. Each inspection point was defined with acceptance criteria, responsible inspector, and hold/witness/review classification. Progress tracking ensured no inspection point was bypassed. The plan dashboard showed inspection completion status and upcoming hold points across all active work.
Missed inspection points dropped to zero with systematic tracking and hold point enforcement. Quality plan compliance improved from 65% to 98%. Client quality audit scores improved by 30% with documented, tracked inspection records. The company eliminated rework costs associated with missed inspections, estimated at 5% of annual fabrication revenue.