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Quality System Manual

DOC. NO. :QSM : 001 Issue : 03 Rev. No. 00 Section : 0 Date : 11.10.10 Page: 1 of 1

TITLE PAGE

QUALITY SYSTEM MANUAL

Ref : ISO/TS 16949:2009

ADDRESS UNIT-I

M&M MACHINE CRAFT (P) LTD. Darbaripur Hasanpur Road,

Vill. Khirki Daula (Behind Haldiram Food Complex) 46 K.M. Stone, Delhi Jaipur Highway

Gurgaon 122004 (HR.)

TELEPHONE & FAX NO. 0124-2370835, 2370836, 2370837 FAX-012402378838

ADDRESS UNIT-II

M&M MACHINE CRAFT (P) LTD 57-58 K.M. Stone, Delhi-Jaipur Highway,

Binola Industrial Area,Bhorakalayan,Gurgaon-122413 E-Mail

[email protected] [email protected]

Website www.mmmcpl.com

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INDEX

Sec. No.

Main Clause

Sub Clause Description No. of Pages

Page NO.

0 TITLE PAGE 1 1 1 INDEX 3 2 to 5 1 Approval and Revision Status 1 6 2 Scope 1 7 3 Application 1 8 4 Amendment Procedure 1 9 5 Distribution 1 10 6 Definition/Abbreviations 1 11 2 Company Introduction 1 12 2 Range of Products 1 13 9 4 4.1 & 4.1.1 Q.M.S General Requirements &

Supplemental 1

14 9 4 4.2.2 Documentation Requirements 1 15 9 4 4.2.3 Control of Documents 1 16 9 4 4.2.3.1 Engineering Specifications 1 17 9 4 4.2.4 Control of Records 1 18 9 4 4.2.4.1 Record Retention 1 19 10 5 5.1 Management Responsibility &

Commitment 1

20 10 5 5.1.1 Process Efficiency 1 21 10 5 5.2 Customer Focus 1 22 10 5 5.3 Quality Policy 1 23 10 5 5.4.1 Quality Objectives 1 24 10 5 5.4.1.1 Quality Objectives - Supplemental 1 25 10 5 5.4.2 Quality Management System Planning 1 26 10 5 5.5.1 Responsibility, Authority &

Communication 1

27 10 5 Organization Chart 1 28 10 5 5.5.1.1 Responsibility for Quality 1 29 10 Responsibility & Authority 20 30 to 49 10 5 5.5.2 Management Representative 1 50 10 5 5.5.2.1 Customer Representative 1 51 10 5 5.5.3 Internal Communication 1 52 10 5 5.6,5.6.1,5.6.2,

& 5.6.3 Management Review 1 53

10 5 5.6.1.1 Quality Management System Performance

1 54

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TABLE OF CONTENTS

Sec. No.

Main Clause


Page NO.

10 5 5.6.2.1 Review input - Supplemental 1 55 11 6 6.1,6.2,6.2.1,6.2.2,6.3

&6.4 Resource Management 1

56 11 6 6.2.2.2,6.2.2.3 &

6.2.2.4 Training, Training on the Job & Employee Motivation and Empowerment

1

57 11 6 6.3.1 Plant, Facility and Equipment

Planning 1

58 11 6 6.3.2 Contingency Plans 1 59 11 6 6.4.1 Personnel Safety to Achieve Product

Quality 1

60 11 6 6.4.2 Cleanliness of Premises 1 61 12 7 7.1 Planning of Product Realization 1 62 12 7 7.1.1 Planning of Products Realization -

Supplemental 1

63 12 7 7.1.2 Acceptance Criteria 1 64 12 7 7.1.3 Confidentiality 1 65 12 7 7.1.4 Change Control 1 66 12 7 7.1.2 & 7.2.2 Customer Related Process 1 67 12 7 7.2.1.1 Customer Designated Special

Characteristics 1

68 12 7 7.2.2.1 Review of Requirements related to

the Product - Supplemental 1

69 12 7 7.2.2.2 Organization Manufacturing

Feasibility 1

70 12 7 7.2.3 Customer Communication 1 71 12 7 7.2.3.1 Customer Communication -

Supplemental 1

72 12 7 7.3.2.2 Manufacturing Process Design Input 1 73 12 7 7.3.2.3 Special Characteristics 1 74 12 7 7.3.3.2 Manufacturing Process Design

Output 1

75 12 7 7.3.4.1 Monitoring 1 76 12 7 7.3.6.3 Product Approval Process 1 77 12 7 7.4.1,7.4.2,7.4.3 &

7.4.3 Purchasing Process 1

78 12 7 7.4.1.1 Regulatory Conformity 1 79 12 7 7.4.1.2 Supplier Quality Management

System Development 1

80

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Quality System Manual DOC. NO. :QSM : 001 Issue : 03 Rev. No. 00 Section : 0 Date : 11.10.10 Page: 1 of 1

TABLE OF CONTENTS

Sec. No.

Main Clause


Page NO.

12 7 7.4.1.3 Customer Approved Sources 1 81 12 7 7.4.3.1 Incoming Products Quality 1 82 12 7 7.4.3.2 Supplier Monitoring 1 83 12 7 7.5.1 Control of Production Provision 1 84 12 7 7.5.1.1 Control Plan 1 85 12 7 7.5.1.2 Work Instructions 1 86 12 7 7.5.1.3 Verification of Job set-ups 1 87 12 7 7.5.1.4 Preventive and Predictive Maintenance 1 88 12 7 7.5.1.5 Management of Production Tooling 1 89 12 7 7.5.1.6 Production Scheduling 1 90 12 7 7.5.1.7 Feedback of Information from Service 1 91 12 7 7.5.2 Validation of Process & supplemental 1 92 12 7 7.5.3 Identification & Traceability 1 93 12 7 7.5.4 Customer Property 1 94 12 7 7.5.4.1 Customer Owned Production Tooling 1 95 12 7 7.5.5 Preservation of Products 1 96 12 7 7.5.5.1 Storage and Inventory 1 97 12 7 7.6 Control of Monitoring & Measuring

Equipment 1

98 12 7 7.6.1 Measurement System Analysis 1 99 12 7 7.6.2 Calibration/Verification Records 1 100 12 7 7.6.3.1 Laboratory Requirement & Internal

Laboratory 1

101 12 7 7.6.3.2 Laboratory Requirement & External

Laboratory 1

102 13 8 8.1,8.2,8.2.1,8.2.2,

8.2.3,8.2.4,8.3,8.4,8.5, 8.5.1,8.5.2,& 8.5.3

Measurement Analysis & Improvement 3 103 to 105

13 8 8.1.1 Identification of Statistical Tools 1 106 13 8 8.1.2 Knowledge of Basic Statistical Concepts 1 107 13 8 8.2.1.1 Customer Satisfaction Supplemental 1 108 13 8 8.2.2.1 Quality Management System Audit 1 109 13 8 8.2.2.2 Manufacturing Process Audit 1 110 13 8 8.2.2.3 Product Audit 1 111 13 8 8.2.2.4 Internal Audit Plans 1 112 13 8 8.2.2.5 Internal Auditor Qualification 1 113

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TABLE OF CONTENTS

Sec. No.

Main Clause


Page NO.

13 8 8.2.3.1 Monitoring and Measuring of Manufacturing Process

1 114

13 8 8.2.4.1 Layout Inspection and Functional Testing 1 115 13 8 8.2.4.2 Appearance Items 1 116 13 8 8.3.1 Control of Nonconforming Product - Supplemental 1 117 13 8 8.3.2 Control of Reworked product 1 118 13 8 8.3.3 Customer Information 1 119 13 8 8.3.4 Customer Waiver 1 120 13 8 8.4.1 Analysis and use of data 1 121 13 8 8.5.1.1 Continual Improvement of the Organization 1 122 13 8 8.5.1.2 Manufacturing Process Improvement 1 123 13 8 8.5.2.1 Problem Solving 1 124 13 8 8.5.2.2 Error Proofing 1 125 13 8 8.5.2.3 Corrective Action Impact 1 126 13 8 8.5.2.4 Rejected Products Test / Analysis 1 127 14 List of Processes (Annex A I) 2 128 - 129 Process Interaction 1 130

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Approval and Revision Status

Para Page Section Date Details of Amendments Rev. Status

Signature

Prepare By S.C.Pandey (MR)

Approved By: H.Kaushik (GM-Operations)

Issued By: S.C.Pandey(MR)

Signature Signature Signature

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Scope

Scope of Unit-I I. The manufacture of aluminium die casted and sheet metal components

II. Machining of ferrous and non ferrous components, and

III. Powder coating of non ferrous components

Scope of Unit-II The manufacture of tubular and turned components and sheet metal pressed

Components

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Application

All requirements of the international standard ISO/TS 16949:2009 applicable, except the following:

Permitted Exclusions:

Clause 7.3 (Product Design and Development) Justification for Exclusion : The company manufacturers products as per customer design,

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Amendment Procedure

1.0 Amendments

1.1 Amendments shall be made as and when required or after any review. 1.2 Amendments shall be approved by Chief Executive Officer/MR before

those are issued. 1.3 Each amendment shall be identified by alphabet from A to J. 1.4 Only the page affected shall be replaced till amendment J is reached. 1.5 After the amendment reaches J, the whole manual shall be reissued with

issue identification changes in figures e.g. 01, 02 etc. 1.6 Amendments shall be recorded in the Record Sheet as per format shown.

Para Page Section Date Details of Amendments Status Signature

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Distribution

1.1 Quality Manuals are available on the Intranet of the Company. Head of Departments/concerned personnel can read it on their computers.

1.2 Uncontrolled copies may be issued to customer with permission of CMD/ED& Chief Executive officer

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Definition/Abbreviations

P & A Personnel & Administration PUR Purchase PRD Production DES Dispatch MKT Marketing F & AC Finance & Account STR Store PDC Pressure Die Casting ENG Engineering TR Tool Room MAT Maintenance PFD Process Flow Diagram QP Quality Plan CMD Chairman & Managing Director PPC Production Planning & Control IT Information Technology BSI British Standards Institution ED & CEO Executive Director & Chief Executive Officer APQP Advanced product quality planning PPAP Production part approval process FMEA Failure Mode And Effects Analysis CP Control Plan PS Paint Shop CNC Computer Numeric Control MSA Measurement System Analysis TS Technical Specification IE Industrial Engineering

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Company Introduction

M & M Machine Craft (P) Ltd. is an ISO/TS 16949 certified company engaged in the manufacturing of engineering metal products such as Aluminium Die Casting, CNC Machined, Cut-to-length Tubes, Precision Tubular and Bright Bar Turned, Sheet Metal Components for automobiles, shock absorbers & front forks and other allied engineering industries.

The company was launched in 1988 by a small group of experienced technocrats, passionate about setting new standards of quality in the engineering metal industry. For this passionate team, M & M was a business later, first an avenue to achieve excellence in manufacturing design, management and client servicing.

Our Ultra-Modern manufacturing plant with all infrastructural facilities is strategically located at Gurgaon, only an hours drive from the National Capital New Delhi. With our production facility run and managed by a highly skilled team of professional, we are continuously striving at setting new standards of precision and reliability.

With an unrelenting commitment to excellence, we have earned immense trust and respect as a vital supply chain link to some of the automotive majors like Sunbeam Auto Ltd., Munjal Showa Ltd. Gabriel India Ltd, SKH & Technico Kogsberge automotive the leading OEM suppliers to the worlds largest motorbikes & Car manufacturer, Hero Honda & MSIL and many more.

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Range of Products

TUBULAR & TURNED COMPONENTS Metal Joints Oil Lock Collars Rebound Seat Shocker Tubes Cylinders Fork Bolts Piston Rods Oil Lock Piece Main Pipes

ALUMINIUM DIE CASTING COMPONENTS Bracket L/H Bracket R/H H.H.Upper Bracket KS P-90 Bracket SS P-90 Cover Rear L Crank Case

MACHINING OF DIE CASTED COMPONENTS Bracket L/H Bracket R/H Cylinder Head Cover Top Cylinder Head Cover L/H Cylinder Head Cover R/H Cylinder Head Cover L/H P-30 Cylinder Head Cover R/H P-30 Cover Oil Filter Rotor HH Under HH Upper Holder Step L/H Holder Step R/H Cap Water Thermostat YE-2 Cap Water Thermostat Car Cap Water Thermostat MPI Cap Water Thermostat Standard

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DOC. NO. :QSM-001 Issue : 03 Rev. No. 00 Section : 9 Date : 11.10.10 Page: 1 of 1

Q.M.S General Requirements & Supplemental

Policy: Quality management System as per requirements of ISO/TS 16949: 2009 Shall be established, documented and maintained, evaluated for effectiveness and improved through process of Continual improvement

Reference: Clause 4.1 & 4.1.1 of ISO/TS 16949:2009

Responsibility: Chairman & Managing Director.

Description:

1. Quality Management System has been established, documented implemented and maintained by following:

1.1 The processes followed in M & M Machine Craft Ltd. have been determined and aligned with requirements of ISO/TS 16949 : 2009

1.2 The sequence of activities and interaction with other processes are defined in the process flow diagram in a clear manner.

1.3 Processes are managed with the objective of achieving effectiveness and efficiency and for this criteria and methods in form of checks/control and data generations are defined in the processes.

1.4 Processes are monitored, measured for which inputs and outputs as well as in process checks are defined, resources and information that are required are determined, and provided as per requirement.

1.5 Processes are reviewed for effectiveness of meeting objectives and targets, and action necessary to achieve planned results and Continual improvement is done as per process flow diagram for continual improvement document No PFD/MR/01

1.6 Processes are managed as per requirements of ISO/TS 16949:2009. 1.7 Such processes that are out sourced, and which has a bearing on Quality of

Products and requirements of system are also controlled. 1.8 A list of processes is given in Annexure A1 1.9 Control over out sourced processes are carried out to ensure the conformity of

customer requirements.

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Documentation Requirements

Policy: Quality Management System shall be documented to ensure effective planning, operation and control of the processes. To fully meet the Quality Policy objectives as well as requirements of ISO/TS 16949:2009.

Reference: Clause 4.2.1 and 4.2.2 ISO/TS 16949:2009

Responsibility: Management Representative

Description:

1.1 Documentation of Quality Management System includes the following:

a) Document statement of Quality Policy and Quality objectives. b) Quality System Manual. c) Documented procedure as required by ISO/TS 16949: 2009

a) Document and Data Control b) Quality Records. c) Internal Quality Audit. d) Control of Non-Conforming product. e) Corrective Actions. f) Preventive Actions. g) Training

d) Documents needed by the Organization to ensure effective planning, operation and control of its processes, and Quality records.

1.2 Quality System Manual is established and it includes the following:

a) Scope of Quality Management System, including justification for any exclusion. b) Documented procedures established for the Quality Management System, and

their references. C) References of processes that have been identified and documented are given in

relevant section of Quality Manual, indicating its inter-relationship.

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Control of Documents

Policy: Documents requirements by the Quality Management system shall be controlled. Records are a special type of document and shall be controlled according to the requirement of clause 4.2.4 of ISO/TS 16949:2009

Reference: Clause 4.2.3 of ISO/TS 16949: 2009


Description:

1. Documents required by the Quality Management System as per Procedure No.QSP/MR/01

2. Documented procedure is established and includes the following for effective control of documents. a) Documents are reviewed for adequacy and approved prior to issue. b) Documents, as and when required are updated after review, and re-approved. c) Changes in the documents, as well as current revision status is identified in the

document, and this is ensured by document change process given in the procedure.

d) Documents that are issued for use are controlled, and made available at required location. It is ensured that only relevant versions are utilized, by removing the obsolete documents promptly.

e) Documents that are issued and utilized are fully legible and readily identifiable by title of documents control no and validation by authorized person, if required. In case any document gets lost/damaged it is promptly replaced as per procedure No. QSP/MR/01

f) Documents of external origin, such as customers drawing, standards, Machine manuals, Legal, Regulatory and Approved requirements applicable to products and processes are identified, documented in master list of documents, and issued to users by ensuring that they are controlled as per procedure no. QSP/MR/01

g) Copies of document that have been revised are collected back from the user department, and disposed off. Master copies of old documents are marked with Obsolete Stamps, and are kept separately re-valuation purpose, if required.

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Engineering Specifications

Policy: The organization has a process to assure the timely review, distribution and implementation of all customers engineering standards/specification and changes based on customer-requirements. Timely review is as soon as possible, and shall not exceed two working weeks. The Organisatation maintains records of the date on which each change is implemented in production. Implementation includes updated documents. Reference: Clause 4.2.3.1 of ISO/TS 16949: 2009.

Responsibility: Head Engineering.

Description:

Engineering Specifications are changed as per procedure of Documents and data control Doc. No.QSP/MR/01

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Control of Records

Policy: Procedure for control of records shall be established to define the controls needed for Identification, storage, protection, retrieval, retention time, and disposition of records. Records are generated to provide evidence of conformity to requirements and of the effectiveness of operation of the Quality Management System.

Reference: Clause 4.2.4 of ISO/TS 16949:2009


Description:

1. Procedure for control of records is documented Ref. Procedure No. QSP/MR/02 2. Records to be maintained are identified. 3. Records are handled and stored to prevent damage. 4. Retention time of records as well as disposition of records is defined and applied. 5. Records are kept in such a way that they are legible and easily retrieve value.

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Record Retention

Policy: The control of records are satisfy regulatory and customer requirements.

Reference: Clause 4.2.4.1 of ISO/TS 16949: 2009.

Responsibility: Management Representative Description: Records are controlled as per requirements and are covered in the record matrix.

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Management Responsibility & Commitment

Policy: Management is committed to development and implementation of the Quality Management System and improving its effectiveness on continual basis.

Reference: Clause No. 5.1 of ISO/TS 16949:2009


Description:

1. Management commitment is based on its belief and values which is reflected through following:

a) Communicating to the organization the importance of meeting statuary requirements.

b) Quality policy has been defined, documented, and communicated to all the employees.

c) Quality objectives have been defined, documented, and communicated to all the employees in such a way that they perform their work for achieving them by setting targets.

d) Management review is done as per process document no. PFD/MR/02 e) Resource that are needed for effective implementation of Quality System is

identified by concerned functionaries and provided as per process document No. PFD/MR/03

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Process Efficiency

Policy: Top management reviews the product realization processes and the support processes to assure their effectiveness and efficiency.

Reference: Clause 5.1.1 of ISO/TS 16949: 2009.

Responsibility: Top Management / Management Representative

Description: Products realization processes are reviewed to the purpose of assessing the value addition and records kept.

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Customer Focus

Policy: Enhancing satisfaction of customers by meeting their requirements.

Reference: Clause 5.2 of ISO/TS 16949:2009

Responsibility: Management Representative /All HODS

Description:

1. Top management is fully involved and committed towards satisfaction of its customers, for which following is done:

a) Customers are identified. b) Needs and requirements of customers are determined and utilized for developing

business plan, as per process document No. PFD/MKT/04 c) Requirements of customers are utilized for developing objectives for the

products and process as per process document No. PFD/MKT/03 d) Resources needed for meeting requirements of customers are provided as per

process document No. PFD/MKT/03 e) Requirements of customers are communicated internally to all concerned as per

process document No. PFD/MKT/03 f) Complaints of customers are handled as per process document No.

PFD/MKT/01 g) Satisfaction of customers is measured as per process document No.

PFD/MKT/02

2. Customer is considered as the most important person of a business process, and continual improvement activities are carried out as per process document No. PFD/MR/01. On this basis of feedback and data analysis to provide delight to them.

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Quality Policy

Policy: Quality policy shall be defined documented, communicated, implemented, and reviewed for Continuing suitability.

Reference: Clause 5.3 of ISO/TS 16949:2009

Responsibility: Management Representative/All HODS

Description:

1. Quality policy has been documented and communicated to all employees through displays at various locations in English and Hindi.

2. Quality policy is as under.

Our Quality Policy is to fully satisfy our customers by manufacturing and supplying die casting , tubular and other automotive components, which fully meet their quality , cost and delivery requirements. Towards achieving satisfaction of our customers all employees are given training and fully involved. Tasks of continual improvement resulting into reduction in errors and defects in products , improve process capability, reduction in machine breakdowns , cycle time and cost, higher productivity and maintaining high degree of house keeping.

3. Quality policy is aligned with the business aim and goal of the organization. 4. Quality policy incorporates commitment to follow requirements of Quality

Management System as well as doing continual improvements. 5. Quality policy is utilized for establishing and reviewing Quality objectives. 6. Employees are involved through training programs and small group activity where

Quality policy and objectives are discussed for improving their understanding and follow up Quality Policy is reviewed for continuing suitability during management review meetings, as per

process document No. PFD/MR/02

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Quality Objectives

Policy: Quality objectives are established and stated in measurable form, and deployed in all Functions / processes. Performance is assessed on the basis of achievements of objectives (Targets).


Responsibility: All HODS

Description:

1. Quality objectives are derived from Quality policy and deployed at all functional level.

2. Quality objectives are given as under:

a) Improve satisfaction of customers b) Reduce errors & defects in products & processes c) Reduce machine breakdown d) Enhance skill of employees with training program. e) Reduce cycle time f) Improve productivity g) Maintain and improve house keeping h) Reduce cost.

Targets:-

From the objectives targets for achievement within specified timeframe determined at various functions and also the levels determined. These are maintained by concerned HODs 3. Quality objectives are reviewed and updated on the basis of changes that are required

as part of continual improvement process, document No. PFD/MR/01

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Quality Objectives - Supplemental

Policy: Top Management has defined the Quality objective and measurements that shall be included in the business plan and used to deploy the quality policy.



Description: Quality objectives are identified and included into business plan and reviewed for achieving the set target.

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Quality Management System Planning

Policy: Quality management system planning is carried out to meet the requirements of Quality Policy, Quality Objectives and Products requirements.

Reference : Clause 5.4.2 of ISO/TS 16949 : 2009.

Responsibility : All HODs

Description: 1) Quality Management system requirements as well as Quality policy and quality

objectives are analyzes and understood by all management functions. 2) Resources needed for implementations of quality system are indentified as per

process document No. PFD/MR/03 and provided. 3) Quality flaws are utilized for developing, manufacturing and delivery of products

as per requirements of quality managements system. 4) Changes as when required to be done on the basis of plan and conducted in

controlled manner. Integrity of the quality management system is maintained.

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Responsibility, Authority & Communication

Policy: Responsibility, authority, and Inter-relationship is defined, documented, communicated to individuals to ensure accountability in carrying out their tasks as per requirements of Quality Management System.

Reference: Clause No. 5.5.1 of ISO/TS 16949:2009

Responsibility: MR/All HODS

Description:

1. Organization chart is defined and documented and given at section 10 Page 2 of 2 2. Responsibility and authority are defined and documented given in section 10 page

1of 20 20 of 20 3. Individuals responsibility and authority are communicated to ensure that each task

performer fully understand his/her role for time implementation of Quality Management System.

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Responsibility for Quality

Policy: Managers with responsibility and authority for corrective action are promptly informed of products of processes which do not conform to requirements.

Personal responsible for product quality have the authority to stop production to correct quality problems.

Production operation across all shifts shall be staffed with personal in changes of, or delegated responsibility for, ensuring product quality.


Responsibility: Head Q.A.

Description: Persons have been identified for various areas and shift who have been authorizes of stopping the production to correct the quality problems. All persons have been informed to communicate to these authorized when ever the process quality is found to be deviating.

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Responsibility & Authority

CMD &ED

Overall responsible for the management of the Organisation.

Development of vision and business goals, business plans and their review with the participation of management teams.

Review and approval of quality policy and objectives.

Review of achievements against targets in strategic areas of operations.

Chairing of management review meetings

Nomination of MR( Management Representative )

Approval and sanctioning of resources needed for effective implementation of quality system.

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Head Marketing

Planning and taking approval and sanction of resources needed for marketing functions.

Implementation of business plan.

Initiating visits/meetings with existing and new customers for improving communication, business relation and getting information enquires and orders.

Collecting market information for analyzing competition, business trends, benchmarks parameters for preparing sale forecast and business strategies.

Providing benchmark data to engineering and quality assurance for purpose of planning for continuous improvement.

Review the functioning to marketing Functions

QSR requirements, enquiries, quotations, order follow up, contract review, customer complaint handling, customer satisfaction,

Review visit reports of marketing and vendor development team members. Review dispatches for 100% timely delivery. Invitation of projects for improvement of customer satisfaction and vendor

development. Review progress of new department projects needing marketing support. Prevent non-conformances for audits conducted by customers, certification

bodies, and internal quality audits. Review achievement of goals and targets for quality objectives Plan and conduct training for employees of the department for improving their

communication skills, meeting with customers and vendors for negotiation as well as on ways of improving their satisfaction.

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Head Marketing

Participate as teams member in:-

Development and review of business plan. Policy on new product development. Customers problem solving and enhancing their satisfaction Internal quality audits. Management review. Analysis of customer rejection. Contract review for new products. Facilities planning and implementation. Policy on inventory management. Selection and training of manpower. Five S and Housekeeping. Communication on voice of customer.

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Unit Head/GM(Operations)

Assist Managing Director in Planning of production capacities and facilities for meeting the requirements of business plans.

Participate in the following tasks as team members

Preparation and review of business plan Policy on development of new products Procurement of new machines Five-S and House Keeping Training and development of employees Customer complaint & satisfaction analysis Management review meeting Selection of new employees Quality and productivity improvement projects.

Review and recommendation of resources needed for the effective implementation of quality system and business plan for all areas under his control:

Production, PPC, Maintenance and Q.A for production item.

Carry out review of following tasks and operations:

Production and dispatches. SPC implementation.

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Unit Head /GM(Operations)

Machine loading and utilizations Five S and House Keeping Small group activity implementation Preventive maintenance Rejection and rework analysis Effectiveness of training given to employees Training needs of employees Inventory management Corrective and preventive action Cost reduction achievements against targets Closing of NCs observed in quality audits Motivation and morale of employees of manufacturing area Leadership and team working skills of managers and supervisors Implementation of business plans Review of achievements in the area of quality, productivity Development of vision & business goals, business plans & their review with the

participation of management teams. Review & approval of quality policy & objectives Review of achievements against targets in strategic areas of operation. Approval sanctioning of resources needed for effective implementation of quality

system.

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Head PDC /Section In charge Machining Die-Casted components/ Section In charge Machining Tubular & Turned Components/ Section In charge Paint Shop &

Section In charge CNC.

Generate requirements of resources for production area under his control and take approval of GM(Operations)/Unit Head

Participate as team member in following tasks:

Selection and training of employees Machine selection and installation Preparation of production plan as per PPC process

Review of documents for production (OCS, Control Plan, work instruction etc.) SPC, Small group activity implementation Management review meetings

Internal quality audits

Five-S and housekeeping implementation and review Preventive maintenance implementation and review Safety guideline preparation and implementation

Initiate projects and achievements for quality and productivity improvements through problem solving, mistake proofing, and corrective and preventive action, idle time report etc.

Generate records on daily production and idle item

Ensure that manufacturing is done as per OCS and quality plan

Develop & implement guidelines for proper handling and storage of products during production.

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Head PDC /Section In charge Machining Die-Casted components/ Section In charge Machining Tubular & Turned Components/ Section In charge Paint Shop &

Section In charge CNC.

Generating Data on rejection, rework, Customer Components, Vendor Rating & Providing the same to MR for initiating projects on quality & Productivity improvements.

Monitoring Inspection activities on the shop floor

Receiving Inspection

Verification and Validation of Fixers, Jigs & Tooling in Co-Ordination with Tool

Room

Planning & Development of Tasks and People for Efficient Performance of the Q.A function in the concerned area.

Bench marking goal for Quality.

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Head (P & A)

Recruitment of employees as per job-specifications Training of employees Analysis & comparison of legal & regulatory requirement Co-ordination for the housekeeping & 5-S Maintenance of building & furniture Maintaining of IR & discipline in the Organisation Arranging & maintaining security of the company Liaison with external training bodies for development of employees for external

training Maintaining of training record of employees. Time office management Carrying out ESI, PF activities of employees Making necessary arrangement for safety (fire fighting in the company) Participate in implementation of continuous improvement.

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Head Engineering

Directing and controlling the activities for development of new products as under:

Feasibility study for new products as feedback to marketing for generating quotations.

Initiating and controlling of product development projects Timely development of new products , tooling and documents Analysis of manufacturing capacities and capabilities for purpose of business plan

and development and manufacturing of products. Contract review along with marketing department Procurement planning and control for tooling, gauges instruments for new

products /needed due to modification. Planning and seeking approval of CEO for resources that are needed for areas under

control as bellow.

Process engineering Tool Design Tool Room Tool Crib Preparation and issue of drawings and documents for development, procurement

and manufacturing. Procurement / receiving, issuing and controlling external origin documents.

Managing and controlling the activities of the functions under his control by following tasks:- Setting and achieving objectives and targets Implementation of business plans. Tool purchasing Training and development of employees for skills needed for the effective

performance on jobs. Tooling management Value Engg. Work Study SPC

Process Engg.

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Head Engineering

Initiating projects for quality and productivity improvement and cost reduction for maximizing customer satisfaction.

Prevention of non-conformances of quality system by analysis of NCs found during audits.

Timely solving of problems related to product/ process quality given by other functions.

Participate as team member in:- Development and review of business plans Development of QSR for vendors in co ordination with QA and VD Internal quality audits Management review Development and deployment of benchmarking targets Customer complaint satisfaction analysis Corrective and preventive action Five S and House Keeping SPC Review of QSR of customers with marketing and QA Machine selection and installation Selection and training of manpower.

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Head Maintenance

Identify analysis and prepare document of preventive and predictive maintenance for all equipment and utilities that are utilities that are utilized in the organization

Machines in production Generators, pumps, motors Overhead cranes, Trolleys.

Develop and implement preventive and predictive schedule in co-ordination with Section-Incharge Machining.

Prepare maintenance objectives and get approval of CEO and review the same for improvement.

Manage and control the activities of maintenance functions as under. Attending of breakdown Review of pending breakdown work Performing of preventive and predictive maintenance tasks by fitters. Corrective maintenance on the basis of analysis of breakdown and preventive

/predictive maintenance reports. Generation of data and reports on maintenance for measurement of achievement

of maintenance objectives and its improvement. Maintenance work and skill analysis of fitters for providing training to them for

upgrading their knowledge and skills to meet the requirements of the organizations

Identification of requirements of spares and keeping inventory to provide timely maintenance service to internal users (customers).

Maintaining documents and records of maintenance. Study of spare parts for purpose of getting them developed and fabricated from

tool room/vendors.

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Head Maintenance

Identify resource requirements for maintenance functions and obtain approval of Plant Head

Plan and organize calibration of gauges / instruments that are fitted in the machine, and send calibration reports to HOD (QA) for computer data.

Participate as team member in following.

Machine selection and installation Five S and House Keeping Manpower Selection and Training Quality and Productivity improvement projects. Machine modification by fitters and / vendors Education and training of operators on machines, safety, etc..

Internal quality audit.

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Head Quality Systems & Management Representative

Preparation of quality system documents such as quality manual, quality system procedure, work instructions & format needed for quality system.

Communication of quality policy & quality objectives throughout the organization.

Organizing management reviews meeting & follow-ups for the decision taken in the management review meeting.

Conducting of internal audit. Planning & conducting training program for ISO/TS 16949:2009 Maintaining library for the quality books & periodicals. Liaison with certification body & other expert for seeking effective guidance for

ISO/TS 16949:2009 Monitoring of the various activities in ISO/TS 16949:2009 & informing top

management from programs of ISO/TS 16949:2009 system from time to time. Maintaining all management records. Direct responsibility for calibration of Gauges and Measuring Instruments.

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Head Information Technology

Implementation of the ERP software in the organization Development & implementation of new packages as per requirement of the

management System study & analysis to provide documentation of each department through

ERP package To provide guidelines to each department for using the computer Backup of all software & data Training of employees

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Head (Finance & Accounts)

In-charge for entire finance & commercial functions of the company Tax planning & estimates Break even analysis Balance sheet finalization Monthly profit & loss account System developments Costing for new components New projects & bank loans Cost control Monthly budgets & cash flow Assessments Roc work & share allotment to directors Maintaining the minutes of board meeting Projections for the future Notice to the directors for meetings Following with the debtors for payments Dealing with various government authorities Business developments All the other work given by the management Analysis of pending payments receiving Analysis of pending payments to supplier Cost analysis for raw materials, labor, wastage, tooling/consumables Cash flow analysis Timely submission of legal & regularity documents Timely audit of accounts Error/Mistakes in records Job responsibility/skill analysis of accounts department staff.

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Head Commercial & Supply Chain

Responsible for over all policies that are to be adopted in purchase Call for the quotations from various parties Setting the quotations as per the rates Supplier rating Rate finalization Purchase order to the parties Supplier development Purchase budget Procurement of material from various parties Purchase ledger Adopt all the purchase procedures & systems as per the norms Maintain various reports as per the requirement of the management Responsible for proper filling in the department Responsible to see the material reach in time & other timely work given by the

management Responsible for report generation Checking the quantity as per purchase order Supplier database Planning of payments terms with finance department.

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Head Store & Dispatch

Responsible for the entire day today functions of the store. Responsible for placing the material in an organized manner in proper bins, &

racks to protect form loss or damage from fire, corrosion, dust etc. Issuing the material against proper authorized requisitions. Maintenance in chronological order a continuous record of goods in stock; all

receipt & issues in terms of quantity for each kind of material. Making a periodic & systematic counts to verify the physical balances. Prepare the stock statements & give a report of slow moving, non-moving &

obsolete stocks. Furnishing the data for standardization of materials with a view to reduce stock.

holding & wasteful & minimizing the blocking of the capital. To be in touch with technical aspects which may effect purchasing & store

keeping. Responsible for the inventory control. Setting up the store properly for smooth running. Inventory valuation. Classification & coding of the material & ABC analysis Maintaining the minimum stock levels & other day today work given by the

management. All the dispatches to the customer. Transport & traffic management.

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Head PPC

Receive schedule & prepare monthly/weekly / daily production plan with concerned production head.

Identify problem / bottleneck in supply chain. Tracking of progress. Monitoring of dispatch against schedule. Provide solution to problem occurring between various departments. Generate MIS on production. Provide information to marketing / Customer about time of dispatch of item

needed by customer. Make change in production plan as per need of customer. Movement of materials between department / supervise movement. Check the all item are identified & has inspection status. Study of layout & propose solution for minimize of transportation. Achieve effective implementation of 5-S. Set target for minimize of inventory with store & purchase.

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Head Industrial Engineering

Study of layout & propose solution for minimize of transportation. Set target for minimize of inventory with store & purchase. Time Study and time standards for the various operations. Identify projects for time reduction. Capacity planning of the basis of business plan. Waste Analysis & Implementation of Low Cost Automation.

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Head QA

Generate requirements of resources needed for the areas under his control as under, and taking approval of GM(Operations)

Receiving Inspection In process Inspection Final Inspection Verification and validation of fixtures, jigs and tooling in co-ordination with tool

room Development, preparation, issue and control of documents for inspection and quality

assurance activities. Generating data on rejection, rework, customer complaints, vendor rating and

providing the same to MR for initiating projects on quality and productivity improvements.

Planning and development of tasks and people for efficient performance of the quality assurance department.

Develop inspection and testing & calibration skills in employees of the QA departments.

Participate in the following tasks as team member: Policy on development of new products New product development Contract Review Vendor selection and audits Benchmarking goals for quality Implementation of voice of customer SPC implementation Five-S and house Keeping Management Review Internal Quality Audits Customer Complaint Analysis, customer satisfaction Continuous improvement and cost reduction analysis Selection and training of employees

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Management Representative

Policy: Managing Director appoints Management Representatives and provides him the authority to carry out all activities to ensure effective implementation, Maintaining, and Continual Management System.

Reference: Clause No. 5.5.2 of ISO/TS 16949:2009


Description:

1. M.D appoints a member of Organization management as MR. 2. Responsibility and authority of Management representative are given in section 10

page 3. Management representative prepares documents of Quality Management System

through involvement and participation of all functions. 4. Management representative ensures that all processes needed for Quality

Management System are established, implemented and maintained. 5. He gives report to the Managing Director on the performance of Quality

Management System and need for improvement. 6. Management Representative ensures promotion of awareness of requirements of

customers throughout the Organization.

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Customer Representative

Policy: Top management has designated personal with responsibility and authority to ensure that customer requirements are addressed. These includes selection of special characteristics, setting quality objective and related training corrective and preventive actions, product design and development.

Reference: Clause 5.5.2.1 of ISO/TS 16949: 2009

Responsibility: GM(Operations)/Unit Head

Description: Persons have been identified as customer representative and the same has been documented and communicated to all concerned.

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Internal Communication

Policy: Internal Communication process to be established to achieve actual and meaningful involvement of all employees for the aim of improving commitment and performance in all functions and activities.


Responsibility: Management Representative/All HODs

Description:

1. Following methods are utilized for internal communications to assess effectiveness of the Quality Management System.

a) Display of Quality Policy and Quality objectives. b) Display of Quality and Process documents at workstations. c) Group meetings conducted for workers by supervisors. d) Regular meetings of head of functions to review progress. e) Collection of suggestions for improvement from employees.

2. Communication process is documented, DOC No. PFD/P&A/07

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Management Review

Policy: Quality Management System is to be reviewed, at planned intervals by top management, to ensure its continuing, suitability, adequacy, and effectiveness.

Reference: Clause 5.6,5.6.1,5.6.2 & 5.6.3 of ISO/TS 16949:2009 Responsibility: Management Representative Description:

1. Process of management review is documented, DOC No. PFD/MR/02 2. Review is done once in three months, or earlier. 3. Review meeting is chained by the Managing Director, and participated by all

Function Heads. 4. Management review is done on the basis of inputs as under:

a) Results of audits, provided by Management representative. b) Customer feedback provided by Marketing and head of QA. c) Process performance and product conformity provided by function heads. d) Status of preventive and corrective actions provided by Management

representative. e) Follow up actions from previous management review provided by Management

Representative. f) Changes that could affect the Quality Management System by Function heads. g) Recommendation for improvements provided by any employee through

Management Representative. 5. Management review is conducted through active participation of all function heads

with sense of commitment, openness, and mutual respect for the aim of enhancing performance in all tasks and operations.

6. Management review records Review output which include decisions and actions related to: a) Improvement of the effectiveness of Quality Management System and its

processes. b) Improvement of product related to customers. c) Resources needed.

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Quality Management System Performance

Policy: These reviews are include all requirements of the quality management system and its performance trends as an essential part of the continual improvement process.

Part of management review is the monitoring of quality objectives, and the regular reporting and evaluation of the cost of poor quality (see 8.4.1 and 8.5.1).

These results is recorded to provide, as a minimum, evidence of the achievement of The quality objectives specified in the business plan, and Customer satisfaction with products supplied.


Responsibility: Top Management / Management Representative

Description: Quality management system performance is evaluated by Top Management and improvements carried out. Quality cost analysis is used as one of the tools for process improvements and records are maintained.

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Review input - Supplemental

Policy: Input to management review includes an analysis of actual and potential field failures and their impact on quality, safety or the environment.



Description: The process for review has been established and records kept.

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Resource Management

Policy: Resources needed for effective implementation, Maintaining and Continual improvement of Quality Management System to be identified, communicated to top management for approval, Budgeting and Financial Planning and Timely provisioning as well as review to be done to eliminate all wastes in the processes. Reference: Clause 6.1, 6.2, 6.2.1, 6.2.2, 6.3, 6.4 of ISO/TS 16949:2009 Responsibility: MR/All HODS Description:

1. Provision of resources. 1.1 Resources needed are determined and provided

a) to implement and improve the processes of Quality Management System, and b) Enhance satisfaction of customer by meeting customer requirements.

2. Human Resources. 2.1 Competency and skills needed for various operations are determined, and

employees inducted on the basis of their capabilities of achieving the planned results. Refer Recruitment Process No. PFD/P&A/03

2.2 Records of education, training, skills, and experience of all employees are kept as per document of training process No. PFD/P&A/04

2.3 Training needs are identified for job-related skills, Quality System implementation as well as for meeting requirements of customers, Training is provided, and results of training evaluated as document No. PFD/P&A/04

3. Infrastructure: 3.1 Infrastructure requirements covering the following are identified

a) Buildings, warehouse, and associated utilities. b) Process Equipment (both Hardware and Software). c) Supporting services. (Such as Transport ,Communication or information

system) 3.2 Requirements are identified and provided as per format No. FMT/MR/10

4. Work Environment 4.1 Work environment which would result in conformity to product requirement are

determined and managed by following methods: a) House keeping is managed as per document No. PFD/P&A/06 b) Feedback to employees is given by supervisors, as well as communicated

through Notice Boards on aspects of Quality performance. c) Employees are asked to participate in serious problem exposure, as well as in

developing solution to fully utilize their creative thinking (Brainpower).

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Training, Training on the Job & Employee Motivation and Empowerment

Policy: Training :- The organization has established and maintains documents / procedures for identifying training needs and achieving competence of all personal performing activities affecting product quality. Personal performing specific assigned tasks are qualified, as required, with particular attention to the satisfaction of customer requirements.

Training on the Job :- The organization has provided on-the-job training for personnel in any new or modified job affecting product quality, including contract or agency personnel. Personnel whose work can affects quality are informed about the consequences to the customer of nonconformity to quality requirements.

Employee Motivation and Empowerment:- The organization has a process to motivate employees to achieve quality objective, to make continual improvements, and to create an environment to promote innovation. The process includes the promotion of quality and technological awareness throughout the whole organization.

The organization has a process to measure the extent to which its personnel are aware of the relevance and importance of their activities and how they contribute to the achievement of the quality objectives [see 6.2.2 d]

Reference: Clause 6.2.2.2, 6.2.2.3 & 6.2.2.4 of ISO/TS 16949: 2009

Responsibility: Head P & A.

Description: Process has been implemented and records kept.

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Plant, Facility and Equipment Planning

Policy: The organization utilizes a multidisciplinary approach (see 7.3.1.1) for developing plant, facility and equipment plans. Plant layouts shall optimize material travel, handling and value-added use of floor space, and shall facilitate synchronous material flow. Method have been developed and implemented to evaluate and monitor the effectiveness of existing operations.


Responsibility: GM(Operations)

Description: Plant and facility development activities are carried out as per business plan and APQP team reports. Records are maintained by PPC.

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Contingency Plans

Policy: The organization has contingency plans to satisfy customer requirements in emergency such as utility interruptions, labor shortages, key equipment failure and field returns.


Responsibility: Head PPC & GM(Operations)

Description: Contingency plans are developed and implemented by PPC. Records are maintained.

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Personnel Safety to Achieve Product Quality

Policy: Product safety and means to minimize potential risks to employees are addressed by the organization, especially in the process development and in manufacturing process activities.



Description: Safety norms are identified while developing the manufacturing process by engineering Dept. Records are maintained.

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Cleanliness of Premises

Policy: The Organization maintains its premises in a state of order, cleanliness and repair consistent with the product and manufacturing process needs.


Responsibility: Head P&A

Description: Cleanliness and order in the organization is maintained utilizing 5-S principles by P & A department. Records of reviews are maintained. /

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Planning of Product Realization

Policy: Products that are to be taken for development shall be developed on the basis of documentation and deployment of process and such process to meet the customer requirements.

Reference: Clause 7.1 of ISO/TS 16949:2009 Responsibility: MR/All HODS

Description: 1. Process for Product realization have been identified and developed to ensure that

requirements of customers, applicable legal and statutory requirement as well as product standards, where available would be fully met. Following processes are utilized: a) Product realization process takes into account the requirement of customers,

which are translated into Quality objective for the product. b) Development of new product as per documents No. PFD/ENG/01 c) Tooling management as per document No. PFD/ENG/02 d) Process planning and approval as per document No. PFD/ENG/01 e) Machine selection and utilization as per document No. PFD/ENG/04 f) Control of customer documents No. QSP/MR/02 g) Resources planning as per document No. PFD/MR/03 h) Control plans for new products i) Customer approvals of new products as per document No. PFD/ENG/01 j) Required verification, validation. Monitoring, measurement, inspection & test

activities specific to the product & the criteria for product acceptance.

2. Records related to product realization are kept.

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Planning of Products realization - Supplemental

Policy: Customer requirements and references to its technical specifications are included in the planning of product realization as a component of the quality plan.



Description: Customers requirements and references to its technical specifications are included in the quality plan prepared for the products.

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Acceptance Criteria

Policy: Acceptance criteria is defined by the organization and, where required, approved by the customer. For attribute data sampling, the acceptance level is zero defects (see. 8.2.3.1).



Description: Acceptance criteria is defined as per customers PPAP requirements. In case of non-conformities rework inspection is carried out by appropriate inspection personnel. For attribute data sampling the AQL is zero defects and only OK samples are accepted.

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Confidentiality

Policy: The organization ensures the confidentiality of customer-contracted products and projects under development, and related product information.



Description: All records/ Drawings of new products development are kept safely to maintain their confidentiality.

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Change Control

Policy: The organization has a process to control and react to changes that impact product realization. The effects of any change, including those changed by any supplier, are assessed, and verification and validation activities are defined, to ensure compliance with customer requirements. Changes are validated before implementation. For proprietary design, impacts on form, fit and function (including performance and / or durability) are reviewed with the customer so that all effects can be properly evaluated. When required by the customer, additional verification / identification requirements, such as those required for new production introduction, are met.



Description: Any change in the products design by a supplier are verified and validated to ensure compliance with customer requirements. Whenever there is a customer requirements for identifications of the products, the same is discussed in APQP meeting and it is mentioned in the control plan. In case of propriety design impact of any change on form, fit and function is jointly discussed with the customer.

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Customer Related Process

Policy: Customer related processes are identified to determine and understood the requirements of customers, and carrying out contract review before commitment.

Reference: Clause 7.2.1 and 7.2.2 of ISO/TS 16949:2009

Responsibility: HOD Marketing/HOD Production/HOD QA

Description:

1. Determination of requirements related to product 1.1 The following customer requirements are determined as per document

No.PFD/MKT/03 a) Product requirements specified by the customers, including availability,

delivery and post-delivery activities. b) Product requirements not stated by customer but necessary for intended or

specified use. c) Statutory and regulatory requirements applicable to the product d) Any additional requirement considered necessary by us.

2. Review of requirements related to the products. 2.1 Review is done to assess capability of meeting requirements of customers before

making commitment to supply a product to the customer (e.g.submission of tenders, acceptance/Changes of contracts or orders). This is done by consideration of following as per document No. PFD/MKT/03 a) Product requirements are defined b) Contract or order requirements differing from previously expressed are

resolved, and the organization has the ability to meet the defined requirements c) Records of results of review and action arising from the review shall be

maintained. d) Where the customer provide no documented statement of requirement, the

customer requirements shall be confirmed with them before acceptance. e) Where product requirements are changed, it shall be ensured that relevant

documents are amended and that relevant personnel are make aware of the changed requirements.

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Customer Designated Special Characteristics

Policy: The organization demonstrates its conformity to customer requirements for designation and control of special characteristics.



Description: Special characteristics are identified in APQP meetings and are also included in FMEA and control plan.

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Review of Requirements related to the Product - Supplemental

Policy: Waiving the requirement stated in 7.2.2 for a formal review (see note) requires customer authorization.


Responsibility: Head Marketing.

Description: Formal reviews are carried out.

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Organization Manufacturing Feasibility

Policy: The organization investigates, confirms and documents the manufacturing feasibility of the proposed products in the contract review process, including risk analysis.



Description: Feasibility study including risk analysis is carried in APQP meeting.

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Customer Communication

Policy: Necessary arrangements for customer communication are identified, documented and implemented to maintain effective professional and business relationship with customer.


Responsibility: HOD Marketing

Description: 1. Process for receiving enquiries, contracts or order handling including amendments

are carried out as per PFD/MKT/03. 2. Meeting with customer is done as per document No. PFD/MKT/03. 3. Customer Feedback is collected and analyzed as per document no. PFD/MKT/03. 4. Customer complaints are handled as per document no. PFD/MKT/01.

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Customer Communication - Supplemental

Policy: The organization has the ability to communicate necessary information, including data, in a customer specified language and format (e.g. Computer Aided Design Data, electronic data exchange.


Responsibility: Head Marketing.

Description: The organization has ability to communicate necessary information in a customer-specified language and format.

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Manufacturing Process Design Input

Policy: The organization identify, documents and reviews the manufacturing process design input requirements, including

Product design output data Target for productivity, process capability and cost. Customer requirement, if any, and Experience from previous developments.



Description: These activities are carried out in APQP meeting and the regulatory reviewed through process review meeting.

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Special Characteristics

Policy: The organization identifies special characteristics [see 7.3.3 d] and Includes all special characteristics in the control plan, Couples with customer specified definitions and symbols, and Identifies process control document including drawings, FMEAs, control plans

and operator instruction with the customers special characteristics symbol or the organizations equivalent symbol or notation to include those process steps that affects special characteristics.



Description: These activities are carried out in APQP meeting.

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Manufacturing Process Design Output

Policy: The manufacturing process design output is in terms that can be verified against manufacturing process design input requirement and validated. The manufacturing process design output includes-

Specification and Drawings, Manufacturing process flow Chart/layout, Manufacturing process FMEAs, Control plan (see 7.5.1.1), Work instruction, Process approval acceptance criteria, Data for quality, reliability, maintainability and measurability, Result of error-proofing activities, as appropriate, and Methods of rapid detection and feedback of product / manufacturing process

nonconformities.



Description: These activities are carried out in APQP meetings.

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Monitoring

Policy: Measurements at specified stages of design and development are defined, analyzed and reported with summary results as an input to managements review. These measurements include quality risks, costs, lead-times, critical paths and other, as appropriate.


Responsibility: CFT & APQP Team

Description: These activities are carried out in APQP Projects.

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Product Approval Process

Policy: The organization confirm to a product and manufacturing process approval procedure approval by the customer. This product and manufacturing process approval procedure are also be applied to suppliers.


Responsibility: APQP Team

Description: These activities are carried out by CFT of APQP Projects.

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Purchasing Process

Policy: a) Ensure that purchased products conforms to specified requirements .

b) Evaluate and select suppliers based on their ability to supply product in accordance with the specified requirements

c) Purchases shall be done by incorporating complete information and data in purchasing requirements

d) Purchased products on receipt shall be inspected by us, also by customer, if required by them

Reference: Clause 7.4.1, 7.4.2, 7.4.3 of ISO/TS 16949:2009

Responsibility: Head Supply Chain

Description:

1. Purchases are done on the basis of following processes and sub processes: a) Process of purchase budgeting, document No PFD/PUR/03 b) Process of receiving and processing indents document No. PFD/PUR/02 c) Process of placing purchase order documents No. PFD/PUR/02 d) Process of selection and evaluation of vendors document No. PFD/PUR/01

2. Purchase process ensures the requirement given in Policy above mentioned

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Regulatory Conformity

Policy: All purchased products of materials used in products conform to applicable regulatory requirements.



Description: The regulatory requirements are completed as per clause 7.4.1.1 of ISO/TS 16949:2009

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Supplier Quality Management System Development

Policy: The organization carries out supplier quality management system development with the goal of supplier conformity with this technical Specification. Conformity with ISO 9001:2008 is the first step in achieving this goal.



Description: All suppliers are developed for achieving the goal of ISO 9001:2008 on the basis of time target given to them and are regularly assessed for the requirement of ISO 9001:2008 and TS 16949:2009 records of assessment are maintained.

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Customer Approved Sources

Policy: Where specified by the contract (e.g. customer engineering drawing, specification), the organization purchases products, materials or services from approved sources. The use of costumer designated sources, including tool / gauge supplier, does not relive the organization of the responsibility for ensuring the quality of purchased products.



Description: These activities are being carried out as per clause 7.4.1.3

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Incoming Products Quality

Policy: The organization shall have a Process to assure the Quality of purchased products(see 7.4.3) utilizing one or more of the following methods:

Receipt of , and evaluation of , statistical data by the organization; Receiving inspection and / or testing such as sampling based on performance; Second or third-party assessments or audit of supplier sites, when coupled

with records of acceptable delivered product quality; Part evolution by a designated laboratory; Another method agreed with the customer;



Description: The above activities are carried out as per clause 7.4.3.1

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Supplier Monitoring

Policy: Supplier performance are monitored through the following indicators:- Delivered products quality; Customer disruptions including field returns; Delivery schedule performance (including incidents of premium freight); Special status customer notifications related to quality of delivery issues.

The organization shall promote supplier monitoring of the performance of their manufacturing process.



Description: Supplier performance is monitored by the delivered product quality, Customers field returns and customer schedule being not met (if any). Records are maintained and reviewed for quality & delivery improvements.

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Control of Production Provision

Policy: Production shall be done in a planned and controlled conditions to ensure that product are made as per specified requirements.


Responsibility: MR/All HODS

Description:

1. Production is done on the basis of following control elements: a) Production program is prepared as per document No. PFD/PPC/01 and

production done as per document No. PFD/PRD/01 to 03 b) Characteristics of products are given in operation control standard, which are

utilized during production stages. c) Suitable equipment are selected and specified in operation control standard. d) Monitoring devices needed for Quality and process checks are specified in

operation control standard and made available for use. e) Quality measurements at various stages are done as per Quality plans. f) Equipment maintenance is done as per document No. PFD/MAT/01 g) Jigs/fixtures are fabricated and also checked/repaired in tool room as per

document No. PFD/TR/01 h) Measurement devices that are used are duly calibrated as per document No.

PFD/QA/01 i) Products are released after due verification as per document No. QP/01 to 61 j) Equipments and premises kept in state of cleanliness, with required safety

guidelines followed as per document No. PFD/P&A/06

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Control Plan

Policy: The organization has Developed control plans (see annex) at the system, subsystem, component and / or

material level for the products supplied, including those for processes producing bulk materials as well as parts, and

Has a control plan for pre-launched and production that takes into account the design FMEA and manufacturing Process FMEA outputs.

The control Plan has List the controls used for the manufacturing process control, Include methods for monitoring of control exercised characteristics (see 7.3.2.3)

define by both the customer and the organization, Include the customer-required information, if any, and Initiate the specified reaction plan (see 8.2.3.1) when the process becomes

unstable or not statistically capable. Control plans are reviewed and updated when any change occurs affecting products, manufacturing process, measurement, logistics, supply sources or FMEA (see 7.1.4).



Description: These activities are discussed and finalized in APQP meeting. Control plans are reviewed and updated a per necessary changes.

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Work Instructions

Policy: The organization shall prepares documented work instructions for all employees having responsibility for the operation of processes that impact product quality. These instructions are accessible for use at the work stations. These instructions shall be derived from sources such as the quality plan, the control and the product realization process.


Responsibility: APQP Team.

Description: These activities is carried out during APQP meeting and work instruction are prepared for all the work stations.

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Verification of Job set-ups

Policy: Job set-ups are be verified whenever performed, such as an initial run of a job, material changeover or job change. Work instructions are available for set-up personnel. The organization uses statisti

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