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Preparing A Quality Manual: Guide
Preparing A Quality Manual: Guide
NABL
NATIONAL ACCREDITATION
BOARD FOR TESTING AND
CALIBRATION LABORATORIES
GUIDE
for PREPARING
A QUALITY MANUAL
10
Amendment sheet 1
Contents 2
1. Introduction 3
2. Process for preparing a Quality Manual 4
3. Structure and format of Quality Manual 7
4. Management Requirements 18
4.1 Organisation 18
4.2 Management system 21
4.3 Document control 24
4.4 Review of requests, tenders and contracts 26
4.5 Subcontracting of tests and calibrations 27
4.6 Purchasing, services and supplies 28
4.7 Service to the customer 29
4.8 Complaints 30
4.9 Control of nonconforming testing and/ or calibration work 31
4.10 Improvements 32
4.11 Corrective action 33
4.12 Preventive action 34
4.13 Control of records 35
4.14 Internal audit 36
4.15 Management review 38
5. Technical Requirements 40
5.1 General 40
5.2 Personnel 41
5.3 Accommodation and environmental conditions 43
5.4 Test and calibration methods and method validation 45
5.5 Equipment 49
5.6 Measurement traceability and calibration 51
5.7 Sampling 54
5.8 Handling of calibration and test items 55
5.9 Assuring the quality of test and calibration results 56
5.10 Reporting the results 58
For preparing the Quality Manual, the laboratory may also get its technical
personnel trained in NABL’s training program on management system for
laboratory personnel. A calendar of such training courses is regularly
published in the NABL News/ web-site.
Quality
Manual
(Level A)
Management system
Procedures
(Level B)
After these pages, should place the section on ‘Quality Policy and
Objectives’ of the laboratory. The Quality Policy is required to be stated
under clause 4.2 of management requirements. It is preferred that it is
placed after the introductory pages, since this is the basic objective, the
laboratory’s management system is designed to meet. The remaining
sections of the Quality Manual should describe all applicable elements of
the ISO/IEC 17025 or ISO 15189. The description of these sections of the
Quality Manual should be in a sequence similar to that of ISO/IEC 17025
or ISO 15189, as applicable. Other sequencing or cross-referencing, as
appropriate to the laboratory, is acceptable.
Title
The title of the Quality Manual should clearly indicate the name of the
laboratory to which the manual belongs. It should also indicate the issue
number, issue date, holders name and the copy number. A typical ‘title
page’ is shown at page 11.
Release Authorisation
Table of contents
The table of contents of a Quality Manual should show the titles of the
sections within it and how they can be located. The numbering system of
sections, subsections, pages, figures, exhibits, diagrams, tables, etc.,
should be clear and logical. A typical ‘table of contents’ is shown at
page 14.
This section of the Quality Manual should clearly mention the compliance
to the applicable standard(s) and NABL documents. It should also define
the field(s)/ discipline(s)/ area(s) and the section(s)/ division(s)
department(s) of the laboratory, to which the Quality Manual is applicable.
To ensure clarity and avoid confusion, the use of disclaimers (eg. what is
not covered by the Quality Manual and situations where it should not be
applied) may also be mentioned.
Use of references
Definitions
Abbreviations
Introduction
The minimum information about the laboratory should be its name, site,
location and means of communication. Additional information about the
laboratory, such as its line of business, a brief description of its
background, history or size, may also be included.
The subsequent sections of the Quality Manual should describe all the
elements of the ISO/IEC 17025 or ISO 15189 as applicable.
All documents which are maintained by the laboratory and the records &
forms, which are used by the laboratory should be listed in these sections.
These must find reference in the Quality Manual or the associated
document.
Page Footer
Page footer shows the Issue status, amendment status, page no. etc. As
and when the manual is amended, the relevant pages where amendment
takes place are replaced by new pages and is cross referred in the
amendment record. A typical ‘amendment record’ is shown at page 13. It
also gives the copy number. As and when each holder is issued a Quality
Manual, a copy no. is allotted to him/ her and this is indicated in the
distribution record, page 15. The signatures of the persons/ position who
have prepared, approved and issued the Quality Manual are also placed in
the page footer.
The title page of the Quality Manual should normally contain the following:
QUALITY MANUAL
of
Issue No. :
Issue Date :
Copy No. :
Holder’s Name :
Immediately after the title page, this page should be placed. A typical authorization
should normally contain the following:
RELEASE AUTHORISATION
Name of Laboratory:
Document No.: Document Name: Quality Manual
Issue No.: Issue Date: Copy No.: Section No. Page No.:
Amend No.: Amend Date Prepared by: Approved by: Issued by:
An amendment page should be inserted immediately after the title page. Specific
instructions to each holder of the Quality Manual as to the amendment procedure to
be followed to maintain each copy upto date should be included. To ensure that
each copy of the Quality Manual contains a complete record of amendments, this
amendment page should be updated and issued with each set of amended/ new
pages of the Quality Manual.
AMENDMENT RECORD
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Name of Laboratory:
Document No.: Document Name: Quality Manual
Issue No.: Issue Date: Copy No.: Section No. Page No.:
Amend No.: Amend Date Prepared by: Approved by: Issued by:
For the ease of reference, the manual should contain a table of contents listing the
major sections, sub-sections and their page numbers. A list of the Annexures should
also be included.
CONTENTS
Management Requirements
Organisation
Management system
Document Control
Technical Requirements
General
Personnel
Name of Laboratory:
Document No.: Document Name: Quality Manual
Issue No.: Issue Date: Copy No.: Section No. Page No.:
Amend No.: Amend Date Prepared by: Approved by: Issued by:
The distribution record should list the holders of the controlled copies of Quality
Manual with their allotted copy numbers. Copies of Quality Manual distributed as
uncontrolled copies, should not be listed.
DISTRIBUTION LIST
The following are the authorised holders of the controlled copy of Quality Manual.
Name of Laboratory:
Document No.: Document Name: Quality Manual
Issue No.: Issue Date: Copy No.: Section No. Page No.:
Amend No.: Amend Date Prepared by: Approved by: Issued by:
4.1 Organisation
4.1.1 Give the name, address, type of corporate structure and whether or not an
affiliate of a larger organisation and any other information required to
identify the laboratory, including its legal status, such as Government, a
registered society or under company’s act. The date of incorporation may
also be mentioned.
4.1.2 The laboratory shall make a compliance statement that it carries out its
testing/ calibration activities in accordance with the requirements of
ISO/IEC 17025:2005, the needs of its customer, the regulatory authorities
or the organisations providing recognition, at all times. The names and
details of the regulatory bodies and the organisations providing recognition
may also be mentioned.
4.1.3 Describe the laboratory and its operations to convey a true picture of the
organisation such as location, size, whether permanent/ part of
permanent/ independent site/ mobile, branches, type of services offered,
major fields of activity etc.
4.1.4 If the laboratory is a part of larger organisation which also performs other
activities, other than testing and/ or calibration, the responsibility of the
key personnel in the organisation that have an involvement or influence on
the testing and/ or calibration activities such as production, commercial,
marketing or finance shall be clearly defined in order to identify the
potential conflict of interest with the laboratory personnel, which might
adversely effect the judgement & integrity of staff and quality of work.
Also include a statement that the Quality Manager has direct access
to the highest level of management at which decisions are made for
laboratory policy and resources, commensurate with the organisation
chart.
4.2.1 General
The Quality Manual of a laboratory is the basic document to describe its management
system. Associated documents like operating procedures, work instructions, forms,
report etc. also form a part of the management system. The management system of the
laboratory need not be complex. Much will depend on the size of the laboratory and the
scope of testing/ calibration requiring accreditation.
The quality policy statement should be concise and may include the requirement that
tests and/ or calibrations shall always be carried out in accordance with stated methods
and customers requirements. It may also include that the laboratory gives emphasis in
producing reliable and accurate tests and/ or calibration results. When test and/ or
calibration laboratory is part of a larger organisation, some quality policy elements may
be in other documents.
Generally the responsibilities of key personnel are defined in Quality Manual and others
having different responsibilities within the management system at appropriate position,
in the second/ third level of documentation.
4.2.7 Describe arrangements that top management ensures that the integrity of
the management system is maintained when changes to the management
system are planned and implemented.
4.3.1 General
All documents generated by the laboratory shall be uniquely identified, which shall
include document number, issue number, date of issue, amendment/ revision number,
date of amendment/ revision, page numbering, total number of pages, approving
authority and issuing authority.
Procedure
Responsibility
Procedure
The laboratory shall state the procedure to identify the altered or new text,
in the amended document.
Policy with respect to all above may be given in Quality Manual and the actual process
may be covered in a separate procedure referred in the Quality Manual.
Responsibility
Policy
State the laboratory’s policy for the review of requests, tenders and
contracts including subcontracted work.
Responsibility
Procedure
Briefly outline the procedure for review of requests and tenders which
shall include:
a defining, documenting and understanding customer requirements
before commencing work
b assessment of laboratory’s capability and resources
c appropriate method selection
d work that is subcontracted by the laboratory.
The details of how the review is actually done, may be covered separately
in a procedure cross referred herein.
Records
Policy
Responsibility
Procedure
Records
Policy
State the laboratory’s policy for purchasing, services and supplies which
affect the quality of test and/ or calibration.
Responsibility
Procedure
Briefly outline the procedure for the selection and purchase of services
and supplies, evaluation of suppliers of critical items, receipt and storage
of reagents/ consumables, inspection & verification.
Also briefly outline the procedure for review and approval of purchase
documents for technical contents. The actual process may be covered in
separate procedure cross referred in the Quality Manual.
The description in the purchase document may include types, class, grade, precise
identification, specification, drawings, inspection instructions, other technical data
including approval of test results, the quality required and the management system
standard under which they were made.
Records
Policy
State the laboratory’s policy for service to the customer. The policy may
address to the following:
a maintenance of good communication
b to clarify their request
c monitor the laboratory’s performance in relation to the work
performed
d provide reasonable access to relevant areas of the laboratory for the
witnessing of test(s)/ calibration(s) performed for the customer
e preparation, packaging and despatch of test(s)/ calibration(s) items
f advice and guidance in technical matters
g opinion and interpretation based on results
h to maintain confidentiality to other customers during the monitoring
i delays or major deviations in the performance of test(s)/
calibration(s).
Responsibility
The person(s)/ position responsible for authorising the customers for these
services, if required shall be identified.
Procedure
Briefly outline the procedure for implementation. It may also include the
procedure for obtaining feedback from the customers on laboratory’s
quality of services. The actual process may be documented separately and
cross referred in the Quality Manual.
Records
Policy
Responsibility
Procedure
Records
Policy
Responsibility
Procedure
Records
Policy
The policy may include use of quality policy, quality objectives, audit
results, analysis of data, corrective and preventive actions and
management reviews.
Responsibility
Procedure
Records
Policy
Responsibility
Procedure
Briefly outline the procedure for implementing corrective action which shall
include:
a sources of information for identification of problems
b cause analysis
c selection and implementation of corrective actions
d monitoring of corrective actions
e additional audits where non-conformities/ departures cast doubt.
Records
Policy
Responsibility
The person(s)/ position responsible for taking preventive actions shall be
identified.
Procedure
Briefly outline the procedure for preventive action and action plan to
implement & monitor to reduce the likelihood of the occurrence of non-
conformities.
The procedure for preventive action shall include initiation of such actions
and application of controls to ensure they are effective.
Records
Make a reference to the document, where the records are maintained.
Records of identification of potential sources of non-conformities, investigations carried
out, required improvements and preventive measures taken shall be maintained.
Policy
Scope
List all quality and technical records maintained by the laboratory and give
a unique identification record number.
Responsibility
Procedure
Briefly describe the procedure for control and time period for retention of
records, especially the test and/ or calibration worksheet, raw data and
test report/ calibration certificate.
Policy
Scope
Responsibility
Procedure
Briefly outline the procedure for conduct of internal audit. The procedure
shall take account of:
a the frequency of conducting the internal audit at regular intervals
b training and qualification criteria of personnel conducting the internal
audit, that they are independent of the activity to be audited to the
extent possible.
The procedure shall also include the procedure for the corrective action(s)
to be taken and its verification including notifying customers in writing, if
the findings of internal audit cast doubt on the effectiveness of operations
or on the correctness/ validity of test and/ or calibration results. The
detailed process may be covered in a separate procedure cross referred in
the Quality Manual.
Policy
It is expected that the top management (chief executive) of the laboratory who has the
executive responsibility for running the laboratory, undertakes the management review.
The members of senior management having overall responsibility for design and
implementation of laboratory’s management system for the Technical Management, may
also be involved in the management review.
Scope
State the activities, the Management Review shall take account of,
however they should not be limited to the following:
a the suitability of policies and procedures
b reports from managerial and supervisory personnel
c the outcome of recent internal audits
d corrective and preventive actions
e assessments by external bodies
f the results of inter-laboratory comparisons or proficiency testing
g changes in the volume and type of the work
h customer feedback
i complaints
j recommendations for improvement
k other relevant factors, such as quality control activities, resources
and staff training.
Responsibility
The procedure shall also include that any action identified during the
review, is implemented within the agreed time limit. The detailed
processes may be covered in a separate procedure cross referred in the
Quality Manual.
Records
5.1 General
State the factors that determine the correctness and reliability of the tests/
calibrations performed by the laboratory. These factors should not be
limited to:
a human factors
b accommodation and environmental conditions
c test and calibration methods and method validation
d equipment
e measurement traceability
f sampling
g the handling of test and calibration items.
The laboratory shall take account of the factors in developing the test and/ or calibration
methods and procedures, in the training and qualification of personnel and in the
selection and calibration of the equipment it uses.
Policy
Job Description
Provide job description of the laboratory staff which shall include atleast
the following:
a name
b qualification
c training attended
d management duties
e expertise
f responsibilities
g further expertise/ training required.
This data may be maintained by the personnel department and be also annexed with the
procedural manual of relevant sections.
Supervision of Personnel
Describe the procedure for identifying the training needs and providing
training of personnel, relevant to the present and anticipated tasks of the
laboratory. A procedure for assessing the competence/ skills of the
personnel should also be described.
Also describe the evaluation procedure for the effectiveness of the training
actions taken.
The details of the training and assessment program of each section may be contained in
the Training Manual of that section. Each sectional laboratory manager may be
responsible to maintain the manual and plan the training schedule of his section to
satisfy these requirements.
Records
Accommodation
Environmental Conditions
Records
Policy
State laboratory’s policy with respect to selecting any particular test and/
or calibration method i.e. whether prescribed in national or international
standards, published in reputed journals, text books, equipment
operational manuals or laboratory developed methods etc. to meet the
customer’s requirements.
The methods published in national or international standards with latest valid edition
shall be used. Methods published in journals, text books, equipment manuals and
laboratory developed methods or non-standard methods suggested by the customer,
shall be validated.
- checks that the equipment is working properly and, where required, calibration
and adjustment of the equipment before each use
- the method of recording the observations and results
Procedure Manuals
Standard Specifications
State the laboratory’s policy for referring to latest standards as the basis
for test and/ or calibration methods, whenever possible.
One or combination of the following techniques may be used for the determination of
performance of a method.
a calibration using reference standards or reference materials
b comparison of results achieved with other methods
c Inter-laboratory comparisons
d systematic assessment of the factors influencing the result
e assessment of the uncertainty of the results based on scientific understanding of
the theoretical principals of the method and practical experience
f any other technique.
For calibration laboratories and testing laboratories performing their own calibrations
shall estimate the uncertainty of measurement for all calibrations and types/ range of
calibrations.
For testing laboratories availing the services from calibration laboratories, shall identify
all the components of uncertainty and make a reasonable estimation for all test
parameters, and shall ensure that the form of reporting of the result does not give a
wrong impression of the uncertainty. The degree of rigor needed in an estimation of
uncertainty of measurement depends on the requirements of test method, requirements
of customer and the existence of narrow limits on which decisions on conformance to a
specification are based.
Describe the arrangement to ensure that all data transfer are subjected to
appropriate checking by responsible staff.
Policy
The laboratory shall confirm that all equipment under the control of
laboratory requiring calibration are identified and labeled to indicate the
status of calibration, date of last calibration and date of next calibration.
Describe the procedure for safe handling, transport, storage, use and
planned maintenance of measuring equipment to ensure proper
functioning and prevent contamination or deterioration.
Equipment Records
The records for authorization of the technical staff for handling/ operating the
equipments shall also be maintained.
The laboratory shall also maintain records of all test and/ or calibration equipment,
reference standards and reference materials requiring calibration which shall atleast
include equipment name, calibration status, date of the calibration and due date of next
calibration.
For chemical reference materials, the expiry date should be indicated. A record of their
usage should be included.
Policy
Calibration program
Responsibility
Briefly outline the laboratory’s plan and procedures for sampling, when
sampling of substances, materials or products for subsequent testing, is
the responsibilities of the laboratory. The procedure should include the
selection, sampling plan, withdrawal and preparation of a sample to yield
required information.
If customer requires deviation for documented sampling procedures, thus two shall be
recorded and included in all documents containing test and/ or calibration results.
Records
Policy
Procedure
Records
Policy
State the laboratory’s policy for assuring the quality of test and calibration
results.
The monitoring shall be planned & reviewed and shall include, but not limited to the
following:
a regular use of certified reference materials and/ or internal quality control using
secondary reference materials
b participation in inter-laboratory comparison or proficiency testing program
c replicate tests or calibrations using the same or different methods
d retesting or recalibration of retained items
e correlation of results for different characteristics of an item.
It is expected that depending upon the nature of test(s) and/ or calibration(s) performed
and volume of work undertaken, one or more of the above measures shall be practiced.
Responsibility
Designate the person(s)/ position responsible for coordinating the
verification practices. Specify the management person responsible for
reviewing the results and deciding on the appropriate investigation and
corrective action.
All NABL accredited testing and calibration laboratories are required to participate in
Proficiency Testing Programs conducted by NABL or the nodal organizations appointed
by NABL. Laboratories shall also participate (as far as available and practicable) in
international Inter-laboratory Comparison/ Proficiency Testing Programs conducted by
APLAC, EA or equivalent organizations. NABL shall keep the accredited laboratories
informed about all such international programs through NABL newsletter.
NABL is expected to enforce the requirements of APLAC MRA 001 and accordingly it will
be essential for all its accredited laboratories to demonstrate technical competence of its
accredited laboratories by satisfactory participation in International/ Regional/ National
Proficiency Testing Programs, including APLAC in a manner so that each major sub-
areas of major disciplines of a laboratory’s scope of accreditation are covered in a cycle
of 4 years. This will of course not apply to those special areas where Inter-laboratory
Proficiency Testing Programs are not available.
Records
Policy
The laboratory shall state its policy with respect to reporting of results of
each test or calibration carried out by them so that they are reported
accurately, clearly, unambiguously and objectively and in accordance with
any specific instructions in the test or calibration methods.
A standard format may be used by the laboratory, which contains atleast the following
information:
a a title (eg. “Test Report” or “Calibration Certificate”)
b the name and address of the laboratory, and the location where the tests and/ or
calibrations were carried out, if different from the address of the laboratory
c unique identification of the test report or calibration (such as the serial number),
and on each page an identification in order to ensure that the page is recognized
as a part of the test report or calibration certificate, and a clear identification of
the end of the test report or calibration certificate
d the name and address of the customer
e identification of he method used
f a description of, the condition of, and unambiguous identification of the item(s)
tested or calibrated
g the date of receipt of the test or calibration item(s) where this is the validity and
application of the results, and the date(s) of performance of the test or calibration
h reference to the sampling plan and procedures used by the laboratory or other
bodies where these are relevant to the validity or application of the results
i the test or calibration results with, where appropriate, the units of measurement
j the name(s), function(s) and signature(s) or equivalent identification of person(s)
authorizing the test report or calibration certificate
k where relevant, a statement to the effect that the results relate only to the items
tested or calibrated.
In addition to the above any other information as stated in ISO/IEC 17025:2005 clause
5.10.3 and 5.10.4, as relevant may also be contained in the test report/ calibration
certificates.
In case of internal customer or written agreement with the customer, the format may be
made short. However any requirement not reported to customer shall be readily available
in the laboratory.
State the policy of the laboratory to notify to its customer, of any event
that cast doubt on the validity of issued results. Also the procedure for
issuing the amended or supplementary reports/ certificates shall be stated.