QUALITY MANAGEMENT SYSTEM MANUAL

CONTENTS
CLAUSE
REF.

TITLE

PAGE No.

1
2
3
4.0
4.1
4.2

CONTENTS
LIST OF COPY HOLDERS
REVISION STATUS OF QUALITY MANUAL
SCOPE AND EXCLUSION
COMPANY PROFILE
QUALITY MANAGEMENT SYSTEMS
GENERAL REQUIREMENTS
DOCUMENTATION REQUIREMENTS

01
02
03
04
05
06-09

5.0
5.1
5.2
5.3
5.4
5.5
5.6

MANAGEMENT RESPONSIBILITY
MANAGEMENT-COMMITMENT
CUSTOMER FOCUS
QUALITY POLICY
PLANNING
RESPONSIBILTY AUTHORITY &COMMUNICATION
MANAGEMENT REVIEW

10-13

6.0
6.1
6.2
6.3
6.4

RESOURCE MANAGEMENT
PROVISION OF RESOURCES
HUMAN RESOURCES
INFRASTRUCTURE
WORK ENVIRONMENT

14-16

7.0
7.1
7.2
7.3
7.4
7.5

PRODUCT REALISATION
PLANNING OF PRODUCT REALISATION
CUSTOMER RELATED PROCESSES
DESIGN & DEVELOPMENT
PURCHASE
PRODUCTION & SERVICE PROVISION

17-27

8.0
8.1
8.2
8.3
8.4
8.5

MEASURMENT, ANALYSIS & IMPROVEMENT

GENERAL,
MONITORING & MEASURMENT
CONTROL OF NON CONFORMING PRODUCT
ANALYSIS OF DATA
IMPROVEMENT

28-34

ANNEXURES
MANAGEMENT RESPONSIBILITIES & AUTHORITIES
PROCESS SEQUENCE & INTERACTION
QUALITY POLICY & OBJECTIVES
ORGANISATION CHART
ABBREVIATION

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ANNEXURE -1
ANNEXURE 2
ANNEXURE 3 & 4
ANNEXURE 5
ANNEXURE 6

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LIST OF COPY HOLDERS
COPY HOLDERS

COPY Nos.

Master Copy

00

Chief Executive Officer

01

General Manager /Management Representative

02

HOD Development

03

Manager Production

04

Manager QA/Engineer QMS

05

Certification Body

06

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REVISION STATUS OF QUALITY MANUAL

NATURE OF CHANGES
SECTION N0.

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SCOPE AND EXCLUSIONS
The scope of the Quality Management System covers all activities such as quality,
manufacturing process, tooling/machine maintenance, purchasing, storage, training,
manufacturing process design & development, management responsibility etc related to
products.
The company is manufacturing products as per design and specifications of customer
and are therefore not engaged in product design activities. The clause 7.3.2.1 Product
Design Inputs and 7.3.3.1 Product Design Outputs of ISO/TS 16949:2009 are not
applicable to the activities of Sebros Industries Pvt. Ltd
SIPL is committed to establish, document, implement and maintain a quality
management system and continually improve upon its effectiveness.
The QMS scope covers:-

MANUFACTURING AND SUPPLYING OF

TUBULAR AND FABRICATED COMPONENTS
FOR AUTOMOTIVE APPLICATIONS
Main works site & correspondence address:
SEBROS INDUSTRIES PVT. LTD.
Plot No. 45, Sector 25,
Faridabad 121 004
E- mail: sebros1st@airtelmail.in, sebrosI@sebrosgroup.com
Telephone 0129-4298800/22
Fax 0129-2231745

Remote location (extended work bench) address:

Plot no. 104, sector 25,
Faridabad 121004

Name of Contact Persons: -

Mr. Rahul Malik (CEO)

Mr. Joseph John GM / MR

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COMPANY PROFILE
Sebros Industries was established in July 1983 to manufacture Tubular and fabricated
components for automotive and other industrial applications.
The company has adequate facilities and infrastructure to manufacture consistent
conformity to product requirements to meet customer requirements and expectations
The various kinds of products manufactured are side impact beams, water, oil & fuel
pipe assys. , shifter & selector rod assemblys, Oil strainer assemblys etc
The companys major customers are

A. Automotive customers:
Maruti Suzuki India Ltd.
Suzuki Power train India Ltd.
Inapex Ltd., Delhi.
Volvo Eicher Commercial Vehicle Ltd.

B. Non Automotive customers:

Fiat New Holland India Pvt. Ltd
Tafe Motors & tractors Ltd.
Escorts Tractors division.
Farmtrac Tractor division
Sonalika International Tractor Ltd.

The manufacturing facilities include bending facilities including CNC bending machines,
Power presses, Hydraulic presses, welding machines, Induction hardening machines,
brazing machines, DG set, compressors etc.
The unit has an extended work bench which supports some manufacturing activities
(i.e. Bending, Flaring, and Welding and Brazing operations with development &
manufacturing).
The unit has an in-house tool room consisting of milling machines, lathes, surface
grinder, drilling machine etc.
The unit also has a standards room with instruments and gauges for carrying out layout
inspection of components and internal calibration of receiver gauges and fixtures.

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4.0 QUALITY MANAGEMENT SYSTEM
4.1 GENERAL REQUIREMENTS
Sebros Industries has established documented, implemented and has been
maintaining a quality management system in accordance with the requirements of
ISO/TS 16949:2009.
SIPL intends to continually improve the effectiveness of the QMS.
Sebros Industries has:
I.
Identified the processes needed for QMS and their application throughout the
organization.
II. Prepared a diagram to show the sequence and interaction of these processes.
(annex.3)
III. Determined the criteria and methods to ensure that operation and control of these
processes are effective. (annex. 1)
IV. Defined the procedures to ensure the availability of resources and information to
support the operation and monitoring of these processes. (annex. 1)
V. Put a system in place to monitor measure and analyze these processes.
VI. Undertaken to implement actions necessary to achieve planned results and
continual improvements of these processes.
SIPL has some out source activities (i.e. Plating, Powder coating, Machining,
Forging, sheet metal work & BOPs) and control of these processes are defined in
documented procedure Monitoring and measurement of products.
4.1.1 GENERAL REQUIREMENT SUPPLEMENTAL
Where company selects to outsource processes related to a product or service, the
controlling organization is responsible for ensuring conformity to all customer
requirements,

4.2 DOCUMENTATIONS REQUIREMENTS

4.2.1 GENERAL
The Quality management system documentation includes the following:
a) Quality policy and Quality objectives as documented in annual business plans signed
by the CEO for the responsible function.
b) Quality Manual
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c) Documented procedures required by ISO/TS16949:2009
Ref: - List of procedures - annex-1
d) Documents needed by company for effective planning, operations and control
(addressed in each section and sub-section of this manual). Where a procedure is
not required, but information and controls are needed, this manual defines the
requirements for specific sections.
e) Required records are controlled in accordance with procedure for control of records.
The organization has established, documented, implemented and maintained a
Quality Management system that includes:
Part A
Part B
Part C
Part D
PART A)

:
:
:
:

Quality manual
Procedure manual
Documents / work instructions
Records

QUALITY MANUAL:

4.2.2 Quality Manual

SIPL maintains a quality manual that includes
a) The scope of the quality management system, including details of and justifications
for any exclusion.
b) Documented procedures which are referenced with in each section, as applicable
c) A description of the interaction between the processes of the quality management
system.
Ref. Annexure -2
PART B)

PROCEDURES MANUAL:

The organization has prepared all the procedures including seven mandatory
procedures as per requirements of ISO/TS16949:2009 International Standard.
PART C)

DOCUMENTS / WORK INSTRUCTIONS:

Documents / work instruction defines all the step by step process for their activities for
all the departments/function as:
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Ref: Master list of documents ML/10
PART D) RECORDS:
All the Records have been prepared that are required to demonstrate conformity of their
processes, products and quality management system. The organization presently is
using both medium as electronic media (Computer) and hard copy for implementation of
the documented Quality management system. All relevant documents have been issued
at various locations as per distribution sheet and are duly controlled. Current issue
status of all the documents is to be defined to prevent the accidental use of obsolete
documents. All the documents are easily accessible with MR.
Ref: - Master list of Records ML/11
4.2.3 CONTROL OF DOCUMENTS
Document Management system defines a minimum set of processes required to ensure
the appropriate management of company generated documents.
a) Documents are approved for adequacy prior to use in accordance with
documented system.
b) Documents are reviewed and updated and re-approved in accordance with
change note.
c) Changes to specifications are consistently reviewed and approved by the
organizations affected by the change. Changes are identified in accordance with
documentation system.
d) Current versions of applicable documents are available at points of use as
required by documentation with in the organization.
e) Management Representative of SIPL ensures that documents remain legible and
readily identifiable.
f) MR is ensured that documents of external origin, such as standards and
customer drawings, are controlled as per the documentation system.
g) Obsolete specifications/documents are promptly removed from all distribution
points in accordance with documentation system.
Ref: - Procedure for control of documents (MR/SP-1/4.2.3/RN)
4.2.3.1

ENGINEERING SPECIFICATIONS

MR ensures that customer engineering standards / specifications are reviewed in a

timely manner .Customer engineering standards / specifications are being reviewed with
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in a week , distribution and implementation is being done as per requirement (at the
time of development & manufacturing).
Internal engineering specifications / control plans / FMEA & process work instructions
are revised (changed) as per customer requirement (changes) with in two weeks after
receiving engineering changes from the customer. A record shall be maintained for the
implementation of changes with date by the development department/MR.
4.2.4 CONTROL OF RECORDS
Records are established and maintained to provide evidence of conformity to
requirements and of the effective operation of QMS.
MR is primarily responsible for ensuring control of records through concerned personnel
responsible for generating the records. As such concerned personnel heading the
section is responsible for control of records.
A procedure is established, documented, implemented, and maintained to define the
controls needed for the identification, storage, protection, retrieval, retention time and
disposition of records.
Management Representative is responsible for ensuring that records are maintained to
provide evidence of conformity to requirements and of the effective operation of the
quality management system.
Ref: - Procedure for control of records (MR/SP-2/4.2.4/RN).
4.2.4.1 RECORDS RETENTION
MR ensures that Record retention is as per statutory, regulatory and customer
requirements.
Ref: - Procedure for control of records (MR/SP-2/4.2.4/RN).

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5.0 MANAGEMENT RESPONSIBILITY
5.1. MANAGEMENT COMMITMENT
CEO provides evidence of its commitment to the development and implementation of
the quality management system and the continual improvement of its effectiveness by
a) Communicating to the organization the importance of meeting customer, statutory
and regulatory requirements by means of e-mail and communication meetings.
b) Establishing the quality policy of the organization.
c) Ensuring that annual quality objectives are established to meet the business needs
for the organization.
d) Conducting management reviews on a scheduled basis at various operational levels
with required input data addressed and rolled up to top management.
e) Ensuring the availability of resources via annual forecasts, business plans and
specific project requirements.
5.1.1 PROCESS EFFICIENCY
Top management of SIPL reviews the product realization processes and the supporting
processes to assure their effectiveness and efficiency at planned intervals as specified.

5.2

CUSTOMER FOCUS

To enhance customer satisfaction SIPL ensures the identification of customer

requirements and measurement of the customer perception.

5.3

QUALITY POLICY

CEO has laid down the quality policy and objectives keeping in view the scope of the
organization and showing commitment to comply with the requirements and continual
improvement in compliance with QMS. Quality Policy and Objectives, which are
communicated and well understood by all employees, shall be periodically reviewed for
their suitability.
Ref: - Annexure No. 3 & 4

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5.4

PLANNING

5.4.1 QUALITY OBJECTIVES

The SIPL has developed the quality objectives to achieve its quality requirements. The
process wise objectives have also been developed to achieve the organizational
objectives. All the objectives are measurable; target based and is consistent with quality
policy and business plan.
5.4.1.1 QUALITY OBJECTIVES (SUPPLEMENTAL)
Top management ensures that measurement of the objectives includes the business
plan of the organization, customer expectations with in a defined time period and used
to deploy the quality policy.
5.4.2 QUALITY MANAGEMENT SYSTEM PLANNING
The top management of SIPL ensures that the planning of QMS is carried out in such a
way that it meets the general and quality requirements of QMS. The integrity of QMS is
maintained when changes to it are planned and implemented.

5.5 RESPONSIBILITY, AUTHORITY & COMMUNICATION

5.5.1 RESPONSIBILITY AND AUTHORITY
SIPL has defined its organizational chart, giving the hierarchical authority, responsibility
and the inter-relation of the personnel who manage, perform and verify work-affecting
quality.
Ref: - Annex. 2
5.5.1.1 RESPONSIBILITY FOR QUALITY
Manager in charge with responsibility and authority for corrective action is promptly
informed of products or processes which become noncompliance with specified
requirements.
Control plans have established reaction requirements to define the responsibility and
authority for personnel that control for conformity to product requirements. The reaction
plan requires that production be stopped, if necessary.
Each manufacturing location allocates personnel for all shifts that have been delegated
responsibility for ensuring conformity to product requirements.

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5.5.2 MANAGEMENT REPRESENTATIVE
CEO has appointed a Management Representative (MR). Besides his routine
responsibilities he will ensure that processes needed for QMS are established,
implemented and maintained. He will report to Top Management on the performance of
QMS, prospective improvement areas and also to ensure the promotion of awareness of
customer requirements throughout the organization. MR will liaison with external parties
relating to QMS.
5.5.2.1 CUSTOMER REPRESENTATIVE
The customer representative is designated by top management for every customer. The
customer representative is responsible for ensuring customer requirements are met.
This includes selection of special characteristics, setting quality objectives and related
training, corrective and preventive actions, and development.

5.5.3 INTERNAL COMMUNICATION

A communication system has been put in place within the organization for an effective
two-way communication through frequent formal / informal meetings, by intercom,
personal interaction etc.

5.6 MANAGEMENT REVIEW

5.6.1 GENERAL
The CEO and assisted by MR perform, as a minimum, six monthly review of the quality
management system recorded as minutes of management revive meeting.
The management review meeting is chaired by the CEO and is attended by all HODs.
The MR acts as a member secretary for the review meetings. He also informs the above
mentioned personnel of the meeting (Date, Time and place) after consultation with the
CEO. Information is circulated by a circular in advance.
Ref: - Procedure for management Review (MR/SP-3/5.6.0/RN).
5.6.1.1 QUALITY MANAGEMENT SYSTEM PERFORMANCE
The purpose of the review is to ensure the continuing suitability and effectiveness of the
quality management system in meeting the organizations goals and monitoring quality
objectives (including business plan), evaluation of the cost of poor quality, customer
satisfaction with product supplied. Satisfying the requirements of ISO/TS16949:2009
and assessing opportunities for improvement.

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5.6.2 REVIEW INPUT
The Management review meetings include the following points in agenda:
a) Results of audits.
b) Customer feed back/complaints & satisfaction data.
c) Process performance and product conformity
d) Status of corrective and preventive action (internal & external)
e) Follow up actions from previous management review meeting
f) Changes that could affect the quality management system
h) Recommendations for improvement.
i) Cost of poor quality (in Rs.)
5.6.2.1 REVIEW INPUT (SUPPLEMENTAL)
CEO also discussed actual and potential field-failures and their impact on Quality,
safety or the environment in the MRM.
5.6.3 REVIEW OUT PUT
The output from the MRM shall include any decisions and action related toa) Improvement of the effectiveness of the quality management system and its
processes.
b) Improvement of product related to customer requirements
c) Resource needs
Ref: - Minutes of MRM

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6.0 RESOURCE MANAGEMENT
6.1 PROVISION OF RESOURCES
The organization follows a formal system to determine and provide the resources
needed to implement and maintain the QMS and continually improve upon its
effectiveness and enhance customer satisfaction by meeting their requirement.

6.2.0 HUMAN RESOURCES

6.2.1 GENERAL
The GM shall ensure that all personnel performing work that affects quality anywhere in
the organization are competent on the basis of appropriate education, training, skill and
experience.
6.2.2 COMPETENCE, TRAINING AND AWARENESS
The management has determined the necessary competence for personnel performing
work in the organization by preparing a skill matrix for the organization. This matrix shall
be reviewed whenever the need arises or at least once annually and necessary action
shall be taken thereafter.
The MR identifies the training needs of the staff by interacting with them & on the basis
of competency gap analysis. The GM also creates awareness amongst the employees
about the relevance of their work and its importance towards achievement of quality
objectives. Based on this interaction, an annual training plan is prepared and training
imparted accordingly. The effectiveness of the training is gauged by the feedback from
the participants and the report of the concerned department in charge on the post
training performance of the participant within month after the training, The MR shall
maintain a record of all such training, the feedback from the participants and the
performance report from the concerned department in charge.
Ref: - Procedure for Training/HRD (MR/SP-4/6.2.2/RN)
6.2.2.1 PRODUCT DESIGN SKILLS
The top management shall ensure that personnel with product design, responsibility are
competent to achieve design requirements and are skilled in applicable tools and
technique, (Presently product designing is not being done, so it will be done as and
when required).
6.2.2.2 TRAINING
Top management has a procedure for identifying training needs and achieving
competence of all personnel performing activities affecting product quality. Personnel
performing specific assigned tasks shall be qualified, as required, with particular
attention to the satisfaction of customer requirements.
Ref: - Procedure for Training/HRD (MR/SP-4/6.2.2/RN)
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6.2.2.3 TRAINING ON THE JOB
Top management provides on-the-job training for personnel in any new or modified job
affecting conformity to product requirements, including contract or agency personnel.
Personnel whose work can affect conformity to product requirements are informed
about the consequences to the customer of nonconformity to product requirements.
6.2.2.4 EMPLOYEE MOTIVATION AND EMPOWERMENT
Top management motivates their employees by providing training, increments,
improving awareness about the QMS, technological awareness for achieving the quality
objectives and continual improvements. Also provide awareness to employees
regarding the importance of their activities and how they contribute to the achievement
of quality objectives through training.
Ref: - Employee motivation policy - D/MR/06

6.3.0 INFRASTRUCTURE
CEO shall determine, provide and maintain the infrastructure needed to achieve
conformity to product requirements including buildings, workplace and associated
utilities process equipment as also the supporting services like telephones for
communication and computers etc.
6.3.1.1 PLANT, FACILITY AND EQUIPMENT PLANNING
Project management methodology is used to establish the necessary infrastructure for
new products, new production and development needs. Plant layouts are determined by
industrial engineering for optimization and cost to ensure value added use of floor
space. Methods are developed and implemented to evaluate and monitor the
effectiveness of existing operations,
e.g. competitive data from subcontractors, simulation models.
Ref: - Procedure for Plant facilities and equipment planning (PROD/SP-1/6.3.1/RN)
Ref: - Plant layout (PLO)
Ref: - Procedure for Plant maintenance (PROD/SP-2/6.3.0/RN)
Maintenance of Plant is being done as per the following1)
Plan of manufacturing areas divide separate for each section.
2)
Entire construction is with R.C.C. floor and all other areas are finished with white
washing.
3)
All areas are well lighted and covered with asbestos roof views for adequate
ventilated and equipped with proper exhaust system and required safety safe
guard are provided.
4)
Overhead tanks are cleaned regularly & finally washed with disinfectants before
the storage of raw water.
5)
Preventive maintenance for premise is a regular process & it will be done by
maintenance in-charge & recorded.
List of equipment and machine is prepared and maintenance of these is being done as
per the maintenance schedule.
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6.3.1.2

CONTINGENCY PLANS

CEO has prepared the contingency plan for business recovery to provide continual
service to the customer during events of emergency such as utility interruptions, labour
shortages, and key equipment failure and field returns.
CEO determines, provides and maintains the infrastructure necessary for the realization
of product while considering the needs and expectation of customers needed to achieve
conformity to product requirements. Infrastructure includes as applicable below as(a) Building, workspace and associated utilities (layout),
(b) Process equipment,
(c) Supporting services.
Ref: - Contingency Plan (CGYP)
6.4.0 WORK ENVIRONMENT
The organization determines the work environment needed to achieve conformity to
product requirements and manages it.
4.1.0 PERSONNEL SAFETY TO ACHIEVE PRODUCT QUALITY
SIPL is committed to provide the environmental, health and safety program, the health
and safety of employees and the surrounding communities.
GM determines and manages the work environment needed to achieve conformity to
product requirements. He ensures that the work environment has positive influence on
motivation, satisfaction and performance of people in order to enhance the performance
of the organization.
Top management developed a system for product safety and means to minimize
potential risks to employees for development process and manufacturing activities.
4.2.0 CLEANLINESS OF PREMISES
Top management defined a system to maintain the cleanliness and repair of the
premises as per the product and manufacturing process need.
There are the written instructions for cleaning all the departments everyday & written
instruction for maintain the 5S system in working areas.
Plant head ensures that:
1) Cleaning of road/drains, plant corridor, toilet, administrative building
2) Cleaning of water tank.
3) Fire fighting
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7.0

PRODUCT REALISATION

7.1

PLANNING OF PRODUCT REALISATION

The management follows a process for product realization to determine quality

objectives and requirement for the product. The management has also evolved the subprocesses, documents and providing resources needed for product realization such as
verification, validation, monitoring, inspection and test activities including criteria for
product acceptance. The record of all these activities is maintained.
7.1.1 PLANNING OF PRODUCT REALIZATION SUPPLEMENTAL
SIPL defined the product realization planning for products. And address the movement
of material between locations within the product realization process. When required,
FMEA methodology is used to ensure preventive planning measures.
Customer requirements and references to its technical specifications are included in the
quality plan
7.1.2 ACCEPTANCE CRITERIA
SIPL defined the acceptance criteria of product and this is approved by customer also.
An acceptation criterion has sampling plan and acceptation level is zero defects.
7.1.3 CONFIDENTIALITY
The confidentiality of customercontracted products and projects under development,
and related product information is ensured by top management of SIPL
7.1.4 CHANGE CONTROL
SIPL has a system for Changes to materials, processes and /or product that occur
during the realization process are controlled and reaction plans established prior to
implementation as specified.
Effects of process changes are verified before and after characterization of the
appropriate device parameters for both proprietary and nonproprietary designs in
accordance with Product specification.
Top management also ensures that the effect of any change in process and product
realization including changes caused by the supplier is assessed. Verification and
validation activity is defined and ensures that it is complying with the customer
requirements. SIPL ensures that implementation of any change is validated.

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7.2 CUSTOMER-RELATED PROCESSES
7.2.1 DETERMINATION OF REQUIREMENTS RELATED TO THE PRODUCT
SIPL determines the product requirements considering the following
a) Requirements specified by the customer for timely delivery and Quality.
b) Requirements not stated by the customer but necessary for specified or intended
use, where known, to ensure form, fit, function, and reliability.
c) Statutory and regulatory requirements via Legal, Environmental Health and Safety,
Human Resources, and the customer. It is the responsibility of the development, and
management team to implement these requirements.
d) Any additional requirements pertaining to the product during realization processes
for inclusion in the data sheet and processing specification. The products of the
company are being produced as per delivery plan received from customer. The
organization plans and develops the processes needed for product realization. The
planning of the processes to meet the requirements of the customers is achieved
through the quality plans, control plan, test specifications etc.
7.2.1.1 CUSTOMER DESIGNATED SPECIAL CHARACTERISTICS
Customer requirements, including special characteristics, are reviewed and
incorporated into SIPL internal requirements in accordance with process specification
system.
Where the customer has not identified special characteristics, but the need exists to
control the product for proper operation, process parameters or product characteristics
are identified on the control plan.
7.2.2 REVIEW OF REQUIREMENTS RELATED TO THE PRODUCT
Initial customer contract and negotiations prior to submission or acceptance of the
customers written or verbal contractual requirements, a review is conducted by CEO.
a) The customers requirements are adequately defined, documented and agreed to
before acceptance.
b) SIPL has the capability to meet the customers requirements, and
c) All customer requirements are met in accordance with Contract Review Process
SIPL maintains all records for contract review. The coordination of these activities
ensures that written or verbal customer requirements are adequately documented.
Ref: - Procedure for product requirement review (MKT/SP-1/7.2.2/RN)
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7.2.2.1 REVIEW OF REQUIREMENTS RELATED TO THE PRODUCT

SUPPLEMENTAL
Waiving the requirements specified in section 7.2.2 requires written authorization from
the customer.
7.2.2.2 ORGANIZATION MANUFACTURING FEASIBILITY
SIPL assures that it has adequately investigated and confirmed the manufacturing
feasibility of proposed products prior to contracting with customers to produce those
products including risk factor.
7.2.3 CUSTOMER COMMUNICATION
A communicating system has been devised to communicate effectively and efficiently
with customer in relation with product, enquiry and contract (RFQ) or order handling,
amendments and feedback including complaints. Communication is done using email,
telephone, Fax, formal letters and personal meetings.
Ref: - Procedure for Customer complaint handling (MKT/SP-2/7.2.3/RN)
7.2.3.1 CUSTOMER COMMUNICATIONS SUPPLEMENTAL
SIPL has established communication system for operations and sub operations required
to realize the products, Inspection and test activities required for product, relative
standard, frequency of inspection etc.
Control plans/ test Specifications have been formulated keeping in view
a)
Quality objective
b)
Product requirements
c)
Customer satisfaction
d)
Need to establish the processes, documents, resources
and facilities specific to the products
Verification, validation (If required), monitoring, Inspection and test activities and criteria
of acceptability
All the Orders of the customers are received directly through CEO/plant head. The
control of these orders is being done as per the documented system.
These orders are communicated to In-charge development. The planning is being done
by the In-charge development and planning schedule is distributed to the
supervisors/operators.

7.3

DESIGN AND DEVELOPMENT

The organization is manufacturing products as per customer requirements, no product

design activity is being performed presently, and hence the requirements of this clause
related to product design have been excluded from the system.
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During the business planning process described in business plan, future development
for processes and assembly processes are considered. This becomes the basis for
establishing future products. The appropriation of funds to support future product
development starts with customer needs that are established by market analysis and
close customer relationships. These inputs drive the long-term roadmaps for technology,
packaging and products. This planning is performed during the annual budgeting
process. Reference Business Planning, Budgets and Forecasting in Financial Planning.
Once management approves the project for development of a new process, the
following requirements are determined in accordance with Management Representative.
a) Quality objectives and requirements for the product,
b) Establishment of the processes, documents, and resources specific to the product.
c) The required verification, validation, monitoring, inspection and test activities specific
to the process and the criteria for process acceptance, and
d) Records needed to provide evidence that the realization processes and the resulting
product meet requirements.
Ref: - Procedure for manufacturing process design & development
(DEV/SP-1/7.3.0/RN)

7.4

PURCHASING

7.4.1 PURCHASING PROCESS

The Top management follows a purchasing process to ensure that purchased product
conform to the specified requirement. A system and criteria has been developed to
evaluate, select and re-evaluate suppliers, for their ability to supply product/services.
Records of these activities are maintained.
When qualification testing or failure analysis is outsourced, any customer specific
requirements are passed on to the supplier.
Ref: - Procedure for Purchasing (PUR/SP-1/7.4.0/RN)
7.4.1.1 REGULATORY CONFORMITY
Purchased material satisfy all governmental, environmental, and safety constraints, as
required, in accordance with Terms and Conditions specified in purchase orders.
7.4.1.2 SUPPLIER QUALITY MANAGEMENT SYSTEM DEVELOPMENT
SIPL works with all direct material as well as distributor suppliers for products to deploy
the requirements of ISO/TS 16949 with the goal of supplier compliance to said
standard. Third party registration to ISO 9001:2008 is the first step in achieving this
goal.
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Ref: - Procedure for Supplier Quality Management System Development
(PUR/SP-2/7.4.1/RN)
7.4.1.3 CUSTOMER APPROVED SOURCES
If contractually agreed upon, purchases materials from customer-approved suppliers in
accordance with procurement system. Suppliers are approved internally and added to
approved suppliers list.
CEO is primarily responsible for all purchases and connected activities. The
organization ensures that purchased product conforms to specified purchase
requirements. Suppliers product plays a vital role in the quality of the final product. The
purchased products are accepted on the basis of monitor and measure the
characteristics of product.
All purchase is executed from the approved suppliers. Suppliers which appear in the
approved suppliers- both for purchase of basic raw materials as well as consumable
have been assisted on the basis of market reputation, their past performance in regard
to their reliability which covers purchase orders (verbally/written).
All records pertaining to quality and delivery of supplies shall be maintained. All the
suppliers shall be evaluated on their quality, quantity and delivery at quarterly basis.
7.4.2 PURCHASING INFORMATION
The system ensures that the purchase order for important inputs is reviewed for
adequacy before it is released/ communicated. Purchase orders are issued to the
approved supplier in prescribed format having the details of quality, quantity and
delivery dates. Suppliers situated nearby are informed initially on telephone, followed by
purchase orders. Records of this communication are maintained.
Ref: - Procedure for Purchasing (PUR/SP-1/7.4.0/RN)
7.4.3 VERIFICATION OF PURCHASED PRODUCT
Methodologies to ensure purchased product meets specified requirements are defined
in Quality Plan. If a customer intends to perform verification at the suppliers premises, it
will be done.
The purchase order shall be raised for purchasing of raw materials and during P.O.
raising, it is ensured that:
(A) The precise specifications of the products are included in the purchase orders,
(B) The brand name / Grade, where applicable & other details are included in the PO
(C) While purchasing products manufactures specification /grade are quoted in the
PO, where applicable
(D) Delivery date of the materials.
Ref: - Procedure for Purchasing (PUR/SP-1/7.4.0/RN)
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7.4.3.1 INCOMING PRODUCT QUALITY
SIPL verifies the incoming material received from the supplier as per the specified
drawing, Specification and sample provided by the customer as well as own
specifications.
If the customer wishes to inspect the supplied material at our premises or at suppliers
premises, all the facilities shall be provided to our customer for inspection.
Verification of the product can be done at our premises or at our suppliers premises by
the customers /their authorized representative shall not be taken as effective control of
quality by the customers. Ultimate responsibility of supply of product meeting customer
specification lies with the company and all rights vest in the customer to reject the
product supplied.
Ref: - Procedure for Purchasing (PUR/SP-1/7.4.0/RN)
7.4.3.2 SUPPLIER MONITORING
SIPL monitors the performance of supplier on the basis of delivery, customer disruptions
including field return, Incoming material quality and customer notification status
regarding quality and delivery issues.
SIPL also monitors the performance of the manufacturing process of supplier.
Ref: - Procedure for Purchasing (PUR/SP-1/7.4.0/RN)

7.5

PRODUCTION AND SERVICE PROVISION

7.5.1 CONTROL OF PRODUCTION AND SERVICE PROVISION

Production processes that affect quality are conducted under controlled conditions
including documented work instructions/process specifications, process monitoring,
Special working environments, adequate production equipment, and workmanship
standards. Management is responsible for ensuring that the following process control
provisions are implemented.
a) Where needed in the process, information that describes the characteristics of the
product is available. These characteristics are covered in the process specification.
b) Process specifications and work instructions are documented in accordance with the
Documentation system and contain clear and complete instructions appropriate to the
circumstances. These work instructions also provide the criteria for acceptable quality
performance or criteria.
c) The use of monitoring and measuring equipments is controlled in all processes as
defined in Documentation System.
e) Each process area monitors and controls critical in-process parameters and product
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Characteristics with specified requirements to determine the acceptability of work and
Products, and the resultant corrective actions taken in connection with any
nonconformance
f) Final In-line Quality Inspection and physical distribution quality inspection are
completed and acceptable prior to product release and any associated data and records
complete and approved. Actions required for field issues pertaining to product
nonconformity are controlled by Customer Corrective Action Request
Manufacturing activities take place in a neat & clean area and maintain as per good
manufacturing practice.
Ref:- Procedure for Process control-Machine/Welding/Brazing/Hardening/Leakage
testing shop (PROD/SP-2/7.5.1/RN)
7.5.1.1 CONTROL PLAN
Control Plans are used for all manufacturing Process. Control Plans are maintained in
accordance with
a) Lists the process controls used in manufacturing,
b) Includes monitoring methods of control exercised over special characteristics,
c) Includes customer specific requirements, and
d) Defines the reaction plan needed for process unstableness.
Control plans are reviewed when changes may occur to the product, manufacturing
Process, logistics, supply sources or FMEA.
Control plans for product include the methods for controlling all processes from receipt
of material to deliver.
7.5.1.2

WORK INSTRUCTIONS

SIPL prepared the Work instructions for all processes done in the organization. All Work
instructions are controlled as per the documented system.
Work instruction also comply the Control plan, Quality plan and product realization
process.
7.5.1.3

VERIFICATION OF JOB SET- UP

SIPL have a record for Job set-up verification at the time of change the job or material.
Job set up verification is being done in the in process inspection report.
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7.5.1.4 PREVENTIVE AND PREDICTIVE MAINTENANCE
Management has a system for preventive and predictive maintenance of machines/
equipments. Preventive maintenance schedule is prepared and preventive maintenance
is being done on daily, weekly, monthly & quarterly basis as per the schedule.
Preventive maintenance record will be maintained only for quarterly basis.
Break down maintenance of machine is being done and recorded in break down
Resister.
Predictive maintenance is being done as work instruction and record is maintained.
Ref: - Procedure for Plant maintenance (PROD/SP-3/6.3.0/RN)
7.5.1.5

MANAGEMENT OF PRODUCTION TOOLING

SIPL has established and implemented a system for tooling management as specified.
Tooling Management covers all the equipments. The above methodology addresses the
effectiveness for: operation efficiency, maintenance schedule, maintenance adjustment
consistent with equipment utilization, and tool change program for perishable tools.
Periodic Inspection and maintenance are carried out for all process equipment Utilities
Indirectly involved in the process are also serviced periodically. Both in-house
maintenance and annual maintenance contracts from manufacturers, all activities are
documented.
Ref: - Procedure for Tooling management (PROD/SP-4/7.5.1/RN)
7.5.1.6 PRODUCTION SCHEDULING
SIPL is scheduling the production as per the customer requirements so that product will
be delivered on time. SIPL informs to customer about the status of production.
7.5.1.7 FEEDBACK OF INFORMATION FROM SERVICE
SIPL has a system for feedback on service concerns like manufacturing, engineering &
development activities. A communication system is maintained for this.
7.5.1.8 SERVICE AGREEMENT WITH CUSTOMER
SIPL is manufacturing the tubular & fabricated parts for automotive industries. The
organization has no any service center. In future if any service process will be identified
then all the information about the service will be recorded like-evaluation of the
Organization service center performance, any special tools or measuring tools and
training of service personnel
7.5.2 VALIDATION
PROVISION

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7.5.2.1

VALIDATION OF PROCESSES FOR

PROVISION (SUPPLEMENTAL )

PRODUCTION AND

SERVICE

SIPL validates all the processes related to the product as per the criteria for review and
approval of the processes, approval of equipment and qualification of personnel,
process method and revalidation. These activities are done and recorded.
7.5.3 IDENTIFICATION AND TRACEABILITY
SIPL ensures proper identification of the product by suitable means from receipt to
delivery stages. Where and to the extent that traceability is a specified requirement, the
company shall maintain it.
7.5.3.1 IDENTIFICATION AND TRACEABILITY (SUPPLEMENTAL)
The system defined in section 7.5.3 is capable of doing a trace forward and backward
within 24 hours. It covers product lots, processes and materials to satisfy customer
needs for risk abatement and containment.
The above system for identification and tractability address the requirements for all
Product and processes.
In charge QA is responsible for maintaining identification, Traceability and determining
the status of product at various stages.
Raw material, in process material, finished goods, goods for reworking and
rejected material is suitably identified at location.
Every inspection, measuring and test equipment is identified by a sticker and a
unique identity number.
Every machine/ equipment (mechanical and electrical) is also identified by a
unique number.
Ref: - Procedure for Identification and traceability control (PROD/SP-5/7.5.3/RN)

7.5.4 CUSTOMER PROPERTY

All the drawing, designs or sample provided by the customer are treated as customer
property. The management of the SIPL has made a system to identify and store the
customer-supplied product/ property. In case of any deterioration or damage to the
customer property, this shall be informed to the customer. Once the order has been
executed, the drawings/designs/samples may be appropriately disposed off at the
discretion of management.
7.5.4.1 CUSTOMER OWNED PRODUCTION TOOLING
SIPL does not utilize customerowned tools and equipment.
7.5.5 PRESERVATION OF PRODUCT
The management follows a system to preserve the conformity of product during internal
processing up to dispatch. The preservation includes identification, handling,
Packaging, storage and protection.
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7.5.5.1 STORAGE AND INVENTORY
Received material shall be verified against the purchase order and Quality Plan; it is
stored in designated secured storage areas to prevent damage or deterioration. The
condition of product in storage is assessed at appropriate intervals in accordance with
Inventory Storage Requirements.
The stocks are checked as per the specified interval. Material issued to the production
department first in first out (FIFO) basis.
7.6 CONTROL OF MONITORING AND MEASURING DEVICES
Production in charge for product and process determine the needed controls to ensure
product quality. The selection of devices for monitoring and measuring product and
process quality are a function of the Quality in charge. Where necessary to ensure valid
results, measuring equipment is
a) Calibrated,
b) Adjusted or readjusted as necessary,
c) Safeguarded from adjustment that would invalidate the measurement, and
d) Protected from damage and deterioration during handling, maintenance and storage.
Calibration Requirements for out of tolerance condition and the need to take appropriate
action for product that was evaluated during this period of out of tolerance are specified
Ref: - Procedure for Control of monitoring and measuring equipments (QA/SP2/7.6.0/RN)
7.6.1 MEASUREMENT SYSTEM ANALYSIS
The requirements for measurement system analysis are specified and performed in
accordance with Measurement Systems Analysis.
The selection of measuring and monitoring devices for SIPL product considers the
resolution of the equipment used to monitor special characteristics.
The organization ensures that monitoring and measuring devices are fit for use and are
maintained to suitable accuracy and accepted standards, as well as a means of
identifying the status of the devices.
As and when the customer seeks technical data pertaining to inspection & measuring
instruments for functional adequacy, the information is made available. It is ensured that
measuring equipments are calibrated or verified at specified intervals.
Precision and accuracy in monitoring and measuring devices used for monitoring and
measurement in works have a critical role to get the described quality of finished
product. The organization ensures that

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(a)
(b)

(c)
(d)

All critical measurement / inspection after each operation are determined and
included in process work instructions.
A comprehensive Master list of all Monitoring and Measuring devices that can
affect quality is prepared. The frequency of calibration or verification initially has
been determined by experience, Practices in the industry and accuracy of
measurement sought and acceptance criteria. The devices are calibrated or
verified at specified intervals or prior to use against measurement standards
traceable to international or national measurements standards.
The list shows the code no. of devices, Type, Calibration frequency, location etc.
basis of calibrations or verifications shall be documented.
All monitoring and measuring devices are adjusted or readjusted as necessary.

(e)

All monitoring and measuring devices are identified by a sticker, which indicates
the calibration status whether done internally or externally.

(f)

All monitoring and measuring devices are tamper proofed and safeguarded to
avoid unauthorized adjustment and calibration or verification that would invalidate
the calibration or verification settings.

(g)

The handling, maintenance, storage and use of all monitoring and measuring
devices are carried out by experienced personnel ensuring that the accuracy and
fitness are maintained. Any shortcoming noticed is removed by periodic training to
such operators/ supervisors.

(h)

If the device is found to be out of calibration or verification at any stage, the validity
of previous monitoring & measurement results of such suspect product is checked
to the extent possible. Appropriate action is taken on the equipment and the
product affected.
(i) The calibration or verification, monitoring and measuring devices is carried out at
environmentally controlled conditions to the extent necessary and possible to
ensure valid measurement results giving due consideration to temperature and
humidity.
Ref: - Procedure for Measurement system analysis (QA/SP-3/7.6.1/RN)
7.6.3 LABORATORY REQUIREMENTS
7.6.3.1 INTERNAL LABORATORY
SIPL has no any internal laboratory.
7.6.3.1 EXTERNAL LABORATORY
SIPL used the External Laboratory for Calibration of instruments only. In-charge Quality
is ensured that external laboratory should be the ISO17025 or national equivalent.
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8.0 MEASUREMENTS ANALYSIS AND IMPROVEMENT
8.1 GENERAL
The Top management has planned implemented monitoring, measurement, analysis
and improvement process to demonstrate the conformity of product, ensure its
conformity and continually improve the effectiveness of QMS.
8.1.1 IDENTIFICATION OF STATISTICAL TOOLS
SIPL uses the appropriate statistical technique for each process being monitored and
the details of the same are included in the quality planning and control plan.
8.1.2 KNOWLEDGE OF BASIC STATISTICAL CONCEPTS
SIPL is committed to provide the basic knowledge of relevant statistical concepts to all
the personnel of quality & production in the organization. The training needs have been
identified and are included in the training calendar.

8.2 MONITORING AND MEASUREMENT

8.2.1 CUSTOMER SATISFACTION
The GM presently monitors customer satisfaction annually. However, the frequency may
be changed as per need.
8.2.1.1 CUSTOMER SATISFACTION SUPPLEMENTAL
The process defined in Customer Satisfaction and Customer Satisfaction Measurement
provide a methodology for the continual evaluation of customer perception. SIPL
internal processes address the evaluation of the realization process performance. The
performance indicators are based on the planned requirements defined in the control
plans.
Performance indicators are established for
a) Delivered part quality performance,
b) Customer disruptions including field returns,
c) Delivery schedule performance (including incidents of premium freight), and
d) Customer notifications related to quality or delivery issues.
SIPL evaluate field issues and determine performance and effectiveness for
product delivered to the customer.
Measurement and monitoring of customer satisfaction is based on review of customer
feed back information. The organization identifies sources of customer and end user
information, available in written (E-mail & Fax) or verbal forms, from internal or external
sources & uses it for improvement of the QMS performance as appropriate.

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(a) Customer surveys
(b) Feed back on aspects of product.
(c) Customer requirements and order information
Sources of information on customer satisfaction may include as appropriate:
Ref: - Procedure for customer satisfaction /Expectation (MKT/SP-3/8.2.1/RN)
8.2.2 INTERNAL AUDIT
SIPL has developed a system to conduct internal audit at planned intervals to conform
that QMS complies with planned arrangements and its effectiveness as per the
requirements of ISO TS/16949:2009. The gap between two audits shall not be more
than four months. The audit criteria, scope, frequency, method and selection of auditor
are defined in the procedure. All the audit records are maintained. All the nonconformities detected in audit shall be closed at the earliest possible.
Ref: - Procedure for Internal audit (MR/SP-5/8.2.2/RN)
8.2.2.1 QUALITY MANAGEMENT SYSTEM AUDIT
MR is responsible for conducting audits of the Quality Management System to verify
that it complies with the requirements of ISO/TS 16949:2009 and any additional
requirements identified by the organization.
8.2.2.2 MANUFACTURING PROCESS AUDIT
The MR shall ensure audit is performed of each manufacturing process to determine the
process effectiveness.
8.2.2.3 PRODUCT AUDIT
Product audits are conducted at appropriate stages of production and delivery to verify
conformity to all specified requirements (like product dimensions, functionality,
packaging and labeling) at a defined frequency. It has established monitors in the
control plans to audit the products at various steps of the process. These products audit
processes are audited to ensure the requirements are followed and that the data
reported is accurate.
8.2.2.4 INTERNAL AUDIT PLANS
Internal audit covers all quality management related processes, activities and shifts, and
is scheduled according to an annual plan. In case of occurrence of customer
complaints, external or internal non-conformities, audit frequency can be increased.
8.2.2.5 INTERNAL AUDITOR QUALIFICATION
Auditors who perform audits to the requirements of ISO/TS 16949:2002 are qualified as
per the standard.
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The Organization conducts internal Audits at four monthly intervals to determine
whether the QMS
(a) Confirms to the planned arrangements established as per QMS requirements;
(b) Is effectively implemented and maintained.
(c) Internal audits are scheduled on the basis of the status and importance of the
processes and areas to be audited viewing complex procedures justifying
independent audits, areas having a history of problems and hands on approach
indicating increased /decreased frequency of audit.
(d) 1. These audits are carried out on four monthly bases by personnel independent of
those having direct responsibility for the activity being audited. Qualified
personnel are assigned the job of internal audit. Such personnel are qualified from
a recognized course conducted by an external agency or trained internally by
Registered /certified Lead Auditor.
2. Such personnel shall possess exhaustive knowledge of all processes of the
organization and has the experience of having been an observer during internal
audit of the company for at least 2 man days. Additionally he shall posses
knowledge of QMS as per ISO/TS16949:2009.
(e) At any instant of time, if qualified internal auditor is not available, services of a part
time auditor who shall be a certified quality auditor or a trained / qualified lead
assessor shall be utilized in lieu of Internal Auditor.
(f) The results of the audits are recorded and brought to the attention of the personnel
having responsibility in the area audited.
8.2.3 MONITORING AND MEASUREMENT OF PROCESSESS
The Top management has developed a system to monitor and where possible take
appropriate corrective measures of QMS processes to demonstrate the ability to
achieve planned results. If any deviation is found, necessary corrective and preventive
actions will be taken to ensure the conformity of the product.
8.2.3.1 MONITORING AND MEASUREMENT OF MANUFACTURING PROCESSES
During the pilot production stage of new process, Manager Production performs process
studies to verify process capability. The results are reported to the management.
Manager Production also establishes the requirements for pre-production and
manufacturing stages, including special characteristics for the processes and monitors
for manufacturing which are included on control plans. This data is reported at
Management Review meetings. All other core processes that comprise the quality
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management system, including support processes, are monitored and measured by
process owners to ensure quality objectives are met. The data from the quality
management system processes are analyzed against planned results and where
planned results are not achieved, correction and corrective action, as appropriate, is
taken by management to resolve the issue.
Process capability or performance levels approved by General Manager are maintained
and improved upon by implementing control plans and monitoring SPC levels.
Significant process. Events are appropriately noted and recorded. Control plans are
maintained statistical process control procedures for specific areas require significant
events to be recorded. Reaction plans are included in the control plan and maintain the
records for process changes.
8.2.4. MONITORING AND MEASUREMENT OF PRODUCT
SIPL monitors and measures the identified characteristics of the product and the
material used in the manufacturing of the product at appropriate stages to ensure the
product meets requirements.
The monitoring and measurement start at the beginning of the product realization. The
criteria for these requirements reside in the following documents:
Process specification
Work instructions
Control Plans and Flow Charts
Records indicate the person authorizing the release of product. The product is not
released until satisfactory completion of all the planned arrangements. Any deviation
from this requirement is documented and approved by the competent authority.
Ref: - Procedure for Measuring and monitoring of products (QA/SP-1/8.2.4/RN)
8.2.4.1 LAYOUT INSPECTION AND FUNCTIONAL TESTING
SIPL performs layout inspection and functional verifications to applicable customer
engineering material and performance standards for each product as specified in the
control plans, results of the same are available in layout inspection report for customer
review.
8.2.4.2 APPEARANCE ITEMS
SIPL have the following arrangements for the verification of appearance items.
1. Appropriate resources including lighting for the evaluation.
2.
Visual aids.
3.
Master samples for appearance.
The personnel who are making appearance evaluations are competent and qualified as
per requirement.
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8.3

CONTROL OF NONCONFORMING PRODUCT

The Top management has developed a procedure to ensure that non-conforming

product is positively identified and controlled to prevent any further damage. The
authority to take decision on non-conforming is defined in the procedure. If the nonconforming product is re-worked, it will be re- inspected for conformity. If the nonconformity is detected after delivery, the management shall take appropriate remedial
action.
It is ensured that product which does not conform to product requirements at any stage
is identified, segregated and kept separately to prevent its unintended use.
Organization deals with nonconformity by the following ways:
(1)
(2)

By taking action to eliminate the detected nonconformity,

By taking action to procedure its original intended use.

Records of the nature of nonconformities and any subsequent action taken are
maintained.
Ref: - Procedure for Control of nonconforming product (QA/SP-5/8.3.0/RN)
8.3.1 CONTROL OF NONCONFORMING PRODUCT SUPPLEMENTAL
SIPL processes do not allow unidentified or suspect material to remain in processing. It
is treated as non-conforming material. Nonconforming product is identified and
immediately placed in a status that prevents its re introduction in to the production flow.
8.3.2 CONTROL OF REWORKED PRODUCT
Rework to meet specified requirements is determined in the control plan. Allowable
rework is documented and remains with the production in-charge. Rework instructions
are accessible and utilized by the appropriate personnel in their designated work areas.
Visible rework on the exterior of the product is not permitted.
Where a process is developed for reworking product, the requirements that were
established for qualification of the initial process are performed to ensure compliance of
the rework method.

8.3.3 CUSTOMER INFORMATION

The SIPL Customer Representative is responsible for informing the customer in the
event that nonconforming product is shipped.

8.3.4 CUSTOMER WAIVER

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SIPL is ensured that whenever the product or process is different from that which is
currently approved, prior customer authorization is required and recorded.

8.4 ANALYSIS OF DATA

The Top management shall determine, collect and analyze data to demonstrate the
suitability and effectiveness of QMS and to explore the opportunity for improvements
relating to customer satisfaction, product conformity, process trends and supplier
performance. Records of the same shall be maintained.
8.4.1 ANALYSIS AND USE OF DATA
SIPL analysis addresses trends in quality and operational performance to compare the
progress of actual results to the objectives. The analysis leads to action to support the
following:
a) Development of priorities for prompt solutions to customer - related issues;
b) Determination of key customerrelated trends and correlation for status review,
decision-making and longer term planning; and
c) An information system for the timely reporting of product information arising from
usage.

8.5 IMPROVEMENT
8.5.1 CONTINUAL IMPROVEMENT
The Top management has developed a system to continually improve the effectiveness
of QMS by monitoring quality policy, objectives, audit results, corrective & preventive
actions and Management review.
8.5.1.1 CONTINUAL IMPROVEMENT OF THE ORGANIZATION
SIPL 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. The data that is collected from the
various processes is used by management to improve the effectiveness of the quality
management system. This is achieved in management review meetings held by top
management. The SIPL organization establishes the needed processes for continual
improvement. These processes include breakthrough projects and small-step ongoing
improvement activities. Changes for continual improvement are managed through
various processes.
8.5.1.2 MANUFACTURING PROCESS IMPROVEMENT
SIPL ensured that the requirements to continually focus upon control and reduction of
variation in product characteristics and manufacturing process parameters.
8.5.2 CORRECTIVE ACTION
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The Top management has developed a system to take action in order to eliminate the
cause of non-conformities for preventing their re-occurrence. The documented
procedure will take care of reviewing of non-conformities; customer complaints root
cause analysis, and actions to remove the cause and its implementation. Records of all
these activities are maintained.
Ref: - Procedure for Corrective and Preventive action (QA/SP-5/8.5.0/RN)
8.5.2.1 PROBLEM SOLVING
SIPL has a system to analysis the root cause of problems and these are solved through
taking corrective action. Manager Production shall maintain the record for this activity.
8.5.2.2 ERROR-PROOFING
The Top management has error-proofing methodologies are utilized in corrective and
preventive processes.
8.5.2.3 CORRECTIVE ACTION IMPACT
Corrective actions are implemented to eliminate the cause of nonconformities.
Information obtained is into process, FMEAs, and process control plans. Corrective
actions are applied to other similar processes and products to eliminate the cause of
nonconformity.
8.5.2.4 REJECTED PRODUCT TEST/ANALYSIS
SIPL make a system for Product rejected by the customer is analyzed in accordance
with Customer Corrective Action Request.
8.5.3 PREVENTIVE ACTION
The Top management has devised a system to maintain the performance of process,
products and services in order to mitigate the effects or loss to the organization from
potential non-conformities.
Ref: - Procedure for Corrective and Preventive action (QA/SP-5/8.5.0/RN)

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Annex-1

MANAGEMENT RESPONSIBILITIES & AUTHORITIES

1. CHIEF EXECUTIVE OFFICER:
a) To formulate Units Quality policy and objectives and approve.
b) To set organizational goals and direction for growth.
c) To approve the units business plan and targets for QMS process measures.
d) To provide adequate resources to achieve the set goals.
e) To approve the units quality manual.
f) To appoint M.R. & C.R. for the unit.
g) To approve responsibilities and authorities of personnel at all levels as well as
their competency criteria.
2. PLANT MANAGER:
a) Overall responsible for plant operations and administration.
b) Monthly production planning to meet the customer schedules.
c) Member of CFT and to ensure tool developments in time.
d) Facilities planning and contingency planning and overseeing their execution.
3. GENERAL MANAGER CUM M.R.:
a) Measurement of customer satisfaction and analysis of related data.
b) To obtain customer specific requirements and ensure their incorporation in quality
management system, APQP and in regular production and supplies
c) Overall responsible for deployment of continual improvement concept throughout
the company and for assigning improvement projects to process owners and
tracking their implementation and effectiveness.
d) To devise ways and means for employee motivation and empowerment. To invite
employee suggestions for improvement and ensure their implementation
e) Determine personnel competency criteria, conduct gap analysis and identify
training needs of personnel.
f) To document training programs and ensure conduct of same. To monitor
effectiveness of training and related actions.
g) Overall responsible for supplier a QMS development activity by documenting
development plans, conducting audits and follow-up for supplier system
upgradation.
h) To approve units quality manual, QMS procedures and other documents as per
documented system.
i) To plan, organize and ensure conduct of internal audits for product, manufacturing
process and systems.
j) To conduct monthly objective reviews and six monthly MRMs as per agenda and
set targets.
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MANAGEMENT RESPONSIBILITIES & AUTHORITIES
4. HOD DEVELOPMENT cum Manager QA:
a) Review of customer enquiries
b) Overall responsible for initiating new part development activities in association
with other CFT members as well as engineering change reviews
c) Team leader for all CFT activities such as APQP, Engineering /process change
and Facilities reviews etc. To approve Control plan, FMEA, PFD and operation
work instructions.
d) To review and approve receipt and final Inspection standards and other quality
assurance documents such as lab work instructions, sampling plans etc.
e) Disposition authority for nonconforming products at all stages. Authority to stop
production to correct quality problems as required.
f) To maintain initial supply control of newly developed products as per procedure.
g) To plan for tool development and sample submission as per customer
requirements.
h) To review processes in line with part requirements and implement modifications
as required.
i) To guide QA engineers in PPAP documentation and submission.
j) To perform manufacturing process audits in association with M.R.
5. ENGINEER QMS
a) Overall responsible for document and record control as per procedure.
b) To compile and analyze data related to process measures, quality cost and
provide as input to monthly reviews and business plan.
c) To coordinate monthly objective review and six monthly MRMs.
d) Internal auditor and responsible for auditing product, process and systems in
association with M.R. and HOD- Development.
e) To assist MR in HR activities such as training, employee motivation etc.
f) To assist MR in initiating continual improvement projects and follow-up for timely
and effective implementation.
g) Conduct of MSA studies as per plan.
6.
QA Engineer cum Customer Representative :
a) Customer representative and shall be responsible and authorized for ensuring
customer requirements are addressed during product development such as
selection of special characteristics, CAPAs, quality objectives setting and related
training.
b) Coordinator for CFT activities such as part development.
c) Overall responsible for PPAP compilation and submission to customer including
supplier PPAP.
d) Handling of customer complaints.
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MANAGEMENT RESPONSIBILITIES & AUTHORITIES
7.

QA ENGINEERS :

a) To ensure conduct of initial and ongoing process capability studies.

b) Overall responsible for inspection & testing of material being carried out from
incoming stage through dispatch as per the inspection standards.
c) Calibration of inspection, measuring and test equipment.
8.

PRODUCTION MANAGER / PRODUCTION ENGINEER :

a) Planning and Execution of production and timely deliver as per customer

schedules.
b) Maintaining cleanliness of premises and housekeeping.
c) Validation of all manufacturing processes as per part development requirements
and for any product / process changes.
d) Approval of special process operators.
e) Control and monitor the production process as per control plans, operator
instructions and work instructions.
f) To ensure packing and dispatch of products as per customer schedules and
monitor delivery performance of the organization.
g) To monitor overall equipment effectiveness of key equipment
h) CFT members and jointly responsible for CFT plans and activities.
i) To coordinate with PE in charge for machine and tool maintenance activities.
9.

MAINTENANCE INCHARGE:
a) Overall responsible for preventive, breakdown and predictive maintenance of
Production equipment & machines etc.
b) Predictive maintenance activities and guidance to maintenance technicians and
production staff in machine maintenance.

10. TOOL ROOM INCHARGE:

a) Tool, Fixture, Gauge design and fabrication, tooling inspection and tool validation
in line with APQP requirements.
c) Maintenance of tool history cards and machine breakdown records.
11.

PURCHASE INCHARGE :
a) Overall responsible for activities related to purchasing and stores.
b) Evaluation and selection of suppliers and maintaining approved supplier list.

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c) Issuing purchase orders to approved suppliers with complete specifications.
d) Purchase planning and issue of delivery schedules to suppliers.
e) Issuing delivery schedules to suppliers as per production & customer
requirements.
f) Follow up with production and ensure delivery of materials as per customer
requirements.
g) Initiating corrective actions on suppliers based on their quality and delivery
performance and other problems.
h) CFT member and responsible for all CFT plans and activities related to his areas
of operation.
12.
a)
b)
c)
d)

PRODUCTION SUPERVISORS:
To execute production as per plan in their allotted areas / processes.
To monitor production and maintain production/rejection reports.
To provide on-the-job training to operators as per plan and instructions.
To ensure daily machine maintenance and housekeeping in shop floor areas.

13.

QC ENGINEERS / INSPECTORS :

a) To perform inspection & testing activities at allocated stages and to generate and
maintain reports accordingly.
b) To maintain identification and inspection status at the respective allocated areas.
c) To identify, record and evaluate nonconforming products at respective allocated
areas.
d) Collection and analysis of data of non conforming materials at all stages in order
to take corrective actions.
e) Application of statistical techniques as per documented procedures.
14.
a)
b)
c)
d)
e)
f)
g)

STORES INCHARGE :
Overall In-charge of Stores activities.
Performance monitoring of suppliers.
Control of receipt and issue of all materials from stores.
Proper handling and storage of materials to avoid deterioration, damage or loss
Periodic assessment of all the materials in stock.
Quality, Delivery performance and premium freight monitoring of all suppliers.
Overall responsible for receipt and control of customer supplied materials and
information to customer in case of discrepancy etc.

Note: Production & QA in charges shall be promptly informed (not later than eight
hours) of products or processes which do not conform to requirements.
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Annex 2

PROCESS SEQUENCE AND INTERACTION

S.
No.

INTRACTION AMONG EACH OTHERS

PROCESS NAME

1.
TOP MANAGEMENT

2.

MR & TRAINING / CUSTOMER

COMPLAINTS HANDLING.

3.

PRODUCTION

4.

MAINTENANCE &
MANAGEMENT OF
PRODUCTION TOOLING

5.

PURCHASE & STORE

6.

7.

QUALITY ASSURANCE

MIS / DMR

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Annex 3

QUALITY POLICY
CUSTOMER SATISFACTION BY SUPPLYING
PRODUCT MEETING FULL SPECIFICATION AND
TIMELY DELIVERY BY ADHERING TO QUALITY
SYSTEM AND CONTINUOUS IMPROVEMENT.

RAH
UL MALIK
(CEO)

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Annex. 4

QUALITY OBJECTIVES

COMPLAINTS.

REDUCE CUSTOMER

REJECTION.

REDUCE INTERNAL

OF SKILL,

CONTINUOUS UPGRADATION

KNOWLEDGE & PROCESSES.

RAHUL MALIK
(CEO)

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Annex 5

ORGANISATION
CHART

MD

GM Works

Production
Manager

Dy Mgr
Prod

Sup. Mixing

Shift
I/C

HouseKeeping

Sup. Curing

Asst. Tech (QA)

Manager

Chief Mgr
(Maint)

Commercial
Manager

Q.C. Sup
Mech. I/C

Elect. I/C

Inspectors
Fitters

Electrician

Store
Asst.

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Personnel
Officer

Dy.Mgr
(Purchase)

Time
Keepers

Asst. Mgr
(Comm)

A/c
officer

Securities

W/H
Incharge

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Annex-6

ABBREVIATIONS
1. APQP

- Advanced Product Quality Planning

2. ASST.

- Assistance

3. ANNEX. - Annexure
4. CR

- Customer Representative

5. EDP

- Electronic Data Process

6. e.g.

- Example

7. FMEA

- Failure Mode & Effect Analyzes.

8. FIFO

- First in First out

9. GM

- General Manager

10. HOD

- Head Of Department

11. HR

- Human Resources

12. IA

- Internal Audit

13. IS

- Indian Standard

14. ISO/TS

- International Organization For standardization / Technical Specifications

15. MR

- Management Representative

16. MRM

- Management Review Meeting

17. MSA

- Measurement System analysis

18. CEO

- Chief Executive Officer

19. SIPL

- Sebros Industries Pvt. Ltd

20. MGR

- Manager

21. NC

- Non Conformity

22. NCM

- Non conforming Material

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23. NO

- Number

24. PPAP

- Production Part Approval Process

25. PO

- Purchase Order

26. QA

- Quality Assurance

27. QC

- Quality Control

28. QMS

- Quality management System

29. QSM

- Quality System Manual

30. QSP

- Quality System Procedures

31. REF

- Reference

32. Rs.

- Rupees

33. RN

- Revision Number

34. SPC

- Statistical Process Control

35. Sup.

- Supervisor

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