A) Purchased material control
(1) As per purchase schedule raw materials are ordered to specific suppliers as per specifications / requirements.
(2) Raw materials when received taken in to receiving section, entered in the day book and tagged for quantity, part no, date, etc.
(3) Dimensional inspection and material composition / hardness are carried to ensure raw material conformance to specification by in house testing or by external agencies and documented
(4)In case of large quantity, formal sampling plans are used as per i.s. 2500
(5) Accepted materials are sent to stores tagged with part number, quantity, date & acceptance.
(6)Non-conforming lots are ordered for sorting. Rejected materials are either reworked or sent back to the supplier as the situation demands.
Free issue material received
(1) Free issue materials supplied by the customers are tagged with customer p / n, material name, quantity, receiving date & entered in day book in separate, and stored on location allotted to "free issue raw material received".
(2) Before taking free issue material into production, to be inspected for dimension or any surface defects by visual. Incase found defective, to be informed to the customer to take necessary action for replacement
b) Sub contracting
1) Subcontracting out side the workshop will be with the consent of the purchaser.
2) Subcontractor to be surveyed for adequate quality control process, inspection aids and process control. If not quality requirement, drawing specification, interpretation to be explained and monitored.
3)If supplier uses their own material, all supplies to be supported with material test report / dimensional report as per specification.
4) All material received to be inspected as per i.s. 2500, recorded and then taken to finish product stock with documentation & identification. A final inspection report to be sent to the supplier with detail.
5) Free issue material, to be subcontracted for other scope of further process outside the factory to be processed after prior permission from purchaser, or purchaser's approved supplier.
All dimensional report, statistical analysis recorded during the process to be made available to the purchaser's quality surveillance from the sub contractor.
c) Process control
1) All production machines are periodically maintained. Documented for change of oil, due on, any break down recorded. Reason for break down investigated & prerecorded. All spares requirement & replacement due date recorded.
2) Specific jobs are allocated to specific personnel for further operation.
3) All machine operators & inspectors are trained sufficiently to utilize the measuring equipment’s and process control concepts / drawing specifications / interpretation.
4) Statistical process control tools like r charts; histograms etc.) are used for first production runs.
New tooling till the process becomes stable and parts produced are well within the control limits.
5) Critical / key / problematic parameters are identified.
6) Trial control limits are calculated and drawn for averages & ranger.
7) X & R charts are drawn as per calculated trial control limits and cpk value calculated.
8) As the process gains stability, x, r & cpk values are acceptable as per formal statistical rules: charts are stopped. But, adequate inspections are carried at key points / critical parameters in regular time interval with special checking blocks, go, nogo, gauges etc.
9) Materials at each stage are properly identified to avoid non-conforming materials coming in the process line.
10) Customer owned (free issue) materials are processed adequately as per their quality requirements with utmost care so that the material is not lost.
11) In-process problem areas / defective areas are identified, analyzed and rectified immediately.
12) All conforming parts are cleaned and kept in containers for final inspection with tags of p / n., name, Quantity & Purchase Order No..
D) Final inspection
1) Final inspection is performed by / or under the surveillance of quality assurance.
2) Formal check-sheets are prepared for all parts to be inspected.
3) Sampling plans are followed as per Indian standards 2500.
4) Acceptable lots are properly tagged with q.c / o.k. and released for packing.
5) In case a particular lot disqualifies in sampling test, 100% inspection is ordered.
6) Non-conforming parts are either reworked /, and reinspected or scraped.
6) Controlled customer drawing / specification are used for final inspection.
E) Measuring equipment calibration control
1) All gauges and test / inspection equipment are properly maintained and adequately stored.
2) All frequently using measuring equipment’s are calibrated once in 6 months, others once in a year.
3) Serial no, calibrated date, calibration due date & inspection personnel initials are printed on the equipment box.
4) All master reference standards are certified by external agencies.
5) All gauges, test equipment, calibration setting & adjustments are safe guarded to prevent unauthorized adjustment / modifications.
6) All worn out instruments, gauges are damaged and replaced with new.
1) Packing are controlled as per customer's purchase order requirements.
2) Adequate packing controls to ensure parts protection upto delivery to final destination depending on mode of transport and commodity of parts.
3) Proper provisions for identification of special materials eg: "hazardous", "handle with care", " this side up" etc. With part name, part no, quantity, customer, supplier & date of despatch.
4) Quality assurance have the authority to stop the release of the product.
G) Non conforming materials
1) All non-conforming materials are identified for defect. Marked and segregated at all stages.
2) Non-conforming materials are reworked if possible and reinspected separately.
3) Scrap materials are identified, separated and immediately dumped in scrap yard.
4) Separate bins are provided for easy identification of scrap and recorded for further action.
5) Adequate corrective action are implemented for both purchased materials & manufactured materials.
Failures from customers
1) Any customer reported failures or product are investigated and feedback given to the customer for corrective action taken by us.
2) Identify all root causes and take adequate corrective action to prevent recurrence of customer reported failures and quality problems.