STANDARD OPERATING PROCEDURE

ISO CLAUSE: 8.6 PROCEDURE FOR QUALITY ASSURANCE

Doc No: SA-QA-SOP-01 Revision No: 04 Effective date: 10-May 2021 Page 1 of 6

1.0 OBJECTIVES:
This procedure defines the methodology to be followed to ensure that the inspection and testing
activities are carried out in order to verify that the dimensions, functional requirements and aesthetics of
products as per the drawing / Quality plan and where applicable to specific customer requirements are met
and required records of inspection and testing are maintained which provide evidence that the
product has been inspected and / or tested

2.0 SCOPE:
The procedure adopted is applicable to the following activities.
 Receiving inspection
 In-process inspection
 Final inspection and testing
 Control of non conforming product (described in each inspection stage)
 Sampling
 Analysis of data

3.0 RESPONSIBILITY:
Dept. Head Quality / Section In charge/ Engineers – inspection &Testing

4.0 METHODOLOGY:
4.1 Procedure for receiving inspection by Extrusion Plant.
4.1.1 The incoming materials received from supplier such as raw materials, components and job
work items after verification by Stores with identification tag
4.1.2 As and when information received from Stores through ICR (mail) / SRN, Check the physical condition of
materials (visual, receiving condition), material test certificate
4.1.3 For raw materials like ingots, billets etc. verification of material test certificate issued by manufacturer and
analysis of chemistry using spectrometer as per the quality assurance plan.
4.1.4 In case of aluminum ingots, analysis details are given to foundry for taking decision on acceptability of raw
material. If the chemical composition is completely out of specification, then the material shall be rejected
and send back to vendor.
4.1.5 If the chemical composition is closed to the specification but out of tolerance, this may be accepted based
on the deviation authorization from the designated authority – VP-QA.
4.1.6 The extrusion tools and dies which are made by tool manufacturer are inspected by tool room department
after checking it thoroughly as per tool drawings.
4.1.7 The other consumable items are checked by the respective department heads and accepted accordingly.

Prepared by: Approved by:

Date: 10-MAY -2021 Date: 10-MAY -2021
 STANDARD OPERATING PROCEDURE
ISO CLAUSE: 8.6 PROCEDURE FOR QUALITY ASSURANCE

Doc No: SA-QA-SOP-01 Revision No: 04 Effective date: 10-May 2021 Page 2 of 6

4.2 Procedure for receiving inspection by Ladders / Scaffolding / Lifts manufacturing unit.
4.2.1 QA shall carry out inspection as per Drawing / Specification / Quality plan. If required raw material tested as
per requirement / procedure
4.2.2 Verify the material test certificates as per requirement
4.2.3 If the material is OK, put the green tag for accepted material and clear the SRN.
4.2.4 If the material is found dimensionally not OK, give the information to supplier through purchase dept. or with
Supplier non conformity report and take corrective actions from the supplier.
4.2.5 Put the rejected tag for rejected material (after sorting) and clear the SRN.
4.2.6 Ensure all rejected materials with Red tag and handover to stores with proper identified.
4.2.7 On minor nonconformity items, deviation will be taken by concern departments with Approval authority,
accept the material and maintain deviation record
4.2.8 Put the deviation tag for deviation material and clear the SRN and related reports.
4.2.9 In a special case/ wherever required , QA will verify the product as per drawing at supplier premises
4.2.10 The list of items and the verification mechanism i.e., MTC requirement and inspection report requirement
etc. has been addressed in Annexure 1

4.3 Procedure for Incoming Material Inspection – Sampling. (New/Development Products).

4.3.1 Receive the samples (new/development products) from stores.
4.3.2 Collect the drawings /Specifications/Master samples from the Design department.
4.3.3 Check the new development samples as per the given specification and drawing.
4.3.4 Prepare FAI report as per drawing.
4.3.5 Hand over the samples and report to concerned departments.
4.3.6 If any deviation observed informed to supplier with inspection report through purchase department for to
take necessary corrective action

4.4 Procedure for in-process inspection of extruded profile.

4.4.1 The profiles are checked for dimensional and physical properties, as per the sampling plan and the results
are recorded in the dimensional / test report.
4.4.2 The physical properties like hardness, UTS, % elongation etc. are checked as per work instructions and the
results are recorded in the test report.
4.4.3 If the dimensions are not OK as per the drawing, then the extrusion press will be stopped till the corrective
action is taken for the die to maintain the dimensions.
4.4.4 The process parameters are recorded by the production operator in the log book as per the defined
frequency.
4.4.5 After ageing, the mechanical properties like hardness and UTS etc. are to be checked and recorded in the
test report.

Prepared by: Approved by:

Date: 10-MAY -2021 Date: 10-MAY -2021
 STANDARD OPERATING PROCEDURE
ISO CLAUSE: 8.6 PROCEDURE FOR QUALITY ASSURANCE

Doc No: SA-QA-SOP-01 Revision No: 04 Effective date: 10-May 2021 Page 3 of 6

4.5 Procedure for In-process (sub-assembly) inspection.

4.5.1 Receive the material from production as per sampling plan/frequency mentioned in quality plan for in-
process inspection.
4.5.2 In-process inspection is carried out by QA to check the conformance to specified requirements during
manufacturing operations at critical stages
4.5.3 While Process setting samples to be checked as per specification/ quality plan, if samples found ok, give the
clearance for production.
4.5.4 If the inspected samples not ok, analyze for the root cause and give feedback to production supervisor and
get the rectification done
4.5.5 Patrol inspection is carried out at regular intervals and inspect the various stages
4.5.6 During inspection in regular intervals any variations found affecting the Quality, QA personnel informs
the concerned production supervisor who in-turn study the problem and take necessary corrective action.
4.5.7 Check the sub-assembly as per the drawing & Check functionality.
4.5.8 Ensure that defined procedures for manufacturing are being followed at all stages of production/assembly
etc processes.
4.5.9 Where reworks are done by production ensure re inspection is done before material clearance.
4.5.10 In both the above cases record the inspection details in in-process inspection reports wherever required

4.6 Procedure for Final inspection and testing of Extruded Aluminium Profile
4.6.1 The profile dimensions are cross verified after ageing.
4.6.2 Mechanical properties are checked, if necessary as per the quality plan.
4.6.3 If the dimensions / mechanical properties are not meeting the specifications, the material will be kept on
hold and appropriate action is initiated as per the procedure for control of non-conforming outputs.
4.6.4 If the materials are accepted or accepted under deviation, test reports are prepared by QA supervisor as per
the specified format or standard and issued to packing section for delivering product to customer.
4.7 Procedure for Final Inspection and Testing of Ladders, scaffoldings, Lifts.
4.7.1 Offered for final inspection by the respective Production departments with identification.
4.7.2 Check the FG as per the drawing, specifications, work instructions and as per quality plan sample Testing
will be carried out as per required procedures / standards
4.7.3 If the FG is found to be ok, put the QA passed sticker and give the feedback to production.
4.7.4 If the FG is found to be defective then analyze for the root cause and inform to production for necessary
actions.
4.7.5 No product shall be dispatched until the required tests and inspections have been satisfactorily completed
and the necessary reports are available and authorized

Prepared by: Approved by:

Date: 10-MAY -2021 Date: 10-MAY -2021
 STANDARD OPERATING PROCEDURE
ISO CLAUSE: 8.6 PROCEDURE FOR QUALITY ASSURANCE

Doc No: SA-QA-SOP-01 Revision No: 04 Effective date: 10-May 2021 Page 4 of 6

4.7.6 Where it is a specific requirement by customer, finished product samples are offered for third party
inspection
4.7.7 Where reworks are done by production ensure re inspection is done before material clearance.
4.7.8 Conduct functional tests as per defined SOPs and maintain records.
4.7.9 Carryout pre dispatch inspection for lifts as per pre dispatch checklist and ensure proper packing is done /
as per procedure
4.8 SAMPLING
4.9
SNO MATERIAL DESCRIPTION SAMPLING PLAN
1 Raw Material Acceptance is based on visual inspection & TC submitted by the
supplier for all raw materials
Aluminum Extrusions
For Aluminum ingots – Supplier MTC verification with STD
For Aluminum Billets – Supplier MTC - alloy chemical composition
compare with standard – once in a month cross verify with SPECTRO
analysis
2 In-process inspection of Petrol inspection, frequency – everyone hr , samples 8nos per shift /
day
profiles
Aluminum Extrusions : whenever any die changeover happens
Dimensional using measuring instruments as per quality assurance
plan. frequency – 1no / 20billets , Dim report/ Trail dim report –
before and after stretching
Final stage: Mechanical properties using Webster Hardness tester
every ageing charge – record Min / Max Ageing hardness and visual
inspection of profiles
3 All incoming components As per IS 2500 ((Part 1):2000 level 4, AQL= 1.0, Record will be
maintained for maximum of 5 no’s wherever required
4 Packing material Based on fitment trials & Visual checks. No recording done
5 Any other items procured User dept and Head QC will inspect and approve the material based
through special indents on the fitment / usability of the material
6 Capital goods Will be inspected and approved by concerned In-charge
7 Material received after The material will be inspected for visual defects
Anodizing, zinc plating and For Coating thickness ,record will be maintained for maximum of 5
powder coating no’s
Review Supplier inspection report

NOTE:
 If the number of Non-Conforming units found is equal to or less than acceptance number, the lot is consid-
ered as Acceptable.
 If the number of Non-Conforming units is equal to or greater than rejection number, the lot is considered as
Not Acceptable, need based 100% inspection to be done
4.10 ANALYSIS OF DATA

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Date: 10-MAY -2021 Date: 10-MAY -2021
 STANDARD OPERATING PROCEDURE
ISO CLAUSE: 8.6 PROCEDURE FOR QUALITY ASSURANCE

Doc No: SA-QA-SOP-01 Revision No: 04 Effective date: 10-May 2021 Page 5 of 6

4.10.1 Graphical methods such as Pie-chart, Pareto chart, trend analysis, Line chart and Bar chart , process
capability study, that help in analyzing the data to diagnose problems and useful in data based decision
making are prepared and submitted as input data to management / review meetings – above quality tools
shall used on need based at incoming inspection, in-process inspection, final inspection , customer
complaints etc.,
4.11 Gauge R & R for Repeatability and Reproducibility shall conduct Gauge R & R once in 6 months for any
one Critical to Quality parameters in any one of the product.

5.0 REFERENCE DOCUMENTS:

5.1.1 Raw material test reports/certificates.
5.1.2 Measuring Instruments calibration certificates.
5.1.3 Process flow for manufacturing lifts
5.1.4 Process sheet for lifts
5.1.5 Quality Plan for Incoming material inspection for lifts (SA-QA-QP-04)
5.1.6 Quality Plan for In-process material inspection for lifts (SA-QA-QP-05)
5.1.7 Quality Plan for Final inspection for lifts (SA-QA-QP-06)
5.1.8 Procedures for testing lifts (SA-QA-SOP-09 to 13)
5.1.9 Procedures for testing ladders (SA-QA-SOP-03 to 08)
5.1.10 WI for packing lift (SA-PRD-WI-24)
5.1.11 Quality Plan for Incoming material inspection (SA-QA-QP-01)
5.1.12 Quality Plan for In-process material inspection (SA-QA-QP-02)
5.1.13 Quality Plan for Final inspection (SA-QA-QP-03)
5.1.14 Quality Plan for Aluminium Extrusion Ingots, Profiles (SA.E-QA-QAP)
6.0 RECORDS
6.1.1 Incoming material Inspection report (SA-QA-FT-04)
6.1.2 Spectrometer analysis report (SA.E-QA-FT-18)
6.1.3 Dimensional Report (SA.E-QA-FT-03)
6.1.4 Trial Dimensional Report (SA.E-QA-FT-05)
6.1.5 Tool / Die Inspection Report (SA.E-TR-FT-04)
6.1.6 Die Hardness Report (SA.E-TR-FT-15)
6.1.7 Die Correction Report (SA.E-TR-FT-05)
6.1.8 Test Report of Aluminium Profile (SA.E-QA-FT-12)
6.1.9 Final inspection report (SA-QA-FT-05)

Prepared by: Approved by:

Date: 10-MAY -2021 Date: 10-MAY -2021
 STANDARD OPERATING PROCEDURE
ISO CLAUSE: 8.6 PROCEDURE FOR QUALITY ASSURANCE

Doc No: SA-QA-SOP-01 Revision No: 04 Effective date: 10-May 2021 Page 6 of 6

6.1.10 List of Monitoring and Measuring Equipments (SA-QA-FT-06)

6.1.11 Deviation form (SA-QA-FT-07)
6.1.12 Supplier Corrective Action report (SA-QA-FT-08)
6.1.13 Ladder Test Report (SA-QA-FT-09)
6.1.14 Material discrepancy report (SA-QA-FT-10)
6.1.15 Ladder testing log book (SA-QA-Ft-11)
6.1.16 In-process inspection report – lift (SA-QA-FT-12)
6.1.17 Final Inspection Report – Lift (SA-QA-FT-13)
6.1.18 Pre-dispatch checklist for Lift (SA-QA-FT-14)
6.1.19 Lift test report (SA-QA-FT-15)
6.1.20 Accepted Tag (Green) ( Format – Not applicable)
6.1.21 Rejected Tag (Red) ( Format – Not applicable)
6.1.22 Rework Tag (yellow) ( Format – Not applicable)
6.1.23 Next operation tag (Blue) ( Format – Not applicable)
6.1.24 Deviation Tag (orange) ( Format – Not applicable)
6.1.25 Daily Casting Report (SA.E-QA-FT-01)
6.1.26 Raw material Inspection Reports (SA.E-QA-FT-02)
6.1.27 Dimensional Report (SA.E-QA-FT-03)
6.1.28 Shift Inspection Report (SA.E-QA-FT-04)
6.1.29 Trial Dimensional Report (SA.E-QA-FT-05)
6.1.30 Material Status Log Book (SA.E-QA-FT-06)
6.1.31 Aging Plan (SA.E-QA-FT-07)
6.1.32 Aging Report (SA.E-QA-FT-08)
6.1.33 NC and Corrective Action Report (SA.E-QA-FT-09)
6.1.34 Material Tags (SA.E-QA-FT-10)
6.1.35 Customer Complaint Register (SA.E-QA-FT-11)
6.1.36 Test Certificate as per EN 755 and EN 573 (SA.E-QA-FT-12)
6.1.37 Test Certificate as per SB 221 (SA.E-QA-FT-14)
6.1.38 Daily Report (SA.E-QA-FT-16)
6.1.39 Chemical Composition (SA.E-QA-FT-17)

Prepared by: Approved by:

Date: 10-MAY -2021 Date: 10-MAY -2021