Professional Documents
Culture Documents
QUALITY MANAGEMENT
SYSTEM MANUAL
Doc. No.
Rev. No.
QMSM 01
00
FRONT PAGE
Date
Page No.
12.07.2012
1 of 1
Copy Holder
Proprietor
Management Representative
Certification
ISSUE 1
2012 July 12
The contents of this Quality System Manual and all related documents are the sole property of M/s.
CGCS and shall not be copied or reproduced, in part of whole by anyone whosoever, without the
written permission of the organization
PREPARED BY :
APPROVED BY :
CGCS
QUALITY MANAGEMENT
SYSTEM MANUAL
Doc. No.
Rev. No.
QMSM 00
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Date
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TITLE
No. OF
PAGES
SECTION No.
REV. No.
QMSM 01
00
Front Page
QMSM 00
00
QMSM 03
00
Organization Profile
QMSM 04
00
QMSM 05
00
Management Responsibility
QMSM 06
00
Resource Management
QMSM 07
00
Production Realization
QMSM 08
00
QMSM 09
00
QMSM 10
00
QMSM 11
00
QMSM 12
00
Quality Objectives
CGCS
S.No.
Doc.
No.
QUALITY MANAGEMENT
SYSTEM MANUAL
Doc. No.
Rev. No.
QMSM 00
00
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Page No.
12.07.2012
2 of 2
Document Name
Page No.
of
Document
Changed
Issue
No. and
Date
Rev.
No. and
Date
Nature of Amendment
CGCS
Doc. No.
Rev. No.
QMSM 03
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ORGANISATION PROFILE
Date
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1 of 1
M\s.CARGO GUARD CONTAINER SEALS (CGCS) was incorporated in the year 2007,Unit was
located at 24/31.Vaithianathan Mudali Street,Azees Nagar,TondiarpetChennai-600 081
This Major customer of the organizations are 1. M/s. Indian Oil Corporation Ltd (SERVO)-Chennai.
2. M/s . BEFALCON TYRES Karnataka
3. M/s . Manjushree Technopack Ltd Karnataka.
The company has excellent infrastructures and Quality control facility with up area of 300 sq.ft.
In-order achieve customer satisfaction through compliance to the requirements of the customer and to
meet the competence in the market, the organization is working on a Quality Management System
Based on ISO 9001:2008.
This manual aims to distance the organizations effectiveness and efficiency in implementing the
Quality Management System. Also the manual defines the various processes and its interactions to
maintain the quality management system, it clear indicate the reference and the linking document to
get an overall clarity with the organizations effective functioning.
CGCS
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The Block diagram in the QSM-10 determined the general process required for our quality
management System.
The order and interaction of the specific (department) quality management system processes
can be founded in QSM-10.
The criteria and methods for effective control of processes are found in internal audit section
and process control plan.
Resources required for the process are determined in the resource Management, to support the
operation and control of these processes. The information necessary for effective operation
and monitoring of these processes is found within available controlled documents through the
organization.
Upon the completion of measurement and monitoring of the process and analysis of the data,
appropriate action id taken to assure that intentions are achieves and opportunities for
improvement are acted on.
Reference:
PROCESS MAP & INTERACTION (QMSM-10)
LIST OF APPROVED SUPPLIERS (PUR-01)
4.2 DOCUMENTATION REQUIREMENT
4.2.1 GENERAL
The organization has documented its entire QMS requirement to facilitate effective
implementation, maintenance and continual improvement of the systems. It includes the
following:
Quality manual.
CGCS
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Reference
QUALITY POLICY AND OBJECTIVE (5.3)
QUALITY SYSTEM MANUAL (QMSM)
LIST OF RECORDS
4.2.2 QUALITY MANUAL
Quality manual is in full conformity with the requirements of ISO 9001:2008 standard
and is supported by further levels of documentation as required in 4.2.1
The scope of the QMS including the detail of justification for any exclusion.
Exclusion of the clause of ISO 9001:2008 and justification for exclusion is explained
bellow.
Clause or Sub
Clause
7.3
Exclusion
Design &
Development
Justification
The organization is manufacturing the components
as per the customers specification Hence it is
excluded.
However, exclusion of the above clauses will not affect organizations ability or
responsibility to provide product that meets customer and applicable regulatory requirement
Reference:
QUALITY MANAGEMENT SYSTEM MANUAL (QMSM)
CGCS
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All documents within organizations quality system are controlled as explained below
The quality system document are prepared, Reviews and Approved as explained bellow.
Sl. No.
Documents
Prepared, Reviewed by
Approved by
1.
Partner / MR
Partner
2.
Partner / MR
Partner
This is evidenced by the Signature of the respective authority in every sheets of the manual.
All the pages of the Manual and procedures are identified by Document number, Revision
number, Date of implementation of the system and Page Number.
Number System
QSM XX where QSM for Quality System Manual
F XXX YY where XXX Process, F Format
CP XX where CP Control Plan
D XX YY where D Document, XX Process
Document issue
All the pages of the Manual belonging to MR are stamped with MASTER COOY stamp in
Green on the back side and other copy holder are stamped with and controlled documents are
subjected to changes.
The controlled Documents are issued to other copy holders except MR and its recorded in the
List of Document
Document Changes
Changes to the documents can be initial by any one in the organization. Its relevance and
advantages discussed by MR.
All the changes are reviewed and approved by same authority that has done the original
review and approval
Changes to the document can be identified ARIAL WORD.
CGCS
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The changes are reviewed by the MR and initial the respective document.
When a particular page has undergone revision, the revision number of that page is
incremented by one and date in that page will be changed to the date of implemented by the
revision.
On revision, the Amendment record in front page of the manual of the manual is updated for
revision details and Revision Record is also updated for the latest revision
The revises document are issued to the copyholders on issued or received documents,
obsolete copy of the document is collected back. One copy of obsolete copy is stamped
obsolete copy and retained by proprietor/ MR for reference purpose and other obsolete
copies are destroyed.
Whenever there is lot of revision in a particular Manual, then the whole manual is re-issued
and issued number in all the pages is made 00 and Date of revision by the Proprietor/MR and
reviewed every year for changes and updated accordingly.
Reference:
LIST OF DOCUMENTS ( CGCS/MLD-01)
DOCUMENT AMENDMENT RECORD
CGCS
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Rev. No.
QMSM 05
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MANAGEMENT RESPONSIBILITY
Date
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At the Organization, the top management provides the evidence of its commitment to the
development and implementation of the QMS and continually improving the effectiveness by
the following methods.
The partner Communicate the importance of meeting the customer requirement as well as
statutory and communicate the importance of meeting the customer requirement as well as
statutory and regulatory requirements during interaction with staff concerned.
Establish the quality policy
Establishing the quality objective
Conducting management review
Ensuring availability of resource.
Reference:
QUALITY POLICY (5.3)
QUALITY OBJECTIVES (QSM-12)
MANAGEMENT REVIEW MEETING PLAN
AGENDA FOR MANAGEMENT REVIEW
MINUTES OF MANAGEMENT REVIEW MEETING
LIST OF STATUTORY REGULATORY REQUIREMENTS
5.2 CUSTOMER FOCUS
At the organization, the top management ensures that, the entire organization has a clear force
towards meeting. Exceeding the customer requirements, and enhancing the level of their
satisfaction
This monitored during the customer satisfaction survey conducted once in a year.
Reference:
CUSTOMER SATISFACTION SURVEY
CUSTOMER COMPLAINT REGISTER
5.3 QUALITY POLICY
The above policy is appropriate to the activity carried out at the organization.
Compliance to lay down requirements and continual improvement is included in the quality
policy, with the object of improving the effectiveness of the QMS.
Framework for establishing and reviewing the quality objectives is provided.
The quality policy is discussed and explained in detail in the meetings, so that it is clearly
understood and communicated within the organization.
The quality policy is reviewed for its continuing suitability, during management review
meeting.
Reference:
CGCS
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MANAGEMENT RESPONSIBILITY
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5.4 PLANNING
5.4.1 QUALITY OBJECTIVES
At the Organization the top management has ensured that the quality objectives have been
established at relevant functions and levels within the organization.
These objectives are measured for the consistency with the quality policy.
The quality objectives are rolled down by MR at subsequent levels who in turn review the
objectives and fixing the target for the subsequent period.
The details of review are maintained in the quality objectives monitoring record.
Reference :
QUALITY OBJECTIVES (QMSM-12)
5.4.2 QUALITY MANAGEMENT SYSTEM PLANNING
The planning at the Organization is done, not only to maintain the QMS implementations, but
also to monitor, measure, analyze and improve on a continual basis.
The integrity of the QMS is maintained when changes to the QMS are planned and
implemented.
Reference:
QUALITY OBJECTIVES DEPLOYMENT RECORD (F-MR-09)
5.5. RESPONSIBILITY, AUTHORITY AND COMMUNICATION
5.5.1 RESPONSIBITY AND AUTHORITY
The organization has structured its activities to ensure that its products meet customer
requirements consistently. The responsibility, authority and interrelation of the personnel who
carry out, manage and verify processes are defined individually, in QMSM -09. The copy of
this QMSM-09 also distributed to the personnel individually. The organization chart of the
organization, indicating the structure of the organization and interrelation amongst its
personnel, is also enclosed given in QSM-09. The responsibility and authority given in QSM09, also identifies and indicates the personnel who have to :
Initiate action to prevent the occurrence QC non-conformities relating to the product and
processes of the QMSM.
Identify and record the problems relating to the product and processes of QMS.
Initiate, Recommend or provide solutions through designated channels.
Verify the implementation of solutions.
Control further processing, delivery or installation of non-conforming products until the
deficiency or unsatisfactory condition has been corrected.
Reference:
RESPONSIBILITY & AUTHORITY (QSM-09)
CGCS
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MANAGEMENT RESPONSIBILITY
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Mr.A.Karthik
Reference:
RESPONSIBILITY & AUTHORITY (QSM-09)
5.5.3 INTERNAL COMMUNICATION
Reference:
NOTICE BOARD
CGCS
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QMSM 05
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MANAGEMENT RESPONSIBILITY
Date
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The management conducts periodic reviews at least once in 6 months, these reviews are
ensure the monitoring of the QMS implementation.
They verify the continuing suitability, adequacy and effectiveness of the QMS in line with the
quality policy for achieving the quality objectives, in addition to the other requirements of
ISO 9001 : 2008 standard.
The reviews are also asses the need for changes if any, required in the QMS including the
quality policy and the quality objectives so that they also remain dynamic and changeable as
per the current needs and future requirements.
Such changes can not only bring about improvement in the existing processes but also create
new system requirements.
The minutes of these management review meetings, are recorded.
Reference:
MINUTES OF MANAGEMENT REVIEW MEETING (CCGS/MR-01)
5.6.2 REVIEW INPUT
The Management Review covers the following:
Results of audits.
Customer Feedback.
Process performance and product conformity.
Status of preventive and corrective actions.
Follow of actions from previous management reviews.
Change that could affect the QMS, and
Recommendations for improvement.
5.6.3. REVIEW OUTPUT
The management, during the management review meetings takes decisions and actions related to
Improvement of the effectiveness of the QMS and its processes.
Improvement of product related to customer requirements, and
Resource needs.
CGCS
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QMSM 06
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RESOURCE MANAGEMENT
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To improve and maintain the QMS and continually improve its effectiveness, and
To enhance customer satisfaction by meeting customer requirements.
Reference:
LIST OF EMPLOYEES (CCGS/HR-01)
6.2 HUMAN RESOURCES
6.2.1 GENERAL
The organization is fully aware of the importance of the human resources available within the
organization and values them.
Employees therefore are treated as an extremely valuable resource of the organization.
At the organization, it is recognized and accepted that product quality depends upon the work
output of the personnel at various stages.
At the organization, personnel performing work, directly affecting product quality are verified
and screened for their competence to undertake the allotted work.
This assessment is carried out based on the individuals education, training, skill and work
experience.
The organization has identified means to determine the following with regard to the people, to
ensure that each person is given a job that suits him the most.
The competence necessary for performing work, affecting product quality at various stages
has been determined and is ensured while allocating the work.
Training needs for personnel identified and suitable training programs are conducted
periodically.
The effectiveness of the training imparted is reviewed and evaluated to verify the need for retraining.
The personnel carrying out the various allotted activities are duly informed and made aware
of the relevance and importance of their activity with regard to the product quality. They are
also made aware, on how their job contributes the achievement of the quality objectives of the
organization.
Appropriate records are maintained for all personnel with regard to their education, training
skill and experience.
Reference :
LIST OF COMPETENCY STANDARD (CGCS/HR-02)
TRAINING RECORD (CGCS/HR-03)
CGCS
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RESOURCE MANAGEMENT
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6.3 INFRASTRUCTURE
The infrastructure required to support the production activities are addressed in List of machines.
All the machineries are subjected to prevent maintenance as per the Checklist for preventive
maintenance.
Whenever a machine breakdown occurs at the time of production, the same is recorded in the
Machine History Card.
The Supervisor attends the machine breakdown and takes remedies.
At the organization, the infrastructures are determined and provided to achieve the conformity to the
product requirements. It includes.
The land, building, workspace and all associated utilities which form the basis of
infrastructures are created and provided.
The process of design, manufacture and supply consists of various process equipment (both
Hardware and Software), are made available.
The support services such as transport, means of communication, etc. are also provided.
Reference:
LIST OF MACHINES (CGCS/MAINT-01)
PREVENTIVE MAINTENANCE SCHEDULE(CGCS/MAINT/HR-02)
6.4 WORK ENVIRONMENT
At the Organization the work environment such as ventilation, lighting, layout, housekeeping,
, First aid box etc.. Are determined and made available to achieve the conformity to the
product requirements.
CGCS
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QMSM 07
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PRODUCT REALISTION
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CGCS
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QMSM 07
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PRODUCT REALISTION
Date
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CGCS
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QMSM 07
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PRODUCT REALISTION
Date
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CGCS
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PRODUCT REALISTION
Date
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12.07.2012
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Intellectual properties of customers are available (eg: Product Drawings, Purchase Orders,
Customer Schedule and Correspondence letters) and it is kept safely for reference purpose.
Reference:
PROCESS FLOW CHART-CUSTOMER COMPLAINT (QSM-11, PAGE NO. 3 OF 3)
PRODUCT DRAWING
PURCHASE ORDER AND CORRESPONDENCE LETTER (CUSTOMER)
7.5.5 PRESERVATION OF PRODUCT
The conformity of the product is preserved during in-house processing and delivery to the
intended destination.
This preservation includes identification, handling, packaging, storage and protection.
Suitable trays are provided for preventing damage to products, while handling.
Suitable storage areas are provided for incoming materials and finished products.
Stocks are monitored on a daily basis.
Finished products are delivered in the trays applied with rust prevention oil.
Final inspection report and delivery Chelan are made available for the verification at the time
of delivery.
Reference:
STOCK REGISTER
7.6 CONTROL OF MONITORING AND MEASURING EQUIPMENT
At the organization, all the identified Monitoring and Measuring equipment (MME), are
controlled, calibrated and maintained.
Suitable MME are identified for ensuring the conformance of products to specifications at all
stages of production.
All MMEs are identified with a unique number.
Instruments are calibrated at specified intervals by external agency. The calibration is done
against standards traceable to any national or international standards.
Equipments, whenever found to be out of calibration are rectified by adjustments or
readjustments wherever necessary, prior to their use.
Care is also taken to ensure that the calibration of the equipment remains valid during use. It
is ensured that the setting and adjustments do not get disturbed, invalidating the
measurements made. This safeguard of the instrument ensures its accuracy, and its fitness for
use continues throughout the period, till the next calibration is due, or done.
When the equipment, in use are found out of calibration, they are not only rectified or
scrapped, but also the previous measurements carried out in the process are reassessed and the
results are documented as observed.
Calibration reports obtained from the external agencies are verified.
We are monitoring measuring to be used Profile Projector in all components.
No software is used for measuring and monitoring of product / process.
Reference:
LIST OF INSTRUMENTS (CGCS/QA-01)
CALIBRATION PLAN (CGCS/QA-02)
CALIBRATION REPORT (EXTERNAL)
CGCS
8.1
QUALITY MANAGEMENT
SYSTEM MANUAL
MEASUREMENT, ANALYSIS &
IMPROVEMENT
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GENERAL
The Organization has planned and implemented the measurement, analysis and improvement process
within the QMS as per the requirements of the standard to ensure that the product meets the specified
requirements. This process of planning and implementation is carried out on a regular basis to ensure
the following.
- Conformity of the product to specified requirements
- Conformity of the QMS
- Continual improvement of the QMS
8.2
8.2.1.
-
Reference:
PROCESS FLOW CHART (QSM011), (Page No. 3 of 3)
CUSTOMER SATISFACTION SURVEY
8.2.2.
-
The following actions are taken by the auditee once non-conformity is raised during an audit.
- An action taken to close the non-conformity raised immediately is called Correction.
- Root cause for the non-conformity is arrived at by a scientific method called as Why-Why
analysis.
- Ask why the non-conformity has occurred.
CGCS
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QUALITY MANAGEMENT
SYSTEM MANUAL
MEASUREMENT, ANALYSIS &
IMPROVEMENT
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Reference:
INTERNAL AUDIT PLAN (CGCS/MR-02)
INTERNAL AUDIT SCHEDULE (CGCS/MR-03)
AUDIT FINDING REPORT (CGCS/MR-04)
NC REPORT (CGCS/MR-05)
8.2.3.
-
Reference:
LINE INSPECTION REPORT (CGCS/QA-03)
8.2.4.
-
CGCS
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QUALITY MANAGEMENT
SYSTEM MANUAL
MEASUREMENT, ANALYSIS &
IMPROVEMENT
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The authorization of release of product under deviation if any is also recorded. The products
are further processed only on acceptance of the product with respect to the Control Plan.
Reference:
LINE INSPECTION REPORT
FINAL INSPECTION REPORT CGCS/QA-04)
JOB CARD
8.3
To ensure that non-conforming products identified at various stages are controlled, and not passed on
to next stage, or used unintentionally, organization has established the following methods.
- All products whether incoming in-process or finished are inspected as per the Process Control
Plan, to verify and ensure their conformity prior to use.
- The deviations to the specification in the Control Plan are considered as Non-conformity.
Incoming Products:
- All incoming products found NC are identified, rejected and returned to the supplier. For
customer supplied products, the NC will be informed to the customer and actions will be
taken as per their advice. It is the responsibility of the Quality Control.
In Process Products:
- The NCs observed during in-process are kept separately and property identified till a decision
of disposal action is taken. The Re-inspection is required on all reworked or repaired
material. Rework material must meet original requirements. Repaired material must meet
intended function and other requirements in accordance with customer needs. This
responsibility is with the Production Supervisor.
Finished Products:
- In case of NCs observed in finished products in relation to the Control Plan the entire lot is
segregated and reworked. This is the responsibility of Production Supervisor.
Post Delivery Products :
- Discovery of nonconforming material after delivery is immediately followed by the actions
necessary to minimize its impact and preserve customer satisfaction to the highest level
possible under the circumstances. It is the responsibility of Partner.
-
All Non-conformities are analyzed for causes and suitable corrective action is taken to ensure
recurrence of the non-conformity. The details of action taken are recorded in NonConformity Report.
Reference :
NON CONFORMENCE REGISTER (CGCS/QA-05)
CGCS
8.4
QUALITY MANAGEMENT
SYSTEM MANUAL
MEASUREMENT, ANALYSIS &
IMPROVEMENT
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ANALYSIS OF DATA
-
At the Organization, the data generated as a result of monitoring and measurement, from all
sources, is collected and analyzed to demonstrate suitability and effectiveness of the QMS.
Evaluation of this data is used to show continual improvement of the QMS.
In order to achieve the above the following areas are covered and analyzed.
Customer satisfaction: Periodical feedback received from customers.
Scope for correction and prevention based on characteristics and trends of product and
process observed leading to continual improvement.
Product conformity to requirements: Results of final inspection, in process inspection.
Suppliers performance available thro suppliers monitoring and rating.
Complaints received from customer are entered in Customer Complaint Register.
Customer complaints are analyzed by finding the root cause of the complaint and solving it by
taking appropriate corrective action or preventive action.
The same is recorded in Non conformity Report.
Reference :
CUSTOMER SATISFACTION SURVEY
CUSTOMER COMPLAINT REGISTER
NC REPORT
8.5
8.5.1
-
IMPROVEMENT
CONTINUAL IMPROVEMENT
Continuous improvement in the effectiveness of quality management system is achieved
through the use of the following
Well defined Quality Policy
Measurable Quality Objectives
Audits that identify opportunities for improvement
Analysis of data of product conformance and process capability
Customer satisfaction and supplier performance
Corrective and preventive actions
Management review
Reference :
QUALITY POLICY (5.3)
QUALITY OBJECTIVES (5.4.1.)
AUDIT FINDING REPORT
CUSTOMER SATISFACTION SURVEY
NC REPORT
MINUTES OF MANAGEMENT REVIEW MEETING
CGCS
8.5.2
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QUALITY MANAGEMENT
SYSTEM MANUAL
MEASUREMENT, ANALYSIS &
IMPROVEMENT
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Reference :
NC REPORT
CORRECTIVE ACTION REPORT
8.5.3.
-
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SYSTEM MANUAL
MEASUREMENT, ANALYSIS &
IMPROVEMENT
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In case the implemented action is found to be lacking in any way, an alternative action will be
identified and implemented.
Product / process related PAs are based on the impact of CAs on other related areas, where,
prevention helps avoid likely problems.
All such actions taken based on the likelihood of problems arising and the consequent
preventive measures are recorded in the Non conformity Report.
The PAs once determined will be discussed prior to implementation and later verified for
effectiveness.
All document changes arising out of the Pa will be taken up as per the instructions for
document change (4.2.3)
The PAs for quality systems related potential NCs will be dealt as per the narration 8.2.2. in
this section.
Reference :
PREVENTIVE ACTION REPORT
CGCS
QUALITY MANAGEMENT
SYSTEM MANUAL
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ORGANISATION CHART
PROPERITOR
Administration
Manager/MR
Machine Operator
Packing Asst
QUALITY MANAGEMENT
Doc. No.
QMSM 09
Perspective Planning.
Organizational Image.
2. Management Representative
Review, control & issue of Quality System Manual, procedure and Work
Instructions and update as required.
3.Manager
In process QC of production
Vetting of invoices
Selecting vendors
Doc. No.
QMSM 10
CGCS
QUALITY MANAGEMENT
SYSTEM MANUAL
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Enquiry
Inform customer
Feasibilit
y Review
Management Review
Meeting
Planning
Define production
Method / Resources
Procurement of
Raw material
Control of
process
Define controls
Provision of
Resources
Calibration
Improvemen
t Activities
in process &
system
Production
No
Monitor
Non
conformed
Product
Analyse
Yes
Conformed
Product
Control of
Documents
Dispatch
Control of
Records
Customer feed
back
Training
QUALITY MANAGEMENT
SYSTEM MANUAL
CGCS
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Do the
material
comply
control
plan ?
Yes
No
Return to Inform to
customer / Supplier
Production
Do the
material
comply
control
plan ?
In process Inspection
/ Sub contractor
Do the
material
comply
control plan
?
No
No
Segregation &
Rework
Final Inspection
Yes
Des patch
End
CGCS
QUALITY MANAGEMENT
SYSTEM MANUAL
PROCESS FLOW CHART
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Start
Review of enquiry
Is
Quotation
Accepted
No
End
Yes
Receive the purchase order and drawings from
customer
Production
process &
dispatch
End
CGCS
QUALITY MANAGEMENT
SYSTEM MANUAL
PROCESS FLOW CHART
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Start
End
CGCS
QUALITY MANAGEMENT
SYSTEM MANUAL
QUALITY OBJECTIVES
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QSM 12
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