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Simulated workplace
Scenario · Quality and Safety

Inspect the stainless hopper welds and control non-conformances

You are the Welding Inspector in the Quality and Safety team.

Advanced3 to 4 hours7 tasks
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The situation

What has happened

The Bellbrook Foods stainless steel ingredient hopper under job card JC-26-0398 is complete and awaiting inspection. It was welded in 316 grade sheet with the gas tungsten arc process to WPS-04 and must meet the customer's food grade finish specification: full penetration on product contact seams, no crevices, welds ground and polished on the product side and passivated. The customer's food safety consultant visits on Thursday and the job has already exceeded its quoted hours. Rohan Pillai wants a documented visual inspection, a check of the weld record and traceability, and a non-conformance raised and dispositioned for anything that does not meet the requirements before the customer arrives.

Your brief. Carry out and record a visual weld inspection of the hopper against the welding procedure and the customer specification, verify the weld record and material traceability, raise non-conformance reports for any defects, agree the disposition with the Quality and Safety Manager and produce the inspection report that releases or holds the job.
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Tasks

Deliverables

  • Weld record and traceability verification checklist
  • Visual inspection report with findings by location
  • Non-conformance reports with agreed dispositions
  • Updated job card JC-26-0398

Documents to use

Systems to use

Job Card Register

Tracks every fabrication, machining and maintenance job from quote to close-out with customer, drawing, hours and status.

Materials and Certificate Register

Records receipts of steel, consumables and spares with purchase order, heat number, certificate reference and the job each item was issued to.

Training and Competency Matrix

Holds each worker's licences, welder qualifications, inductions and training with expiry dates so supervisors can allocate work to people who are current.

WHS Incident and Hazard Register

Records injuries, near misses, hazards and environmental events at every site with investigation status and corrective actions.

For trainers and assessors

Units of competency

Current on training.gov.au for the Manufacturing and Engineering as at 10 September 2026.

MEM05077Perform welding inspection
MEM05014Monitor quality of production welding/fabrications
MEM15004Perform inspection
MEM05065Maintain weld records
MEM16010Write reports

Qualifications

MEM50119Diploma of Engineering - Advanced Trade
MEM40119Certificate IV in Engineering
Assessor notes

What to look for

Evidence guide

Look for inspection findings expressed in terms of the acceptance criteria (undercut, lack of fusion, porosity, crevices, surface finish) with locations a welder could find, a clear link from each non-conformance to a disposition, and a release decision the student can defend to the customer. The traceability check should identify whether every heat number on the weld record appears in the materials register. Report writing must be factual and free of blame.

The student's evidence summary lists every record they created or changed in the systems named above, their notes and the tasks they ticked. Verify it against the deliverables and your own assessment tool.