DMC Quality Manual

Quality Manual
Document No : QMDMC/01 Issue No. : 01 Date : 01.05.2008 KOLHAPUR Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01 TITLE : EXCLUSION & SCOPE OF QUALITY MANAGEMENT SYSTEM The activities of the plant that are covered under ISO system are as follows. Construction of Roads, irrigation ,Public works projects & commercial buildings etc.
DM CORPORATION PVT.LTD.
REF: ISO 9001:2000 PREPARED BY:
CLAUSE : 1.2 APPROVED BY:
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Document No. : QMDMC/02 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 02 PAGES 01 02 01 03 01 03 03 01 01 01 02 01 05 01 01 02 01 01 01 01 01 01 01 CLAUSE : 4.2 APPROVED BY
TITLE : INDEXING SEC. ISO 9001:2000 DESCRIPTION NO. CLAUSE 01 Exclusion & Scope Of Quality Management System 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 4.2.3 4.2.3 4.2.3 4.1 4.2 5.1 5.2 5.3 5.4.1 5.4.2 5.5.1 5.5.2 5.5.3 5.6 6.1 6.2 6.3 6.4 7.1 7.2 7.3 Indexing Revision Sheet List Of Abbreviation List Of Controlled Copy Holders General Requirements Documentation Requirements Management Commitment Customer Focus Quality Policy Quality Objectives Quality Management System Planning Responsibility, Authority And Communication Management Representative Internal Communication Management Review Provision Of Resources Human Resources Infrastructure Work Environment Planning Of Product Realization Customer Related Processes Design And Development
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TITLE SEC. NO. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 : INDEXING ISO 9001:2000 CLAUSE 7.4 Purchasing 7.5.1 7.5.3 7.5.4 7.5.5 7.6 8.1 8.2.1 8.2.2 8.2.3 8.2.4 8.3 8.4 8.5 8.5.3 Document No. : QMDMC/02 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 02 of 02 DESCRIPTION PAGES 02 02 01 01 01 02 01 01 02 01 02 01 01 01 01
Production Provision Identification And Traceability Customer Property Preservation Of Product Control Of Monitoring And Measuring Devices Measurement, Analysis And Improvement Customer Satisfaction Internal Audit Monitoring And Measurement Of Rocesses Monitoring And Measurement Of Product Control Of Nonconforming Product: Analysis Of Data Improvement Preventive Action
CLAUSE : 4.2 APPROVED BY
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Document No. : QMDMC/03 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
Original Issue with Revision 00 of all QMDMC: 01.05.2008

Approved By : CEO TITLE
QMD MCN O
: REVISION SHEET
Previous Rev. Revised To Rev. Date Basis of Revision Details of Revision Approved By
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TITLE : LIST OF ABBREVIATION ABBREVIATION ISI ISO Document No. : QMDMC/04 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 03 DESCRIPTION
INDIAN STANDARD INSTITUTE INTERNATIONAL ORGANISATION FOR STANDARDIZATION ASSISTANT CHECK LISTS DEPARTMENT DEVELOPMENT FORMAT FINAL INSPECTION INSPECTION INTERNAL AUDIT LIST LABORATORY MAINTENANCE CHIEF EXECUTIVE OFFICER MANAGEMENT REVIEW MARKETING MANAGEMENT REPRESENTATIVE SERIAL NUMBER WORK INSTRUCTIONS WORK IN PROCESS CLAUSE : 4.2
ASST. CL DEPT. DVP F FI INSP. IA L / LST LAB. MAIN CEO MGR MKT. MR SR. NO. WI REF: ISO 9001:2000 MRM PREPARED BY:
APPROVED BY: MANAGEMENT REVIEW MEETING
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TITLE : LIST OF ABBREVIATION ABBREVIATION NC NCR NO. PO PR PUR QMDMC QP REF REG./Reg. REV RI RS. SEC STD STR W.R.T. COM MFG DESP REF: ISO 9001:2000 PREPARED BY: NON-CONFORMITIES NON-CONFORMITY REPORT NUMBER PURCHASE ORDER PROCEDURE PURCHASE QUALITY MANUAL SECTION QUALITY PLANS REFERENCE REGISTER REVISION RECEIVING INSPECTION RUPEES SECTION STANDARD STORE WITH RESPECT TO COMMERCIAL MANUFACTURING DESPATCH CLAUSE : 4.2 APPROVED BY: Document No. : QMDMC/04 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 02 of 03 DESCRIPTION
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TITLE : LIST OF ABBREVIATION ABBREVIATION TRG PP MATL M/C PRD DRG. DT. GEN. TRAINING PROCESS PLAN MATERIAL MACHINE PRODUCTION DRAWING DATE GENERAL Document No. : QMDMC/04 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 03 of 03 DESCRIPTION
Quality Manual
Document No. : QMDMC/05 Issue No. : 01 Date : 01.05.2008 KOLHAPUR Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01 TITLE : LIST OF CONTROLLED COPY HOLDERS
COPY HOLDER ORIGINAL COPY MANAGEMENT REPRESENTATIVE (MR) 01 : CONTROLLED COPY : SITE
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TITLE : GENERAL REQUIREMENTS DM CORPORATION PVT LTDhas established, documented, implemented and Document No. : QMDMC/06 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 03
maintained a Quality Management System and continually improved its effectiveness in accordance with the requirements of International Standard ISO 9001:2000. Which are, the organization has, a) Identified the processes needed for the Quality Management System and their application throughout the organization. b) Determine the sequence and interaction of these processes. c) Determine criteria and methods needed to ensure that both the operation and control of these processes are effective. d) Ensure the availability of resources and information necessary to support the operation and monitoring of these processes. e) Monitor, measure and analyse these processes, and f) Implement actions to achieve planned results and continual improvement of these processes. In our company, all the major processes are controlled & monitored by us. Hence the controls exercised through clause No.7.4 are suitable for achieving product conformity with the requirements for the limited out sourced processes. The companys Quality Management System is documented in Four levels, which covers the entire scope for which certification is sought. The details of each level is as below: Documentation structure of our organization is of Four levels as described below: Level l Documentation Level II Documentation : Quality Manual. : Procedure Manual
Level III Documentation : All reference documents like Quality Plans, Process Plans , lists , Flow Charts , Work Instructions etc. Level IV Documentation : Registers, Formats, Test Formats etc
REF : ISO 9001 - 2000 PREPARED BY: CLAUSE : 4.1 APPROVED BY:
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TITLE : GENERAL REQUIREMENTS Document No. : QMDMC/06 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 02 of 03
Level 1 Quality Manual - This is the apex document of our Quality Management System called as Quality Manual. This includes all requirements mentioned in Clause 4.2.2 Quality Manual. This manual contains various processes, which covers the relevant topics of the Quality Management System. Quality Manual is prepared by MR approved by CEO & issued by MR. MR prepares the Quality Manual procedures in consultation with concerned departmental Managers. While designing this manual, the facility is provided to identify each page separately. The information written in top portion of each page states the status of each page. It gives Section No. to which the page belongs to and the exact number of page out of total pages (of each section ), issue No. (The latest issue of the companys manual with its date), Revision No. (The latest revision status of each section with its date). The information written in the bottom portion states the reference of clause(s) of the standard against which the information written on that page refers to. Level II - Procedure Manual - Procedure Manual is prepared by MR approved by CEO & issued by MR. MR prepares all the procedures in consultation with concerned departmental managers. Level III Quality Plans, Work instructions, Lists are prepared by MR in consultation of Concerned Managers & it is approved by CEO and issued by MR. Drawings, if any, are to be prepared by MR and approved by CEO. Level IV Formats, Registers, are prepared by MR & approved by CEO. THE PROCESSES IDENTIFIED FOR THE QUALITY MANAGEMENT SYSTEM ARE: 1. 2. 3. 4. 5. 6. 7. Marketing & Purchasing Store & Dispatch Construction with Quality Control Training and Resources Customer Satisfaction Continual Improvement Maintenance
REF : ISO 9001 - 2000 PREPARED BY:
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Document No. : QMDMC/07 Issue No. : 01 Date : 01.05.2008 KOLHAPUR Rev. No. : 00 Date : 01.05.2008 Page : 01 of 03 TITLE : DOCUMENTATION REQUIREMENTS
4.2.1 - General : Our Quality Management System documentation includes: a) Documented statements of quality policy and quality objectives. b) Documented procedures required by the International Standard ISO 9001: 2000 whose references are given at the end of respective section of this Quality Manual in Reference of Documented Procedures c) Documents needed by our organization to ensure the effective planning, operation and control of our processes, whose references are given in respective sections of the Quality Manual, in the documented Processes, or in the list, charts, etc. d) Records required by the International Standard ISO 9001:2000 and our Organization, which are controlled through documented Procedure written in same section of page 03 of this Quality Manual.
4.2.2
Quality Manual:
Our organization has established and maintained a Quality Manual which includes a) The scope of the Quality Management System including details of justification, mentioned in the Section titled as Introduction of this Quality Manual. b) The documented Procedures established for the Quality Management System. c) A description of the interaction between the processes of the Quality Management System, The contents and control of the Quality Manual is explained in the documented Procedure titled as Control of Document in detail. 4.2.3 Control of Documents: Every document and record required by our Quality Management System is controlled. Records are special type of document and are controlled as mentioned in the Control of Records in same section.
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Document No. : QMDMC/07 Issue No. : 01 Date : 01.05.2008 KOLHAPUR Rev. No. : 00 Date : 01.05.2008 Page : 02 of 03 TITLE : DOCUMENTATION REQUIREMENTS
Following are the various documents identified in our Organization: 1) Quality Policy 2) Quality Objectives 3) Quality Manual 4) Procedure Manual 5) Work Instructions 6) Quality Plan / Process Quality Plans 7) Formats 8) Registers 9) Lists 10) External Origin Documents: a) Customers Specification / drawings b) National / International Standards, c) Reference documents / Books. A documented procedure is established to define the controls needed a) To approve documents for adequacy prior to issue, b) To review and update as necessary and re-approve documents, c) To ensure that changes and the current revision status of documents are identified, d) To ensure that relevant versions of applicable documents are available at the point of use, e) To ensure that documents remain legible and readily identifiable, f) To ensure that documents of external origin are identified and their distribution controlled, and g) To prevent the unintended use of obsolete documents, and to apply suitable identification to them if they are retained for any purpose. Where document and data is stored in computers such as Quality Management System documents, drawings etc., and password is given to protect. A virus control system is operative in computer. A backup is taken on floppies whenever a revision is made in the original information. At present documents are not controlled in computers.
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TITLE : DOCUMENTATION REQUIREMENTS Changes in documents and data are reviewed by the same functions / authorities, which performed the original review and approval. The sources for initiating document changes are: 1. The modifications made in existing practices. 2. NCRs risen in Internal Audits and External Audit. Obsolete documents are removed and previous Master Copy if required is kept by stamping it with Obsolete Copy stamp. All controlled copy holders should destroy earlier revisions after receipt of latest revisions. Reference of documented Procedure : PR/03 .. Control of Documents. 4.2.4 Control of Records: MR is primarily responsible for this activity. Records are established and maintained to provide evidence of conformity to requirements and for the effective operation of the Quality Management System. Every employee takes care that records remain legible, readily identifiable and retrievable. A documented procedure is also established to define the controls needed for the identification, storage, protection, retrieval, retention time and disposition of records. Records stored in electronic media such as computers are also maintained to demonstrate conformance to specified requirements and effective operation of Quality Management System. These records are also made accessible to the customers whenever it is contractually agreed. Reference of documented Procedure : PR/04 - Control of Records. REF : ISO 9001 - 2000 PREPARED BY: CLAUSE : 4.2 APPROVED BY: Document No. : QMDMC/07 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 03 of 03
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TITLE : MANAGEMENT COMMITMENT Document No. : QMDMC/08 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
5.1 - Management Commitment : Our top Management commitment is evident through following points: a) Importance of meeting customer , statutory and regulatory requirements is communicated to all employees of organization through means of internal communications and various training programs. Quality policy : This quality policy is stated in Quality Policy section of this manual. This is documented by following guidelines mentioned in Clause 5.3 of Quality Management Requirements. Quality objectives are established and understood. These are stated in Quality Objective section of this manual. Management reviews which are conducted, as mentioned in Conducting Management Reviews section of this manual, and Availability of resources is ensured, as mentioned in Resource Management section of this manual.
b)
c)
d)
e)
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TITLE : CUSTOMER FOCUS Document No. : QMDMC/09 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
5.2 - Customer focus
CEO & MR ensure that customer requirements are determined and are met with the aim of enhancing customer satisfaction. They ensure determining the requirements related to the product as mentioned in Customer-related Processes of this Quality Manual, and monitoring and measuring customer satisfaction as mentioned in Customer Satisfaction of this Quality Manual.
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TITLE : QUALITY POLICY Document No. : QMDMC/10 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
5.3 Quality Policy DM CORPORATION PVT LTD has established a Quality Policy which 1. States purpose of the organization, 2. Includes a commitment to comply with requirements and continually improve the effectiveness of the Quality Management System, 3. Provides a framework for establishing and reviewing quality objectives, 4. Is communicated and understood by all employees. This policy is translated in the local language Marathi and displayed at various places in the company. This quality policy is reviewed in the management review meeting for its continuing suitability.
Quality Policy
We, at DM CORPORATION , Engineers and Contractors Pvt.Ltd , are committed to enhance Customer Satisfaction by meeting their requirements & to enhance its reputation as the Best Quality Infrastructure Developer Continual Improvement in all areas of operation giving emphasis on outgoing quality, treating all human beings as internal customer, by reducing overall cost of project to serve for the betterment of Nation.
COMMUNICATION AND FEEDBACK: This policy is explained to all employees during various training programs conducted. This policy is displayed at various places in the company in English as well as in Local Language Marathi.
CLAUSE : 5.3
REF : ISO 9001 - 2000
Quality Objectives derived from Quality Policy are reviewed in every Management Review Meeting PREPARED BY: APPROVED BY:
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TITLE : QUALITY OBJECTIVES Document No. : QMDMC/11 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
5.4 .1 Quality Objectives CEO and MR & all departments Managers have established quality objectives at relevant functions and levels within the Organization including those needed to meet requirements specified by the customer for the product. All these quality objectives are measurable and consistent with the quality policy. All defined quality objectives and their performance indicators are mentioned. The monitoring and measurement of these quality objective is ensured in the Organization by each responsible department Managers. Marketing Department: To increase annual turnover of assured quality. To achieve the set target of the Customer Satisfaction.
Purchase Department: To enhance the overall quality rating of the selected & accepted suppliers.
Construction & Quality Department: To complete the activities as per construction programs agreed. To minimize the wastage of main raw material. To reduce the customer complaint. To minimize the cost of NC Work.
MR Department: To conduct the audits as per specified intervals. To train persons for quality assurance and ensure continual improvement.
CLAUSE : 5.4.1 APPROVED BY:
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TITLE : ORGNISATION STRUCTURE Document No. : QMDMC/12 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
5.4.2 Quality Management System planning :

MR is primarily responsible for Quality Management System planning. They ensure that a) The planning of the Quality Management System is carried out in order to meet the requirements given in Section 4.1 as well as the Quality Objectives. b) The integrity of the Quality Management System is maintained when changes to the Quality Management System are planned and implemented. ORGANISATION STRUCTURE SITE INCHARGE _______________________________________________________________
ADMINISTRATION WING TECHNICAL WING
________________________________________
PURCHASE ICHARGE ACCOUNTATNT MESS INCHARGE
___________________________________________________
STRUCTURE ENGINEER SUPPLIERS EARTHWORK ENGINEER SUPPLIERS LAB INCHARGE HELPERS MECHANICS MUKADAM LABOUR CONTRACTORS MUKADAM LABOUR CONTRACTORS HELPERS STORE ASSISTANT STORE KEEPER WORKSHOP INCHARGE MR INCHARGE
CIVIL STORE KEEPER HELPERS
CLERK
HELPERS
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Document No. : QMDMC/13 Issue No. : 01 Date : 01.05.2008 KOLHAPUR Rev. No. : 00 Date : 01.05.2008 Page : 01 of 05 TITLE : RESPONSIBILITY, AUTHORITY AND COMMUNICATION 5.5.1 - Responsibilities And Authorities: The individual responsibilities of people who manage, perform and verify work affecting quality are as follows.
SITE INCHARGE :
I : FINANCIAL MANAGEMENT : a) b) c) d) His main duty is to keep contact with Head Office, informed the progress of the work, send fortnightly reports, make arrangements for payments from Head Office. He has to verify all the Bills for which payments are to be made at site. He has to enter the amounts of the payments done into the records of the payment (counter entry). If advances are done, the entry has to be done in the advance register. He has to verify contractors ledger before making payments.
II : MATERIAL MANAGEMENT : In consultation with engineering staff, he has to work out materials required (Cement, sand, metal Steel etc.) according to work programme. For the material which is seasonally available (sand) he has make entire stock for one year. b) He has to fix agencies for the material supply taking into consideration their capacity record, and comparative rates. c) He has to make arrangements for vehicles for transport of these materials. d) He has to see that up-to-date records are maintained for these items. e) He has to see that timely payments of these items are made so as to keep the flow of material smooth. III : LIASION WITH CUSTOMER : a) b) c) d) e) He has to see that drawing and estimates submitted to Department are approved in time. He has to see that periodical reports that are to be submitted to Department are submitted in time. He has make arrangements for the visits of the Departmental officers. He has to get the monthly bills prepared and get checked by the concerned officers and submit to the Department and follow up till the payments are made. He has to maintain the records that are required by the Department and get their signatures as required by the agreement. a)
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Document No. : QMDMC/13 Issue No. : 01 Date : 01.05.2008 KOLHAPUR Rev. No. : 00 Date : 01.05.2008 Page : 02 of 05 TITLE : RESPONSIBILITY, AUTHORITY AND COMMUNICATION IV. STAFF MANAGEMENT : a) b) c) d) e) f) g) h) He has to divide the responsibilities between the available staff. He has to request for any additional staff if required from Head Office. He has to look after the residing and other facilities of the staff. He has to look after the mess arrangement that are made are proper. He has to see that the staff is maintaining records and returns timely and properly. He has to make proper arrangement of vehicles for the staff. He has to see that the labours engaged on muster rolls are kept busy and are not idle. He has to see that the labours of the Sub-contractors are kept busy. Also make all arrangements of raw material required by them.
V : VEHICLES MANAGEMENT: a) b) c) He has to prepare a estimate of machinery that is required according programme of work. He has to see what machinery is available with him and inform the Head Office regarding the balance machinery. He has look after workshop arrangements that all the vehicles are in condition, fuel stocks are sufficient, inventory is proper, Tax records are clear, skilled staff is qualified. He has to keep watch on the output of the machinery. HIRED MACHINERY : a) b) He has to keep the record of hours of the machinery per day. The work done per hour by the machine. Fuel consumed per Hour etc. Records of the machinery and advances and their periodical payments.
WORKSHOP : a) b) c) d) e) He has to see if sufficient staff is available to do a particular job. If not he has to engage outside staff on job basis. He has keep stock of all the spares that are required on regular basis. He has to see that workshop staff perform day to day maintenance and major breakdown repair in time. He has to see that diesel supply is nonstop. CLAUSE : 5.5.1 APPROVED BY:
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Document No. : QMDMC/13 Issue No. : 01 Date : 01.05.2008 KOLHAPUR Rev. No. : 00 Date : 01.05.2008 Page : 03 of 05 TITLE : RESPONSIBILITY, AUTHORITY AND COMMUNICATION
RAW MATERIAL PURCHASE-IN-CHARGE : a) b) c) d) e) In consultation with S.I.C., he has to place the orders for the raw materials, keep the records of the material received and material issued. He has to see that the payments are made for these supplies. He has to maintain staff payment Register and advance Register. He has to watch on tax payments of vehicles. Keep account of money received from Head Office and submit reports to Head Office.
ACCOUNTANT AND CLERKS : a) Helps Purchase-In-Charge to perform above duties.
CIVIL STORE-KEEPER a) b) c) d) To receive & issue the raw material. Preparation of the bills. Stock management. Keeping the related records. TECHNICAL WING ENGINEER-IN-CHARGE OF STRUCTURES : a) b) c) d) e) f) He has to see that drawings of the structures approved are on site as per the construction programme. If not he has to follow the matter with S.I.C. or Departmental Engineers. He has to give all site data to company Engineer preparing drawing and estimates. He has to see that stock of all the raw material is available as per the construction programme. If shortage is there he has to inform the S.I.C. He has to clarify the drawings to sub-contractors, give line out to them and see that they do the work as per drawings and specifications. Keep in touch with quality control people and take their signatures on records maintained on site. Prepare sub-contactors bills and submit to S.I.C.
ENGINEER-IN-CHARGE OF EARTHWORK : a) As in case of structural Engineer, but in case of Earthwork. REF : ISO 9001 - 2000 PREPARED BY: CLAUSE : 5.5.2 APPROVED BY:
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LAB-IN-CHARGE : a) b) c) d) He has to see that all the apparatus required for carrying out tests as per agreement are available. He has to collect all the data and material from field staff, that is required for carrying out tests. He has to maintain all the registers and records that are required as per agreement. He has to obtain the signatures of the Department people on these registers.
SUPERVISORS : a) The Engineer will divide his work area in parts and entrust each part to different Supervisors. He will be assisted by mukadams. He has to assist the Engineers in all his duties as far as his part is concerned. b) Giving line out to Sub- Contractors. c) Engaging departmental as well as hired machinery on work and not keeping the idle. d) Keeping the record of machinery as under: i) Working Hours, ii) Diesel Consumed & iii) Oil Consumed etc. Submitting this record to site office. e) Counting blasting holes, their depth and blasting material used. To keep the record of the same & submit the weekly records. f) No. of trips done by vehicles every day with time taken and quantity conveyed per trip. g) Supervise Sub- Contractors Work: i) To watch water cement ratio. ii) Whether the sand is properly washed. iii) Whether correct cement quantity is used. iv) Whether centering and shuttering is in plumb. v) To keep record of number of labours, unskilled, semi skilled and skilled working under his work area and keep record of it. WORKSHOP IN CHARGE: a) He has to handle all the staff under him b) He has to allot various machinery to various people and get the work done from them. c) If company staff is insufficient, he has to allot the work to outside agencies on job basis in consultation with S.I.C. d) He has to attend breakdown of machinery on various locations through his staff. e) He has to take care that there are no accidents due to negligence of the staff. f) He has to maintain mater-roll of people under him. MECHANICS:MECHANICAL STORE KEEPER : a) To receive & issue the material. b) Stock management. c) Keeping the related records.
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MANAGEMENT REPRESENTATIVE : Preparation Quality Manual ,Process Manual & Reference Documents ( R ) Issue of all I , II & III level documents.( R ) Document control. ( R ) Plan & implement internal audits. ( A & R) Control of records. ( A & R) Liaison with certification body/ External bodies. ( R ) Ensure data for management review meeting. ( R ) Identification of training needs. ( A & R) Implementation of training programme/plan. ( R ) To conduct House-keeping Audit. ( R ) Maintaining copies of regulatory & statutory laws. ( R ) Control of national & International standards. ( R ) Responsible for Ensuring the promotion of awareness of customer requirements throughout the organization.
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TITLE : MANAGEMENT REPRESENTATIVE 5.5.2 Appointment of Management Representative : DM CORPORATION PVT LTD has appointed Mr. A. D. Patil - as management representative who irrespective of other Responsibilities, has responsibility and authority for Ensuring processes needed for the Quality Management System are established, implemented and maintained. Reporting to top management on the performance of the Quality Management System and any need for improvement. Ensuring the promotion of awareness of customer requirements throughout the organization. Liaison with external parties on matters relating to the Quality Management System. Document No. : QMDMC/14 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
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DM CORPORATION PVT.LTD
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TITLE : INTERNAL COMMUNICATION Document No. : QMDMC/15 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
5.5.3 - Internal Communication:

CEO along with MR & Concerned Managers ensure that appropriate communication processes are established within the organization and that communication takes place regarding the effectiveness of the Quality Management System.
The communication process established within the Organization is mentioned in every process. Management representative for the effectiveness of the Quality Management System carries out the verification of these practices in the internal audit.
Also for communicating the messages, Telecommunication services , e-mails & display boards are used.
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TITLE: MANAGEMENT REVIEW Document No. : QMDMC/16 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 02
5.6.1 General : CEO reviews the Organizations Quality Management System, once in a 4 months. in Management Review Meeting; to ensure its continuous suitability, adequacy and effectiveness. Management representative arranges Management Review Meeting by issuing a circular. This meeting is chaired by the CEO. All Managers including Supervisors attends the meeting. This review includes assessing opportunities for improvement and the need for changes to the Quality Management System, including the quality policy and quality objectives. The inputs decided for the management review are stated in the same section Review input and the output from the management review are stated in the same section. 5.6.2 Review input : The input to management review includes the information on following topics which is collected by Management Representative from concerned Person. Department Manager/In charge, Supervisors presentation will include a) Results of audits (findings of internal / external audit, Summery of internal audits) b) Present Customer feedback (Analysis of data of customer satisfaction). c) Process performance and product conformity, (Review of Accepted product, Rejection, Deviation and Rework of the product) d) Status of preventive and corrective actions, (Status of preventive action and corrective action taken for customer complaint, product , process , Quality Management System) e) Follow-up actions from previous management reviews (Review of previous minutes of Management Review Meeting) f) Changes that could affect the Quality Management System g) Recommendations for improvement. h) Review quality policy and objectives i) Supplier performance. REF: ISO 9001:2000 PREPARED BY: CLAUSE : 5.6 APPROVED BY:
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TITLE: MANAGEMENT REVIEW Document No. : QMDMC/16 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 02 of 02
5.6.3
- Review output : The output from the management review includes
a) Current performance of Quality Objectives. b) Internal customer satisfaction, customer complaint & feedback from customers representative. c) Improvement of product related to customer requirements, and d) Resource needs (in the form of training, infrastructure, work environment). These are discussed and decided in the management review and recorded with target dates for Completion. Records from management reviews in the form of minutes of Management Review Meeting are prepared and maintained by Management Representative. MR. circulates a copy of minutes of Management Review Meeting to all Managers. Retention period for minutes of meeting is 1 year
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TITLE: PROVISION OF RESOURCES Document No. : QMDMC/17 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
6.1 - Provision of resources All Managers & MR determines the resources needed as & when required and CEO is responsible to provide it a) To implement and maintain the Quality Management System and continually improve its effectiveness, and b) To enhance customer satisfaction by meeting customer requirements. This is managed by the organization as mentioned in the section Human Resources & Infrastructure
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TITLE: HUMAN RESOURCES Document No. : QMDMC/18 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
6.2.1 - General : Production Manager along with MR ensure that the personnel performing work which is affecting product quality are competent on the basis of appropriate education, training, skills and experience at the time of appointing a new employee. 6.2.2 - Competence, awareness and training: MR and respective department Managers a) Determines the necessary competence for personnel performing work affecting product b) Provide training or take other actions to satisfy their needs, c) Evaluate the effectiveness of the actions taken, d) Ensure that the personnel are aware of the relevance and importance of their activities. How they contribute to the achievement of the quality objectives, through awareness training in the induction training program (for new employee), or various training programs consisting of technical training as well as other aspects like quality awareness, communication skills, attitudinal training etc conducted in the organization. MR maintains appropriate records of education, training, skills and experience. Our organization has a team of internal auditors trained by professional Lead Auditor of Quality Management System. Appropriate process is written with details of the method of identification of training needs, planning training activity and implementation of training programs and their verification for the training imparted. Also, impact of training is reviewed, during the Management Review Meeting. Persons performing specific assigned tasks such as internal quality audits, inspection and testing are trained on the basis of appropriate education, training or experience as required to make them qualified to perform their task.
REF: ISO 9001:2000 PREPARED BY: CLAUSE : 6.2 APPROVED BY:
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TITLE: INFRASTRUCTURE Document No. : QMDMC/19 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
6.3 Infrastructure: Our organization determines, maintains and provides the infrastructure needed to achieve conformity to product requirements. This infrastructure includes: a) Building, workspace and associated utilities, b) Process equipment (both hardware and software), and c) Supporting services (such as transport or communication).
The responsibility for this activity is with MR, CEO. Determination is also done through getting information from the concerned Managers.
31
Quality Manual
KOLHAPUR
TITLE : WORK ENVIRONMENT Document No. : QMDMC/20 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
6.4 - Work Environment: MR , CEO & Site I/C determine and manage the work environment needed to achieve conformity to product requirements. Suitable machines, equipments are used for Manufacturing. The process parameters, which are critical, are recorded and monitored suitably. For product, acceptance standards, which can be well defined, are followed. For subjective aspects, reference samples are available. Suitable methods of maintenance of machine and utilities are laid down and implemented to ensure continuing process capability. The MR ensures this. Processes are defined and are written in local language Marathi and controlled copies are displayed at all locations where their absence may adversely affect quality of products processed. With a view to maintaining conductive work environment DM CORPORATION -PVT.LTD has provided for employees welfare measures like P.F. , leave facilities, Safety equipments, First Aid, lodging & boarding & get together facility etc.
32
Quality Manual
Document No. : QMDMC/21 Issue No. : 01 Date : 01.05.2008 KOLHAPUR Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01 TITLE : PLANNING OF PRODUCT REALIZATION
7.1 Planning of product Realization : DM CORPORATION PVT LTD plans and develops the processes needed for product realization. The consistency is maintained to meet the requirements of the other processes of the Quality Management System while planning of product realization, which are mentioned in Section 06 General requirement of this Quality manual. In planning product realization, the following points are determined, as appropriate: a) Quality objectives and requirements for the product . b) The need to establish processes, documents, and provide resources specific to the product. c) Required verification, validation, monitoring, inspection and test activities specific to the product and the criteria for product acceptance in the form of receiving, In-process, Final Quality Plan, Specifications sheet or Data sheet of the item, Charts etc; d) Records needed to provide evidence that the realization processes and resulting product meet requirements as mentioned in point no. 4.2.4 of QMDMC/07 of this Quality Manual. Concerned Manager with the help of MR carry out this process for the existing and new product. The output of this planning is in the form of Quality Plan.
33
Quality Manual
KOLHAPUR
TITLE : CUSTOMER RELATED PROCESSES Document No. : QMDMC/22 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
7.2.1 Determination of Requirements related to the Product : The Organization determines a) Requirements specified by the customer, including the requirements for delivery and post-delivery activities, b) Requirements not stated by the customer but necessary for specified or intended use, where known, c) Statutory and regulatory requirements related to the product, and d) Any additional requirements determined by our Organization. This determination is done at the time of Review of requirements related to the product as mentioned in same section. 7.2.2 Review of requirements related to the product: PUR Manager reviews the requirements related to the product prior to acceptance of order. 7.2.3 Customer communication: DM CORPORATION PVT LTDdetermines and implements effective arrangements for communicating with customers in relation to : a) Product information is communicated through specifications, standard practice and written notes, b) Enquiries, contracts or order handling, including amendments through monthly Production schedule and notes / amendments thereof, and c) Customer feedback, including customer complaints in form of verbal / written, email, phone, letters, fax etc.
34
Quality Manual
KOLHAPUR
TITLE : DESIGN AND DEVELOPMENT Document No. : QMDMC/23 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
CEO , Site I/C & technical Manager are primary responsible for it. All team with Customer representative survey the land. This facility is outsourced. Steps are as follows : 01 : Collection of related maps, command area survey as per specifications given by customer, plotting ,contouring and preparation of block contour map with the help of computer software & planning of distribution system. 02 : Block counter Map is submitted to customer for approval. 03: After getting approval: alignment survey, planning, design, drawings, estimates & preparation of land plan schedules of distribution system including structures is done.
REF: ISO 9001:2000 PREPARED BY :
CLAUSE : 7.3 APPROVED BY :
35
Quality Manual
KOLHAPUR
TITLE : PURCHASING 7.4.1 Purchasing process: Our Organization ensures that, the purchased material obtained from supplier conforms to specified purchase requirements. PUR Manager is responsible for carrying out these processes. We control the supplier and purchased material. The type and extent of control applied to the supplier and the purchased material is dependent upon the effect of the purchased material, on subsequent product realization or the final output. Our Organization also evaluates and selects suppliers based on their ability to supply material in accordance with our organizations requirements. Criteria for selection, evaluation and re-evaluation are established. This is defined in the process titled Evaluation and Selection of supplier PR/09. The selected suppliers are included in the List of approved supplier which includes suppliers supplying Raw Material, components and services like consultancy / training, maintenance and calibration, transport, which gives details like items supplied, type and extent of control exercised. Suppliers who are already supplying raw materials as on 01/ 05 /2008 are approved and included in List of approved supplier. PUR Manager maintains records of the results of evaluations, Quality performance of approved supplier and any necessary actions arising from the evaluation as per QMDMC/07.of this Quality Manual. 7.4.2 Purchasing information: Our purchasing information describes the material to be purchased, including where appropriate a) Requirements for approval of product, procedures, processes and equipment, b) Requirements for qualification of personnel. c) Requirements of Quality Management System. Document No. : QMDMC/24 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 02
REF: ISO 9001:2000 PREPARED BY
CLAUSE : 7.4 APPROVED BY
36
Quality Manual
KOLHAPUR
TITLE : PURCHASING Document No. : QMDMC/24 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 02 of 02
PUR Manager raises the Purchase orders, which contain accurate data about material description, type, class, and grade wherever applicable. We also give reference wherever required to applicable issue of specifications, drawings, process requirements, and inspection Processs. Purchase order are reviewed and approved before release. PUR Manager ensures the adequacy of specified purchase requirements, prior to their communication to the supplier. 7.4.3 Verification of purchased material: The Organization has established and implemented the inspection and verification activities necessary for ensuring that purchased material meets specified purchase requirements. If need arises, PUR Manager arranges the intended verification arrangements and method of material release in the purchasing information, where our organization or our customer intends to perform verification at the suppliers premises. The purchasing document gives specific instructions.
Reference of Documented Processes: PR/09 ..Evaluation and Selection of supplier.
REF : ISO 9001:2000 PREPARED BY:
37
Quality Manual
KOLHAPUR
TITLE : CONSTRUCTION Document No. : QMDMC/25 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
7.5.1
Control of construction provision : Our Organization plans and carries out construction under controlled conditions. Controlled conditions are include, as applicable
a) The availability of information that describes the characteristics (specifications) of the product, b) The availability of work instructions, as necessary. c) The use of suitable equipment, d) The availability and use of monitoring and measuring devices, e) The implementation of monitoring and measurement, and f) The implementation of release, delivery and post-delivery activities. Since our product does not require servicing, the scope of certification excludes servicing.
38
Quality Manual
Document No. : QMDMC/26 Issue No. : 01 Date : 01.05.2008 KOLHAPUR Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01 TITLE : IDENTIFICATION AND TRACEABILITY
7.5.3 Identification and Traceability: Where appropriate, our Organization identifies the raw material by suitable means (names, tags or keeping it at designated locations, racks, bins) throughout product realization. Concern Manager & Supervisor is primary responsible for this quality element. The organization identifies the material status such as accepted, rejected, accepted under concession (i.e. deviation), for Rework / Repair, rejected with respect to monitoring and measurement requirements by affixing the Tags and keeping it at designated location, throughout the manufacturing of the product to ensure that only material that has passed the inspection is dispatched or used. Where traceability is a requirement from the customer then only our organization controls and records the unique identification of the material as per customer requirement.
CLAUSE : 7.5.2 APPROVED BY :
39
Quality Manual
KOLHAPUR
TITLE : CUSTOMER PROPERTY Document No. : QMDMC/27 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
Our Organization exercises care with customer property such as intellectual property (data, and information) while it is under our control or being used by us. We identify, verify, protect and safeguard customer property provided for use or incorporation into their product. If any customer property is lost, damaged or otherwise found to be unsuitable for use, this is reported to the customer and records maintained as mentioned in point 4.2.4 of Section 4.2 of this Quality Manual.
40
Quality Manual
KOLHAPUR
TITLE : PRESERVATION OF PRODUCT Document No. : QMDMC/28 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
Our organization preserves the conformity of product during internal processing. This preservation includes identification, handling, packaging , storage and protection. Departmental Managers & Supervisors are primarily responsible for this activity. Suitable methods of handling the product throughout are used and documented in processes. Designated storage areas are used to store raw materials to prevent damage / deterioration. Appropriate methods of receipt and issues from such areas are implemented. First in first out system is implemented for issue of materials in the Stores. The condition of product in stock at raw material stage and finished product stage are periodically checked to detect damage / deterioration .
41
Quality Manual
Document No. : QMDMC/29 Issue No. : 01 Date : 01.05.2008 KOLHAPUR Rev. No. : 00 Date : 01.05.2008 Page : 01 of 02 TITLE : CONTROL OF MONITORING AND MEASURING DEVICES
Site I/C is primarily responsible for this function. Our organization determines the monitoring and measurement to be undertaken. Determine the monitoring and measuring devices needed to provide evidence of conformity of product, to determine requirements, which are identified by following the activities mentioned in Customer Related Process of this manual. Such devices are included in the list called as list of Calibrative type of instruments/ equipment. Our Organization has established processes to ensure that monitoring and measurement can be carried out in a manner that is consistent with the monitoring and measurement requirements. Where necessary to ensure valid results, measuring equipment a) Are calibrated or verified at specified intervals, or prior to use, against measurement standards traceable to international or national measurement standards; where no such standards exist, the basis used for calibration or verification are recorded; b) Are adjusted or re-adjusted as necessary; this frequency is determined and mentioned in the list of calibrative type of instruments /equipments. c) Are identified by suitable means , to enable the calibration status to be determined; d) Are safeguarded from adjustments that would invalidate the measurement result; e) Are protected from damage and deterioration during handling, maintenance and storage. In addition, our Organization assesses and records the validity of the previous measuring results. When the equipment is found out of calibration our organization takes appropriate action on the equipment and any product affected. Records of the results of calibration and verification are maintained as mentioned in 4.2.4 of QMDMC/07.
REF : ISO 9001:2000 PREPARED BY: CLAUSE : 7.6 APPROVED BY :
42
Quality Manual
Document No. : QMDMC/29 Issue No. : 01 Date : 01.05.2008 KOLHAPUR Rev. No. : 00 Date : 01.05.2008 Page : 02 of 02 TITLE : CONTROL OF MONITORING AND MEASURING DEVICES
When used in the monitoring and measurement of specified requirements, the ability of computer software to satisfy the intended application are confirmed. This are undertaken prior to initial use and reconfirmed as necessary. Where equipment is calibrated / verified in-house, the documented processes are available, defining the process employed for calibration / verification, the basis used for calibration, frequency of checks, acceptance criteria, suitable environmental conditions to be maintained for calibration, result of calibration and verification. Where equipment are calibrated by external agency, the supplier is evaluated, selected. A documented process gives details about care to be taken during handling, storage, and preservation of measuring equipment. Concerned employees are trained to ensure accurate and safe handling and operation of equipment, so as to prevent them from adjustments, which would invalidate the calibration settings. Where the availability of technical data pertaining to the inspection, measuring and test equipment is a specified requirement, such data is made available, when required by the customer or customers representative, for verification that the inspection, measuring and test equipment is functionally adequate.
43
Quality Manual
Document No. : QMDMC/30 Issue No. : 01 Date : 01.05.2008 KOLHAPUR Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01 TITLE : MEASUREMENT, ANALYSIS AND IMPROVEMENT
8.1 General DM CORPORATION , -PVT.LTD plans and implements the monitoring, measurement, analysis and improvement process needed. a) To demonstrate conformity of the product, b) To ensure conformity of the Quality Management System, and c) To continually improve the effectiveness of the Quality Management System. This includes determination of applicable methods, including statistical techniques, and the extent of their use. All this is explained in the following sections: a) Monitoring and measurement of customer satisfaction and Internal audit as the measurement of the performance of the Quality Management System b) Monitoring and measurement of processes c) Monitoring and measurement of product d) Control of nonconforming products e) Analysis of data to demonstrate the suitability and effectiveness of the Quality Management System , f) For continual improvement of the quality management of the system our Organization takes the corrective and preventive actions .
44
Quality Manual
KOLHAPUR
TITLE : CUSTOMER SATISFACTION Document No. : QMDMC/31 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
8.2.1 Customer satisfaction: As one of the measurements of the performance of the Quality Management System, our Organization monitors information relating to customer perception as to whether our Organization has met customer requirements. The method for obtaining and using this information is determined and is documented in the process. MR is primary responsible for this activity.
45
Quality Manual
KOLHAPUR
TITLE : INTERNAL AUDIT Document No. : QMDMC/32 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 02
Our Organization conducts internal audits at planned intervals of once in a four months to determine whether the Quality Management System. a) Conforms to the planned arrangements to the requirements of the International Standard and to the Quality Management System requirements established by our Organization , and b) Is effectively implemented and maintained. Management Representative is primarily responsible for this activity. MR. plans an audit program taking into consideration the status and importance of the processes and areas to be audited, as well as the results of previous audits. The audit criteria, scope, frequency and methods is defined in the documented Process. MR. Select auditors who conduct audits in such a way that the objectivity and impartiality of the audit process is maintained. Also MR plans the internal audit in such a way that internal auditors should not audit their own work. A documented Process is available defining the responsibilities and requirements for planning and conducting audits, and for reporting results and maintaining records as mentioned in QMDMC/07 of this Quality Manual. It is ensured that the internal quality auditors meet the qualification criteria stipulated in Process for internal quality audit and training. Records are maintained. The audit schedule gives relevant clauses of the standard which are applicable to the department and auditor uses Back-up sheet to record the audit evidence. By reviewing the back-up sheet, MR. ensures comprehensiveness of the audit covering all requirements of ISO 9001:2000 standard. Results of the audit are reported on non-conformity report forms and are brought to the notice of the auditee.
REF : ISO 9001:2000 PREPARED BY: CLAUSE : 8.2.2 APPROVED BY :
46
Quality Manual
KOLHAPUR
TITLE : INTERNAL AUDIT Document No. : QMDMC/32 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 02 of 02
All Department Managers, responsible for the area audited, ensure that the actions are taken on or before target dates without undue delay, to eliminate detected non-conformities and their causes. A follow-up activity (in next Internal Audit) includes the verification of the actions taken (correction and corrective action) and, the reporting of verification results. A summary of audit report forms a part of the agenda of Management Review. Possibilities of preventive actions are explored and initiated, implemented and monitored for effectiveness in various areas based on the trends & types of non conformities in an area Reference of Documented Process: PR/05 - Internal audit
47
Quality Manual
Document No. : QMDMC/33 Issue No. : 01 Date : 01.05.2008 KOLHAPUR Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01 TITLE : MONITORING AND MEASUREMENT OF PROCESSES
Our organization applies suitable methods for monitoring and where applicable, measurement of the Quality Management System processes. These methods demonstrate the ability of the processes to achieve planned results. When planned results are not achieved, correction and corrective action are taken, as appropriate, to ensure conformity of the product. All the processes are monitored through functional quality objectives and if any deviation / non-conformity observed corrective action is taken.
MONITORING AND MEASUREMENT OF PROCESSES IS DONE THROUGH QUALITY OBJECTIVES. MONITORING AND MEASUREMENT OF SYSTEM IS DONE THROUGH INTERNAL AUDITS. MONITORING AND MEASUREMENT OF PRODUCT IS DONE THROUGH INSPECTION AT VARIOUS STAGES.
48
Quality Manual
Document No. : QMDMC/34 Issue No. : 01 Date : 01.05.2008 KOLHAPUR Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01 TITLE: MONITORING AND MEASUREMENT OF PRODUCT
8.2.4 Monitoring and measuring of product Our organization monitors and measures the characteristics (specifications) of the product to verify that, product requirements have been met. This is carried out at appropriate stages of the Product Realization Process i.e. at receiving inspection of purchased product, in-process inspection of the product and final inspection of the project, in accordance with the planned arrangements mentioned in the Planning of Product Realisation of this Quality Manual. Site I/C is primary responsible for incoming, Supervisors are responsible for in-process Site I/C is responsible for final inspection. Service Agencies carry out inspection at various in-process stages of Works. Receiving inspection and testing of all incoming raw materials is done as per quality plan. We do not issue any material without verification even in urgency. In-process inspection and in-process parameters verification is carried out by the Supervisor from time to time during manufacturing process to ensure that, respective specifications are met as per specifications / Process Plans /drawings. In case of non-conforming product resulted during the process, it is recorded and corrected by repair / rework or rejected after inspection. Final inspection is carried as per relevant Process Plans / Customer suggestions and non-conformances observed are corrected before hand over to the customer. We also help customers representative for inspection, whenever agreed in the contract review. Evidence of conformity with the acceptance criteria is maintained in the form of Inspection records at receiving, in-process & final stage. These records also indicate the person(s) authorizing release of product. Inspection and test records are properly maintained. Product is not despatched until the planned arrangements mentioned in the Planning of Product Realisation of this Quality Manual have been satisfactorily completed, unless otherwise approved by a relevant authority by the customer.
49
Quality Manual
Document No. : QMDMC/35 Issue No. : 01 Date : 01.05.2008 KOLHAPUR Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01 TITLE : CONTROL OF NONCONFORMING PRODUCT:
8.3
Control Of Nonconforming Product: Our organization ensures that product which does not conform to product requirements is identified and controlled to prevent its unintended use. The controls and related responsibilities and authorities for dealing with nonconforming product are defined in a documented Process. Our organization deals with nonconforming product by one or more of the following ways:
a) By taking action to eliminate the detected nonconformity; such doing rework to fulfill the specified requirements or repair to fulfill the intended use requirements although it may not conform to the originally specified requirements or rejected / scraped. b) By authorizing its use, release or acceptance under concession by a Customers representative, where applicable, by the customer, and c) By taking action to preclude its original intended use or application. Records of the nature of non-conformities and any subsequent actions taken, including concessions obtained, are maintained as mentioned in point 4.2.4 of QMDMC/07 of this Quality Manual. When nonconforming product is corrected by rework or repair, the reverification (re-inspection) is carried out as per relevant quality plans / Drawings to demonstrate conformity to the requirements. Our organization takes action appropriate to the effects, or potential effects, of the nonconformity, when nonconforming product is detected after handed over or use started. Reference of Documented procedure : PR/06 Control of non-conforming product
50
Quality Manual
KOLHAPUR
TITLE : ANALYSIS OF DATA Document No. : QMDMC/36 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
Our Organization determines, collects and analyses appropriate data to demonstrate the suitability and effectiveness of the Quality Management System and to evaluate where continual improvement of the effectiveness of the Quality Management System can be made. This includes data generated as a result of monitoring and measurement and from other relevant sources. MR & CEO are responsible for this activity. The analysis of data provide information relating to a) Customer satisfaction as one of the measurement of the performance of the Quality Management System. b) Conformity to product requirements that are mentioned in Customer Related processes of this Quality Manual. c) Characteristics and trends of processes and products including opportunities for preventive action, and d) Suppliers performance monitoring.
51
Quality Manual
KOLHAPUR
TITLE : IMPROVEMENT 8.5.1 Continual improvement: Our Organization continually improves the effectiveness of the Quality Management System through the use of the quality policy, quality objectives, audit results, analysis of data, corrective and preventive actions and management review. 8.5.2 Corrective action Our Organization takes action to eliminate the cause of non-conformities in order to prevent recurrence. Corrective actions are appropriate to the effects of the nonconformities encountered. A documented Process is established to define requirements for a) b) c) d) e) Reviewing non-conformities (including customer complaints), Determining the causes of non-conformities, Evaluating the need for action to ensure that non-conformities do not recur, Determining and implementing action needed, Records of the results of action taken as mentioned in Section : 07 of this Quality Manual, f) Reviewing corrective action taken. PRD Manager & PUR Manager reviews nonconformity observed in the verification of purchase material and determines the causes of non-conformities. Analysis is carried out for appropriate corrective action and is implemented. If it needs the corrective action from supplier, the supplier is requested for the same and the effectiveness of the corrective actions taken, is monitored in the subsequent lots received from the supplier. Non-conformities regarding customer complaints, material, process, are reviewed for determining the causes of nonconformity and analysis is carried out for corrective action. The implemented corrective action is monitored in further processing for effectiveness of corrective action taken. Records of the results of these analysis and investigations and effectiveness of results of action taken are maintained. Corrective action taken for non-conformities in Quality Management System are dealt with by MR as per documented Process. Reference of Documented procedure : PR/07 - Corrective action. REF : ISO 9001:2000 PREPARED BY: Document No. : QMDMC/37 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
52
Quality Manual
KOLHAPUR
TITLE : PREVENTIVE ACTION Document No. : QMDMC/38 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 01 of 01
8.5.3 Preventive action : Our Organization determines action to eliminate the causes of potential nonconformities in order to prevent their occurrence. Preventive actions are appropriate to the effects of the potential problems. A documented Process is established to define requirements for a) Determining potential non-conformities and their causes in the management review meeting from, 1. 2. 3. 4. 5. 6. Record of management review meeting. Records of preventive maintenance. Records of non-conformities. Process and quality system non-conformities. Training records. Customer complaints
b) Evaluating the need for action to prevent occurrence of non-conformities, c) Determining and implementing action needed, d) Records of results of action taken, as mentioned in QMDMC/07 of this Quality Manual, and e) Reviewing preventive action taken. Primary responsibility of preventive action, is with M.R. for quality system, and for products / processes with CEO & Concerned Manager. Suitable preventive actions are taken through amendments in pertinent documents. The results are monitored to prevent occurrence of potential nonconformities. Reference of Documented Process: PR/08 - Preventive action
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55
Quality Manual
KOLHAPUR
TITLE : GENERAL REQUIREMENTS
INTERACTION OF PROCESSES Construction Department Quality Control Department Enquiry / Information Collection Project Realization Planning (including training & resources needed) Review for the Purchase Requirement Collecting Samples for Test Purchase Department
Document No. : QMDMC/06 Issue No. : 01 Date : 01.05.2008 Rev. No. : 00 Date : 01.05.2008 Page : 03 of 03
Marketing Department
Feasibility Construction Planning
Evaluation & Selection Of new Suppliers
If not OK-for new
If OK
Application for Tender Determination & review of tender requirements Purchase Planning
Conducting various tests
Release of Purchase Order
Commencement of Work
Submitting reports to concerned persons / Dept. Heads
Inspection of purchasing material
Tender Filling & Submitting Proceed for further construction Activities Inspection of site Work
Procurement of material
If no for new
Tender Opening
If yes
Acceptance of Tender In-processes Inspection of Construction Activities Reporting to Management
Take appropriate action on Rejection
If not OK
If OK
Repair / rework & Re-inspection Receiving Work Order Informing to Construction Department Final Inspection Handing Over to Construction Department
Completion of all the activities
If not OK
Repair / rework / Reinspection if required
Receiving Work Completion Letter from Customer
Informing To MKT Dept.
Handing Over to Customer.
Post-delivery Maintenance

56
TARGET & ACHIEVEMENT OF QUALITY OBJECTIVES
Process
Quality Objectives
Indicator
Methodology Annual Turnover Calculation. Avg. Percentage achieved from all customers Set Target % achieved ------------------Set Target No. of pit sample tests rejected. ------------------------Total no. pit sample tests taken. Total Quantity of Work Done ------------------------Total Quantity of Work Planned Actual quantity of construction ingredients used ------------------------Quantity of construction ingredients required Present frequency of audits -----------------------Planned frequency of audits. No. of employees trained -----------------------Total no. of employees.
Frequency Annual
Responsibil Set Target ity CEO
STATUS
Jan Feb Mar Apr Ma y Jun e July Au g Sep Oct No v Dec
Tender Dept.
To increase Annual Turnover. To achieve the set target of the Customer Satisfaction.
In Rupees In Percentage In Percentage
Per Six Months Once in a Year
GM Purchase officer
Purchas ing
Constru ction
To maintain quality consistency as per standard.
In Percentage
Per Month
Project Manager
In Percentage To minimize wastage and ensure optimum use of available resources.
Per Month
Project Manager
In Percentage
Per Month
Project Manager
Human Resourc es
In Percentage
Per Month
MR
50%
Per 6 month
MR
40%
Prepared By :
Approved By :
57
TARGET & ACHIEVEMENT OF QUALITY OBJECTIVES ACHIEVEMENT FOR THE PERIOD JUNE 2008 MAY 2009 Process Quality Objectives To increase Annual Turnover. Tender Dept. To achieve the set target of the Customer Satisfaction. To enhance the overall quality rating of the selected & accepted suppliers. Indicator In Rupees Methodology Annual Turnover Calculation. Avg. Percentage achieved from all customers Calculate the rating of RM suppliers Monthly planning V/S actually work done Ideal consumption V/S actual consumption Count the customer complaints Calculate the cost of NC Work. Frequency Annual CEO Annual MR Responsib ility Set Target STATUS
In Percentage
Purchasi ng Constru ction
In Percentage
Annual
PUR Manager
June july aug Sep oct nov dec jan feb mar
To complete the activities as per agreed construction program. agreed. To minimize wastage of main Raw Material. To reduce the customer complaint. To minimize the cost of rejection / rework.
april
In Percentage
Monthly
In Percentage In numbers
Monthly
Site I/C
Monthly
In Rupees
Monthly Yearly
MR
MR
To conduct the audits as per specified intervals.

To train persons for quality assurance and ensure continual improvement.
In Percentage
% of No. of audits conducted in time Planned training V/S actual training
Yearly
In Percentage
To conduct the audits as per specified intervals. To train persons for quality assurance and ensure continual improvement.
58

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REF: ISO 9001:2000 PREPARED BY:

CLAUSE : 1.2 APPROVED BY:

REF: ISO 9001:2000 PREPARED BY:

REF: ISO 9001:2000 PREPARED BY:

CLAUSE : 4.2 APPROVED BY

Original Issue with Revision 00 of all QMDMC: 01.05.2008

REF: ISO 9001:2000 PREPARED BY:

CLAUSE : 4.2 APPROVED BY:

APPROVED BY: MANAGEMENT REVIEW MEETING

REF: ISO 9001:2000 PREPARED BY:

CLAUSE : 4.2 APPROVED BY:

REF: ISO 9001:2000 PREPARED BY:

CLAUSE : 4.2 APPROVED BY:

REF : ISO 9001 - 2000 PREPARED BY:

REF : ISO 9001 - 2000 PREPARED BY:

CLAUSE : 5.1 APPROVED BY:

5.2 - Customer focus

REF : ISO 9001 - 2000 PREPARED BY:

CLAUSE : 5.2 APPROVED BY:

REF : ISO 9001 - 2000

REF : ISO 9001 - 2000 PREPARED BY:

5.4.2 Quality Management System planning :

CIVIL STORE KEEPER HELPERS

REF : ISO 9001 - 2000 PREPARED BY:

CLAUSE : 5.4.2 APPROVED BY:

REF : ISO 9001 - 2000 PREPARED BY:

CLAUSE : 5.5.1 APPROVED BY:

REF : ISO 9001 - 2000 PREPARED BY:

ACCOUNTANT AND CLERKS : a) Helps Purchase-In-Charge to perform above duties.

REF : ISO 9001 - 2000 PREPARED BY:

CLAUSE : 5.5.2 APPROVED BY:

REF : ISO 9001 - 2000 PREPARED BY:

CLAUSE : 5.5.2 APPROVED BY:

REF : ISO 9001 - 2000 PREPARED BY:

CLAUSE : 5.5.2 APPROVED BY:

5.5.3 - Internal Communication:

REF : ISO 9001 - 2000 PREPARED BY:

CLAUSE : 5.5.3 APPROVED BY:

- Review output : The output from the management review includes

REF: ISO 9001:2000 PREPARED BY:

CLAUSE : 5.6 APPROVED BY:

REF: ISO 9001:2000 PREPARED BY:

CLAUSE : 6.1 APPROVED BY:

REF: ISO 9001:2000 PREPARED BY:

CLAUSE : 6.3 APPROVED BY:

REF: ISO 9001:2000 PREPARED BY:

CLAUSE : 6.4 APPROVED BY:

REF: ISO 9001:2000 PREPARED BY:

CLAUSE : 7.1 APPROVED BY:

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CLAUSE : 7.2 APPROVED BY:

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CLAUSE : 7.3 APPROVED BY :

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CLAUSE : 7.4 APPROVED BY

Reference of Documented Processes: PR/09 ..Evaluation and Selection of supplier.

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CLAUSE : 7.4 APPROVED BY :

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CLAUSE : 7.5 APPROVED BY :

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CLAUSE : 7.5.2 APPROVED BY :

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