QUALITY MANAGEMENT SYSTEM MODERN PREFAB MANESAR QUALITY ASSURANCE PLAN : INCOMING MATERIAL Doc. No.

: MPS - QAP - 01

ISSUE NO: 1 ISSUE DATE: 24/05/2011 REV NO: 0 REV DATE: Page No: 01 of 03

S.No

Process Part

Check parameter

Equipment / instrument / tool used

Sampling size / testing frequency

Specification Customer / Manufacturer Internal test certificate

Tolerance limit / acceptable deviation

Control point

Periodicity of calibration / servicing

Calibration Method External / internal Record Responsib ility

(A) Dimensions
W - width, T - thickness Measuring tape Micrometer One in every five 1040 / 1220mm coils One in every five coils Customer spec Internal NA 2mm 2% Calibration Calibration Once in a year Once in a year Comparison with standard scale Measuring Standard thickness Internal External

(B) Attributes
scratch, dent, damage, paint peel off Visual inspection One in every five coils One in every five coils One in every five coils NA Internal Zero tolerance NA Inspection against standard sample NA Calibration NA NA NA

Pre-Painted Galvanised Iron (PPGI) Coil

Colour

Visual

Customer spec 65 HRB maximum 6.5mm

NA

Zero tolerance

NA

NA

NA

QC Incharge

(C) Hardness test

Hardness tester

Internal Internal

65 HRB - 0.5mm to + 2mm Visual penetration of scratch into substrate Visual - peel off of paint. Zero

Once in a year Once in a year

Standard sample Comparison with standard length Comparison with standard weights

External External

Cupping machine / One in every five (D) Cupping Test visual inspection coils for fracture of paint

(E) Scratch Hardness test

(F) Paint Adhesion Test

Hand operated scratch tester

One in every five Apply load 1.8 to coils 2.5 kg One in every five Satisfactory coils adhesion visual Every Lot Matched with given Test Certificate

Internal

Calibration

Once in a year

External

Cross hatch test Visual

Internal Internal

NA NA

NA NA

NA NA

External Internal QC Incharge

(A) Batch no. 2 Polyol/ Isocyanate (B) PU Property

Free Rise Density

Weighing M/C

Every Batch

27Kg/m3

Internal

2 Kg/m3

Calibration

Once in a year

Comparison with standard weights

External

REVIEWED AND APPROVED BY: DIRECTOR (OPERATIONS) SIGNATURE: DATE : 24.05.11

ISSUED BY: MANAGEMENT REPRESENTATIVE, QMS SIGNATURE: DATE : 24.05.11

QUALITY MANAGEMENT SYSTEM MODERN PREFAB MANESAR QUALITY ASSURANCE PLAN : INCOMING MATERIAL Doc. No.: MPS - QAP - 01

ISSUE NO: 1 ISSUE DATE: 24/05/2011 REV NO: 0 REV DATE: Page No: 02 of 03

S.No

Process Part

Check parameter

Equipment / instrument / tool used

Sampling size / testing frequency

Specification Customer / Manufacturer Internal test certificate

Tolerance limit / acceptable deviation

Control point

Periodicity of calibration / servicing

Calibration Method External / internal Record Responsib ility

(A)Dimensions
L- Length
W - width

Measuring tape
Vernier Callipers Micrometer

Five in every Lot Five in every Lot Five in every Lot

NA Customer spec Customer spec

Internal
NA Na

10% 10% 10%

Calibration Calibration Calibration

Once in a year Once in a year Once in a year

Comparison with standard scale NA NA

Internal External External QC Incharge

MS Pipe T - thickness

(B) Attributes
Rust/ Oil free Visual Five in every Lot NA Internal Satisfactory NA NA NA NA

(A) Dimensions
L- Length
W - Width

Measuring tape Measuring tape Micrometer

Five in every Lot

NA NA Customer spec

Internal Internal Internal

10% 10% 8%

Calibration Calibration Calibration

Once in a year Once in a year Once in a year

Comparison with standard scale Comparison with standard scale Measuring Standard thickness

Internal Internal External

Five in every Lot

CR sheet T - Thickness
Five in every Lot

QC Incharge

(B) Attributes
Dent, damage, Rust, Oil free Visual inspection
Five in every Lot

NA

Internal

Zero tolerance

NA

NA

NA

NA

(A) Dimensions
L- Length
W - Width

Measuring tape Measuring tape Micrometer

Five in every Lot

6300mm 1500mm Customer spec

Internal Internal Internal

10% 10% 8%

Calibration Calibration Calibration

Once in a year Once in a year Once in a year

Comparison with standard scale Comparison with standard scale Measuring Standard thickness

Internal Internal External QC Incharge

Five in every Lot

HR sheet T - Thickness
Five in every Lot

(B) Attributes
Dent, damage, Rust, Oil free Visual inspection
Five in every Lot

NA

Internal

Zero tolerance

NA

NA

NA

NA

REVIEWED AND APPROVED BY: DIRECTOR (OPERATIONS) SIGNATURE: DATE : 24.05.11

ISSUED BY: MANAGEMENT REPRESENTATIVE, QMS SIGNATURE: DATE : 24.05.11

QUALITY MANAGEMENT SYSTEM MODERN PREFAB MANESAR QUALITY ASSURANCE PLAN : INCOMING MATERIAL Doc. No.: MPS - QAP - 01

ISSUE NO: 1 ISSUE DATE: 24/05/2011 REV NO: 0 REV DATE: Page No: 03 of 03

S.No

Process Part

Check parameter

Equipment / instrument / tool used

Sampling size / testing frequency

Specification Customer / Manufacturer Internal test certificate

Tolerance limit / acceptable deviation

Control point

Periodicity of calibration / servicing

Calibration Method External / internal Record Responsib ility

(A) Dimensions
L - Length W - Width, Measuring tape Measuring tape Micrometer
Five in every Lot Five in every Lot

2440mm

Internal Internal

5mm 2mm 2%

Calibration Calibration Calibration

Once in a year Once in a year Once in a year

Comparison with standard scale Comparison with standard scale Measuring Standard thickness

Internal Internal External QC Incharge

Aluminium Plate

T - Thickness

Five in every Lot

Customer spec

Internal

(B) Attributes
Dent, damage, Rust, Oil free Visual inspection
Five in every Lot

NA

Internal

Zero tolerance

NA

NA

NA

NA

(A) Dimensions 7 Aluminium Extrusion

Size Measuring tape/Vernier callipers Five in every Lot

Internal

2%

(B) Attributes
Dent, damage, Anodising,Coating Visual inspection
Five in every Lot

QC Incharge NA NA NA NA
QC Incharge

NA
Customer spec

Internal

Zero tolerance Zero tolerance 2%

8 9

Door Lock Hinge

Properties

Five in every Lot

Properties

Five in every Lot

Customer spec

QC Incharge

(A) Dimensions
Size Measuring tape/Vernier callipers/Micrometer Five in every Lot

Internal

2% QC Incharge

10

Hard ware

(B) Attributes
Rust, coating,Thread Visual inspection
Five in every Lot

NA

Internal

Zero tolerance

NA

NA

NA

NA

REVIEWED AND APPROVED BY: DIRECTOR (OPERATIONS) SIGNATURE: DATE : 24.05.11

ISSUED BY: MANAGEMENT REPRESENTATIVE, QMS SIGNATURE: DATE : 24.05.11

ISSUE NO: 1 ISSUE DATE: REV NO: 1 QUALITY ASSURANCE PLAN : INPROCESS FABRICATION REV DATE: 10/02/2012 QUALITY MANAGEMENT SYSTEM Doc. No.: Page No: 01 of 02

S.No

Description

Characteristic

Type of Check

Extent of Check

Reference Document

Specification Codes & Standards for Acceptance Criteria

Inspection By Client / TPI Format of Record Remarks

1.0 Raw material a) Physical 1.1 Plates b) Chemical c) Mechanical a) Physical 1.2 Hot Rolled Sections b) Chemical c) Mechanical 2.0 BOUGHT OUT ITEMS a) Physical 2.1 Bolts Nuts & Washers b) Mechanical Manufacturer TC c) Chemical a) Physical 2.2 Paint b) Chemical Manufacturer TC 100% Visual, Manufacturer TC Verification 100% 100% Challan, Manufacturer IS: 101, ASTM D 2697 TC R R Manufacturer TC Visual / Measurement 10% of each lot 100% Challan, Manufacturer TC IS: 1367, IS: 3757, IS:4000, IS: 1599 I R R R RW R R RW IR Manufacturer TC Manufacturer TC Manufacturer TC Measurement, Visual Mill TC & Fabricator Lab Report / Independent Lab TC Verification Measurement, Visual Mill TC & Fabricator Lab Report / Independent Lab TC Verification 10% of each lot 100% 100% 10% of each lot 100% 100% Challan, Mill TC / Lab TC IS 2062 IS 1852 Challan, Mill TC / Lab TC IS 2062, IS: 1730, IS 1852 I R R I R R W R R W R R IR Mill TC Mill TC IR Mill TC Mill TC --do-Tensile, Bend & Chemical test for each Heat Number per 50 MT.

a) Dimension 2.3 Welding Consumables b) Chemical

Measurement Manufacturer TC

Per Batch 100% 100% Challan, Manufacturer TC AWS D1.1 (2010) / ASME Sec II Part C

I R R

RW R R

IR Manufacturer TC Manufacturer TC

c) Mechanical 3.0 FABRICATION PROCESS 3.1 3.2 Cutting & Shearing Fit Up Dimension Visual & dimension a) Procdure Specification 3.3 Welding Qualification b) Procdure Specification c) Welder Qualification Visual & Measurement Measurement Verification Verification Verification

10% 10% 100% 100% 100%

Drawing Approved Drawings

IS: 800 IS: 800

I I I

RW RW R R R

IR IR WPS PQR WPQR

Reference Documents & Test Reports

AWS D1.1 (2010)

I I

ISSUE NO: 1 ISSUE DATE: REV NO: 1 QUALITY ASSURANCE PLAN : INPROCESS FABRICATION REV DATE: 10/02/2012 QUALITY MANAGEMENT SYSTEM Doc. No.: Page No: 02 of 02

S.No

Description

Characteristic

Type of Check

Extent of Check

Reference Document

Specification Codes & Standards for Acceptance Criteria

AWS D1.1 & ASME Sec V

Inspection By Client / TPI

I I I RW IR RW RW RW IR

Format of Record

Remarks

a) Visual 3.4 Welding Inspection b) NDT 3.5 Drilling through approved Jigs / Templates Dimension a) Dimension 3.6 Final Inspection b) Physical Damage c) Part Identification 4 GALVANIZING a) Surface Defects 4.1 Galvanizing b) Mass of Coating 5 5.1 5.2 Legend :I - Inspection R - Review W - Witness IR - Inspection Report RW - Random Witness TC - Test Certificate MT - Metric Tonne SURFACE CLEANING & PAINTING Sand Blasting Painting Surface Preparation DFT & Adhesion Test

Free from Cracks, Porosity, Inclusion, etc defects. DP & RT Measurement Measurement Visual Verification

100% Approved Procedures 10% 10% 100% 100% 100% Approved Drawings Approved Drawings

RT if applicable on 10% of length of each Butt Joints & DP on atleast 10% of Length of all other joints

IS: 800

IS: 800, IS: 7215, IS 9595 & Approved Drawings

RW RW

IR

Visual Random Measurement

Technical Specification

IS: 2629; IS: 6745; IS: 2633

RW

IR

Measurement Measurement

Random Random

Approved Procedures Approved Procedure

IS: 1477 (1971) Part I or SA 2.5 IS: 1477 (1971) Part II

I I

RW W

IR IR

IS - Indian Standard TPI - Third Party Inspector DFT - Dry Film Thickness AWS - American Welding Society

UT - Ultrasonic Test DP - Dye Penetrant Test TPI - Third Party Inspector ASME: American Sosciety of Mechanical Engineering

ASTM - American Society for Testing and Materials

Prepared By :-

Reviewed & Approved By :Client / Third Party Inspector .