Inspection is where fabrication finds out what cutting, welding and coating did. A pass/fail count and an NCR total tell you how much you lost; they do not tell you that this month’s hydrotest failures are the same weld procedure that failed last month. On pipe the stakes rise — a hydrotest fail is a cut-out and re-weld, and the repair loop is the cost.
Your ERP records the result: passed, rejected, NCR raised.
It won’t tell you this is the third batch running that failed on the same joint detail, or how many repair loops it took to clear.
Why the gap existsWhere the losses hide
An NCR count is a total. A recurring defect is a cause — and causes are what you can act on.
Weld defects, dimensional faults and coating failures each trace to a different stage. Counted together they average into a number; grouped by family and traced back, they point at the procedure or the shift that keeps producing them.
A hydrotest fail is expensive — a cut-out, a re-weld and a re-test. The failures cluster by joint detail and procedure, and reading them that way is the difference between fixing a WPS and re-testing forever.
A joint that fails, is repaired and fails again has been through three cycles booked as one. The loop is invisible unless each pass is logged against the joint.
The join
Same run, same clock, same asset — three streams that only mean something together.
Inspection outcome, NCRs raised, hydrotest pass/fail, disposition.
The defect and hydrotest result tagged by cause against the joint, weld procedure and batch — and NDT results tied to the same record.
NCRs and hydrotest failures grouped by cause and traced to the procedure that produced them, with the repair loop counted — instead of a total that resets every month.
What Munshi surfaces
Teal is normal, maroon is flagged. Illustrative data.
Grouped by cause at the bench, not lumped into a single NCR count.
Average repair passes per failed joint. A rising line is a procedure that has not been fixed.
When an outcome moves and a signal moves with it, Munshi shows both and says they moved together. It does not tell you one caused the other. The operator confirms the cause, and the confirmed cause is written back to that asset’s register — so the pattern is already named the next time it appears.
Related stages
The coat that went on, and the part of it that went on twice.
Cranes, hydraulic packs, compressors, extraction and utilities.
Get started
See this on your own line.
Bring a month you already understand. The useful test is whether Munshi finds what you already know — and then what you didn’t.