QUALITY SYSTEM MANUAL
We are a small scale manufacturing company and no elaborately documented quality assurance programmer is available. However utmost care is taken for manufacturing of quality product as per Spec. All testing on coming material implant manufacturing & finished goods is done as per quality manual on bans of following system followed by us:-
1.ENQUIRIES & ORDERS:-
All incoming enquiries are recorded, compared with corresponding quotation and acknowledged. The order acknowledgement number is the reference number for all internal records.
2.DESIGN:-
We prepare job cards giving complete instructions regarding manufacturing, special technical requirements by customer delivery schedule and list of material.
3.PLANNING AND MATERIAL PROCUREMENT SYSTEM:-
Planning department prepares production programme based on delivery schedule required by customer and prepares procurement schedule. Purchase orders are issued to vendors giving technical specifications, price and delivery schedule. The material received at different time is given separate lot no. offer complete checking on receipt.
4.VENDORS OR SUPPLIER CONTROL:-
Material is purchased from approved & reputed suppliers. Purchase & design staff regularly visits them for keeping close cooperation.
5.CHARGE CONTROL:-
Any charge required by customer in the ordered material is reviewed and if it is possible to implement it is acknowledged by sending amendment to the order acknowledgement. Necessary changes are made by design department in the job-cards. Any change required to be done for better performance is properly communicated to the floor & customer.
6.IMPLEMENTATION:-
As the products are tailor made the production is taken up strictly according to schedule worked out by planning department and processing is done as per job cards. Majority of jobs are braiding, weaving, slitting and coating. The activities are done as per procedures laid down.The quality manual is followed up for final finishing by dip coating. Record of each batch of braided, weaving, Sleevings, weaving, women cloth, slitting of tapes & coating is kept and reviewed by quality assurance department. Adequate in process testing is done to see that the products are as per Specifications. Mechanical and other tests are done on the lots as per lot no. allotted & subsequently compared to specifications.
7.HOUSE KEEPING:-
Special attention is given to keep the working & shortage area clean and tidy. Rejected material is kept separately in the stores and rejection reports are sent to the suppliers.
No un- authorized person is allowed in test are, stores & workshop. Material handling, storage, packing & delivery is done with proper care.
8.INSPECTION & TESTING:-
a.Receiving inspection & testing:-
Material is received in stores & is thoroughly inspected as per drawings & specifications and accepted material is entered in the stock registers. Either 100% checking or sample checking is done depending upon the item. Each lot is identified by separate lot no. Suppliers delivery documents & test certificates are verified & preserved.
b.In process inspection & Testing:-
Adequate in process inspection & testing is done to check conformity of products to drawings, specifications & standards.
c.Final Inspection & Testing:-
Final Inspection & Testing is done on each & every product. Tests are conducted as per relevant standard and test results recorded. Physical verification is done as per drawings and standards.
d.Documentation:-
Documents of test results and test reports are done in standard formats. The records are maintained in job- cards serial number wise. All the records pertaining to a particular product can be traced easily merely from the serial number mentioned in the name plate affixed to it.
The test reports are checked verified and signed by Senior Assistance Engineer.
e.The Inspection of Test Equipment:-
Test Equipment is regularly calibrated internally by self check or comparison method and periodically got calibrated from recognized independent testing laboratories.
f.Control of non conforming product:-
Due to thorough in process testing it is hardly possible that the final product does not confirm to the specification. However in a remote possibility of product not conforming to the specification due to minor errors ( such as error in the name plate) are rectified in presence of quality assurance engineer & the product is re-checked & passed for dispatch. The Discrepancy noticed in recorded in daily report and steps are taken to avoid repetition of the error.
g.Corrective Action:-
The non- confirming products which cannot be rectified are totally rejected. In case of failure through investigation are done by quality assurance engineers to locate the place & cause of failures. The investigations are discussed with production and design engineers & corrective steps are taken to avoid similar defects, such failures though very rare reported to the Chief Executive of the company.
9.QUALITY MANUAL SYSTEM OF MAITAINING Q.C. RECORDS:-
The sample documents used in the quality management system and the procedures are enclosed. All the Q.C. Reports are maintained for future references up to end utilization.
10.QUALITY CONTROL ORGANISTIONS:-
The control operation is as follows:-
11.QUALITY AUDITS:-
The Chief Executive receives continuous feedback by way daily reports from different
department & based on those reported & actual surprise checks. He audits the performance
of all the staff members & departments.
12.REVIEW:-
The Chief Executive & Engineer periodically review the whole quality management system & programme taking into account.
(I). Study on waste reduction / increased productivity.
(II). Customer feedback
(III). Costs of Quality