Professional Documents
Culture Documents
AKPEAF follows the undermentioned ‘Document Numbering System’ for all its
internally generated Quality System Documents ( QDs ) & Forms & Formats ( QFs )
throughout the organization :
NOTE :
1.
2..
3.
All QMS FORMS & FORMATS have the following printed / typed / stamped as
appropriate, on the document :
DOCUMENT APPROVALS :
NOTE : All internally generated documents are prepared and approved by the
following functions :
S.N. ISO 9001 ALL RECORDS RELATED TO FORMAT NOS. RETENTION TIME RESPONSIBILITY FOR
CLAUSE NO. [ QFs ] UPKEEP & RETRIEVAL
11 8.2.4 INSPECTION AND TEST REPORTS 37, 38, 39, 40, 41,42, THREE YEARS Q.C.I/C
43,43,
44,45,48,49,50,51,
14 7.5.5 PRESERVATION OF MATERIAL STOCK 60, 61,62, ONE YEAR OF STORES I/C
COMPLETION OF WORK
19 5.4.1, 8.5.1, RECORDS RELATED TO 02, 03, 04, 05 & 06 THREE YEARS M.R.
8.4 MEASUREMENT OF Q. OBJECTIVES
NOTE : 1. DISPOSITION INSTRUCTIONS [ as destroy, retain further for knowledge preservation / legal purposes etc ] FOR
EACH RECORD SHALL BE GIVEN BY THE M. P. - I AT THE END OF THE RETENTION PERIODS ON CASE
TO CASE BASIS.
2. * THE RETENTION PERIOD SHALL BE CALCULATED FROM THE END OF THE CALENDER YEAR ON
WHICH THAT PARTICULAR RECORD HAS BEEN GENERATED.
4. ALL RELEVANT DATAS / RECORDS IN THE COMPUTORS SHALL HAVE BACK – UPS RETAINED IN
COMPACT DISCS [ C.Ds ] AND THESE C.Ds SHALL BE KEPT WITH THE M. P. - I. THESE DATA
BACK – UPS SHALL BE DONE AT LEAST ONCE A WEEK.
5. ALL HARD COPIES OF RECORDS SHALL BE APPROPRIATELY FILED AND DULY LABELLED.
THESE FILES SHALL BE KEPT IN CUPBOARDS WITH MOTHBALLS OR SUBJECT TO PERIODIC
TREATMENTS FROM PEST CONTROL AGENCIES.
6. DATAS / RECORDS GENERATED OR KEPT AT THE SHOPFLOOR SHALL BE PUT IN PLASTIC ENVELOPS
TO PROTECT THEM AGAINST LUBRICANTS, DUST, OIL AND OTHER MATERIALS.
FOR ‘PROCEDURE FOR CONTROL OF QUALITY RECORDS’ – VIDE SECTION NO. 18 OF THE QUALITY MANUAL.
MANAGING PARTNER - II
ACCEPTANCE
10
11
12
ARRANGE FOR TRAINING [ intimating date, time, venue, trainees ] – DESIGNATE TRAINER M.R.
NO
INFORM M.R. & ARRANGE FOR EFFECTI
RE - TRAINING VE
YES
RECORD TRAINING DATE, DURATION AND FACULTY [ Vide Format No. QF / 18 ] M.R.
AKPEAF have set the following minimum competence criterias while assigning
functional designations to personnel doing quality related jobs :
S.N. FUNCTIONAL MIN. REQD. MIN. REQD. YEARS OF MIN. SKILL ANY OTHER
DESIGNATION QUALIF. EXPERIENCE REQUIREMENT EXTRAORDINARY
/ EDUCATION IN SIMILAR REQUIREMENTS
POST / JOB REQUIRED
[ if reqd.]
NOT APPLICABLE NOT APPLICABLE MANAGEMENT SKILL / AWARENESS OF THE
1 MANAGING PARTNER - II NEGOTIATION SKILL / COMPANY LAWS
SKILL TO RUN THE
BUSINESS
NOT APPLICABLE NOT APPLICABLE MANAGEMENT SKILL / AWARENESS OF THE
2 MANAGING PARTNER - I NEGOTIATION SKILL STATUTORY &
REGULATORY
REQUIREMENTS
GRADUATE INTERPERSONNEL THOROUGH
3 MANAGEMENT SKILL / UNDERSTANDING OF
REPRESENTATIVE COMMUNICATION REQUIREMENTTS OF
SKILL / THE ISO STANDARDS
TRAINING SKILL
COMMUNICATION
4 Q.C. I/C LEVEL II ONE YEAR SKILL/
MEASUREMENT SKILL
QUALIFICATION
TESTS.
NOTE : If any person is appointed without satisfying the above criterias, for any reason,
the management arranges for his / her training and is made to qualify before being
inducted to the job.
1. PURP0SE :
To establish a standard procedure for handling all customer enquiries till the
confirmation of the receipt of the orders and ensure adherence to the QMS during
this process.
2. SCOPE :
All activities from enquiry to order from customers.
4. ABBREVIATIONS :
QMS = Quality Management System.
5. PROCEDURE :
All customer enquiries received verbally / mail / email / fax or by any other means
are initially recorded in the ‘Enquiry cum Quotation Register’
( Vide Register No. REG / 03 )
M.P. – II reviews all enquiries and decides whether to submit an offer against the
enquiry.
The M.P. – II prepares and sends offer proposals / regret letters, as applicable, to the
customer against the enquiries.
All offer proposals / quotations are approved by the M.P. - II
prior to submission to the customers.
All offers / quotations submitted to the customers are uniquely numbered and are
referenced in the ‘Enquiry cum Quotation Register’
To maintain traceability all quotations / offers refer to the customer enquiries against
which these are sent.
Follow up of an offer proposal / quotation with the customer is done by the M.P. - II
till the enquiry is ‘alive’.
On receipt of the customer order, M.P. – II reviews the same and issues an ‘Order
Ackwoledgement’[vide Form No.QF / 20 ] .
In case of customer supplied design, Job Order [vide Form No.QF / 21 ] is prepared
by the M.P. - II and issued to M.P. - I for design & execution. The customer orders
are referenced in the respective Job Order to maintain traceability.
The M.P. - II monitors the ‘Customer Order’at all stages of the project and
communicates with the customer for the job status till the completion of the order
execution.
The acknowledgement / endorsement of the relevant commissioning report by the
customer against the order on installation constitutes the ‘closure of the order’
6. RECORDS :
Internal Job Order : Format No. QF / 21
Order Acceptance : Form No.QF / 20
Enquiries cum Quotation Register : Register No. REG / 03
7. REFERENCES :
ACTIVITIES RESPONSIBILITIES
YES
Communicate to the Customer after taking the neccessary remedial action TOP MGTM
Close the complaint in the Customer Complaint Handling Register - REG 04 M.P. - II
Analyse the customer complaints over a review period and present the result of M.R.
analysis at the MRM
RESPONSIBILITIES
In the month of April of each year to send the Customer Satisfaction Survey Form M.R.
[ Form No. QF / 23 ] by registered post / fax / email. to all the customers who
have placed orders in the previous financial year and keep a record
ACTIVITIES
On recept of the filled forms from the customers, calculate the Customer Satisfaction M.R.
Index [ C.S.I. ] by the formula given in Doc. No. QD / 11, for each Customer
Make entry in Form No. QF/ 05 – titled Measurable Quality Objective - for the financial year under ref. M.R.
Evaluate the significant trend in customer dissatisfaction and present the same M.R.
at the subsequent MRM
NOT O.K.
TOP MGTM
Take corrective /
Review at MRM the
preventive action as
C.S.I. against target
neccessary
TOP MGTM
Revise upwards the Average C.S.I. target
for the next financial year
CUSTOMER :-
i WORKMANSHIP
50 %
ii COMMUNICATION SYSTEM 20 %
iii RESPONSE TO INQUIRIES 10 %
iv INFRASTRUCTURE 5%
v TECHNICAL EXPERTISE 5%
vi STAFF BEHAVIOUR 5%
vii HANDLING OF COMPLAINTS 5%
RESPONSIBILITIES
In - House
Fabricate in – house M.P. - I
To the assigned section or Buy Decision
/ person
Buy
1. Send Inquiries to suppliers from the ASL[ QD / 13 ] for the existing product PURCHASE ASST.
Float
Headfresh
[ Admn.]
inquiries to M.P. - II
Assess quotations for technicality
other & commrrcial terms & select
suppliers supplier
from ASL
Supplier
Send P.O. to the supplier PURCHASE ASST.
[ cont. in
page 2 ]
Supplier
Expediting, surveillance
Retain status
Verify Annually
of ASL
conformance $ Evaluate
[ QD / 13 ]
Supplier
Compliment
Performance
Supplier *
[ QF /
26 ]@
Vide NonConformance Control Accep NOT OK
Procedure [ QM 18 ] NO t
Delete from Approved
Supplier List [ QD / 13 ]
Warn Supplier*
YES
NOTE :
1. SUPPLIERS OF MATERIALS
2. 2. 2.
2. 2. 2.
C. FASTNERS
1. 1. 1.
2. 2. 2.
D. GASKETS
1. 1. 1.
2. 2. 2.
E. FLANGES
1. 1. 1.
2. 2. 2.
F. WELDING RODS
1. 1. 1.
2. 2. 2.
G. FORGINGS
1. 1. 1.
2. 2. 2.
H. CASTINGS
1. 1. 1.
2. 2. 2.
2. SERVICE PROVIDERS
B SAND BLASTING
1.
2.
3.
C HEAT TREATMENT
1.
2.
3.
D COLD FORMING
1.
2.
3.
E MACHINING / DRILLING
1.
2.
3.
F PAINTING
1.
2.
3.
*NOTE :
CLASS A : ISO 9000 CERTIFIED & DEMONSTRATED CAPABILITY.
[ The Organisation has done business with the Supplier before for a long time ]
CLASS B : DEMONSTRATED CAPABILITY.
[ The Organisation has done business with the Supplier for a long time though the Supplier is not ISO 9001 certified ]
CLASS C : CAPABLE WITH ADDITIONAL ASSURANCE.
[ First time Supplier – need to impose certain requirements for confidence ]
CLASS D : UNACCEPTABLE PERFORMANCE , BUT CAN’T BE AVOIDED. NEEDS CONSTANT MONITORING.
[ Sole Supplier of the product / service ]
S.N. STAGES OF THE DESIGN AND DEVELOPMENT TIME PERIOD RESPONSIBLE REMARKS
PROCESS FUNCTION
3 SENDING THE COMPLETE DESIGN INPUTS WITHIN 2 DAYS AFTER THE M.P. - I
TO THE DESIGNER [ OUTSOURCING ] FOR THE ABOVE REVIEW
DESIGN & SUBMISSION OF THE DRAWINGS.
4 REVIEWING THE DRAWINGS AND CALCULATIONS WITHIN 2 DAYS OF RECEIPT Q.C. I/C &
RECEIVED FROM THE DESIGNER. FROM THE DESIGNER M.P. - I
5 SENDING THE DRAWINGS AND CALCULATIONS TO WITHIN 2 DAYS AFTER THE M.P. - I
THE CUSTOMER / THIRD PARTY FOR APPROVAL. ABOVE REVIEW
6 REVIEWING THE CHANGES ( if any ) IN THE WITHIN 2 DAYS AFTER THE M.P. - I
DRAWINGS / CALCULATIONS MADE BY THE RECEIPT OF THE DRAWINGS
CUSTOMER / THIRD PARTY AND SENDING THE SAME FROM THE
TO THE DESIGNER FOR AMMENDMENT. CUSTOMER / THIRD PARTY
MATERIAL UNLOADING
FOLLOW
NONCONFORMING MATERIAL APPROVED
PROCEDURE
TAKE IN STORE STOCK
FOLLOW
NONCONFORMING STAGE APPROVED
PROCEDURE
WELDING and OTHER APPLICABLE OPERATIONS
FOLLOW
NONCONFORMING APPROVED
PROCEDURE
COMPLETE FABRICATION
FINAL INSPECTION, PRESSURE TEST, RUNNING TRIAL [ as applicable ] BY CUSTOMER or THIRD PARTY
RECTIFY AND
RETEST TO
ORIGINAL FINAL APPROVAL
SPECIFICATION
NOTE : QUALITY ASSURANCE PLAN SPECIFIC TO THE INDIVIDUAL JOB, IF REQUIRED , IS ALSO PREPARED AND
FOLLOWED IN CONSULTATION WITH THE INDIVIDUAL CUSTOMER .
AKPEAF have the following equipments on which its process capabilities depend
and makes all arrangements for upkeepment of these equipments :
1.
2..
3.
1.
2..
3.
1.
2..
3.
1.
2..
3.
1.
2..
3.
1.
2..
3.
1.
2..
3.
10
11
12
NOTE :
1. THE Q.C. I/C GETS THE MEASURING EQUIPMENTS CALIBRATED ON SCHEDULE AND MAINTAINS THE
CALIBRATION CERTIFICATES.
2. * MEASURING EQUIPMENTS WHICH ARE NOT RELATED TO PRODUCT / PROCESS MEASUREMENTS &
SAFETY ARE NOT REQUIRED TO BE CALIBRATED.
3. # VIDE FORM NO. QF/ 53 – CALIBRATION CARD OF MEASURING EQUIPMENTS.
1 HOISTS 1. 1. 1. 1. 1.
2. 2. 2. 2. 2.
3 3 3 3 3
3 AIR RECEIVERS 1. 1. 1. 1. 1.
FOR
COMPRESSORS 2. 2. 2. 2. 2.
3 3 3 3 3
4 CHAIN PULLEY 1. 1. 1. 1. 1.
BLOCKS
2. 2. 2. 2. 2.
3 3 3 3 3
5 SLINGS 1. 1. 1. 1. 1.
2. 2. 2. 2. 2.
3 3 3 3 3
NOTE : THE M.P. - I ARRANGES FOR THE CALIBRATION OF THE ABOVE EQUIPMENTS FROM THE COMPETENT
AUTHORITIES.
3. 3. 3. 3.
.
NOTE : M.P – I ARRANGES FOR THE CALIBRATION FROM THE APPROVED SERVICE PROVIDERS.
1 ELECTRODES
2 GRINDING WHEELS
3 FASTNERS
VEE BELTS
ELECTRODES
PAINTS
CHEMICALS FOR
LIQUID PENETRANT
TES
CHEMICALS FOR
LIQUID PENETRANT
TESTS
NOTE : 1. THE EXPIRY DATES ARE PUT ON THE LABELS OF ALL ITEMS HAVING LIMITED SHELF LIVES.
2. REVALIDATING THE SHELF LIVES AFTER THE EXPIRY DATE IS DONE BY A COMPETENT PERSON.
ACTIVITY
PREPARE BUSINESS PLAN & SET BUSINESS TURNOVER TARGET FOR THE SUBSEQUENT M.P. - II
FINANCIAL YEAR IN THE MONTH OF MARCH EACH YEAR [ Vide Format No. QF / 03 ]
ENTER VALUES OF THE MONTHWISE BUSINESS EXECUTED FOR THE REFERRED ACCOUNTANT
FINANCIAL YEAR IN DESIGNATED FORMAT [ Vide Format No. QF / 03 ]
M.P. - II
QUARTERLY REVIEW OF THE BUSINESS PERFORMANCE
NOT O.K.
REVIEW YEARLY PERFORMANCE AGAINST THE SET TARGET AND ANALYSE M.P. - I
Prepared by M.R. Approved by M. P. - I
RPS : PK :
AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]
THE M.P. - I IS RESPONSIBLE FOR ALL OUTSOURCING ACTIVITIES. HE REVIEWS ALL OUTSOURCING CONTRACTS
PRIOR TO THEIR RELEASE.
A. QUALITY OBJECTIVE : TO ACHIEVE ATLEAST 90% FOR ‘SUCCESS RATE’ FOR ‘ON TIME DELIVERY’ OF THE
CONTRACTED GOODS TO OUR CUSTOMERS FOR THIS FINANCIAL YEAR.
1 ESTABLISH BASE LEVEL OF THE DELIVERY ‘SUCCESS RATE’ ACHIEVED IN LAST M.R
FINANCIAL YEAR
2 ESTABLISH THE MAIN REASONS FOR DELAYS IN DELIVERY IN THE LAST FINANCIAL M.R
YEAR
3 CONDUCT MEETINGS WITH THE CONCERNED SECTIONAL I/Cs – M.R, PRODUCTION I/C , M.P. - I
Q.C. I/C TO DISCUSS THE DELAYS AND ESTABLISH A CORRECTIVE / PREVENTIVE PLAN
4 MINUTE THE MEETINGS AND SEND TO THE CONCERNED INCHARGES M.R
5 TAKE THE NECESSARY ACTIONS CONCERNED I/C
6 RECORD THE DELIVERIES IN FORM NO. QF / 02 DESPATCH I/C
7 CONDUCT MEETINGS WITH THE CONCERNED SECTIONAL I/Cs EVERY QUARTER M.R, M.P. - I
PRODUCTION I/C , Q.C. I/C TO ANALYSE AND MAKE MID – COURSE CORRECTIONS
[ IF REQD ]
8 MINUTE THE MEETINGS AND SEND TO THE CONCERNED INCHARGES M.R.
9 TAKE THE NECESSARY ACTIONS CONCERNED I/C
10 EVALUATE ON A QUARTERLY BASIS WHETHER THE TARGET FOR THE OBJECTIVE HAS M.R.
BEEN MET
11 PRESENT AT THE SUSEQUENT MRM M.R.
12 REVIEW TARGET FOR THE OBJECTIVE M.P. - I
E. ACTION PLAN START DATE : 01/ 05/ 09 ACTION PLAN DEADLINE : 31/ 03/ 10
M.R. M.P. - I
DATE : M.P. - I :
A. RESOURCE ALLOCATION :
B. PROCESS OBJECTIVE : TO INCREASE BUSINESS TURNOVER BY ATLEAST 10% EACH YEAR OVER THE
PREVIOUS FINANCIAL YEAR.
D. EVALUATION PROCEDURE :
THE M.P. - II WILL EVALUATE THE TARGET DEADLINES ON A QUARTERLY BASIS. APPROPRIATE CORRECTIVE /
PREVENTIVE ACTION WILL BE TAKEN AFTER ANALYSING THE ROOT CAUSE.
E. TRAINING REQUIREMENTS :
F. ACTION PLAN START DATE : 01/ 05/ 09 ACTION PLAN DEADLINE : 31/ 03/ 10
M.R. M.P. - II
DATE : EVALUATOR :
A. RESOURCE ALLOCATION :
B. PROCESS OBJECTIVE : TO ENHANCE THE SATISFACTION LEVEL OF OUR CUSTOMERS BY INCREASING THE
CUSTOMER SATISFACTION INDEX [ C.S.I. ] BY ATLEAST 1. 0 % OVER THE BASE LEVEL
ESTABLISHED FOR THE PREVIOUS YEAR.
D. EVALUATION PROCEDURE :
THE M.R WILL REGULARLY EVALUATE ALL TARGETS ON A MONTHLY BASIS. NONCONFORMANCE WITH RESPECT
TO THE ACTION PLAN WILL BE REPORTED TO THE M.P. - I WHO WILL TAKE THE APPROPRIATE CORRECTIVE /
PREVENTIVE ACTION.
E. TRAINING REQUIREMENTS : TO TRAIN THE MARKETING / FIELD STAFF TO APPROPRIATELY CAPTURE THE
CUSTOMER REQUIREMENTS.
F. ACTION PLAN START DATE : 01/ 05/ 09 ACTION PLAN DEADLINE : 31/ 03/ 10
M.R. M.P. - I
Prepared by M.R. Approved by M. P. - I
RPS : PK :
AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]
DATE : EVALUATOR :
A. RESOURCE ALLOCATION :
B. PROCESS OBJECTIVE : TO IMPART ATLEAST 12 HOURS OF TRAINING PER YEAR TO EACH PERMANENT
EMPLOYEE DOING QUALITY RELATED WORK, TO RETAIN / ENHANCE THE EMPLOYEE’S
COMPETENCY LEVEL ON THE JOB.
D. EVALUATION PROCEDURE :
THE M.R WILL REGULARLY EVALUATE ALL TARGETS ON A QUARTERLY BASIS. NONCONFORMANCE WITH
RESPECT TO THE ACTION PLAN WILL BE REPORTED TO THE M.P. - I WHO WILL TAKE THE APPROPRIATE
CORRECTIVE / PREVENTIVE ACTION.
F. ACTION PLAN START DATE : 15/ 06/ 09 ACTION PLAN DEADLINE : 31/ 03/ 10
M.R. M.P. - I
DATE : EVALUATOR :
A. RESOURCE ALLOCATION :
B. PROCESS OBJECTIVE : TO MAINTAIN AND CONTINUALLY REDUCE FIRST – TIME REJECTION .[ RATIO OF THE
NO. OF REWORKS / REJECTIONS TO THE NUMBER OF IN – HOUSE INSPECTIONS
CARRIED OUT ] LEVELS TO LESS THAN 1.0 % DURING THE
IN – PROCESS FABRICATIONS.
D. EVALUATION PROCEDURE :
THE M.R WILL REGULARLY EVALUATE ALL TARGETS ON A QUARTERLY BASIS. NONCONFORMANCE WITH
RESPECT TO THE ACTION PLAN WILL BE REPORTED TO THE M.P. - I WHO WILL TAKE THE APPROPRIATE
CORRECTIVE / PREVENTIVE ACTION.
F. ACTION PLAN START DATE : 15/ 06/ 09 ACTION PLAN DEADLINE : 31/ 03/ 10
M.R. M.P. - I
DATE : EVALUATOR :