Metal Manual P-I

Page 1 of 59

COVER PAGE CUM DISTRIBUTION LIST

ISO 9001: 2008 Manual

MANUAL CONTROL

THIS MANUAL IS THE PROPERTY OF

HEAD OFFICE : METAL TECH INDUSTRIES Gat No. : 138, Dhanore(Alandi), Tal. Khed, Dist.Pune-411015

INDIA WORKS : METAL TECH INDUSTRIES Gat No. : 138, Dhanore(Alandi), Tal. Khed, Dist.Pune-411015

AND THIS MANUAL IS ISSUED TO THE PERSON MENTIONED BELOW IS A HOLDING AUTHORITY OF THIS MANUAL. NO FURTHER ISSUE OF THIS MANUAL IS AUTHORISED WITH OUR PRIOR APPROVAL AND AUTHORIZATION OF MR. THIS MANUAL CONTAIN QUALITY MANUAL CUM PROCEDURE MANUAL. TOTAL COPIES :01 COPY SR.NO. :01 / 02

ISSUED TO : MR & PROPRIETOR/ SHOP

ISSUE NO : 01

ISSUED DATE : 01-11-2011

DISTRIBUTION LIST

SR NO COPY HOLDER COPY NO.

01 MR & PROPRIETOR -MASTER COPY 01 02 CONTROLLED COPY- SHOP 02

Page 2 of 59

METAL TECH

INDUSTRIES Gat No. : 138, Dhanore(Alandi), Tal. Khed, Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/01

ISO Section 00 TITLE: Table Of Content Rev. no : 01

Date : 01-01-2012 Page : 01 of 01

Sr.

No.

ISO Section

No. Doc. No.

Rev

No. Description

Pa

ges

1. 00 ---- -- Cover Page Cum Distribution List 01

2. 00 QM/01 01 Table of Contents 01

3. 00 QM/02 00 Amendment Record Sheet 01

4. 00 QM/03 00 Abbreviations 01

5. 00 QM/04 00 Company Profile 02

6. 1.0,2.0,3.0 QM/05 01 Application, Scope and Exclusions &

Justifications 01

7. 4.1 QM/06 00 Sequence and Interaction of processes 04

8. 5.1 QM/07 00 Management Commitment 01

5.2 QM/08 00 Customer Focus 01

9. 5.3 QM/09 00 Quality Policy 02

10. 5.4.1 QM/10 00 Quality Objectives 01

11. 5.4.2 QM/11 00 QMS Planning 02

12. 5.5.1 QM/12 00 Organization Chart 03

13. 5.5.1 QM/13 00 Responsibility and authority 08

14. 4.2.3 QSP/01 00 Procedure for Control of Documents 04

15. 4.2.4 QSP /02 00 Procedure for Control of Records 01

16. 5.6.1, 5.6.2,

5.6.3

QSP /03 00 Procedure for Management Review 02

17. 6.1, 6.2, 6.3,

6.4

QSP /04 00 Resource management, and Trainings 03

18. 7.1,7.2 QSP/05

00 Product realization, customer related

process, customer communica tion 03

19. 7.4.1, 7.4.2,

7.4.3

QSP/06 00 Purchasing ,Receipt Inspection 04

20. 7.5 QSP /07 Production and service provision 01

21. 7.5.2 QSP/08

00 Validation of processes for production &

service provision 01

22. 7.6 QSP /09

00 Control of Monitoring and Measuring

Equipments 01

23. 8.2.1,8.2.3,8.

2.4

QSP /10 00

Monitoring and Measuring of

Process,Product,Customer satisfaction 02

24. 8.2.2 QSP /11 00 Internal Audit 02

25. 8.3 QSP /12 00 Control of Non –Conforming Products 03

26. 8.4 QSP /13 00 Analysis of Data 01

27. 8.5.1 QSP/14 00 Continual Improvement 02

28. 8.5.2, 8.5.3 QSP/15 00 Corrective & Preventive Action 02

** QM- Quality Manual , QSP : Quality System Procedure Date : 01-01-2012 Name Designation Signature

PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 3 of 59

METAL TECH


QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/02

ISO Section 00 TITLE: Amendment Record

Sheet Rev. no : 00 Date : 01-01-2012 Page : 01 of 01

Sr No

.

Doc No.

Old Rev.

No.

Old Rev.Dat

e

New Rev.

No.

Revised

Date

Details of Changes Approved By

Date :01-01-2012 Name Designation Signature PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 4 of 59

METAL TECH


QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/03

ISO Section 00 TITLE: Abbreviations Rev. no : 00

Date : 01-01-2012 Page : 01 of 01

Sr

No.

Abbreviatio

n Stands for

Sr

No.

Abbrevi

ation Stands for

1 ISO

International Organization for Standardization

25 IPCP In Process Work Standard

2 QM Quality Manual

26 FGCP Finish Goods Work Standard

3 Doc. No. Document Number 27 RMCP Raw Material Control Plan.

4 MK Marketing 28 BOCP Bought Out Control Plan

5 MR Management representative

29 OLCP Offloaded Control Plan.

6 MTRLS Material

30 QMS Quality Management System

7 PUR Purchase 31 Dept. Department

8 HR Human Resource 32 w.r.t. With Respect To

9 MGT Management 33 Sr.No. Serial Number

10 PRD Production 34 QR Quality Rating

11 QA Quality Assurance 35 DR Delivery Rating

12 QC Quality Control 36 IQA Internal Quality Audit

13 QMS Quality Management System

37 PO Purchase Order

14 PROPRIETOR.

Managing PROPRIETOR.

38 Desp Dispatch

15 NC Non Conformance 39 M/C Machine

16 CAPA Corrective & Preventive Action

40 B/D Break down

17 NCR

Non-Conformance Report

41 PM Preventive Maintenance

18 RMCP

Raw Material Work Standard

42 Drg Drawing

19 OLCP

Off Loaded Work Standard

43

20 BOCP

Bought Out Work Standard

44

21 PP Process Plan 45

22 CP Control Plan 46

23 WI Work Instruction 47

24 SA System Administrator 48


APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 5 of 59

METAL TECH


QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/04

ISO Section 00 TITLE: COMPANY PROFILE Rev. no : 00

Date : 01-01-2012 Page : 01 of 01

Name Of Organization METAL TECH INDUSTRIES

Office address Gat No. : 138, Dhanore(Alandi), Tal. Khed,

Dist.Pune-411015

Works : Gat No. : 138, Dhanore(Alandi), Tal. Khed, Dist.Pune-411015

Contact Person Mr.Balasaheb. Shendage.(PROPRIETOR. & MR)

Contact Number Mr.Balasaheb. Shendage.(MR & PROPRIETOR.)- 9822174426

E-mail id [email protected] [email protected]'

Scope of activities Manufacturing & Supply of Machined Metal Components and Provision of Electroplating & Nitriding

Infrastructure and

Facilities

Work Place near by 5,000 Sq. Feet

Nature of company Process of following parts as per Customer specification/Requirements.

i) Hard Chrome Electroplating, ii) Nitriding, & iii) Machining

Working Hours 09.00 a.m. to 06.00 p.m. Weekly OFF Sunday Major Customers Some of Our Major Customers are

i) Perfect Engine Components Pvt Ltd ii) Star Ways Precision Pvt Ltd. iii) Varroc Engineering Pvt Ltd iv) Kandhenu Valves Pvt Ltd.


APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 6 of 59

METAL TECH INDUSTRIES

Gat No. : 138, Dhanore(Alandi), Tal. Khed, Dist.Pune-411015

QUALITY MANAGEMENT SYSTEM MANUAL

Doc no.: QM/05

ISO Section 1.0,2.0,3.0

TITLE: Application, Scope and Exclusions

Rev. no : 01 Date : 01-01-2012 Page : 01 of 01

APPLICATION :

The purpose of this manual is to have a documented Quality Management System in accordance with ISO-9001: 2008 . The clauses mentioned in the documents pertain to ISO-9001: 2008 . This Quality Manual Covers the Quality Management System implemented At METAL TECH INDUSTRIES The QMS established in the Organization meets the requirements of ISO 9001: 2008.

Organization Name : METAL TECH INDUSTRIES

Scope of Quality Management System is :

Manufacturing & Supply of Machined Metal Components and Provision of

Electroplating & Nitriding. Some of Out Source Processes

• Instrument Calibration •

Exclusions and Justification: Exclusions Justification

Clause No.

Description

7.3

Design & Development

Since METAL TECH INDUSTRIES. does not design or develop products. All Product Designing & Validation is carried out by Customer. All principal product characteristics are specified by the

customers or their consultants . METAL TECH INDUSTRIES activities are limited to manufacturing as per customer specifications.


APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 7 of 59

QM/06 This page print from My Maual-26-12-2007P-II- Sequence and Interaction of processes-Page01 of 04 (Manual Page 06)

Page 08 of _____

Page 8 of 59

METAL TECH INDUSTIRS

Gat No : 138, Alandi Markal Road,Dhonare, Tal: Khed, Dist Pune-412105

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/06

ISO Section 4.1

TITLE: Sequence and

Interaction of processes Rev. no : 00 Date : 01-01-2012 Page : 02 of 04

OPEN. SEQUE

NCE

OPERATIONS QUALITY CHECKS

FOR MACHINING PROCESS

10

MATERIAL RECEIPT (Customer Supplied )

VERIFICATION OF RECEIPT MATERIAL BY

A] Verification of Customer Supplied Material i) Visual Check for Dent , Damage i) No Record .

30a

30b INRPCESS INSPECTION

Verification of all Above Processes(Inhouse) By

i) Checked as per In Process / Quality Plan ii) Record the Inspection in QF/PRD/05 iii) Record NC Product in Product NC Report(All Stages) in Format

QF/QA/10

40 FINAL INSPECTION & DESPATCH

VERIFICATION OF DESPATCH PROCESS BY i) Verified By Customer & Accepted lot. ii) Despatch to Customer


APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Customer Supplied /

RM

Inspection

Despatch

Cutting Turning

Page 9 of 59

METAL TECH


QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/06

ISO Section 4.1

TITLE: Sequence and


OP. OPERATIONS QUALITY CHECKS

FOR HARD CHROME ELECTROPLATING PROCESS

10

MATERIAL RECEIPT (RM)

VERIFICATION OF RECEIPT MATERIAL BY A] Customer Supplied Valve / Material Checks

ii) Visual Check of Customer Supplied Material : Visual Check –Dent, Damage, Rust. No Record.

iii) Any reject in Receipt inspection due to Dent, Damage, Rust will be communicate customer immediately.

B] Verification of Raw Material, Checks(Chemicals) i) Verification of Supplier Raw Material TC Kept Record in GIN QF/QA/09

C] Record & Update of Material status in ii) GIN / Goods Inward Inspection Report Format No.: QF/QA/09 iv) Product NC Report(All Stages) in Format No.: QF/QA/10 v) Identified the all material by TAG

Check Stem dia before Electroplating

Degressing Clean Job with Hot Water

Insert Top & Bottom caps

Jiging & Load in Bath

Check Solution Level

Check Solution Bath Temperature

Apply Current for Etching

Apply Current for Chrome Electroplating

Hard Chome Electroplating

Remove jigs from Bath

Top & Bottom Caps remove

Jobs clean with water

100% Inspection

Oiling on Head & Packing

20 INRPCESS INSPECTION


ii) Kept Pre Treatment(Degreasing) Report in QF/PRD/04 iii) Checked as per In Process sheet/Drawing(MTI STD)no.: QF/QA/07 iv) Record the Inspection in Setup Approval Report QF/PRD/06 vi) Record NC Product in Product NC Report(All Stages) in Format No.:

QF/QA/10


VERIFICATION OF DESPATCH PROCESS BY

i) Checked Checked as per In Process sheet/Drawing(MTI STD)no.: QF/QA/07 , Kept Record in Pre Despatch Inspection Report QF/QA/18

i) Packing as per Work Instruction / Customer Requirement ii) Attached PDIR & Raw Material TC to Challan (If Required / Specified By

Customer & Despatch to Customer


APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 10 of 59

METAL TECH


QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/06

ISO Section 4.1

TITLE: Sequence and


OP. OPERATIONS QUALITY CHECKS

FOR HARD CHROME NITRIDING PROCESS

10

MATERIAL RECEIPT (RM)

VERIFICATION OF RECEIPT MATERIAL BY A] Customer Supplied Valve / Material Checks

iv) Visual Check of Customer Supplied Material : Visual Check –Dent, Damage, Rust. No Record.

v) Any reject in Receipt inspection due to Dent, Damage, Rust will be communicate customer immediately .

B] Verification of Raw Material, Checks(Chemicals) iii) Verification of Supplier Raw Material TC Kept Record in GIN QF/QA/09

C] Record & Update of Material status in iv) GIN / Goods Inward Inspection Report Format No.: QF/QA/09 vii) Product NC Report(All Stages) in Format No.: QF/QA/10 viii) Identified the all material by TAG

Jigging Pre Treatment (Alkaline Degreasing- NAOH)

Jobs clean with water (Quech)

Pre Heating

Liquid Nitriding

Jobs clean with Hot water (Quech)

Final Inspection

Oiling & Packing

20 INRPCESS INSPECTION


v) Kept Pre Treatment(Degreasing) Report in QF/PRD/04 vi) Checked as per In Product Specification Mention in List of Customer,

Drawing & Product Specifications- Nitriding Process : QF/QA/01, vii) Record Inspection in Daily Production Cum Inspection Report( Nitriding)

QF/PRD/05 ix) Record NC Product in Product NC Report(All Stages) in Format No.:

QF/QA/10 x) Kept record on Daily basis of Chemical Analysis- Nitriding Salt - QF/QA/23


VERIFICATION OF DESPATCH PROCESS BY

ii) Checked as per In Product Specification Mention in List of Customer, Drawing & Product Specifications- Nitriding Process : QF/QA/01, Kept Record in Test Certificate-Nitriding QF/QA/18

iii) Packing as per Work Instruction / Customer Requirement iv) Attached PDIR & Raw Material TC to Challan (If Required / Specified By

Customer & Despatch to Customer


APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 11 of 59

METAL TECH


QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/07

ISO Section 5.1

TITLE: Management

Commitment


5.1 Management Commitment Management of the company as provided evidence of its commitments to develop & implement Quality Management System. Management is improve the effectiveness of QMS by following means,

i) Establishing the Quality Policy. Ref QM/09

ii) Ensuring that quality objectives are established. Ref QM/10

iii) Conducting the management reviews. Ref QSP /03

iv) Ensuring the availability of resources. Ref. QSP/04

v) PROPRIETOR./GENERAL MANAGER, PROPRIETOR.s & MR ensures that customer requirements are determined and are met with the aim of enhancing the customer satisfaction. Ref. QM/ 08 & QSP/ 05,QSP/10

vi) Communicating to the organization the importance of meeting customer as well as

Statutory & regulatory requirements, by means of meeting ,circular, Notice Board, Mails etc.

vii) Ensuing the quality system meet the requirement as per ISO 9001-2008 & verification of the same through Internal Quality audits . Ref. QSP/11

viii) Mr.Balasaheb. Shendage is appointed as Management Representative(MR)


APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 12 of 59

METAL TECH


QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/08

ISO Section 5.2

TITLE: Customer Focus


The MR, ensures that customer requirements are determined and are met with the aim of enhancing customer satisfaction. Management of company also ensure that all the activities is be carried out by keeping in view requirements of customer satisfaction. Customer satisfaction is being determined & corrective / preventive action is being initiated in case of customer dissatisfaction. Customer Requirements related to product, process, Dispatch & other requirements are determined & reflected through followings 1. New enquiry : Feasibility of Customer product or new enquiry is recorded in Development Enquiry Register in - QF/MGT/05 2. Customer Specification : Customer P.O., Specification, Drawings, Or our own Drawings approved by customers. Refer – List Of Customer, Drawings, Purchase Order & Comparison in QF/QA/01

3. Customer Schedule and Despatch : Customer Schedule in Schedule Vs Delivery Performance (Monthly)- QF/MGT/06

4. Monthly Weekly Production Planning & Internal Work Order

5. Customer Requirements are Documented in any of followings document a) Electroplating - : All Specification of are Documented List of Customer,

Drawing & Product Specifications/QA/01 & Process sheet/Drawing(MTI STD)QF/QA/07.

b) Nitriding - : All Specification of are Documented List of Customer, Drawing & Product Specifications/QA/01

6. Customer Requirements related to Documents are Documented in any of followings document

a) Customer Drawings b) Customer PO, c) Control Plan, as applicable.

7. Effective Customer Communication is done as per details mention in List of Customer- QF/QA/01

8. Any Type of Customer Complaint related to product, process, Dispatch, Qty, is recorded in Customer Complaint Log- QF/QA/11

9. Level of Customer satisfaction is evaluated in Customer Satisfactory form.- QF/MGT/04

10. Any dissatisfaction of Customer will evaluated for its root cause, corrective action & preventive actions in QF/QA/12 & or Improvements Continual Improvement Projects in QF/MR/11

DATE :01-01-2012 Name Designation Signature

PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 13 of 59

METAL TECH


QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/09

ISO Section 5.3 TITLE: QUALITY POLICY-

GROUP Rev. no : 00

Date : 01-01-2012 Page : 01 of 01

QUALITY POLICY We at METAL TECH INDUSTRIES , are committed to provide our customers electroplating, nitriding and machining of engine parts that meets their expectation. To realise the vision we will continually improve customer satisfaction by focussing on required quality, right quantity, cost and on time delivery. Our Overall objectives is to become the preffered choice of customers. 1) Defining individual responsibility and authority 2) Planned and efficient utilization of technological,

human and material resources. 3) Training of our employees 4) Encouraging teamwork 5) Contniual Improvement 6) Doing things right first time.

Rev. No . 00 Mr.Balasaheb. Shendage Date : 01-01-2012 PROPRIETOR.

Page 14 of 59

METAL TECH


QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/09

ISO Section 5.3 TITLE: QUALITY POLICY-

GROUP Rev. no : 00

Date : 01-01-2012 Page : 01 of 01

maoTla Tok [MDsT/Ija AaLMdI-markL raoD, Qaanaaoro, ta.KoD, ija.puNao 412105

,-

gauNava%ta QaaorNa AamhI maoTla Tok [MDsT/IjamaQyao gaàhkaMcyaa garjaonaUsaar [Mijana paT-sa\naa [lao@T/aoPlaoiTMga, naayaT/ayaDIMga va maiSanaIMga k$na doNyaasa vacanabaQd va samaip-t Aahaot.yaaogya gauNava%%aa vaajavaI ikMmat va yaaogya saM#yaot maalaacaa vaoLovar purvaza yaavar Bar doNao ho Aamacao Qyaoya Aaho. gaàhkaMcaI p`qama psaMtI banaNao haca Aamacaa ]d,doSa Aaho.AamhI ho KalaIlap`maaNao saaQya krNaar Aahaot. 1. p`%yaokacaI jabaabadarI va AiQakar zrvauna doNao. 2. taMiHak manyauYyabaL AaiNa saaQanasaamaugaÌcaa inayaaoijat va

pirNaamakark vaapr. 3. garjaonausaar pìSaxaNa doNao. 4. saMaiGak kayaa-saazI pào%saahna. 5. inarMtr sauQaarNaa krNao. 6. Pihlyaaca vaoLosa baraobar kaya-p`NaalaIcaa AvalaMba krNao.

Rev. No . 00 Mr.Balasaheb. Shendage Date : 01-01-2012 PROPRIETOR

Page 15 of 59

METAL TECH


QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/10

ISO Section 5.4.1 TITLE: QUALITY

OBJECTIVES Rev. no : 00 Date : 01-01-2012 Page : 01 of 01

QUALITY OBJECTIVES

At the beginning of every financial year the management, decides objectives for the year, METAL TECH INDUSTRIES become part of this manual. These are stated below. These objectives are consistent with the Quality Policy and are measurable. Performance of the various levels/ functions is tracked against the set objectives so as to measure the effectiveness of the Quality Management System and decide improvement opportunities.

List of KPI’S/Quality Objectives (Key Performance Indicators)

Sr.No.

Objective Existing Trend 11-12

Planned Results Responsibility

2012-13 2013-14

2014-15

WESTFALIA METAIL COMP. PVT LTD

1 Customer complaints 1/Quarter 1/Quarter 0 0 QA

2 Customer satisfaction

index 95% 98% 99% 100% Prop. /

management

3 Inhouse Rework 1% /Month 0.8% /Month 0.6%

/Month 0.5%

/Month QA

4 Delivery Performance 95% 98% 99% 100% Despatch


PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 16 of 59

METAL TECH


QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/11

ISO Section 5.4.2

TITLE: QMS PLANNING Rev. no : 00

Date : 01-01-2012

Page : 01 of 02

The organization has established, documented, implemented maintains Quality Management System & continually improves its effectiveness in accordance with the requirements of this QMS as per ISO 9001:2008.

METAL TECH INDUSTRIES. has established Quality Management System, and includes: A] Documentation Requirements:

1) Quality Manual (QM) The Quality Manual covers the requirements of ISO 9001:2008 It describes a summary of

Quality Planning done in line with clauses of ISO 9001:2008 Ref. QM/01, All Quality manual are identified by QM/XX , Where XX : is serial No of

2) Quality System (Operating) Procedure (QSP) Operating Procedures define the methodology of work carried out in functional areas.

Operating procedure gives reference at appropriate places of respective forms/formats. Ref. QM/01, All Quality System Procedure are identified by QSP/XX

Where XX : is serial No of Quality System Procedure

3) Work Instructions (WI) Work Instructions define the method of doing specific task. Operating procedure give

reference at appropriate places of respective work instruction. Ref. QF/MR/08, All Work Instructions are identified by WI/XX

Where XX : is serial No of Work Instructions

4) Blank Formats (QF) Form & formats are used to generate Quality Record & Quality Planning documents. All Forms & Formats are identified by QF/XX/YY

Where QF : Quality Format, XX : is Dept Code & YY : is Serial No of Department Format

which is incremental

5) All quality planning documents (Work Standard, Customer Specifications, & Required Standards for Manufacturing the products, customer products brochures) CONTROL OF FORMATS , DOCUMENTS & RECORD: Ref. Control of Documents done as per QSP/01 Ref. Control of Record as per QSP/02

B] Management Responsibility:

Management commitment- Ref. QM/07, Customer focus- Ref. QM/08, Quality Policy - Ref. QM/09, Quality Objectives- Ref.QM/10, Responsibility & Authority- Ref. QM/ 13 &, Management Review Meeting- Ref.QSP/03

Page 17 of 59

METAL TECH


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SYSTEM MANUAL

Doc no.: QM/11

ISO Section 5.4.2

TITLE: QMS PLANNING Rev. no : 00 Date : 01-01-2012 Page : 02 of 02

c) Resource Management: - Ref.QSP/04

d) Production Realisation:

Planning of products realization (Production Planning, Customers PO/AO, Our quotation, purchasing process, purchasing information, verification of purchase product, product realization & traceability. Ref QSP/05, QSP-06, QSP/07,QSP/ 08

e) Measurement, analysis Improvement: Ref QSP/10, QSP/11, QSP/12, QSP/13, QSP/14

f) Corrective Preventive Action : Ref. : QSP/15


PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 18 of 59

QM/12 THIS Page id on File My Maual-26-12-2007P-II.doc ORG CHART Page 18 of 15

Page 19 of 59

METAL TECH

INDUSTRIES Gat No. : 138, Dhanore(Alandi), Tal. Khed,

Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/13

ISO Section 5.5.1

TITLE: RESPONSIBILITY

AND AUTHORITY Rev. no : 00 Date : 01-01-2012 Page : 01 of 08

RESPONSIBILITY AND AUTHORITY

A] Designation: - Head Marketing

RESPONSIBILITY

1. Over all administration of the organization and setting the direction.

2. Communicating to the organization the importance of meeting customer

as well as statutory and regulatory requirements

3. Defining, documenting, implementing and maintaining the Quality Policy

and objectives.

4. Fixing responsibilities & authorities and interrelationship of various

functions.

5. Conduct Management Reviews for effective implementation of Quality

Management System with MR and Supervisor.

6. Identify and determine applicable government safety and environmental

regulations

7. To provide all types of resources. Analysis and review of company level

data

8. Initiate, recommend or provide solutions (to avoid recurrence of non

conformances) through designated channels

9. New business development

10. Prepare and submit quotations, negotiate and finalize orders

11. Determining and analysis of customer satisfaction levels.

12. Customer Liaising

13. Monitor and follow-up of project schedules of all the products under

development.

14. To Implement the group policy throughout the company.

Authority

1. To Accept the Order

2. Communicate the Development Progress to HO

Page 20 of 59

METAL TECH


Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/13

ISO Section 5.5.1




A] Designation: PROPRIETOR.- Marketing, Development, Plant Activity

RESPONSIBILITY

1. Over all administration of the organization and setting the direction.

2. Compliance of customer as well as statutory and regulatory requirements

3. Conduct Management Reviews for effective implementation of Quality

Management System with MR and Supervisor.

4. Compliance to applicable government safety and environmental regulations

5. To provide all types of resources. Analysis and review of company level data

6. Prepare and submit quotations, negotiate and finalize orders

7. Determining and analysis of customer satisfaction levels.

8. Monitor and follow-up of project schedules of all the products under

development.

9. He is ultimately responsible for ensuring that the Quality Policy is understood,

implemented and maintained.

10. Responsible for marketing and business development of the company.

11. Responsible for entire operations of the company.

12. Responsible for plant efficiency, productivity and profitability.

13. Responsible for understanding requirements of the products specified by

customer, including delivery & post-delivery activities, statutory & regulatory

requirements.

14. Ensure amendments to contracts are correctly transferred to production.

15. Price increase, estimation and negotiation.

16. Responsible for procurement of raw materials, consumables,

Maintenance spares, capital items and administration supplies.

Authority 1. Revision of Costing

2. Supplier Purchase – Approval, Costing, Selection

3. NC Product Disposition

4. Deal with Govt. Agencies

5. Final approval authority for commercial terms & condition.

6. To approve the Purchase Order

Page 21 of 59

METAL TECH


Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/13

ISO Section 5.5.1




A] Designation: HEAD COMMERCIAL Responsibility 1. Overall administrative control of the business. 2. Chair management Review Meetings. 3. To prepare Business Plan for every year. 4. To ensure adequate availability of resources & cash flow to meet Business Plan. 5. Measurement & control over resource utilization. 6. Periodic visits to key customers to review areas requiring improvement. 7. To review all aspects of quality related technical / commercial functions & to

achieve customer expectations 8. To ensure Quality Management Systems are understood by all. 9. To recommend solution through designated channels to prevent recurrence of NC's

and thereby assist the functions concerned in improving their perception of quality requirements to meet or exceed customer expectations.

10. Focus on areas crucial for future growth & profitability Authority

1. To decide on corrective actions on disposing NC as a final authority. 2. To approve expenses/payments of suppliers. 3. To accept customers purchase orders on authorized price and terms. 4. To approve budget sanction. 5. To take policy decisions on all operational matters. 6. To ensure implementation of continuous improvement plans 7. To monitor product development activities 8. To monitor the corrective & preventive actions for effectiveness

Page 22 of 59

METAL TECH


Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/13

ISO Section 5.5.1




B] Designation: HEAD Account /Material Procurement /Outsourcing/Dispatch

Responsibility 1. To approve the supplier, update the supplier list, monitored the supplier performance,

purchase the steel from approved suppliers as per the schedule released by marketing.

2. To maintain plant’s accounts and connected matters and records.

3. Timely arrangement and allocation of funds to their most productive uses.

4. Dealing with financial institutions, Company’s Bankers / various Govt., Depts. Like Excise / Sales Tax,Octroi etc. for day to day work and preparation and collection of all information connected therewith.

5. Co-ordination with company’s statutory auditors / internal auditors / Excise and Sales Tax Consultants. & Octroi agents.

6. Control over matters relating to direct and indirect taxation / company law / sales tax, TDS [Tax deduction at source] & octroi refunds.

7. Timely submission of various forms / returns to various Govt. agencies including Company bankers.

8. Maintenance of the records or orders issued by the management from time to time concerning dept/personnel financial matters. And ensuring their implementation.

9. To confirm the dispatch status.

10. Payment collection from all customers from time to time.

11. To assess periodically stocks & report on slow / non-moving items for disposal action.

12. To take Care of hazardous material with certification from competent authority.

13. To create minimum stocks level for all consumable products.

14. To monitor the quality & delivery performance of the suppliers in co-ordination with )

15. To identify training needs for all deputies in his department Authority

1. Final approval authority for commercial terms & condition.

2. To approve the Purchase Order

3. To establish authorized receipts & issues systems in Stores for all items including Consumables.

4. To sale scrap in concern with PLANT INCHARGE

5. To approve & ensure compliance to department manual.

6. To approve vender commercial terms & condition.

Page 23 of 59

METAL TECH


Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/13

ISO Section 5.5.1




C] Designation: HEAD All plant activity –Production/Quality Control /HR

Responsibility

1. To receive customer requirements form Marketing & prepare Dispatch Plan 2. To refer Dispatch Plan & WIP and prepare monthly Production Plan. 3. To ensure that proper raw material is released for manufacturing. 4. To prepare Daily Production Report and conduct daily meeting. 5. To take daily follow up of material flow to fulfill Dispatch Plan. 6. To prepare daily / monthly analysis of schedule v/s dispatch along with HOD (MKT). 7. To receive and store the steel as per the specification and requirement 8. To organize steel checking in co-ordination with H.O.D. - MQC. 9. To issue accepted raw material steel as per requirement & control inventory, raw

material consumption. 10. To handle the functions of Steels - Store

11. To keep all equipment’s in working condition and upkeep of machines and equipment's as per the user manuals.

12. To analyze downtime & time bound plan to reduce it.

13. To improve maintainability & functional upgradation of all equipment's.

14. To carry out calibration of process control equipment's, gauges

15. To ensure Erection &Commissioning of new machines and establish Preventive Maintenance plan.

16. To present trends of "Time Lost in BD" in MRM

17. To initiate & implement Corrective & Preventive action & assess for effectiveness.

18. To identify Training needs for all deputies in his dept.

19. To prepare & implement preventive maintenance schedule and make it known to all Concerned Hod’s

Authority

1. To make changes in the production plan to meet changing priorities & based on steel availability.


3. To approve manpower requirement of different shops & co-ordinate with HRD for fulfilling the same.

4. To approve & implement the continual improvement proposals in line with the cost, productivity, quality.


6. To approve vender commercial terms & condition.

Page 24 of 59

METAL TECH


Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/13

ISO Section 5.5.1



RESPONSIBILITY AND AUTHORITY D] Designation: QA HEAD/ INCHARGE 1. Responsible for incoming, inprocess & final inspection and testing.

2. Preparation of quality plans & process plans as per customers requirement.

3. Calibration of all measuring instruments & gauges as per calibration schedule.

4. To maintain inspection & test status of a product.

5. To maintain calibration status of measuring instruments & gauges.

6. To record & review of nonconforming product.

7. To safe guard measuring instrument & gauges against unauthorised use.

8. Member of management review meeting.

9. Authority to release final product.

10. Maintain all records of inspection & testing.

11. Customer satisfaction determination

E] Designation: Production In charge 1. Man & machine planning as per production planning.

2. To provide production aids to operator.

3. To control nonconformatives during production.

4. To carryout preventive & breakdown maintenance & maintain record

5. To maintain product identification & traceability during manufacturing.

6. To maintain good house keeping & safety working conditions on shopfloor.

7. To monitor production as per plan & initiate corrective action in case of deviations.

8. To provide work instruction & quality plans at the point of use.

9. To monitor process parameter like speed, feed, tooling etc.

10. To keep all nonconforming items at designated area or identify by tags & record it

concerns report.

11. Periodic verification of jig fixture as per list of jigs & fixtures & update the list.

Page 25 of 59

METAL TECH


Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/13

ISO Section 5.5.1



RESPONSIBILITY AND AUTHORITY F] Management Representative: 1. Management has appointed member of management for establishing QMS inn the

organisation his responsibility & authority includes as follows, 2. Overall responsible for implementation of quality management system in the

organisation. 3. To organise management review meeting. 4. To prepare documents as per requirement of TS ISO9001 with concern person. 5. To prepare master list of documents. 6. To maintain record of issue of documents. 7. To maintain record of document changes. 8. Preparation of internal quality audit plans. 9. To conduct internal quality audit as per internal quality audit plan. 10. Interaction with external agencies likes certification bodies, consultant etc. 11. Responsible for quality management system related nonconformance. 12. To identify training needs of all employee with concern department head. 13. Preparation of training plans & organise training activity as per plan.

G] Designation: Purchase Incharge:

1. Preparation of purchase order.

2. To follow up with supplies for procurement of items

3. To maintain list of acceptable suppliers.

4. To inform supplier about discrepancies purchase items

5. To maintain purchase item specification.

6. Periodic rating of suppliers.

H] Development In charge: 1. Manufacturing of tooling required for new jobs.

2. Inspection & testing of new component.

3. Preparation of documents for new job development.

4. To rectify problems observed in pilot lot/ sample

I] Workers: 1. To carry out production as per instructions given .

2. To do visual inspection during production to bring NC Product in notice.

3. Maintain good housekeeping.

4. To do productive maintenance.

Page 26 of 59

METAL TECH


Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QM/13

ISO Section 5.5.1



SR.

NO. CLAUSE NO

PROPRIE

TOR. MR MKT MTRLS QA PRD.

1. 5.3 P P P P P P

2. 5.5.1 P P P P P P

3. 6.1, 6.2 P P P P P P

4. 5.5.2 P P S S S S

5. 5.6 P S - - - -

6. 4.1, 4.2 P P P P P P

7. 5.2, 7.2 - - P S S S

8. 7.3 - - - - - -

9. 7.4 P - - P S -

10. 7.5.4 - - P S S S

11. 7.5.3 - - - P P P

12. 6.3, 6.4, 7.5 - - - S S P

13. 7.4.3, 8.2.4 - - - S P S

14. 7.6 - - - - P S

15. 8.3 - - - P P P

16. 8.5 P P P P P P

17. 7.5.1, 7.5.5 - - - P P P

18. 4.2.4 S P P P P P

19. 8.2.2, 8.2.3 S P S S S S

20. 6.2.2 P S S S S S

21. 7.5.1 - - - S S P

22. 8.1, 8.2, 8.3, 8.4 - P - - P -


PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 27 of 59

METAL TECH


Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/01

ISO Section 4.2.3

TITLE: QUALITY SYSTEM

PROCEDURE FOR : CONTROL OF DOCUMENTS

Rev. no : 00 Date : Page :

01-01-2012

01 of 04

PURPOSE

To ensure quality system documents issued at METAL TECH INDUSTRIES. are properly controlled and that modification to existing documents are approved by appropriate authority prior to issue.

RESPONSIBILITY

It is the responsibility of Management Representative, to ensure that this procedure is implemented. The MR is responsible for the control and updating of quality manual, quality procedures and the related documentation. The Managing PROPRIETOR./GENERAL MANAGER /General Manager approves the quality manual and the Quality Manager approves the quality procedures Sr No

Procedure Resp. Doc/Format Ref.

01 All information and data essential to be up-to-date for effective functioning of the quality system are identified as ‘Documents’. Documents are grouped as follows :

i. Quality Policy ii. Quality Objectives iii. Quality Manual iv. Organization chart v. Operating procedures, METAL TECH INDUSTRIES

are Part of Quality Manual

MR Table Of Content page of Quality Manual QM/01

vi. Customer Drawings vii. Specifications and other technical documents viii. Work instructions ix. Forms and Registers x. Documents of External Origin xi. Process sheets, Work Standards

MR All Documents are mention in List of Formats in QF/MR/01

02 A Master List of format is maintained by MR. The list contains the all formats identified by format no. When this formats are filled by relevant information,& organization are used for reference purpose for effective QMS process.

List of Formats in QF/MR/01 ---“”----

03

Type of Documents / Record are identified as Doc. / Record in master list of formats.

MR

Page 28 of 59

METAL TECH


Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/01

ISO Section 4.2.3




01-01-2012

02 of 04

Sr No


03 All Manual, QSP All Manual, QSP are document controlled through table of contents QM/01. Each page of Manual is identified by Doc no., revision no., & revision date.

MR Manual-QM-01

04 The Master List of Formats contains Format Number, Format Rev no., Format effective date,. Issued To, Document/Format, & if Document, revision no.& revision date of that document. All details are mention in master list of formats. All the mention in master list of formats as Doc. are

identified as document Every Documents contain Rev. No, Rev. Date, & DCN no. when document changes or modified for adequacy

MR List of Formats in QF/MR/01 & Documents All Documents are identified as ‘’DOC.’’ in Master list of Format

05 Document Issue: MR issues internal as well as external documents in a controlled manner. Original copy is stamped as ‘MASTER COPY’ by blue colour on back side of the document. Master copy of all the documents is maintained by MR. Further issue of the master copy for reference will be done. Photocopies of the Master Copy are distributed by stamping them in RED colour ink as ‘CONTROLLED COPY ’ on front side of the document.

MR All Documents

A master List of forms and formats is Maintained to indicate the revision status of the document and the copies distributed.

MR List of Formats in QF/MR/01

This list is updated whenever a new revision is introduced into the system. It is ensured that the current revision is available at the point of use.

MR

Page 29 of 59

METAL TECH


Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/01

ISO Section 4.2.3




01-01-2012

03 of 04

Sr No


06 EXTERNAL ORIGINE DOCUMENTS External Documents are also controlled and distributed in the same manner .A separate List of forms and formats is maintained for documents of External Origin. for example Standards

i) for Raw material, Testing, Reference books & manuals , customer supplied formats & formats, Customer approval, Customer standards related to product, process

ii) Customer Drawings and / or specifications, Customer PO

MR List of External Documents in Format QF/MR/03 Customer PO as per List in QF/QA/01

All Standards of external origin, are controlled by the MR. Standards of external origin are reviewed and updated yearly on the basis of BIS catalogue & Or

Updating authority agency.

MR

07 Document and Data Approval and Issue:

MR

All Documents are prepared by respective department head.

Prior to issue, the documents are reviewed for adequacy and approved by MR. The issue is maintain as per Sr No:05

List of Formats in

QF/MR/01 & all List

08 Document and data change:

MR

All Documents are identified for adequacy or correctness by its document rev no & document revision date along with the Document change note .

Respective dept. head changes the required document, along with the Document Change Request. MR reviews the document & if adequate, approves the DCR & Document.

MR ensures before the issuing the latest document to user, that all previous versions of documents from all locations are stamped as “OBSOLETE COPY” in red colour

MR also ensures that DCR no, Rev Date, Rev No is correct on documents. Same is updated in Master list of Formats

Document Change Request

QF/MR/02

List of Formats in QF/MR/01

All revised documents are issue as per Sr No: 05 of this procedure

MR ---

Page 30 of 59

METAL TECH INDUSTRIES Gat No. : 138, Dhanore(Alandi), Tal. Khed,

Dist.Pune-411015


Doc no.: QSP/01

ISO Section 4.2.3

TITLE: QUALITY SYSTEM PROCEDURE FOR :

CONTROL OF DOCUMENTS


01-01-2012

04 of 04

Sr No


09 FORMAT CONTROL

All Formats are revised are updated for its revision no, rev date along with the DCR(Document Change Request) MR ensured that the current revision of format is available at the point of use.

MR List of Formats in QF/MR/01 & Document Change Request QF/MR/02

10 DOCUMENTS STORED IN PERSONAL COMPUTER

Documents such as drawings, cad data, customer specifications stored on personnel computers are controlled by the concerned engineer/manager. Such data is protected by password and should not have unauthorized access. Where the Software based programmed installed , backup of Software will be taken. All Software Original CD, Backup will be stores in Lock & Key. Regular back up is taken to avoid possibility of documents and data due to breakdown/corrupt.

MR & Dept. Heads

List of Formats in QF/MR/01 Backup / Storage of License Copy


PREPARED & APPROVED BY:

Mr.Balasaheb. Shendage

MR & PROPRIETOR.

Page 31 of 59

METAL TECH


Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/02

ISO Section 4.2.4


CONTROL OF RECORDS


01-01-2012

01 of 01

Sr No


01 Quality records will be scrutinized with respect to legibility and clarity. Records are suitably, indexed / numbered, filed and stored in proper place by indicating Name of Record, File No., Document Number (where applicable), Format Number, Retention Period,

Dept. Head

All Retention Records Filing System

02 The records will be indexed and properly filed ensuring easy retrievability. Where there are many files containing same record, Volume Number may be used to denote connectivity between files

Dept Head

03 Retention period for each quality record will be established in list of Formats. On expiry of retention period specified in the list, quality records are disposed. Such disposal is done periodically. The retention periods are decided on the basis of customer, functional, legal and the Government requirements, importance of activity and data in future. Where applicable, quality records, METAL TECH INDUSTRIES are contractually required for evaluation by the customer or the customer's representative, are identified, controlled and maintained for an agreed period.

MR & Dept Head

Retention Period as mention on List of Formats in QF/MR/01

04 GOVT RULES, REGULATION, EXCISE DOCUMENTS. Generally the all Govt. related documents such as excise Challan, balance sheet, Govt. licenses, Communication willm kept 3 years after generation. Records METAL TECH INDUSTRIES are not to be disposed, even after expiry of retention period (for various reasons such as legal exposure, risk coverage, anticipated governmental legislation and regulation, etc.) will be identified by the PROPRIETOR., stored separately. Authorized personnel will dispose quality records other than Special .

MR & Dept Head

Special Records as per Govt. Rules &

Regulations (Min. 3 years)

05

Upon expiry of the retention period, shredding destroys Quality Records

MR & Dept Head

frequency mention in List of Formats in QF/MR/01


PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 32 of 59

METAL TECH

INDUSTRIES Gat No. : 138,

Dhanore(Alandi), Tal. Khed, Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/03

ISO Section 5.6.1, 5.6.2, 5.6.3


PROCEDURE FOR : MANAGEMENT REVIEW MEETING


01-01-2012

01 of 02

Sr No


MRM in QF/MGT/03 once in Three Month Interoffice memo for MRM along with Agenda Points & Dates

01 To ensure the continuing suitability, adequacy and the effectiveness of the quality management system, management review meeting is conducted once in a THREE MONTH. Managing PROPRIETOR. chairs the management review meeting.

The management review meeting is scheduled and arranged by MR. MR informs to all members of MRM regarding the meeting.

Minutes of management review meeting are prepared and circulated to all the concerned by the MR , Including actions decided in the meeting. MR maintains all management review records.

Apart from schedule, the on emergency basis,

PROPRIETOR./GENERAL MANAGER may call

management review meeting.

PROPRIETOR./ & MR

02 The members of management review are 1. PROPRIETOR./GENERAL MANAGER, 2. Dept Head & , 3. Staff Members.

Meeting Member

03 MRM must be conducted on following agenda

5.6.2 REVIEW INPUT The input to management review shall include information on a. Results of Internal & External audit b. Customer feed back including complaints c. Process performance and product conformity d. Status of preventive and corrective actions e. Follow up actions from previous management reviews f. Changes that could affect the quality management system g. Recommendations for improvement h. Review of Quality Policy and quality objectives i. Business plan

PROPRIETOR., MR & Dept Head

Meeting Agenda

IQA Summary in QF/MR/08

Customer Complaint in QF/QA/11

Inhouse NC & CAPA in QF/QA/10, 12

Business plan in QF/MGT/01

KPI Trend in QF/MGT/02

Page 33 of 59

METAL TECH


Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/03

ISO Section 5.6.1, 5.6.2, 5.6.3


PROCEDURE FOR :

MANAGEMENT REVIEW MEETING


01-01-2012

02 of 02

Sr No


04 The functional Heads prepare and submit appropriate data to PROPRIETOR./GENERAL MANAGER for discussion in the meeting. Any constraint or problem area reported is also discussed. Changes in the QMS , METAL TECH INDUSTRIES are expected or have been carried out are discussed in order to provide necessary resources to ascertain the suitability.

PROPRIETOR., & Meeting members

MRM in QF/MGT/03

05 The output of Management review is action plan.

The output includes any decision and actions taken related to a. Improvement of the effectiveness of quality management system and its processes b. Improvement of product related to customer requirements c. Resource needs

PROPRIETOR., MR & Dept Head

MRM Action Plan Revised KPI Target in QF/MGT/02

06 Action Plan

Any pending actions, not meeting the targets and or quality objectives will require a detailed action plan to meet the requirement or targets given by management. A Detailed action plan will be made on the basis of 5W-1H basis (What->Why->Where->When->Who & -1H(How)

or WHY-WHY Analysis, OR 8D to fulfill the targets. The action plan includes the responsibility & target date of completion.

MR & Dept Head

Action Plan in MRM

QF/MGT/03

or

in Continual Improvement Projects QF/MR/11

or CAPA in

QF/QA/12

07 The action plan is distributed to all committee members. The action plan is monitored for implementation of decisions as per the targets. The feedback on the status is discussed once in a month.

08 MR maintains the record of MRM in minutes of MRM


PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 34 of 59

METAL TECH INDUSTRIES Gat No. : 138, Dhanore(Alandi), Tal. Khed,

Dist.Pune-411015


Doc no.: QSP/04

ISO Section 6.1, 6.2, 6.3, 6.4


Resource management,

and Trainings


01-01-2012

01 of 03

Sr No


01 02

RESOURCE MANAGEMENT

The company determines, provides & maintains the infrastructure needed to achieve conformity to product requirements . Infrastructures includes (as applicable)

a) building, work space & associated utilities b) process equipment (List of Machine –QF/PRD/01 ), (List of Instrument & Gauges )- QF/QA/04 c) supporting devices (telephone, Fax & Mobile ) d) List of Employee in QF./HR/01

The company determines & manages work environment needed to achieve conformity to product requirements by virtue of a) proper lighting arrangement b) adequate resources c) Proper housekeeping d) Adequate natural air ventilation. e) Proper drinking water availability

PROPRIETOR., & All Dept. Head

Adequacy of Plant, Facility, Resource to meet the Product & Customer Requirement in Development Enquiry Register In QF/MGT/05 List of Machine in QF/PRD/01 List of Instrument & Gauges in QF/QA/04 List of Employee in QF/HR/01

03 In case any of machines, equipment, etc. facilities are expected to be stored Organization & not in use for a period beyond one month, the facility status is indicated by means of ‘Not In Use’ tags, boards etc. Concerned Department is responsible for the cleanliness and damage protection of such a facility. The Maintenance Department is responsible for preservation of the facility by appropriate means such as oiling, greasing, covering, etc., as applicable

Maint. Dept. Head

‘NOT IN USE’ Tag

Page 35 of 59

METAL TECH


Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/04

ISO Section 6.1, 6.2, 6.3, 6.4


PROCEDURE FOR :

Resource management, and Trainings


01-01-2012

02 of 03

`

Sr No


04 Machine Maintenance

The List of Machine is maintained.

Prod. Head

List of Machine in QF/PRD/01,

05 In case of machine and / or equipment (facility) related problem, Breakdown Memo & or Verbal Intimation must be sent to the Maintenance department. All Breakdown time is recorded from start to completion of Maintenance are recorded on Daily production report. Once the maintenance job is completed the facility must be checked for suitability. Any part replaced during the breakdown is recorded in Machine History Card, & is prepared machine-wise.

Prod. Supervisor Maint. Engr./Supervisor

Breakdown Memo, Communication Record Breakdown in Machine History Card in QF/PRD/03 ---‘’------

06 Preventive Maintenance

Weekly, Monthly, Quarterly Preventive Maintenance Checklist are prepared based on technical known things, past experience and manufacturer’s recommendations.

Maint. Engr./Supervisor

Annual Preventive Maintenance Plan Cum Record QF/PRD/02

Machine-wise Daily, Weekly, Monthly, Quarterly, & Half yearly PM Check points are designed to cover all known maintenance aspect of particular machine.

The frequency of PM will be based on the usage & criticality of machine.

Preventive Maintenance Schedule is worked out based on the Checklists. Planned Preventive maintenance is carried out as per the PM Schedule.

Checklists of PM activity may be reviewed and appropriately revised based on analysis of observations during Preventive / breakdown maintenance.

07 Safety Equipment : As per Govt. Rules & Regulations, Fork List, & Pressure Vessel are calibrated once in Year. Initially where the manufacturer supplied the Certification of compliance, will be treated as Calibration Once in Year after the equipment taken for use.

Page 36 of 59

METAL TECH

INDUSTRIES Gat No. : 138, Dhanore(Alandi), Tal.

Khed, Dist.Pune-411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/04

ISO Section 6.1, 6.2, 6.3, 6.4


PROCEDURE FOR : Resource

management, and Trainings


01-01-2012

03 of 03

Sr No


07 HUMAN RESOURCE & TRAINING

Training is an essential element of Quality Policy of the company. The company is dedicated to provide training to each employee and to empower him to make the best possible contribution to improve quality and performance in the respective area of responsibility.

HR Head

08 Every person must be trained to perform his work through training in operating, inspecting instructions relevant to the work, training in the relevant portion of quality system inclusive of Quality Policy, relevant Quality Objectives and Targets.

09 Training Activity is planned by HR Department. The department planned training as per list of employees..

LIST OF EMPLOYEE –QF/HR/01

10 The minimum level of competence including skills, experience and qualifications needed for specific jobs in specific functions are defined in the Skill Matrix.

Employee Qualification & Comp. Criteria in QF/HR/02

11 Determines the necessary competence for personnel

performing work affecting product quality. Accordingly skill matrix will be prepared

HR Head

Comp.Matrix Evaluation in QF/HR/03 ---””---

12 The areas where required improvement or competency required, training plan will be made. Annual Training plan to be prepared for satisfy these needs.

Annual Training plan QF/HR/04

13 14

As and when an employee is taken on roll, an Employee History Card is generated. The card is maintained till the employee is in service. Training will be recorded in Employee training card. It is ensures that the personnel are aware by training. The effectiveness of training will be evaluated in training card.

History Card maintains the maintains appropriate records of education, training, skills & experience

All Training are evaluated for the effectivess based on exam, on job knowledge working, or interview. Same is

updated in employee history card.

Employee Training Record QF/HR/05


PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 37 of 59

METAL TECH

INDUSTRIES Gat No. : 138, Dhanore(Alandi), Tal.


QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/05

ISO Section 7.1, 7.2


PROCEDURE FOR : PRODUCT REALIZATION, CUSTOMER

RELATED PROCESS, CUSTOMER

COMMUNICATION


01-01-2012

01 of 03

Sr No


01

7.1 Planning Of Product Realisation: Company has planned & developed process needed for product development. During development of new product technical parameter is reviewed for adequacy of existing processes. If existing processes are not found adequate then, provision is to be made to fulfill requirement of new product. PROPRIETOR./GENERAL MANAGER review the adequacy & effectiveness of following, � Machines & Equipment’s. � Documentation. � Product specifications. � Inspection & testing requirements. � Tooling requirements. � Records requirements If any ambiguity is observed in the requirements, the customer is contacted and differences are resolved. It is ensured that the capability to manufacture as per customer requirements exists The new product development is a planned and reviewed at appropriate stage. Accordingly, Control Plans are prepared.

PROPRIETOR. & Development Team

Feasibility in Product Manufacturing Development Enquiry Register in QF/MGT/05 Product Requirement in QF/QA/01& QF/QA/07

02 Customer Related Process(7.2)

7.2.1 : Determination of requirement related to

product The company determines : a) requirements specified by the customer, including

the requirements for delivery & post delivery activities , stated on customer P.O. , customer schedule ,customer drawing, customer Amendments for regular products .


Review of Customer PO(Including Terms, Condition), Drawings, Specifications Schedule

Page 38 of 59

METAL TECH INDUSTRIES Gat No. : 138, Dhanore(Alandi),

Tal. Khed, Dist.Pune-411015


Doc no.: QSP/05


TITLE: QUALITY SYSTEM PROCEDURE FOR : PRODUCT REALIZATION, CUSTOMER RELATED PROCESS,

CUSTOMER COMMUNICATION


01-01-2012

02 of 03

Sr No


02 b) Requirements not started by the customer but necessary for specified or intended use, where known.

c) Statutory & regulatory requirements related product, and

d) Any additional requirements determine the company such as preparation

Where the customer does not provide any written evidence of the requirements, such requirements are documented and confirmed before accepting.


Despatch Requirement, Product Requirement in QF/QA/01, & QF/QA/07

03 04

7.2.2 : Review of requirements related to the product The company reviews the requirements related to the product with respect to availability of resources and customer specifications.

The company ensures that a) product requirements are defined b) contract or order requirement differing from those

previously expressed are resolved & c) The company has ability to meet the defined

requirements . This done by virtue of contract review . The records of the results of the review and action arising from the review are maintained for each customer.

Where the customer do not provide documented statement of requirements, the customer requirements are conformed by the company before acceptance in writing through letter

Records of such reviews and subsequent actions resulting out of the review are maintained. Feasibility review is done for new / Modified components. Engineering changes Where the customer / Our Design is changed , following issues are to be reviewed & resubmitted the PPAP to customer.

a) Change in design(Dimensional), b) Change in Supplier, c) Change in Machine, d) Change in Location, e) Change in Material, f) Change in Manufacturing Process, & g) Change of RM


Acceptance of Purchase Order, Contracts,

Review of Drg, Specification, Mtrls, Qty, Terms Condition, Rejections Targets

Development Enquiry Register QF/MGT/05 Acceptance of Contract, Purchase Order Letter Acceptance of Order, PO, Contracts

Page 39 of 59

METAL TECH


Dhanore(Alandi),


QUALITY MANAGEMENT SYSTEM

MANUAL

Doc no.: QSP/05


TITLE: QUALITY SYSTEM PROCEDURE

FOR : PRODUCT REALIZATION, CUSTOMER RELATED PROCESS,

CUSTOMER COMMUNICATION


01-01-2012

03 of 03

Sr No


05 06 07 08

All Product Developed, are followed as per Customer

Guidelines.

7.2.3 Customer communication Company determines & makes provision for communication with customer regarding product information’s (TC, PDIR, Deviation), inquiries, Customer feedback, including customer complaints, enquiries , Acceptance of Contracts, Communication may be by one or more of the following means, � Telephonic. � E-mail. � Letters � Personnel meeting & discussion If required by the customer, communication is carried as per customer specified/ prescribed format. Customer satisfaction survey is conducted to know the expectations of customers if found the customer is unsatisfactory corrective action is taken and communicated to customer


-- Customer Feedback Customer Specified Format / List of External Documents in QF/MR/03

Customer satisfaction survey in

QF/MGT/04


PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 40 of 59

METAL TECH

INDUSTRIES Gat No. : 138, Dhanore(Alandi),

Tal. Khed, Dist.Pune-

411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/06

ISO Section 7.4.

TITLE: QUALITY SYSTEM PROCEDURE FOR : PURCHASING ,SUPPLIER SLECCTION, APPROVAL & RECEIPT INSPECTION

Rev. no : 00 Date : 01-01-2012

Page : 01 of 04

Sr No


01

7.4 PURCHASING

1. SUPPLIER SELECTION/APPROVAL PROCESS

Subcontractor supplying any item mentioned in the scope of this procedure, whose performance has been acceptable during past six month or more period of time before 1st Jan 2012, is automatically considered as Approved Subcontractors of the company. Their names and product / service supplied by them are registered in the List of Approved Subcontractors.

Head Materials/ Purchase

List of Approved Supplier in QF/PUR/01

02

New Supplier Selection & Registration

Suitable controls are exercised on the suppliers in order to ensure that the purchased product meets all the specified requirements. Organization.le registering new supplier as approved supplier the Extent of Control to be exercised by the company by a), b)

b) Selection of Supplier is decided based on the 1. Nature of product concerned, 2. type of purchase, 3. criticality of the input with respect to product quality

and product safety, 4. Past experience based on performance of

subcontractor, 5. Subcontractor development status, etc.

c) After getting the satisfactory acceptance, QA person will audit the supplier for its other compliance verification as per the Supplier audit checklist

Supplier is approved if get score in Selection audit more than

85%. All the approved suppliers are addressed in List of

approved Supplier List.

Re-evaluation of supplier is done in case the supplier rating (3 Monthly) goes below 85 %. The re-evaluation is done with help para b) as mention above cum record for Supplier Assessment


Supplier Assessment & Registration form in QF/PUR/04 Supplier Audit Report List of Approved Supplier in QF/PUR/01

02 7.4.2 Purchasing Information: The suppliers are rendered adequate purchasing information in Purchase Order so as to ensure that all the requirements of the product are communicated and understood. purchase order, includes description of the product, delivery terms, commercial terms, legal and other requirements as applicable for particular purchases. Refer Purchase Order. Purchasing is done from the approved suppliers only


Supplier Purchase Order in QF/PUR/03

Page 41 of 59

METAL TECH



411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/06

ISO Section 7.4.

TITLE: QUALITY SYSTEM PROCEDURE FOR : PURCHASING ,RECEIPT INSPECTION


01-01-2012

02 of 04

Sr No


02

Purchase order is raised to approve suppliers. Purchase order to be raised for item costing above Rs. 5000/- Purchase order gives details to supplier about the following,

2. Product specification . 3. Delivery requirements. 4. Rates. 5. Regulatory requirements. 6. Documentation requirements. 7. Inspection & testing of product. 8. Payment terms.

Purchase order is reviewed & approved by Purchase Head for adequacy, before issue. For suppliers of raw material & machining subcontractors, purchase order is raised once in a year & schedule is informed time to time.

Purchase Order in QF/PUR/03 Supplier Schedule

03 Modified /Changed specification of Product

As and when required and on revision of relevant drawings, specifications / standards, and control plans, the Materials and Purchase In-charge obtains controlled copies from M.R. and issues to concerned subcontractor(s). Specification of Changed or Modified products communicated through Modified Drawings, BO, OL, and Control Plan. Records are maintained of such issues of product specification in PO, Letter, or Issue Register as appropriate

Obsolete copies are destroyed by subcontractors

QA/Store/Purchase Engr.

Subcontractor Drawing /PO/BO/OL Plan Issue Register Recall Old Specification Via Revised Purchase Order

04 Material Inward: All Inward Material are recorded in Inward Register. GA Number, Receipt Date Supplier Challan No, & Supplier Inspection report(Dimensional as well as Raw Material TC number should be recorded. On Every receipt of Material Store Asst. will verify the adequacy of required Challan, availability of supplier Qty as per Challan, Purchase Order, Qty as per Challan, Availability of Inspection report & Raw Material Test Certificates. Store Asst. handover the Inspection Report & Raw Material TC to QA for Further Inspection process.

Store Assistant

Material Inward Register in QF/PUR/02

Page 42 of 59

METAL TECH



411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/06

ISO Section 7.4.

TITLE: QUALITY SYSTEM PROCEDURE FOR : PURCHASING ,RECEIPT INSPECTION


01-01-2012

03 of 04

05 Verification of Purchased Product: a) Products are inspected as per sampling plan in QF/QA/03&

Control Plan(RM/BO/OL) in QF/QA/09, the evidences are recorded in Incoming Inspection Report(RM/BO/OL)

QA Engineer

Incoming Inspection Report in QF/QA/09, Or Deviation in QF/QA/13

05 b) Any non dimensional Or non-productive (Consumables like

oil) are inspected as per the Challan / brand name & nature of use. The verification remarks as per the inspection results are noted in Material Inward Register. Accepted material is stamped backside of supplier Challan Or in Goods Inward Register.

c) In some cases verification of Receipt Product may be done during trial run processing at the company (in case of tooling, Machine Parts-Elect. & Mech. etc.)

d) All accepted material / Rejected / Under Hold material are kept with respective Tag.

e) NC Product : During the Receipt inspection any observed non Conformance which not meet the customer requirement(Dimensional, Profile, Raw Material) are registered in Product NC Report in QF/QA/08. Same is communicated to Supplier. QA Incharge will verify the all actions taken Or Proposed by supplier. After the successfully completion of action QA Incharge will close the NC along with objective evidences.

Material Inward Register in QF/PUR/02 & GIN in QF/QA/09 Accept / Rejected /Hold Tag Product NC Report in QF/QA/10, Supplier CAPA, Minutes of Meeting

Page 43 of 59

METAL TECH



411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/06

ISO Section 7.4.


PROCEDURE FOR : PURCHASING ,RECEIPT INSPECTION


01-01-2012

04 of 04

Sr No


06 The extent of control exercised on OUTSOURCED may be

through one or more of the following:

a) Supplier Audit: All Supplier are audited as an when supplier

rating is below 85% disqualify or Re Audit is planned to compliance to non conformance raised in audit.

b) Supplier Performance Monitoring: The suppliers are

monitor their performance based on their supplied quality, Delivery, & service. Supplier Performance will be

monitored ONCE in a QUARTER. The suppliers who are not consistent are asked to improve their performance and necessary help and guidance is given by ORGANIZATION.

Supplier Audit Plan in , Minutes of Meeting Supplier Rating Summary in QF/PUR/05

07 The incoming material is not issued to production unless it is inspected and accepted. All Material will be identified by Tag.

Material Identification Tag. In QF/QA/03

08 Inventory, Re Order & Issue :

All Material are monitored through Material Stock register, Maximum, & Minimum Level Define in Stock Register. According the max. & min. Level material is Order / Schedule to supplier is raised. During the Issue of Material FIFO(First In First Out ) System

is maintain( By GIN)

Store Asst.

Stock register QF/PUR/05

Note :

1. Presently customers do not carry out any verification activity at our supplier’s premises.

2. Presently we don’t have any customer supplied

material.

3. Presently we procure only Chemicals, Heaters, Oil etc.

all are non dimensional material. Are material are

verified its requirement based on its use during the

production. Hence all material is accepted / rejected

on GIN /Good Inward Inspection Report (QF/QA/09)

4. Ref . QSP/15 for CAPA

Date :01-01-2012 Name Designation Signature Prepared & Approved By:

Mr.Balasaheb. Shendage MR & PROPRIETOR.

Page 44 of 59



411015


Doc no.: QSP/07

ISO Section 7.5

TITLE: PRODUCTION AND SERVICE PROVISION


01-01-2012

01 of 01

Sr No


01 7.5.1 Control of production and service provision

The organization is plan and carry out production and service provision under controlled conditions. Controlled conditions shall include, as applicable,

i) The availability of information that describes the characteristics of the product Ref. QSP/05, QSP-10

ii) The availability of work instructions(Work Instruction QF/MR/11, List of WI-QF/MR/09), as necessary,

iii) The use of suitable equipment,(List of Machine –

QF/PRD/02, List of Measuring Devices-QF/QA/12) Ref QSP/04

iv) The availability and use of monitoring and

measuring equipment, Ref.: QSP-09

v) The implementation of monitoring and measurement Ref. QSP/10, and

vi) the implementation of product release, delivery

and post-delivery activities. Ref QSP/05 7.5.2 Validation of processes for production and service provision : Refer QSP : 07

QSP/05 QSP/10 Work Instruction QSP/04 QSP/09 QSP/10 QSP/05 QSP/07

02 7.5.3 Identification and traceability, Preservation of Product : Refer WI

Work Instruction

03 Customer property : Presently No Customer Property except PO

---

04 Control of monitoring and measuring equipment : Refer QSP /07

QSP/07

Date :01-01-2012 Name Designation Signature Prepared & Approved By:

Mr.Balasaheb. Shendage MR & PROPRIETOR.

Page 45 of 59

METAL TECH



411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/08

ISO Section 7.5.2

TITLE: QUALITY SYSTEM PROCEDURE FOR : VALIDATION

OF PROCESS FOR PRODUCTION AND SERVICE PROVISION


01-01-2012

01 of 02

Sr No


01

02 03

SPECIAL PROCESSES:

Processes where the output cannot be fully verified by subsequent inspection and testing of the product and

where processing deficiencies may become apparent

only after the product is in use.

These processes are specially controlled as per QSP for Special Processes. Records are maintained for these processes requiring qualification of process, equipment and personnel.

Following are the process identified as Validation of Process(Special Process) Sr. No

Special Process Type of Control

1 ELECTOPLATING Time, Temp, Specific Gravity

2 NITRIDING Time & Temp

Definition of Qualification of Process: A process is said to be qualified if the qualified personnel, using specified production equipment, after operating the process in the manner specified in the WI or Other specification. QUALIFICATION OF PERSONNEL, PROCESS AND

EQUIPMENT: Personnel performing special process to be identified along with the relevant manufacturing equipment . For qualification we conduct series of experiments with varying process parameters for all combination of machine & operator and type of Joint and test outcomes of the Qualified operating range. The conditions, which give us acceptable output, are set as operating conditions and whenever the process is run, the operating conditions and operator and machine combinations strictly followed.

Page 46 of 59

METAL TECH



411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/08

ISO Section 7.5.2

TITLE: QUALITY SYSTEM PROCEDURE FOR : VALIDATION

OF PROCESS FOR PRODUCTION AND SERVICE PROVISION


01-01-2012

02 of 02

Sr No


04 05 06 07 08 09

The Special process equipments(Machines) are identified in List of machine All machine are calibrated Or validated for ensuring the machine input required and actual output, to ensure machine can used for the desired output range. Qualification of Process Qualification of process is done as series of experiments with varying process parameters The conditions, which give us acceptable output, are set as operating conditions. All the data is recorded in Procedure Qualification Record(and 'Procedure Qualification Record(Welding/ PVC Coating) Operator Qualification : With the qualified operating range of process parameter, for which the process is qualified are consider for operator qualification. The result of Operator qualification will be maintain. List of qualified Operators will be maintain & ensure the qualified operator is performing the operations in special process. All the Qualified range of operating will be documented in Work instruction and displayed in shop floor to ensure the setting parameter during the process.

Production ---‘’---

List of Machines in QF/PRD/01 Calibration of machine Procedure Qualification Record, for Welding & Coating in QF/QA/02

Operator Qualification Report, for Welding in QF/QA/02 List of Employee in QF/HR/01 Work Instruction List of Employee in QF/HR/01

Page 47 of 59



411015


Doc no.: QSP/09

ISO Section 7.6


PROCEDURE FOR : CONTROL OF MONITORING AND MEASURING EQUIPMENTS


01-01-2012

01 of 01

Sr No


01

02 03

05

06

07

08

09

10

All Measuring Equipments which directly affect Product Quality, used for control of process parameters as well as tooling is identified for calibration. The list is maintained. Calibration frequency is determined considering the accuracy, precision and robustness of the equipment, the methods, environment and extent of use as well as past experience. Based on frequency decided, Calibration Plan is made and followed. Inspection, measuring and test equipment are kept in respective boxes / original packing wherever possible and safeguarded from adjustment which would invalidate Calibration setting,

Calibration of all inspection, measuring and test equipment’s is carried out through outside agency.

Calibration certificates received from external lab will be cross verified for the error. Based on the operating range, type of measurement, or accuracy of measurement acceptance of error will be decided. Same is recorded in History Card. Same IMTE is identified if used in specific operation, area, measurement.

History Cards are maintained for IMTE and Gages giving the details about instrument ID and calibration status. When IMTE is found to be out of calibration, Identified by ‘Out of Calibration’ tag. Such IMTE’s prevented from usage.

IMTE beyond repair will be scrapped.

If agreed contractually, calibration data is made available to customer.

QA Head/ Engr.

List of Inspection, Measuring & Test Equipments QF/QA/04 Yearly Calibration Plan QF/QA/05 Handling of IMTE as per Work Instruction Outside Lab Tag IMTE History Card in QF/QA/06 -- --


PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 48 of 59

METAL TECH


Dhanore(Alandi), Tal.


QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/10

ISO Section 8.2.1,8.2.3,8.2.4


PROCEDURE FOR : MONITORING AND MEASURING OF PROCESS, PRODUCTS, CUSTOMER SATISFACTION

Rev. no : 00

Date : Page :

01-01-2012 01 of 02

Sr No


01

MONITORING AND MEASURING OF PROCESS,

PRODUCTS

In all Stages of Manufacturing, product & process requirements are identified in Work Standard / WI /QAP/ Quality Plan/ Control Plans as required

1.A Receipt Stage

1. All Receipt material are inward in inward register. The Product related requirement is verified as per Work Standard, Inward Material Quality Plan

2. Verification of inward material is done as per Control Plan

3. Record the observation in Receipt Inspection Report

4. All Non Conforming material disposition done as per QSP-11, QSP-13

Material Inward Register in QF/PUR/02,

Receipt(BO/OL/CSM) in QF/QA/05 GIN / Goods Inward Inspection Report in QF/QA/09

02 1.B In Process Stage

All products in In Process stage is manufacturing as per following documents, and includes Process and product parameter required to perform the operations as mention in respective Work Instruction Inprocess Specification Document & Number Production Cum Inspection Report For-all the work station will be done as per respective operation Control Plan. The verification/ Inspection will be recorded in the same Machine Setting parameter as per respective machine Work Instructions

1. All Non Conforming products not meeting requirement are recorded in Inhouse NC Register

2. All Non Conforming material disposition done as per QSP-12, QSP-15

In Process Verified as Specification Mention in QF/QA/01, & QF/QA/07 Production Cum Inspection Report in Plating- QF/PRD/06, For Nitriding-QF/PRD/05 'Inhouse NC Register in QF/QA/10' & CAPA in QF/QA/12

Page 49 of 59

METAL TECH




QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/10

ISO Section 8.2.1,8.2.3,8.2.4


PROCEDURE FOR : MONITORING AND MEASURING OF PROCESS, PRODUCTS, CUSTOMER SATISFACTION

Rev. no : 00

Date : Page :

01-01-2012 02 of 02

Sr No


03 1.C Final Stage All products in final stage is inspected as per following documents, &respective work instructions Customer drawings, Or MRS(Manufacturing release Sheet) or Customer Approved QAP

All Non Conforming products not meeting requirement are recorded in Inhouse NC Register

All Non Conforming material disposition done as per QSP-12, QSP-15

QA Insp. As Product Specification mention in QF/QA/01 Or QF/QA/07 & Record in -QF/QA/18

1.D All Products are Inspected for Layout (Drawings Dimensions as an when customer required.

Layout Insp. Report

04 05

MONITORING AND MEASURING OF CUSTOMER

SATISFACTION

1. Customer satisfaction survey is conducted to know the expectations of customers related to customer satisfaction in service, Quality, & Delivery along with any future expectation.

2. Customer satisfaction survey / Interview is conducted ONCE IN A YEAR from identify potential customer to collect customer requirements.

3. The target for achieving minimum CSI is defined in the Quality Objectives(Key Performance Indicators) Where the Customer satisfaction is below the level, Cause & Effect analysis is done to overcome customers dissatisfaction areas. The detail action Plan is prepared to achieve the customer satisfaction level.

4. Customer is informed regularly about action taken & customer response about effectiveness is collected.

5. Every Customer Satisfaction/ Dissatisfaction along

with the actions are discussed / review in MRM

Monitoring & Implementation of Engineering

Changes.

Any Change in Design should be validated through a) Document Change Note(With Reason) b) Development Feasibility through Development

enquiry register c) APQP Guidelines d) Resubmission of PPAP

Prop.

Customer Satisfaction Survey Form in QF/MGT/04 Cause & Effect Analysis in QF/QA/12

Customer Feedback

MRM in/MGT/03 Engineering Change Document


PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 50 of 59




Doc no.: QSP/11 ISO Section 8.2.2

TITLE: QUALITY SYSTEM PROCEDURE FOR : INTERNAL AUDIT

Rev. no : 00 Date : 01-01-2012

Page : 01 of 02

Sr No


01 INTERNAL AUDIT PLANNING

a) Annual audit plan is prepared in advance for internal auditing. Audit schedule is prepared on the basis of Annual Audit Plan.

b) All functions are audited every 6(Six ) Months

c) All IQA cover all shifts.

d) Additional emphasis in terms of additional audits is given where quality activities are terms of additional audits is given where quality activities are complex, requirements are stringent and customer complaints are high.

All Auditors and Auditee should inform the audit schedule 8 days before through Internal Quality Audit Circular in QF/MR/05

MR

Annual Internal Quality

Audit Plan QF/MR/04

Additional /Resular Audit in Internal Quality Audit

Circular in QF/MR/05

02 CHECK LIST

a) Each procedure is audited point by point for adequacy and compliance. The Detailed Audit Checklist is used for auditing.

IQA

Auditors

IQA

Checklist QF/MR/06

03 IQA

a) Trained auditors who do not have direct responsibilities of functions being audited conduct audits. Contract may prepared with second party trained auditors to conduct the internal audits. b) Audit is conducted every quarter as per schedule and observations are recorded. Non conformance in audit are recorded and issued to concerned persons. c) Non conformities and audit summary report is discussed for long term and short-term action for improvements. Follow up audit is carried out to verify status and effectiveness of planned actions for closing of non-conformities.

All concer

ned Auditor

s Auditee

s

MR

External / Internal Auditor

IQA NC Report

QF/MR/07

Annual IQA Plan

QF/MR/04

Page 51 of 59

METAL TECH



411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/11

ISO Section 8.2.2


PROCEDURE FOR : INTERNAL AUDIT

Rev. no : 00

Date : 01-01-2012 Page : 02 of 02

Sr No


c) Unscheduled audits are also conducted depending upon seriousness of relevant incidences of product and / or system problems. Such unscheduled audits are decided quarterly in MRM.

MR ---

04 REPORTING NC status is reported as per summary format in every MRM.

MR

Audit Summery

Report QF/MR/08

05 FOLLOW UP Within every 15 working days follow up audit is conducted for ensuring closing of NC and checking its implementation/effectiveness. Such audits are recorded on relevant NCR.

All

concerned

Corrective

Action Report

QF/MR/07

06 REVIEW

a) The findings of all audits held during period are reviewed in subsequent MRM. Record of pending NC’s is available in MRM. The status is available in respective NCR. b) The analysis of internal as well as external audit is carried out to determine the effectiveness of QMS. The internal audits are planned and revised on the basis of status and importance of activity. c) The NCRs, analysis of external and internal audit findings and actions are decided. Areas, functions, progress etc. where the QMS is effectively implemented are highlighted. d) The audit plan is revised as per the decision taken in the meeting.

MR

MRM

QF/MGT/03

Annual IQA Plan

QF/MR/04

Audit Planning


PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 52 of 59

METAL TECH



411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/12

ISO Section 8.3


PROCEDURE FOR : CONTROL OF NON –CONFORMING PRODUCTS

Rev. no : 00

Date : Page

01-01-2012 01 of 03

Sr No


OBJECTIVE : Applicable to Non - confirming product that does not conform to specified requirements is prevented from unintended use , identified in receiving. in process and at final Inspection.

SCOPE : Identify & prevent mixing up of non-conforming ones and disposition of NC Products Specification.

01 Any material found at incoming, in-process or final stage of manufacturing METAL TECH INDUSTRIES has not comply to the product requirement, specification, or is suspected the identity, or traceability, must be treated as nonconforming materials and this procedure must be applied to them

QA/ PROD ENGR.

NC PRODUCT

02 03

IDENTIFICATION OF SUSPECT & N.C PRODUCTS AND

DOCUMENTATION The identification of suspect / N.C products is done at all stages of processes. by tag mentioning the following details A] RECEIPT INSPECTION:

i. During incoming inspection suspect / NC products are identified by tag and recorded on receipt inspection reports.

ii. The NC Qty is recorded in Inward Register

iii. The NC product along with the reason communicates

to supplier.

iv. In Case of urgency the material is reworked at our end. The cost of rework will be debited to supplier.

v. All the corrective & preventive action on the product

will be verified by QA Engr. At supplier end.

QA ENGR.

QA ENGR.

Pur. Engr./ Incharge

QA Engr

Tag &

Receipt inspection

Report QF/QA/09

Inward Register

QF/PUR/02,

Debit Note, letter, mail

Supplier CAPA in

QF/QA/12

Page 53 of 59

METAL TECH



411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/12

ISO Section 8.3



Rev. no : 00

Date : Page :

01-01-2012 02 of 03

Sr No


04 B] INPROCESS & FINAL INSPECTION.

All the Material not comply to the product requirement, specification, or is suspected the identity, or traceability, must be registered in In house NC & CAPA Register

QA

In house NC in QF/QA/10 & CAPA in QF/QA/12

05 The Lot Identified as a ‘’Product For Rework’’, SCRAP’’ and or ``Reject’’ to avoid mix up in the routine production

Tag

06 QA Head decides the product METAL TECH INDUSTRIES can be reworked to get required dimensions/ specification. Otherwise scrap the product with appropriate approval from Plant Head/PROPRIETOR.s along with the Scrap Note.

QA Engr

Scrap Note

07 The non-conforming products are placed in separate area. NCR is reviewed and disposition action is finalized and recorded on the NCR .The non-conforming products are handled as per Table1.

QA Area for Rework, Rejection

08 All non conforming products METAL TECH INDUSTRIES have been corrected are subjected to re verification. Inspection records are maintained.

QA prod. Cum Insp. Report

in QF/PRD/05,

09 In case of urgency, where the non-conforming product is not going

to affect the characteristics of finished product, the deviation is obtained. In case of non-conforming finished product, customer is contacted and concession is requested.

QA Deviation Acceptance

Note QF/QA/13

10 If the non-conforming product is identified after delivery to customer, the customer is informed about the fact and requested to return the non-conforming products. The reasons for delivery of non- conforming products are identified and necessary actions are taken to avoid recurrence of this.

QA ---‘’----

11 C] CUSTOMER COMPLANTS All customer returned Product & communication regarding Product quantity, delivery, and response related complaints will be received are handed-over to the Quality Assurance department. The QA In-charge / Engineer records the details Reason for Return / complaints in customer complaint register

QA Head

Customer Complaint

Log in QF/QA/11

Page 54 of 59

METAL TECH



411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/12

ISO Section 8.3




01-01-2012 03 of 03

Sr No


12 The corrective and preventive actions are applied across similar products / similar processes.

13 The non-conforming products are disposed off every month to avoid accumulation. PROPRIETOR./GENERAL MANAGER takes this decision.

QA Meeting on rejection

14 The data Generated through NCR is analyzed. Based on this analysis areas for initiating corrective actions are prioritized. The root cause for non-conformity is identified and corrective actions are planned and implemented. REF. QSP-12, 13, 15

QA Head

QSP-12, 13 15

TABLE-1

SrNo

Stage

Disposition Record Resp. Authority

1.

Receiv

ing

Segregation Material Inward Register-QF/PUR/02, Inspection as per by past experience Or after use in production, Record Inspection in GIN/Goods Inward Inspection Report(RM/BO/OL) in QF/QA/09

QA Engr./ Supplier

QA Manager

Accept with concession

Deviation Acceptance Note in QF/QA/13 QA Manager PROPRIETOR.

Reject Material Inward Register-QF/PUR/02, GIN/Goods Inward Inspection Report(RM/BO/OL) in QF/QA/09

QA Engr. QA Manager

2.

In-P

roce

ss l

Inspect

ion

Segregation Record NC Product in In house NC in QF/QA/10 & record the CAPA in QF/QA/12

Operator QA Manager


Deviation Acceptance Note in QF/QA/13 QA Engr. PROPRIETOR.

Repair/Rework

Record NC Product in In house NC in QF/QA/10 & record the CAPA in QF/QA/12

Operator / Prod. Engr

QA Manager

Reject Record NC Product in In house NC in QF/QA/10 & record the CAPA in QF/QA/12

QAEngr. QA Manager

3.

Fin

al In

spect

ion

Segregation Record NC Product in In house NC in QF/QA/10 & record the CAPA in QF/QA/12

QAEngr. QA Manager


Deviation Acceptance Note in QF/QA/13 QAEngr. QA Manager

Repair/Rework

Record NC Product in In house NC in QF/QA/10 & record the CAPA in QF/QA/12

QAEngr. QA Manager

Reject Record NC Product in In house NC in QF/QA/10 & record the CAPA in QF/QA/12

QAEngr. QA Manager

4.

Custo

mer

Segregation Customer Complaint Log in QF/QA/11 , or Customer Visit Report

QA Engr./ Operator

QA Manager


Deviation Acceptance Note in QF/QA/11, or Customer Visit Report

QA Manager QA Manager

Repair/Rework

Customer Complaint Log in QF/QA/11 , or Customer Visit Report, & CAPA in QF/QA/12 Send Customer feedback on Effectiveness of CAPA

QA Engr./ Operator

QA Manager

Reject QA Manager


PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 55 of 59

METAL TECH



QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/12

ISO Section 8.4


Procedure for : Analysis of Data

Rev. no : 00

Date : Page :

01-01-2012 01 of 01

Sr No


01

02

03

04

05

06

07

08

Company has following data trend for analysis i) Key Performance Indicators(Quality Objectives)

QF/MGT/02

ii) Business Plan –in format QF/MGT/01 iii) Rejection / Rework in QF/QA/10, Defect wise , iv) production report Cun Insp . Report in

QF/PRD/05,QF/PRD/06 v) Customer Satisfaction in QF/MGT/04, and complaints in

QF/QA/11 vi) Despatch on time delivery in QF/MGT/06, vii) Sales, Stock, Inventory viii) Effectiveness of CAPA in QF/QA/12

These Data/ Data Trend generated from daily basis documents, records.

These are related to operational performance, and current quality levels of key product features.

These Trend / data indicate past & current trends, including targets to be achieved.

3 Monthly data is collected by analyzing appropriate records available in company to compute the Quality Objectives, METAL TECH INDUSTRIES are followed by respective functions.

After studying earlier performance of the company & general industrial practices self developed Benchmarks are decided for each KPI. CEO authorizes these.

The current status is discussed in every MRM. For KPI METAL TECH INDUSTRIES are not as per bench marks an action plan is prepared and followed.

Further corrective & Preventive actions are taken in QMS through changes in documentation

Priorities are given to improve Quality Objectives related to customer - related problems.

For this the dissatisfaction reported by customer are correlated with company Quality Objectives.

Decisions about additions/deletions about above indicators are taken during first MRM of every financial year.

This also includes up-gradations for any or all Quality Objectives targets. Records of above reviews are kept in MRM .

All Staff Along with

Management

Analysis from

record generated during all processes.

Analysis in Cause &

Effect , CAPA Analysis in QF/QA/12

OR

in Continual

Improvement Projects in QF/MR/11

Discuss

Progress in MRM in

QF/MGT/03


PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 56 of 59

METAL TECH



411015

QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/14

ISO Section 8.5.1


PROCEDURE FOR : CONTINUAL IMPROVEMENT


01-01-2012 01of 02

Sr No


01

02

03

Establish Opportunities

The Organization has established opportunities in the areas of Quality and productivity improvements in the form of Quality Objectives. Organization.le deciding Quality Objectives highest priority is given to special characteristic of product.

Target setting for improvement

Targets for improvement are set by virtue of Customer requirements, comparison with benchmark of ORGANIZATION.. PROPRIETOR./GENERAL MANAGER/ PROPRIETOR. approves these goal.

Training

The philosophy of continuous improvements has been deployed throughout organizations by various training programs. Such training includes training about various techniques required to be employed by staff members so as to achieve pre-set targets. All employees are explained about need of continuous improvement through various meetings, training programs and displays.

All Dept. Head

Continual Improvement

Projects in QF/MR/11

Data from

MRM QF/MGT/03,

KPI List QF/MGT/02,

Monthly Meeting,

04 Methodology MR ensures that management staff has used company level data to help complete analysis.

a. Quality Objectives related to all areas are distributed for all related functions

b. MR prepares work instructions about methodology employed.

c. Organization deciding this methodology, it is ensured that training is imparted to all staff members.

d. Monthly data is collected and analyzed by teams to arrive at various areas needing improvement

Quality Objectives

in QF/MGT/02

Monthly Meetings

05 Improvement Area 5.1 Improvements shall be classified as:

� Innovative Improvements � Process , Product, Productivity Improvements � Quality Management System Improvements � Cost savings, Safety and Health, Customer Satisfaction

Area for Improvements in Continual Improvement

Projects in QF/MR/11

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PROCEDURE FOR : CONTINUAL IMPROVEMENT


01-01-2012 02of 02

Sr No


05 5.2 For the improvement purpose following data/ trend may

be analyzed Production Trend, Rejection Trend, Defects Trend, Downtime Trend, Customer Satisfaction Trend, Quality Objective Trend, Shortage, Stock Level, Business Plan Targets

5.3 Annually all Quality Objectives targets are studied.

a. Quality Objectives where targets are achieved, targets are upgraded for the next year.

b. Actions are planned to help achieving upgraded targets.

c. Study & analyzed the data the Daily/ Monthly/ Quarterly/Six Monthly/ Yearly data.

PROPRIETOR.

KPI List

QF/MGT/02

Trend Charts/Data

06

Reporting Monthly Quality Objectives are analyzed with respective members and necessary guidelines are given for further improvements. Quality Objectives, METAL TECH INDUSTRIES are not as per target, are discussed with all the concerned persons to arrive at action plans. The progress of Quality Objectives is discussed in MRM Guidelines received from MRM as regards to target improvements, addition / deletion of Quality Objectives are implemented subsequently

PROPRIETOR.

PROPRIETOR.

PROPRIETOR.

Quality Objective Monitoring

in QF/MGT/02

---‘’----

---‘’---- & MRM in QF/MGT/03

The trend not meeting the target, Objectives are

analyzed &€ taken for improvement projects. Data for the improvement must be documented.

Continual Improvement Projects

in QF/MR/11


PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Page 58 of 59

METAL TECH



QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/15

ISO Section 8.5.2, 8.5.3

TITLE: QUALITY SYSTEM PROCEDURE FOR : CORRECTIVE & PREVENTIVE ACTION


01-01-2012 01 of 02

Sr No


01 The problem solving person / team must differentiate between the following four types of actions and use his judPROPRIETOR.ent to select appropriate one or many:

Any complaint / rejection (Receipt / In Process / At Customer end) will be resolved in above manner

a.) Problem Description :Problem desc. Should be very clear. Means everything should be measurable, mentioned severity of problem(e.g. 200 part supplied, out of that 3 nos defective. 3 Nos found with heavy burr at upper corner)

b.) Disposition Action(s): Write the actions taken to protect the problem first. This is done by 100% checking, replacing parts, or rework bad parts. This action must be result into uninterrupted supply to customer.This is an action on specific product / document that is found nonconforming in order to remove nonconformity in the product / document.

c.) Root Cause: This step required objective / technical thinking. Never assume the cause theory or anything before following these steps. Do not accept the cause theory unless agreed and verified. Generally defect is the end product of series of event just as product is product of some long process. A defect is caused by some event(say event1) . event no 1 is in turn is result of some previous event(say event 2). Event 2 in turn results from event 3, and so on.A root cause is the event that has started this chain. A root cause may be present for long time but cause defect occasionally only.

d.) Corrective Action: This is a stop-gap action on process that results in nonconforming product / document.

e.) Preventive Action: This is an action on process that precludes possibility of nonconforming outputs in future times to come

Cross Functional

Team(CFT)

-----

Page 59 of 59

METAL TECH




QUALITY MANAGEMENT

SYSTEM MANUAL

Doc no.: QSP/15

ISO Section 8.5.2, 8.5.3

TITLE: QUALITY SYSTEM PROCEDURE FOR : CORRECTIVE & PREVENTIVE ACTION


01-01-2012 02 of 02

Sr No


2 1. The corrective actions are initiated for the NC observed in the product, process and system. Preventive actions are initiated for the potential NC identified.

2. At the end of the month the NC registers are reviewed for major and recurring nonconformance. Corrective action is initiated for such nonconformance.

3. The corrective/Preventive actions are along with the NC and the root cause of the NC is recorded in the CAPA Report.

4. The corrective/Preventive actions taken are reviewed for their effectiveness after the specified target date of its implementation date.

Ref. QSP-12 Control of Non –Conforming Products

Inhouse NC in QF/QA/10 & CAPA Register in QF/QA/12, Customer Complaint Log in QF/QA/11 CAPA Register in QF/QA/12


PREPARED &

APPROVED BY:

Mr.Balasaheb.

Shendage

MR & PROPRIETOR.

Metal Manual P-I

Documents

machined metal components

metal tech industries

customer complaint log

continual improvement projects

quality system procedure

customer satisfaction levels

customer satisfaction survey

quality management system