DUNGSAM CEMENT CORPORATION LTD

REFRESHER COURSE ON ISO 9001:2008

I would like to thank all those who helped me in preparing this

presentation. Any mistake and short-coming are of my own.

Facilitator: Ram Krishna NeopaneyDungsam Cement Corporation Ltd

ISO 9001:2008QUALITY MANAGEMENT SYSTEM

What is it? A quality management system (QMS) is a collection of business processes focused on achieving your quality policy and quality objectives — i.e. what your customer wants and needs. It is expressed as the organizational structure, policies, procedures, processes and resources needed to implement quality management system.

WHY ISO 9001:2008 ?a. ACHIEVING INTERNATIONAL RECOGNITION: International

Standards Organization (ISO) , is recognized globally as the leading authority on quality management.

b. BOOSTING EMPLOYEE MORALE: There are factors present in any organization which play very important roles in motivating staff. Examples of these factors are: - Management Commitment, having clearly defined Roles & Responsibilities, established training systems and programs etc.

c. ENSURING CUSTOMER  SATISFACTION AND INCREASED EFFICIENCY: By implementing the ISO 9001:2008 in your organization, customer satisfaction is ensured as the quality system ensures consistency, efficiency and the organization’s dedication to rendering a quality service or product to the consumer.

d. CONSISTENCY OF ALL PROCESSES WITHIN THE ORGANIZATION: Consistency within all processes in an organization minimizes the opportunity for error.

CONTINUEDe. IMPROVEMENT OF PROCESSES BASED IN DOCUMENTED FACTS: As mentioned above, it will be necessary to make changes to processes within an organization to improve and maintain the quality of a service or product. Audit processes, Management Review and Improvement processes based on documented data are outlined by the ISO 9001:2008 Quality Management Systemf. FACTUAL APPROACH TO DECISION MAKING: There are a clear set of instructions within the ISO 9001:2008 Quality Management System regarding the process reviews and audits. These instructions facilitate decision making and information gathering based on factual data collected within the processes.g. WELL STRUCTURED AND EFFECTIVE DOCUMENTATION: The ISO 9001:2008 Quality Management System requires that all processes are documented including any discrepancies, errors and changes. Staff accountability and consistency throughout production is then therefore ensured. Traceable records are therefore also then available. h. INCREASED REVENUE : Companies which implement and maintain the ISO 9001:2008 experience improved financial performance as well as increased productivity when compared to other companies who do not implement such systems

WHAT DO WE UNDERSTAND, WHEN WE SAY PROCEDURE AND PROCESS

DOCUMENTA procedure is a particular way of accomplishing something.

This is also defined as a series of steps in a regular definite order; a traditional or established way of doing things in your Department/Division/Section. Procedures are focused on steps, order and instruction

A process refers to a series of actions, but does not place a particular order on those actions.

A. Each individual company has their own processes for each department, Division and section.  It is through those processes, those actions, that you would comply with the intent of the standard.  The value of controlling and improving on those processes is reflected in your audits.

B. Input -> Process -> Output

C. Which are the process, adopted in your Department/Division/Section (List Down)

CTM to Highlight to the mass.

(Open the procedure one by one and discuss in brief)

SYSTEM PROCEDURE System procedure are those procedure laid out to monitor the total system (adopted process and procedure with/without exclusion in DCCL)System Process/ Procedure Include following; 1. Control of document 2. Control of record3. Internal Audit4. Control of Non-confirming Product5. Corrective action6. Preventive action7. Management Review

INTERNAL AUDIT

“Systematic, independent and documented process for obtaining audit evidence and evaluating it objectively to determine”

The organization shall conduct internal audit at a planned interval to determine whether the QMS;

confirm to the planned arrangement, to the requirements of this international standard and to the QMS requirement established by the organization.Is effectively implemented and maintained

PROCESS OF INTERNAL AUDIT

Established Annual Audit

Plan

Generate and distribute audit Plan

Conduct opening meeting

Carry out Audit

Present Finding in

Closing Meeting

Follow Up Action

NON-CONFIRMING PRODUCT

In QMS, a nonconformity (also known as a defect) is a deviation from a specification, a standard, or an expectation. Nonconformities are classified as either critical, major, or minor.Example: PP Bag Specification(Discuss with reference to PP bag and Mechanical spare parts specification)

Control of nonconforming product. Each manufacturer shall establish and maintain procedures to control product that does not conform to specified requirements. The procedures shall address the identification, documentation, evaluation, segregation, and disposition of nonconforming product. The evaluation of nonconformance shall include a determination of the need for an investigation and notification of the persons or organizations responsible for the nonconformance. The evaluation and any investigation shall be documented.

CONTROL OF DOCUMENT Controlled document is a reference document which, through the course of its lifecycle may be reviewed, modified and distributed several times.

Examples of a controlled document include: technical drawings, manual, specifications, procedures, data-sheets, contracts, application forms and plans.

PURPOSE

Document control provides a framework for deciding how information is created in the organization and how it is managed once created. The purpose of a document

control method is to ensure

Documents fulfill a useful purpose, Only valid information is published

Resources are not wasted on the distribution of unimportant or useless information

Information is kept up to date, Information is provided in a form that can be used by the audience

Continued….Classified, confidential, or proprietary information is restricted to the people who have a real need to access it

Information is retained that could help solve a problem, improve opportunities, avoid costly errors, or deflect potential litigation

MANAGEMENT REVIEW

The purpose of these meetings is to provide a vehicle for the top management group in an organization to evaluate the status and any issues that arise relative to the Quality Management System. They should look at the following inputs and develop actions to achieve the outputs:

CONTINUEDVvvvv

Source: John Novak, KAVON International, Inc.

CONTINUOUS IMPROVEMENTContinual improvement is defined as a recurring activity to increase the ability to fulfill requirements.  The ‘ability to fulfill requirements’ refers to both conforming as well as nonconforming products/processes. Conforming processes can be further improved; and nonconforming processes must be improved by taking corrective action to prevent recurrence

STANDARD OPERATING PROCEDUREA Standard Operating Procedure (SOP) defines the key processes of the business and identifies who is responsible for various aspects of their implementation . They identify “What” is to be done and “When”An SOP is an agreed description of a stage or part of a process, which gives sufficient information for an existing or new staff member to understand what steps must be carried out, what inputs or supporting documents are required, and what outputs should be produced

CONTINUED

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QUALITY POLICYQuality Policy Statement, is an organization’s general statement of its beliefs about quality, how quality will come about and its expected result. The Quality Policy Statement is the first layer of documentation in a Quality Manufacturing System

DCCL QUALITY POLICY

QUALITY MANNUALA Quality Manual is a document that describes the elements of the quality system used to assure that the process of customer requirements, needs, and expectations are met. Quality Manuals shall include responsibilities and authorities for each element of the quality system

VISION & MISSIONVision Statement describes the

future state.This statement tells, what you

want to be in future.

Mission statement describes the present state of a organization. It guide the organisation to move

towards the organisation VISION