Qms Manual

QUALITY SYSTEM MANUAL
VHV/QM/A Rev. 00
This manual and information contained therein is a

sole property of VHV Precision Engineering. It must
not be re-produce in whole or in part of otherwise
disclosed without prior consent in writing from VHV
Precision Engineering.
VHV PRECISION ENGINEERING

Plot No.:- 2523, Kranti Gate, Road-H1,GIDC Lodhika ,
METODA – 360 021. Dist.:- Rajkot , Gujarat-INDIA
Prepared by: MR Approved by :-MD

Edition No. :-01
Effective Date :- 01.06.2022
Quality Manual Quality Policy
Ref.: ISO 9001:2015 Section: Annexure 1 Rev. No. / Date : 00 / 01.06.22
Quality Policy
VHV PRECISION ENGINEERING Believes
In Achieving Excellence Through
Continual Improvement In Our
Products, Process & Systems.
We Are Committed to Provide Quality

Assured Products on Time and Ensure to
satisfy Customer’s Need and
Expectation.
MANAGING DIRECTOR
1st June. 2022
Prepared by Approved by
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Quality Manual Context of the organization
Ref.:ISO 9001:2015, clause 4 Section: VHV/QM/4 Rev. No. / Date : 00/01.06.2022
General Policy :
It is the policy of the company to establish, document, implement and maintain a Quality Management
System and continually improve its effectiveness and efficiency in accordance with the requirements
of ISO 9001:2015 standard.
Scope :
Applicable to entire system relating to ISO 9001:2015 requirements. Identification of internal &
external issue.
Managing Director, Vice President, Sr.GM Project, and all concerned Head., MR : For day to day
affairs.
Description:
4 Context of the organization
4.1 Understanding the organization and its context.
The company has determine external and internal issues that are relevant to its business
purpose , direction & affect its ability to achieve the intended result of its quality management system.
The company has monitor & review information about these external & internal issues with
consideration of following factor:
 Issue can include positive and negative factor or conditions for consideration.
 Understanding the external context can be facilitated by consideration issues arising from
legal, technological, competitive, market, cultural, social & economic environments,
whether international, national, regional or local.
 Understanding the internal context can be facilitated by consideration issues related to
values, culture, knowledge and performance of the organization.
SWOT Analysis in QM/G of this manual.
4.2 Understanding the needs & expectation of interested parties.
Company has determine the effect or potential effect on the organization’s ability to
consistently provide products and service that meet customer and applicable statutory &
regulatory requirements, the organization determined following :
Company consider the effect or potential effect for following interest parties:
A) Government department –VAT, Excise Department

B) Customer
C) Supplier
D) Employee
E) Banking service
F) Calibration agency
Requirement & effect or Potential effect of above interested parties address in List of Interest parties
with their need and expectation.
Prepared by . Approved by.

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Company address the monitoring & review information for all above interest parties in quality manual,
procedure, Drawing, Work instruction, Certificate ,Control plan & quality plan
4.3 Determining the scope of the quality management system
The company has determined the scope of the quality management system .
When determining this scope, the organization shall consider following factor :
a) The external and internal issue as define in SWOT analysis.

b) The requirement of relevant interested parties as define in List of Interest parties with
potential effect.
c) Manufacturing activity of the organization.
Scope statement are define as per below :
Scope : Manufacturer and Export of Forged, Cast & Precision Machined Components.
Not applicable and Justifications:-
Clause 8.3: - Design & Development
 Since the customer is design responsible who gives the design records, the clause 8.3
Design and development does not apply. However the Product quality planning team
assesses the feasibility of the proposed design at the time of product quality planning as per
the Processing of development of new parts.
4.4 : Quality management system and its processes :
 The company has established, documented, implemented and maintained a quality

management system.
 The company also ensures to continually improve its effectiveness in accordance with the
above-mentioned standard.
 The company has carried out following activities to implement the quality management
system.
o Has identified the processes needed for the quality management system and
determined the sequence and interaction of these processes, which are addressed in
the various sections of this manual. For the simple understanding of processes, flow
process charts are used in the Annexure .
o Has determined criteria and methods required ensuring the effective operation and
control of this processes in the respective procedures and control plans.
o Ensures the availability of resources and information necessary to support the

operation and monitoring of these processes and are mentioned in the respective
procedures and control plans.
o Company done outsource process like turning, Heat treatment, Calibration

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o Monitors, measures and analysis these processes. Process capability, customer

satisfaction etc are monitored to know the process performance. Statistical
techniques are used to analyze the gathered information.
o Implement actions necessary to achieve planned results and continual improvement

of these processes
 Company controls those processes, which have been outsourced by providing adequate
information to the suppliers and its verification of its arrival at the company.
 Company takes the responsibility of conformity to all customer requirements of all the
outsourced processes and this has been identified within the scope of quality management
system.
4.4.1.1 Conformance of products and processes
At present company not carry out any job works at outsourced. These outsourced processes
do affect the conformity of the final product and the controls of this process is defined in
Control plan/Drawing. Issue of the Drawings to Supplier. Drawing used for production by the
suppliers.
Statutory & regulatory requirement related to supplier/job work process cover in supplier
registration form.
4.4.1.2 Product safety
Following product safety point consider in design of product :
 Identification of statutory & regulatory requirement of product safety.

 Customer notification on statutory & regulatory requirement.
 Special approval for design FMEA
 Product safety –related characteristic identify in control plan & PFMEA.
 If customer required special approval of control plan & PFMEA.
 Reaction plan related to sampling plan, measuring technique, escalation process.
 MR is responsible for escalation process and flow of information, including management and
customer notification.
 HR Manager shall plan the training related to product safety if required involve the customer.
 Change of product or process shall captured in engineering change note and also potential
effect consider in PFMEA.
 Product safety transfer to supply chain through control plan.
 Batch no. use for Product traceability.
 Covered the lesson learned for new product introduction.
Determined criteria and methods required ensuring the effective operation and control of the product
safety in the procedures for product safety.

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4.4.2 To extent necessary, the organization shall :
a) Documented information identify in process turtles of each process capturing in process map.
b) Retention time of documented information define in list of records.
c) MD ensures that quality objective, are established at relevant functions and levels within the
organization. It shall be measurable and consistent with the quality policy.
d) Quality Objectives or KPI defined in Annexure 2.
Reference Document :
1) SWOT Analysis –VHV/QM/G

2) List of Interest parties with their need and expectation
3) Procedure for Product safety – VHV/P/4/01
4) Process turtles for customer complaint handling
5) Process turtles for marketing
6) Process turtles for management
7) Process turtles for Quality
8) Process turtles for Internal Audit
9) Maintenance Process Analysis and Notes
10) Product and Process Audit Process Analysis and Notes
11) Process turtles for Development
12) Process turtles for Production
13) Process turtles for Purchase
14) Process turtles for QMS
15) Process turtles for store
16) Training Process Analysis and Notes

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Quality Manual Leadership
Ref.: ISO 9001:2015, clause 5 Section: VHV/QM/5 Rev. No. / Date : 00/01.06.2022
Purpose:
To provide evidence of management commitment to the development and implementation of the

quality management system and continually improving its effectiveness by communicating to the
organization the importance of meeting customer requirements, by establishing the quality policy &
objectives, by conducting management reviews and by ensuring the availability of resources.
VHV PRECISION ENGINEERING has always believed in excellence in all areas of operation through
services of high quality and values. Our strength lies in responding to the customer needs. We have
strived to bring the best possible technologies, methodologies, manpower and equipments to ensure
customer satisfaction.
VHV PRECISION ENGINEERING is committed to total quality at all levels. We believe in high quality
services at an economic price. We upgrade the quality of our services not just on a one time basis,
but as part of an ingrained culture, which drives us to make continuous improvements.
VHV PRECISION ENGINEERING is now taking a new positive step towards total quality by
establishing a documented Quality policy. We are sure that the spleen did and innovative efforts of
our employees and their commitment to Quality would ensure our Company continuous progress.
VHV PRECISION ENGINEERING aims at not only achieving Customer satisfaction by meeting
specified quality requirements but also enhancing the same through continual improvement of quality
levels.
Responsibility and Authority :
1) Top Management: Top management is responsible to analyze the company level data with
help of employees and respective Managers and based on the analysis and discussion to establish
objectives and policy.
Top management is also responsible to assess the resources availability and their utilization
including the human resources.
The top management has taken strategic decision to implement and to improve it continually to
achieve higher standards of effectiveness and efficiency.
Description:
5.1 : Leadership & commitment
 Management commitment demonstrates by Quality policy. Quality policy communicates

to the organization, visitors, subcontractor, share holder and other interested parties.
Quality policy prepared on basis of ISO 9001:2015 requirements.
 Quality policy is established as per Annexure I of this manual.
 Top management ensures that quality objectives are established and is addressed in
Annexure 2 of this manual and it link with business plan & strategic direction.
 Top management ensures that management reviews are conducted and provide
appropriate resources for Implementing of ISO 9001:2015 requirement.
 Ensuring the integration of the quality management system requirements into the
organization’s business processes.
 Process approach & risk base thinking promoting by regular meeting with staff.
Prepared by . Approved by
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 Communicating to the organization the importance of meeting customer as well as

statutory and regulatory requirements.
 Engaging & directing of supporting person by conducting meeting.
 Promoting improvement by motivation.
 Supporting other relevant management roles to demonstrate their leadership as it
applies to their area of responsibility.
5.1.1.1 Corporate responsibility
 Vice President has define and implement corporate responsibility policies which including of
minimum an anti-bribery policy, an employee code of conduct and ethics escalation policy.
 CSR Policy and code of conduct is established as per Annexure 5 of this manual.
5.1.1.2 : Process effectiveness & efficiency
 Top management has defined the measures of process efficiency and effectiveness in
the respective Processes.
 Top management reviews the product realization process and support processes in the
management review meetings to assure their effectiveness and efficiency, with respect
to the defined quality Objectives.
5.1.1.3 : Process owners
 Top management has appoint competent person as process owner.

 Competence of process owner define in skill matrix.
 Responsible process owner name capturing in Process wise process turtles.
 Appointed Process owner shall responsible for managing processes related output & their
role.
5.1.2 : Customer focus

 Top management ensures that customer requirements are determined and met with the
aim of enhancing customer satisfaction.
Fronts Received from

Product related requirements Engineering drawings, master samples,
customer standards and other contract review
documents etc
Quality Management System requirements Customer purchase order, Quality system
requirement (QSR) obtained from the customer,
MSDS, Customer Quality Management System
requirement manual ,CSR etc
Performance related requirements Customer satisfaction survey results, customer
given ratings, Delivery ratings
Statutory & regulatory requirements Purchase order copy from customer,
 Outputs of all the above requirements are met with the aim of enhancing customer
satisfaction.
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5.2 Policy
5.2.1 : Establishing the Quality Policy
 Top management has made the Quality policy, which contains the purpose of the
organization in satisfying the customer needs and expectations. (Refer Annexure I for
the Company’s quality Policy).
 The company’s Quality Policy statement is signed by the MD.
 Company’s Quality policy reflects its commitment to comply with requirements and
continually improve the effectiveness of the Quality Management System includes
customer satisfaction.
 It also provides a framework for establishing and reviewing Quality objectives.
 Quality policy is reviewed (at least once in year) in management review meetings for its
continuing suitability.
5.2.2 Communicating the Quality policy
Quality policy shall communicate by following means:
 Quality policy shall document in Annexure I of this manual.

 Quality policy is displayed at strategic locations, so that it can understand all levels of
organization.
 Quality Policy is displayed and available to the public, other interested parties and
strategic locations in local language to ensure that the employees of the Company read
and understand the same.
5.3 Organizational roles, Responsibility & Authorities :-
Responsibility and authority are defined in the Quality management system and communicated to the
concerned within the organization.
 Company’s organization structure is as per the Annexure III of this manual
 Responsibilities and authorities are defined in the Annexure of this manual and
communicated to the concerned within the organization.
 Production Manager, who is responsible & authorized for taking corrective action, is promptly
informed of products or process, which do not conform to requirements.
 Quality Manager who is responsible for product quality is given authority to stop production to
correct quality problems
 Section Head across all shifts are staffed with personnel in charge of or delegated
responsibility (ref appendix) for ensuring product quality.
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 Top management has appointed Mr. Kalpeshbhai are member of management , irrespective of
other responsibilities, has responsibility and authority that includes
 Ensuring that processes needed for the quality management system are established,
Implemented and maintained
 Reporting to top management on the performance of the quality management system and
any need for improvement
 Ensuring the promotion of awareness of customer requirements throughout the organization
The responsibility of a Management representative includes liaison with external parties on matters
relating to the quality management system
5.3.1. Organizational roles, responsibilities & authorities
Top management has designated responsibility and authority to the following personnel to ensure
that customer requirements are addressed
Responsibility and
Requirements
authority
Selection of special
Development Manager
characteristics
Setting quality objective Vice President
Related training HR Manager
Corrective and preventive

Quality Manager
actions
Product design &
Development Manager
development
Capacity Analysis Production Manager
Logistic information Dispatch Manager
Customer
Marketing Manager
scorecards/Complaint
Customer Portal Marketing Manager
5.3.2 Responsibility and authority for product requirements and corrective actions
 Supervisor for all shift are authorized to stop production and correct quality problems.
 Supervisor for both shift have responsibility for ensuring conformity to product requirement.
 Supervisor have responsibility and authority for corrective action on product or processes that
do not confirm to requirements to ensure that non conforming product is not shipped to the
customer and also keep separate of all potential non conforming product produce.
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Quality policy – Annexure I

CSR policy & Code of Conduct – Annexure 5
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Quality Manual Planning
Purpose:
This section outlines is to balance the risk and opportunities for all process for that provide
resources including human resources, infrastructure, work environment etc. To determine and
provide resources needed to quality Management System, address risk and opportunity and
continually improve its effectiveness and to enhance the planning through effective contingency
plan.
Description:
6.1 Action to address risks and opportunities
Management of Company ensures that:-
The planning of the quality management system, the company considers the internal & external
issue and the requirement related to risks and opportunities that need to be addressed in process
turtles.
 Give assurance that the quality management system can achieve its intended result.
 Enhance desirable effects – Opportunity
 Prevent or reduce, undesired effects – Risk
 Achieve improvement
Risk & Opportunities are identifying by SWOT analysis & Process wise Risk Analysis.
a) Action to address these risks and opportunities

b) How to
1) Action is Integrate and implement with department wise procedure.
2) Evaluation & effectiveness verify with respect to action define in each department wise
procedure.
6.1.2.1 Risk Analysis

Following point shall include in risk analysis
 Lessons learned from product recalls
 Product audits
 Field returns & repairs
 Complaint
 Scrap
 Rework
Above all the factor included in Process wise risk analysis
6.1.2.2 Preventive action
 Potential nonconformities are discussed in the Management Review Meeting and
actions are identified there to eliminate the causes in order to prevent their occurrence.
 Once the potential nonconformities are identified, methodology adopted for the
corrective actions is followed and actions are recorded in the Management review
report.

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(a) The uses of appropriate sources for information such as processes and work operation
which affect product quality, concessions, audit results, records, customer complaints
and data analysis to detect, analyze and eliminate potential causes of non conformities.
(b) Determining the steps needed to deal with any problems requiring preventive action.
(c) Initiating preventive action and applying controls to ensure that this is effective.
(d) Ensuring that relevant information on actions taken including changes to procedure is
subjected to management review.
The company maintain records of corrective and preventive actions taken and their results. If any
action is found to be effective, is may be implemented on permanent basis.
The company implements and records any changes in the documented procedures resulting from
corrective and preventive actions.
Summary of corrective and preventive actions is submitted in management review.
Self Assessment done as per procedure for continual improvements supports this objective of
taking preventive actions and aims at making all processes best in class with special focus on key
processes
6.1.2.3 Contingency Plans
 Contingency plan shall define on following basis:
 Identify & evaluate internal & external risk to all manufacturing processes and infrastructure
equipment essential to maintain for production output and ensure that customer
requirements are met.
 According to risk and impact to the customer.
 Contingency plans for continuity of supply in the event of any of the following
1 Key equipment failure
2 Interruption from externally provided products, processes and service;
3 Recurring natural disasters.
4 Fires
5 Utility Interruptions
6 Labor shortages
7 Infrastructure disruptions
 Contingency plans also include a notification receive from the customer and other
interested parties for the extent and duration of any situation impacting customer operation.
 Contingency plan test once per year for effectiveness.
 Contingency plan review once in year by MDT and update as required.
 Contingency plans keep and retain as documented information describing any revision and
Production Manager having authority for changing the Contingency plan.
 Contingency plan shall include the provisions to validate that the manufactured product
continues to meet customer specification after the re-start of production following an
emergency in which production was stopped and if the regular shutdown processes were
not followed.

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6.2 Quality objective and planning to achieve them
It shall be
a) measurable and
b) consistent with the quality policy
c) account applicable requirement
d) relevant to conformity of product and enhancement of customer satisfaction.
e) Monitored
f) Communicated through meeting & display.
g) Update as appropriate.
6.2.2 Following plan carry out for achievement of quality objective, the organization shall
a) What will be done – Objective define by Vice President/Process owner

b) What resource will be required – resource provided by MD
c) Who will be responsible – QMS Representative responsible for quality objective
d) When it will be completed – target define by MR/Department head
e) How the result will be evaluated – By Calculation of data.
f) To enhance customer satisfaction, Marketing Manager shall review customer requirement
through customer feedback, product quality etc. and on the basis of analysis of the same
will provide necessary resources.
MD ensures that quality objectives are established at relevant functions and levels within the
organization.
Quality objective include the customer specific requirement.
Quality objective result review once per year by MD.
Customer target also taken in quality objective and monitored it.
6.3 Planning of change
 Top management has identified the resource requirement on basis of each processes
requirement, risk and opportunity and customer requirement.
 Company shall consider the following point in plan of change
A) Purpose of the changes and their potential consequences

B) Integrity of the quality management system
C) The available of resource
D) Allocation and reallocation of responsibility and authorities
 Infrastructure related change capturing in Business plan and MRM.
1) Business Plan
2) Contingency Plan
3) Process Wise Risk Analysis

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Quality Manual SUPPORT
Ref.: ISO 9001:2015, clause 7 Section: VHV/ QM/7 Rev. No. / Date : 00 / 01.06.2022
Purpose :-
To plan and develop the processes needed support are implement for operation activity.
Responsibility & Authority:-
 Vice President: - He is responsible for maintenance of Quality Management System throughout

the organization and has a authority for review, change, approve and re-approve Quality Manual.
 M.R. : He is overall responsible for the control of documents and records and having authority to
review, approve and re-approve the same.
 Quality Manager: He is overall responsible for the calibration activity.
 HR Manager: He is overall responsible for the awareness, competence, motivation &
Organizational knowledge.
Description:-
7.1 Resources
7.1.1 General
 Top management has provided resources required for Implementing and maintaining the quality
management system and for continually improving its effectiveness, including
o Trained personnel for the operation of various processes
o Regular training for the employees
o Air conditioner in the Standard room for maintaining the temperature.
o Extra Lighting in the Final Inspection for easy visual inspection.
o Machineries, with required capability.
o Necessary tooling, fixtures etc.
o Safety Goggles for employees doing machine operate.
o Safety Shoe for Mech. & Elect. Maintenance Person.
 Top management identifies resources (human, infrastructure, work environment requirement), in

the
o Management Review meetings
o Team feasibility meetings
o Internal / external issue
o Risk and opportunity
o Potential consequence.
 Resource requirements are identified and provided with respect to the following, to meet their
requirements, for enhancing the customer satisfaction

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o Customer requirement (Ref. Purchase order, Customer drawings, Customer manuals &
Standard and)
o Customer feedbacks (Customer complaints, Customer Satisfaction survey, etc)
7.1.2 People
 Top management identifies person necessary for the effective implementation of its quality
management system and for operation and control of it processes.
 Person requirements are identified and provided with respect to the following, to meet their
requirements, for enhancing the customer satisfaction
o Customer requirement (Ref. Purchase order, Customer drawings, Customer manuals)

o Customer feedbacks (Customer complaints, Customer feed back ,etc)
o Trained personnel for the operation of various processes
o Risk & opportunity
7.1.3 Infrastructure :
 MDT determines the infrastructure like buildings, workspace and associated utilities like
machineries, fixtures, measuring equipment, process equipment and supporting services such as
transport or communication technology, including hardware & software & associated utilities
needed to achieve conformity to product requirements.
 Company provides the infrastructure needed to achieve conformity to product requirements, in the
Management review meetings.
 Following are the personnel assigned responsibility for maintaining the following utilities.
S. no. Utility description Responsible

1 Fax Administrative Executive
2 Internet connection Administrative Executive
3 Material trolleys / Bins Mgr. Production
4 Water cooler Administrative Executive
5 Vehicle Facility Administrative Executive
6 Water Filter Administrative Executive
7 Stop Production line immediately QC Mgr.
7.1.3.1 Plant, facility, and equipment planning
 Company uses a cross functional team for developing plant, facility and equipment plans.
 MDT reviews the plant layout for the optimization of material travel, handling and value-added use
of floor space including control of non conforming product, synchronous material flow, during the
development of new products.
 MDT developed and implemented to evaluate manufacturing feasibility for new product or new
operation.
 MDT review and include the capacity planning in Manufacturing feasibility assessment.

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 MDT maintain process effectiveness, including periodic re-evaluation relative to risk incorporate
any changes made during process approval, control plan maintenance and verification of job set-
ups.
 Assessments of manufacturing feasibility and evaluation of capacity planning shall discussed as

input of MRM.
 Overall equipment effectiveness (OEE) are monitored and evaluated for the effectiveness of the
existing operations.
7.1.4 Environment for the operation of processes
The organization determines and manages the work environment needed to achieve conformity to product
requirements in the Management review meetings
Following factory consider in environment for the operation of processes
 Social like non-discriminatory, calm, non-confrontational

 Psychological like stress reducing, burnout prevention, emotionally protective.
 Physical like temperature, heat, humidity, light, airflow, hygiene, noise
Company has provided safety devices including gloves, hoist, fire extinguishers etc as a means to
minimize potential risks to employees in the manufacturing process activities
7.1.4.1 Environment for the operation of processes – supplemental
 Section head has responsible for maintaining the premises in a state of order, cleanliness and
repair consistent with the product and manufacturing process needs.
7.1.5 Monitoring and measuring resources/7.1.5.2 Measurement traceability/

7.1.5.2.1 Calibration/Verification records/ 7.1.5.3 Laboratory requirements / 7.1.5.3.1 Internal
laboratory / 7.1.5.3.2 External laboratory
 Manager – Quality determine the monitoring and measurement to be undertaken and the
monitoring and measuring devices needed to provide evidence of conformity of product to
determined requirements in the Control plans.
 The company has processes to ensure that monitoring and measurement can be carried out and
are carried out in a manner that is consistent with the monitoring and the measurement
requirements. Manager – Quality selects the instruments, which are to be calibrated and entered
in the Calibration History Card (As mentioned in applicable records).
 Note: Company laboratory has a well defined Laboratory Manual defining the lab policy, scope,
standards used and the applicable work instructions and calibration procedures etc.
 Instrument Calibration Plan as per List of Instrument with Calibration Frequency. Calibrated
Instrument Identified as per Monthly color code.
 Collect the monitoring and measuring device from various locations for calibration as per the
schedule date mention in calibration History Card.
 On the receipt of instrument for calibration, calibration is done and results are noted down in the
Calibration History Card.

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External laboratory:
 Company selects the external laboratories that are acceptable to the customer or a laboratory,
accredited to ISO/IEC 17025 or national equivalent, for calibration where in-house calibration
facility is not available.
 External laboratory facility used for inspection, test or calibration service by the company shall
have a define laboratory scope that includes the capability to perform the requirement inspection,
test or calibration.
 Company obtains the laboratory scope from the external laboratory showing that they have the
capability to perform the required calibration. Manager – Quality arranges to send instruments for
calibration as per the frequency decided.
 Calibration service may be performed by the equipment manufacturer when a qualified laboratory
is not available for a given piece of equipment in such case the organization shall ensure that the
requirements listed in control plan.
 On receipt of the instruments after calibration from external agency, Standard room incharge
verifies following details:
o Whether equipment is calibrated against measurement standard traceable to international

or national measurement standards
o Where no such standards exist, basis used for calibration is recorded
o Any out-of-specification readings as received for calibration
o An assessment of the risk of the intended use of the product caused by the out of
specification condition.
o Statements of conformance to specification after calibration (adjustment or readjustment)
 When the equipment is found not to conform to requirements, Manager – Quality may assess the
validity of the previous measuring results, and inform the user department to assess the impact of
out of specification conditions.
 Manager Quality informs the Marketing department, if suspected parts are dispatched to the
customer.
 Manager Quality maintains the Calibration certificates received from the external laboratories, till
the equipment is used for the monitoring & measurement.
 Errors in the measuring devices (if any) are communicated to the users to correctly read the
measurements taken. If required, they are sent outside to adjust or re-adjust.
 Company ensures that the monitoring and measuring instruments are safeguarded from
adjustments that would invalidate the measurement result.
 Company protects the monitoring and measuring instruments from damage and deterioration
during handling, maintenance and storage.
 Since the Company does not use any computer software for the monitoring and the measurement,
the standard requirement of confirming and reconfirming the ability of computer software to satisfy
the intended application, is not applicable.

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Measurement system analysis :
 Statistical studies, including Gauge – Repeatability & Reproducibility, Bias, Linearity studies etc
are conducted to analyze the variation present in the results of each type of measuring and test
equipment system as identify in control plan.
 All type of instrument, measuring and test equipment identified in the control plans is covered by
MSA studies.
 Gauge – Repeatability and Reproducibility study is conducted for all the type of inspection,
measuring and test equipment to find out the appraiser as well as equipment variation.
 Linearity study is planned to conduct for measuring instruments whose operating ranges are used
in the measurement of various product characteristics.
 Attribute study is conducted for all types of gauges identified in the control plans.
 Stability study is carried out for the equipment, whose frequency of calibration is more than 3
years.
7.1.6 Organizational Knowledge
The company gained knowledge for product conformities from past experience are below :
Internal Knowledge :
 Customer Drawing
 Control Plan
 Customer audit result
 Customer complaint
 New product development
 Work instruction
 Machine manual
 Past developed sample storage
 Insert/tool selection book from supplier
 Setup wise Program
External Knowledge:
Company gain external Knowledge from :

 Standard
 Outside training
 Conferences
 Detail Gathering from customer during audit
 Detail Gathering from consultant during visit
 Gathering from experience employee.
 CSR manual
Process wise Knowledge requirement and available shall be define in List of process wise Knowledge.

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7.2 Competence/7.2.1 Competence - supplemental
Management ensures that personnel performing work affecting product quality is competent on the basis
of appropriate education, training, skills and experience.
 Company identifies necessary competence like expertise, skills etc for the personnel performing
the work affecting product quality, and is documented in Skill Matrix and skill available Vs skill
Required (gap Analysis) recorded in Skill Mapping.
 Records of qualification and experience of each employee and their compliance with the skills
defined in the Skill Matrix are recorded in the Employee History Cards & skill available recorded in
skill mapping.
 Training needs are identified in the Management Review Meetings, to provide necessary
competence based on the outcome of following processes.
 Special Process Requirement
 New Technology Adopted
 Root cause of customer complaints
 Customer feedback
 Product/ Process nonconformities
 Internal/ External audits
 Training detail given for each individual are also noted down in the Training achievement &
evaluation report and effectiveness of the trainings is verified in the internal audits or asking
question to trainee.
 Quality objectives are displayed at strategic locations in the company to make personnel aware of
their relevance and importance of their activities and how they are contributing to the achievement
of the quality objectives.
 Company has established and maintained documented procedures for identifying training needs
and achieving competence of all personnel performing activities affecting product quality in the
Procedure.
 Company ensures that personnel performing specific assigned tasks are qualified, as required,
with particular attention to the satisfaction of customer requirements.
7.2.2 Competence – on the job training
 Company provides on-the-job training to the personnel in any new or modified job affecting
product quality with respect to the skill matrix.
 On the job training include the customer requirement training.
 Personnel whose work can affect quality are informed about the consequences to the customer of
nonconformity to quality requirements.

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 Details of on the job training are recorded in the Training records and Training Effectiveness
assessment form record format.
7.2.3 Internal auditor competency
Quality Management system auditor , Manufacturing process auditors and product auditor competency
cover min. of following point :
 Understanding of the automotive process approach for auditing, including risk based thinking.
 Understanding of applicable customer specific requirement
 Understanding of applicable ISO 9001 requirement related to the scope of the audit.
 Understanding of applicable core tool requirements related to the scope of the audit.
 Understanding how to plan conduct report & close out audit findings.
 Manufacturing process auditors have technical understanding of the relevant manufacturing
process.
 Product auditor have understanding of product requirements and use of relevant measuring and
test equipment to verify product conformity.
Training detail given for each auditor for above subject are also noted down in the Training records and
effectiveness of the trainings.
Improvement in internal auditor competence demonstrated through:
 Executing a minimum number of auditors per year, as defined by the organization.
 Maintaining knowledge of relevant requirements based on internal changes (e.g. process

technology, product technology) and external changes ( e.g. ISO 9001 ,core tools, and customer
specific requirement).
7.2.4 Second party auditor competency
Following competency required and available in second party auditor :
 Understanding of the automotive process approach for auditing, including risk based thinking.
 Understanding of applicable customer specific requirement
 Understanding of applicable ISO 9001:2015 requirement related to the scope of the audit.
 Knowledge of manufacturing process to be audited, including PFMEA & control plan.
 Applicable core tool requirements related to the scope of the audit.
 Understanding how to plan conduct report & close out audit findings.
7.3 Awareness
Management ensures that personnel performing work under the organization control are aware of the
following:
 The Quality Policy
 Relevant quality objective
 Their contribution to the effectiveness of the quality management system, including the benefits of
improvement performance.
 Suggestion for not conforming with the quality management system requirement.
7.3.1 Awareness-Supplemental

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HR Manager & Quality manager ensure that the all employees are aware of their impact on product quality
and the importance of their activities in achieving, maintaining and improving quality, including customer
requirements and the risk involved for the customer with non conforming product.
7.3.2 Employee motivation & empowerment

 Company has process to motivate employees to achieve quality objectives, to make continual
improvements, and to create an environment to promote innovation.
 For a proper motivational climate company creates condition when….
o Creates a climate for interdependent work rather than dependency
o Creates a competitive climate through recognition of good work, Award give & Award photo
with name display on notice board etc
o Creates productive climate through personal example
o Creates a climate of approach and problem solving rather than avoidance
o Motivates individually through guidance and counseling
o Conduct the employee motivation survey (Every 12 Month) and note down the details in
employee survey form
 Company conducts employee surveys with the aim of employee motivation & empowerment.
 This process includes the promotion of quality & technological awareness throughout the whole
company. Posters are displayed for this.
 Company has a process to measure the extent to which its personnel are aware of the relevance
and importance of their activities and how they contribute to the achievement of the quality
objectives
7.4 Communication
Top management ensures that appropriate communication processes are established within the
organization and the communication takes place regarding the effectiveness of the quality management
system.
Where all documented procedures & formats are defined, they are used as a means in the communication
within the company. In all the other cases, communication is through verbal means.
Weekly meetings, management review meetings, Notice boards etc are used as means to communicate
among the functions, regarding the effectiveness of the quality management system

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7.5 Documented information:

The quality management system documentation of company includes: -
For the simplification, Quality system documentation is divided in to four levels as described
below:
Levels
Quality Manual
Procedures/Activity chart
Control plan, work instruction,

Drawing etc.
Formats, Forms, Registers etc.
Level – 1
It includes the Quality manual, which provides and overview of the quality management system
considering the standard requirements. Procedures and Processes are defined and highlights in
respective Sections of the Quality manual.
Level – 2
It includes Procedures as required by this international standard and other documented processes. (e.g.
Management review process, Purchasing process, Production Planning process, etc.) Quality records
are defined and referred to, in respective procedures and / or processes.
Level – 3
It includes External standards, Work Instructions, Control plan, Drawing, etc, to ensure the effective
planning, operation and control of its processes.
Level – 4
It includes formats, forms, registers, etc. to provide evidence of conformity to requirements and of the
effective operation of the quality management system.

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7.5.1.1 Quality management system documentation
Documented system include a quality manual, which can be a series of documents (electronic or hard
copy)
The format and structure of the quality manual is at the discretion of the organization and will depend on
the organization size. culture, and complexity. If a series of documents is used, then a list shall be retained
of the documents that comprise the quality manual for the organization.
Quality Manual shall include, at a minimum , the following:

a) The scope of the quality management system, including details of and justification for any
exclusion.
b) Documented processes established for the quality management system or reference to them
c) The organization processes and their sequence and interactions ,including type and extent of
control of any outsourced processes.
d) CSR matrix indicating where within the organization quality management system their customer
specific requirements are addressed.
e) CSR matrix linkages with QMS standard and same shall be address in process.
7.5.2 Creating and updating

 Functional Head/Process owner would like to change any documents then he/she will written
amendment detail in amendment form and forward to MR with old document copy. MR in turn shall
discuss the same with approving authority of the document.
 Approving authority reviews it and re-approves the new document, drawings, control plans.
 Management Representative issues the new document to the concern, mentioning the current
revision & the latest changes in the master copy of the newly released document. Document
changes detail mention in amendment form.
 Design I/c issues the new drawings against the obsolete drawings.
 Management Representative & Design I/c takes back the obsolete copy from the user, and
disposed off and master copy of obsolete document are retain till the next revision.
 If the obsolete copies are to be retained for any purposes, Management Representative identifies
it by putting red stamp of ‘OBSOLETE COPY’ on every page.
 For the external standards (national/international standards, TS 16949, QS 9000 reference

manuals etc), company uses an external agency for subscription and updating services.
 Documented information are identification, description, ref. No., Date, author shall define in
Procedure for control of document.
 Format no. shall define as per procedure for control of records.

 Documents are approved for adequacy prior to its issue.

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 Current revision status of all documents is identified by revision number and or by effective dates
and is addressed in the Document & Record Distribution Sheet.
 All the latest version of the applicable documents is issued to the relevant functions.
 The documents are identifiable by its name and / or number and are neatly written to ensure the
legibility.
 The documents of external origins are identified by their name and are distributed to relative
functions through Document & Record Distribution List.
 Only latest version of documents is available with concern function. All the obsolete documents will
dispose by the person who has issued the same, to prevent its unintended use. In case, any of
the obsolete documents is required to be retains for any purposes, they are identified with the “
OBSOLETE COPY” stamp by the issuing authority.
Documented procedure for control of documents has been established to define the controls as follows.
7.5.3 Control of documented information

 For the approval of documents / drawings:
o Following are the approving authority for the documents, who approves the documents on
reviewing its adequacy & legibility.
Type of Document Prepared By Issue By Approving Authority
Quality Manual MR MR Vice President

Procedure, Process Flow Chart Dept. Head MR M.R.
Activity Chart Dept. Head MR M.R.
Control plans, Specifications, PFMEA MDT MR Quality Manager
Technical drawings Design I/c Design I/c Sr.GM Project & Technology
Formats, Register Dept. Head MR MR

Work Instructions Dept. Head MR MR/Quality Manager
Master copies of original document are identified by the blue stamp of ‘MASTER COPY’ on backside of
every page of the document.
 For the Issue of documents, drawings, W.I. (including documents of external origin):
Management Representative Issues related documents to the concerned persons by putting Blue stamp of
‘CONTROLLED COPY’ on the front side of every page for the document. Management Representative
maintains its issue details in the Distribution List, including the current revision status and the location in
which they are distributed.
All the documents are identified by no. and its contents and also through its revision number and effective
date.
1. The numbering system shall be mentioned in Procedure for control of document.

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2. MR shall ensure that all the documents numbered is as per the numbering System mentioned
above.
3. Following is the list of department code.
Sr. No. Department Name Department Code

1. Management MGT
2. Management Representative MR
3. Quality Management System QMS
4. Quality Control QC
5. Production PDN
6. Material MAT
7. Marketing MKG
8. Maintenance and Tool Room MAI
9. Human Resources HR
10. Electronic Data Processing EDP
11. Development DEV
12. Metallurgical MET
13. Standard Room / Metrology Lab STD
14. Administration ADM
 Control of documents maintained in computers:
o Documents, which are maintained in the computers, are controlled through passwords.
 Control of documents maintained in computers:
o Documents, which are maintained in the computers, are controlled through passwords.
 Quality records are identified by their no. as per the documented procedure for control of records &
are referred in the respective sections of this manual & list of record.
 Quality records are made legible and are kept in files and are indexed for the easy retrieval.
 Various files are named by the quality records and are arranged systematically at the user
location, for the easy access to the user.
7.5.3.2.1 Record Retention
 MR shall prepared retention policy.
 Retention time of all the quality records is addressed in the list of record, which satisfies statutory
regulatory, organizational and customer requirements as applicable.
 All the quality records are retained for the period as per the defined retention time and are
disposed off subsequently by the person responsible for retention.
 Production part approval, tooling records, product and process design records, purchase orders or
contracts and amendments shall be retained for the length of time that the product is active for
production requirements, plus one calendar year, unless otherwise specified by the customer or
regulatory agency.
 Quality records are protected from damage, loss and deterioration while on storage by the user.
 Control of records stored in computers:

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o Records, which are stored in the computers, are protected by taking backups to protect
the loss of the data till its retention period.
o Records that are maintained in the computer are protect by user password.
7.5.3.2.2 Engineering specification

 Company prepared the Engineering change process with describing the review ,distribution and
implementation of all customer engineering standard/specifications and related revision based on
customer schedules.
 PPAP document submit against the ECN shall be captured in ECN format.
 Company has defined the process to assure timely review (within 10 working days), distribution
and implementation of all customer engineering standards/ specifications and changes based on
customer-required schedule through engineering change note.
 The company maintains a record of date on which each change is implemented in production in
the control plans and other related documents and actual date of production. All the appropriate
documents are updated PPAP Submission as per AIAG Manual.
Procedure for control of document : VHV/P/7/01

Procedure for control of records : VHV/P/7/02
Procedure for Training : VHV/P/7/03
Procedure for Calibration : VHV/P/7/04

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Quality Manual Operation
Ref.: ISO 9001:2015, clause 8 Section: VHV/QM/8 Rev. No. / Date : 00 / 01.06.2022
Purpose :-
The purpose is to plan and implement the monitoring measurement, analysis and improvement
processes needed to demonstrate the conformity of the product, to ensure conformity of the quality
management system and to continually improve the effectiveness of the quality management system.
Responsibility and Authority :-
Production Manager: - For the monitoring and the measurement of the product, control of non-
conforming product and authority to dispose the non conforming product.
Purchase Manager:- For Monitoring and measurement of supplier evaluation.
Quality Manager: Responsibility of product identification and traceability, control and monitoring of
measuring .
Development Manager : For new product development related activity.
Description:-
8.1 Operational planning & control/8.1.1 Operation planning and control - supplemental
 Company plans and develops the processes needed for product realization, whenever new
products are to be developed or when there is a major change in the existing product.
 Company ensures that planning of product & service is consistent with the requirements of
the other processes of the quality management system.
 During the planning of product & service, following are reviewed,
o Company reviews the quality objectives and may update it, if required.
o Manufacturing Process FMEA is carried out for the entire customer designated special
Characteristics.
o Company determines the requirements for the product and is addressed in the Control plan
 Manufacturing process FMEA outputs are taken in to account in the Control Plan.
 Control plans are developed for all the parts at various stages starting from receiving to the
final.
 Risk assessment outputs are taken in to account in the Control Plan/WI.
 The Control Plan has following information:
o List of controls used for the manufacturing process control
o Characteristic of controls used for the manufacturing process control.
o Methods for monitoring of control
o Control method
o Frequency for measurement

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o Reaction plan, when the process become unstable.
 Customer requirements and references to its Technical specification (Drawings) are included
in the control plans.
 Acceptance criteria are defined in the control plans. If required it is sent to the customer for its
approval before the PPAP lot submission. For the attribute data sampling, acceptance level is
taken as zero defects and are mentioned in the control Plans.
 Control plans are reviewed and updated when any change occurs effecting product,
manufacturing process, measurement, supply source or FMEA.
 Company reviews the existing processes and documentation with respect to the specific
requirement of the product and if necessary, it establishes new processes or modifies the
existing processes.
 Company also determines and provides new resources requirement like machineries, fixtures,
qualified personnel etc, specific to the product.
 Company determines verification, validation, monitoring, inspection and test activities specific
to the product and the criteria for product acceptance and is addressed in the control plan.
 Records (like inspection/test records, SPC records, etc.) are maintained to provide evidence
that the realization processes and resulting product meet requirements.
 Company also ensures that the output of this planning is in a form suitable for the company’s
methods of operations.
 Company done outsource process like rough machining, casting.
 Company controls those processes, which have been outsourced by providing adequate
information to the suppliers and its verification of its arrival at the company.
 Company takes the responsibility of conformity to all customer requirements of all the
outsourced processes and this has been identified within the scope of quality management
system.
8.1.2 Confidentiality
 Confidentiality of customer contracted products and projects under development and related
product information is ensured.
8.2 Requirements for products and services
8.2.1 Customer communication /8.2.1.1 Customer communication - supplemental
 The Company has implemented effective arrangements including FAX, Telephone, language
agreed with customer and Internet (Email, Website) for communicating with customers in
relation to
o Product information like Product drawings, Inspection methods, standards, sample

etc.

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o Enquires, contracts or order handling, including amendments, and
o Customer feedback, including customer complaints and customer satisfaction survey

results.
o Handling or controlling customer property.
o Establishing specific requirements for contingency actions when relevant.
o Customer –specified computer language and format (e.g. computer –aided design
data, electronic data interchange)
 Company maintains a computerized system for the receipt of customer planning information
and ship schedules.
8.2.2 Determining the requirements for products and service/8.2.2.1 Determining the
requirements for products and service – supplemental.
Company provides technical details for it’s product range and existing customer, technical capability ,
and its specifications/application are briefed in the same.
Inquiry receive from customer with drawing recorded in inquiry status report and quotation sending
detail mentioned in inquiry status report.
Marketing Manager & development conduct feasibility study of customer inquiry and get approval from
MD and accordingly prepared quotation and send to customer.
Quotation follow up taken by Marketing Manager.
M.D. & Manager Marketing receives delivery requirements including timing, quantity, recycling,
environmental impact and characteristics identified and transportation mode are received from the
customer. Presently post delivery activities are not a requirement, hence not addressed.
Requirements not stated by the customer but necessary for specified or intended use, where known,
are take care by the Company.
Also company take care for following requirement but not to be limited.
 All applicable government,
 Safety
 Environmental regulations related to acquisition,
 Storage, Handling, Recycling, Elimination or disposal of material.
Presently, any authorized bodies do not prescribe any statutory and regulatory requirements related
to the product. However, we shall address this, whenever it is required so.
Company determines any additional requirements like packing related to product.
b) Company resolves with the customer if any of the contract or order requirements are differing from
expressed.

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8.2.3 Review of the requirements for products and services/8.2.3.1.1 Review of the
requirements for products and services-supplemental , 8.2.3.1.2 Customer designated special
characteristic 8.2.3.1.3 Organization manufacturing feasibility
 For new products
o On receipt of inquiry for the new product, Manager Marketing notes down the details in
the Enquiry – Order Review Form and MDT Leader carry out the Team feasibility
commitment to review requirement related to the new product and to ensure
manufacturing feasibility including risk analysis of the proposed product.
o Manufacturing feasibility conduct for new product/new process & new technology or any
change in manufacturing process or product design.
o In the risk analysis CFT/MDT assess the following to effectively & efficiently provide the
customer specific requirements of the proposed product or changed process or product
design…
 Adequacy of customer requirement
 Availability of raw material
 Manufacturing capability (tolerance, Cp / Cpk)
 Manufacturing capacity
 Capital cost for developing (equipment, tooling, measuring devices etc.)
 Inspection feasibility and capability
 Customer designated special characteristic
 Approval of documentation for special characteristic
 Control of special characteristic
Based on the feasibility study (risk analysis) on the above points, Asst. Manager Marketing &
Development manager takes the decision of whether the product is to be developed or not.
Team Leader conducts the team feasibility study with multi disciplinary team and results of study is
communicates to the Manager Marketing to communicate to customer.
Team leader validate through production runs, bench marking studies or other appropriate methods ,
Ensure the ability to make product to specifications at the required rate.
Team Leader uses the APQP / MDT Responsibility Matrix & Timing Chart for the feasible products for
execution of new product development as per the customer-timing requirement.
 For regular product
o Upon the receipt of the customer order, (written), Manager Marketing reviews the
requirements related to the product, including the product specifications, timing and
quantity requirement, packaging, transportation requirement etc and Manager - Marketing
shall acknowledgment the order by email same shall be add in customer order
monitoring sheet.

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o Mgr. Marketing resolves with the customer if any of the contract or order requirements are
differing from those previously expressed.
o Asst. Manager Marketing receives schedule from customer (OEM) for regular order &
review the same for delivery with Managing Director, Technical Director and Executive
Director, if required.
o Status of the pending order shall be monitored through Computer system. Asst. Manager
Marketing shall inform to customer change in schedule if delay.
o Order Amendments: Mgr. Marketing shall process any amendment in the customer’s
order after any change in tech./ Commercial terms for the product, review & amendment
to contract and request to customer for P.O. Amendment (if applicable).Customer revised
P.O. received and P.O. accepted status inform to customer by email. Revised order detail
communicate to PPC.
 Mgr. Marketing contacts the customer, if any of the requirements are not clearly defined or
understood.
 Records of the results of the review and actions arising from the review (Team feasibility form,
customer communication on schedule matters, Management review) are maintained.
 If customer given any authorized waiver for the requirements stated shall be keep as
document information for review.
 Manager Marketing prepared the Daily Dispatch Advise Form and gives to dispatch incharge.
 Asst. Manager Marketing monitors the actual dispatches with the committed in the Daily
Delivery Performance Monitoring – Product Wise.
 Asst. Manager Marketing presents the Customer & Product wise delivery performance report
in Management review meetings.
 Production planning
 Manager Marketing shall prepared tentative production plan on the basis of customer
schedule, pending order and order received from OEM in consultation with M.D. and G.M.
(Operation).
 On the basis of tentative production plan and availability of the material, PPC I/c & Production
I/c. shall prepared production plan on monthly basis.
 Make monthly production plan of components before the starting of month in 'Monthly
Production Schedule Cum Production Performance Monitoring.'
 Based on orders and stock, component planning is carried out than release P.O. to supplier.
 Daily and monthly production PPC I/c reviewed through ‘Monthly Production Schedule cum
Production performance Monitoring’ & Production S.H. reviewed through ‘Week wise
Production Schedule Cum Date & Operation wise Production Monitoring’ - monitor the
progress of daily production against the commitment

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8.2.4 Changes to requirements for products and services
 Mgr. Marketing shall process any amendment in the customers order/change in tech./
Commercial terms for the product, review & amendment to contract and communicate to
respective department.
 For regular production item, technical change directly communicate to quality manager and
those change related document change by Quality manager.
 If needed then quality incharge send the change related email to CAD engg. And they make
the technical change in drawing and issue to user.
 For New development product ,customer change detail directly communicate to development
manager and those related feasibility study carry out by MDT and accordingly amend the
document and issue to respective department.
 Vice President shall make plan for Infrastructure/Machinery related modification/change and
take approval from MD. Accordingly modify the plant and machinery.
8.3 Design & development of product and services.
Exclusions and Justifications:-
Clause 8.3: - Design & Development:
At present company made product as per customer drawing.

At present company is not engaged in design and development of products.
Hence not addressed in the system.
8.3.3.2 Manufacturing process design input
 The product development team identifies, documents and review the manufacturing process
design input requirements, including
o Product design output data
o Targets for productivity, process capability and cost
o Manufacturing technology alternatives
o Customer requirements, if any, and
o Experience from previous developments.
o New material
o Product handling and ergonomic requirement
o Design for manufacturing & design for assembly.

 Company uses a multidisciplinary approach to prepare for product realization, including
o Development / finalization and monitoring of special characteristics,
o Development and review of FMEAs, including actions to reduce potential risks, and
o Development and review of control plans

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8.3.3.3 Special characteristics
 Special characteristics identify by multidisciplinary approach & those determined by the

customer & out come of PFMEA.
 The product development team identifies special characteristics (included product
characteristics and process parameters) and,
o Includes all special characteristics in the control plan,
o Complies with customer-specified definitions and symbols, and
o Identifies process control documents including drawings, PFMEA, and control plans
with the customer’s special characteristic symbol or the organization’s equivalent
symbol (CS or CC) or notation to include those process steps that affect special
characteristics.
8.3.4 Design and development control:
The Development department shall carry out OR Undertaking design verification ,Design Verification
and action include the measures and method.
 Process design review conduct during production of pilot lot.

 Process design verification carry out by In process dimension verification
 Process design validation carry out by during pilot lot production at PPAP stage.
 Verification or validation shall be conducted through required test & job results and shall be
compared with the designed parameters. The variance, if found shall be analysis and
corrective action shall be taken . if corrective action shall be taken and action is not possible
then concession from customer is taken. The design validation of proven design is included in
machine testing checklist.
Process Design Review included :
 Customer Requirement
 Functional, Maintenance and safety point of review.
 Adequacy to meet expected environment condition
 Material Availability
 Permission Tolerance and process capability
8.3.4.1 Monitoring
 Measurements {quality risks, costs, lead-times, critical paths and others, as appropriate) at
specified stages of design and development are defined, analyzed and reported with
summary results as an input to management review.
8.3.4.3 Prototype program
 When required by the customer, company has a prototype program and control plan. The
company uses, wherever possible, the same suppliers, tooling and manufacturing processes
as well be used in production.
 All performance-testing activities are monitored for timely completion and conformance to
requirements.

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The company takes the responsibility for the outsourced services, including technical leadership,
when the services are outsourced
8.3.4.4 Product approval process
 The company conforms to a product and process approval procedure recognized by the
customer.
 This product and manufacturing approval procedure is also applied to suppliers.
 PPAP document prepared as per AIAG manual.
8.3.5.2 Manufacturing process design output
 The manufacturing process design output is expressed in terms that can be verified against
manufacturing process design input requirements and validated.
 The manufacturing process design output includes,
o Specifications, data sheet, and drawings,
o Manufacturing process flow chart,
o Manufacturing process FMEAs,
o Control plan
o Work instructions (Standard operating procedures)
o Process approval acceptance criteria
o Data for quality, reliability, maintainability and measurability,
o Results of error-proofing activities, as appropriate, and
o Methods of rapid detection and feedback of product/manufacturing process

nonconformities.
8.3.6 Control of design and development changes/8.3.6.1 Design and development changes –
supplemental.
The Development Manager is authorized to change the process design. The process design changes
may be due to one OR more of Following Reasons:-
1) Production feedback
2) Inspection result
3) Technological improvement OR change
4) Verification feedback
5) Availability of Material
All design changes after initial approval, including those proposed by the organization or its suppliers,
for potential impact on fit ,form, function, performance or durability. These change validate against
customer requirement.

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The concerned dept. manager such as production, Q.C. OR Dispatch shall give process design
change as per procedure for control of document. Process design change add in ECN report.
The process design Change shall be properly incorporated at required location such as drawing
changes, change in material, specification. All the connected drawing & control plan shall be
connected in line with the product design change OR Modification.
8.4 Control of externally provided processes, products and services/8.4.1.1 General

supplemental , 8.4.1.2 Supplier selection process
Company purchases from approved suppliers to ensure that purchased products conforms to
specified requirements.
 The Company purchases its products like raw material, Job worked material, bought out
items, packaging material etc. from the Approved suppliers to ensure that purchased product
conforms to specified purchase requirements and applicable regulatory requirements.
 Supplier is selected based on evaluation on various factors like
o Their customers and products
o Availability of adequate facilities like machineries, measuring equipment etc
o Compliance to ISO 9001quality management system requirements
o Their system of On-time delivery performance monitoring, control of production

provision, monitoring and measurement of products, control of monitoring and
measuring devices, corrective action on customer complaints, Govt., safety and
environmental compliance etc.
o Assessment of the selected supplier’s risk to product conformity and uninterrupted

supply of the organization product to their customer.
 Party is assessed and selected based on the above factors in the Supplier self assessment
form. Job Work Supplier select based on auditing and fulfill the requirement of ISO – 9001.
Audit conduct by receive quality control manager.
Other supplier selection criteria that should be considered include the following:
 Volume of automotive business

 Financial stability
 Purchased product, material or service complexity
 Required technology
 Adequacy of available resource
 Design and development capabilities
 Manufacturing capability
 Change management process
 Business continuity planning
 Logistic process
 Customer service

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8.4.1.3 Customer-directed source
 All supplier selection steps not followed for customer approved source unless specific
agreements or defined by the contract between the organization and the customer.
 Company purchases products, materials from the approved sources, where contractually
agreed with the customer
8.4.2 Type and extent of control/8.4.2.1 Type and extent of control - supplemental.
After receipt of the purchase item/Job work item receive from the suppliers, they are verified with
respect to the Control plan. Raw Material test report /GRN to ensure that the purchased product
meets specified purchase requirements. Supplier’s delivery and quality performance is evaluated
based on their supplies.
If purchased item is released for further processing prior to verification they are identified so and are
not used till the verification is completed.
Vendor effectiveness monitoring by evaluation as per criteria given in document process of Job work.
8.4.2.2 Statutory and regulatory requirements
Statutory and regulatory requirement like VAT no./Excise law verify during selection of supplier.
No any special control needed for Statutory and regulatory requirement related to product.
8.4.2.3 Supplier quality management system development
 Company performs supplier quality management system development with the goal of
supplier conformity with ISO 9001:2015.
 Based on the following factors, suppliers are developed (from the approved supplier list).
o Performance of Supplier
o Importance of the product they supply
 Supplier’s quality management system is developed by using any of the following means:
o On site supplier quality management system second party audit

o Certification to ISO 9001 through third party audit: suppliers to the organization shall
demonstrate conformity to ISO 9001 by maintaining a third party certification issued by a
certification body bearing the accreditation mark of a recognized IAF MLA.
o Participating them in the in house training program
o Sending quality performance ratings and obtaining corrective actions of their process or
systems
o Getting self assessed from the suppliers them selves, based on the company’s quality
management system checklist
o Sending useful training materials to the suppliers for upgrading their knowledge & its
implementation etc.
o If Required Technical Support Given for upgrading.

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 Rec. QC. Mgr. identifies and communicates the areas for improvement based on the Supplier
Performance.
 Rec. QC Mgr. obtains the corrective action plan with target dates of the completion from the
supplier.
 Progress of the supplier development activities is reviewed in MRM on regular basis.
 If the suppliers are not certified with the ISO 9001, M.D. or Manager Marketing takes the
concession from the customer through the questionnaire of customer specific requirement.
 Company ensures that the dealers are authorized by the respective sources.
 Company controls the materials received from dealers by control plan.
8.4.2.3.1 Automotive product related software or automotive product with embedded software
At present company not use any software for automotive product.
8.4.2.4 Supplier monitoring
 Approved suppliers are evaluated on regular basis on following factors and results are
recorded in the Supplier Evaluation form.
o Delivered product quality
o Customer disruption with the field returns
o Delivery schedule performance (including incidents of premium freight)
o Special status customer notification related to quality or delivery issues
o Dealer returns, warranty, field actions and result
 Suppliers may be re evaluated on following situations
o When there is a change in quality system requirements
o On consistent poor performance
o When supply has been stopped for a considerable period of time (more than one year)
 Company monitors the supplier’s performance of their manufacturing processes (Rejection

trend, process capability trend etc) during the supplier on-site quality management system
assessment.
 Supplier graphical evaluation (Quality and Delivery) is reviewed in the Management Review
meetings and actions arising from the review are recorded.
 Company uses quality, quantity, special status, Line stoppage, Warranty and delivery rating
criteria as defined in supplier performance report.

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 Overall performance guide line mentioned in Supplier performance report
Evaluation criteria:-
Rating is = (B/A)*100
A = Schedule Qty.
B = Receive Qty.
Premium Freight Consider in over all rating has been
Criteria For Premium Freight Paid

1000< Amount Than Penalty (-) 0%
1000<= Amount <5000 Than Penalty (-) 5%
Amount <=15000 Than Penalty (-) 20%
8.4.2.4.1 Second party audits
Supplier audit conduct as per supplier audit plan with their supplier management approach, second
party audits may used for the following:
a)Supplier risk assessment

b) Supplier monitoring
c) Supplier QMS development
d) product audits
e) process audits
Supplier audit need, criteria scope & frequency decided on basis of product safety/regulatory
requirement, performance of the supplier. and QMS certification level at a minimum.
8.4.2.5. Supplier development
Active supplier priority, type ,extent and timing of required supplier development actions for its active
suppliers.
Regular supplier audit conduct on following inputs but not limited:
a) Performance issue identify through supplier monitoring
b) Second party audit findings
c) Third party quality management system certification status
d) Risk analysis
8.4.3 Information for external providers/8.4.3.1 information for external providers-supplemental
Purchasing information shall describes the product to be purchased including the following
appropriates :
 P.O. contains purchasing information describing the product to be purchased like the material
specification, dimensional requirements, delivery requirements etc.
 P.O. may also contain information related to the requirements for approval of product,
procedures, processes and equipment, requirements for qualification of personnel and quality
management system requirements, if required so.

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 MD reviews the PO to ensure the adequacy of specified purchase requirements and after
getting approval from MD releases to the supplier.
 External provider interactions with Purchase In charge.
 All statutory and regulatory requirements are communicate to supplier in PO
 Any special product and process characteristics requirement communicate through Drawing
by mentioned symbol.
 Suppliers laid down this requirement at point of mfg.
8.5 Production and service provision

8.5.1 Control of Production and service provision
 The Company plans and carries out production under controlled conditions.
o Control plans or drawing sheet are accessible to the workstations, which contain all
information that describes the characteristics of the product.
o Work instructions for machine set up for all the employees having responsibilities for
operation of processes that impact product quality, they are made accessible for use
at the workstation. These instructions are derived from the control plan.
o Equipment, suitable for the operation is available for use.
o Equipment for the monitoring and measuring is mentioned in the control plan and is
made available for use.
o Production processes are validated by first piece verification and results are noted
down in First Piece Approval & Inprocess Inspection Report.
o Upon the completion of all the operations as mentioned in the control plan they are
released for the final inspection, packing and delivery.
8.5.1.1 Control plan
 Company plans and develops the processes needed for product realization, whenever new
products are to be developed or when there is a major change in the existing product.
 Company ensures that control plan is consistent with the requirements of the other processes
of the quality management system.
o Pre launch & production Control plan that have linkages and incorporates information from
the design risk analysis, process flow & manufacturing process risk analysis outputs.
o Manufacturing Process FMEA is carried out for the entire customer designated special
characteristics.
o Company determines the requirements for the product and is addressed in the Control plan
 Control plans are developed for all the parts at various stages starting from receiving to the
final.
 Manufacturing process FMEA outputs are taken in to account in the Control Plan.
 The Control Plan has following information:

Page 13 of 23
o List of controls used for the manufacturing process control including verification of job
setups.
o First off/last off part validation as applicable.
o Methods for monitoring of control exercised over special characteristics defined by both
the customer and the company
o Customer required information, if any
o Reaction plan, when the process become unstable or not statistically capable/non
conforming product detect.
 Customer requirements and references to its Technical specification (Drawings) are included
in the control plans.
 Acceptance criteria are defined in the control plans. If required it is sent to the customer for its
approval before the PPAP lot submission. For the attribute data sampling, acceptance level is
taken as zero defects and are mentioned in the control Plans.
 Control plans are reviewed and updated when any change occurs effecting product,
manufacturing process, nonconforming product shipped to the customer, measurement,
supply source, production volume change, or FMEA.
 Control plan are reviews after customer complaint and implementation of the associated
corrective action,
 Company reviews the existing processes and documentation with respect to the specific
requirement of the product and if necessary, it establishes new processes or modifies the
existing processes.
 Company also determines and provides new resources requirement like machineries, fixtures,
qualified personnel etc, specific to the product.
 Company determines verification, validation, monitoring, inspection and test activities specific
to the product and the criteria for product acceptance and is addressed in the control plan.
 Records (like inspection/test records, SPC records, etc.) are maintained to provide evidence
that the realization processes and resulting product meet requirements.
 Company also ensures that the output of this planning is in a form suitable for the company’s
methods of operations.
8.5.1.2 Standardized work – operator instructions and visual standard
Following point consider in standardized work document

 Work instruction ,Visual standard & Standard operating instruction display near to work
station & Communicate and understood by the employees who are responsible for
performance the work.
 Legible at work station
 All WI Made in operator understandable language
 Accessible for use at the designated work area.
 Also include the rules for safety.

Page 14 of 23
8.5.1.3 Verification of job setup/8.5.1.4 Verification after shutdown
 Job setups are verified whenever a setup is performed (e.g. initial run of a job, material
changeover, job change, significant time periods lapsed between runs, etc) and are recorded
in First Piece Approval & In process Inspection report. Job instructions are available for setup
personnel as applicable. Company uses statistical methods of verification for all the special
characteristics as identified in the control plans.
8.5.1.5 Total productive maintenance
Following point include in total productive maintenance system:
 Identification of process equipment necessary to produce conforming product at the required

volume.
 Prepared list of critical spare for critical machine
 Maintenance facility provide for machine and equipment maintenance at In house /outside.
 Preservation of equipment, tooling & gauge by checking of dial PM check sheet.
 At present no customer specific requirement related to maintenance.
 Maintenance objective cover with OEE,MTBF.MTTR same shall be consider in MRM.
 Prepared Preventive maintenance plan and records for review.
 Predictive maintenance activity not applicable.
 Maintenance method where to prevent a major unplanned breakdown where based on fault or
interruption history, a piece of equipment, or subsystem of the equipment, is proactively taken
out of service and disassembled, repaired, parts replaced, reassembled and then returned to
service. same shall be recorded in Break down maintenance register.
8.5.1.6 Management of production tooling and manufacturing, test, inspection tooling and
equipment.
 A system for tooling management is established and implemented as per the following:
o Maintenance and repair facilities and personnel
o Storage and recovery
o Setup
o Tool change programs for perishable tools
o Tool design modification documentation, including engineering change level of the

product.
o Tool modification, including tool design documentation
o Tool Identification, such as serial or asset number the status, tool production, repair
or disposal by production In charge.
 The company provides necessary technical resources for tool and gauge design, fabrication
and full dimensional inspection, if any of this work is subcontracted. Company also ensures to
track and follow-up on these activities as per the activity chart.
 At present we are not use customer owned tools, manufacturing equipment and test
/inspection equipment.

Page 15 of 23
8.5.1.7 Production scheduling
 For regular product
o Upon the receipt of the customer order, (written), Manager Marketing reviews the
requirements related to the product, including the product specifications, timing and
quantity requirement, packaging, transportation requirement etc and Manager - Marketing
shall acknowledgment the order by email same shall be add in customer order
monitoring sheet.
o Mgr. Marketing resolves with the customer if any of the contract or order requirements are
differing from those previously expressed.
o Asst. Manager Marketing receives schedule from customer (OEM) for regular order &
review the same for delivery with Managing Director, Technical Director and Executive
Director, if required.
o Status of the pending order shall be monitored through Computer system. Asst. Manager
Marketing shall inform to customer change in schedule if delay.
o Order Amendments: Mgr. Marketing shall process any amendment in the customers
order after any change in tech./ Commercial terms for the product, review & amendment
to contract and request to customer for P.O. Amendment (if applicable).Customer revised
P.O. received and P.O. accepted status inform to customer by email. Revised order detail
communicate to PPC.
 Mgr. Marketing contacts the customer, if any of the requirements are not clearly defined or
understood.
 Records of the results of the review and actions arising from the review (Team feasibility form,
customer communication on schedule matters, Management review) are maintained.
 If customer given any authorized waiver for the requirements stated shall be keep as
document information for review.
 Manager Marketing prepared the Daily Dispatch Advise Form and gives to dispatch incharge.
 Asst. Manager Marketing monitors the actual dispatches with the committed in the Daily
Delivery Performance Monitoring – Product Wise.
 Asst. Manager Marketing presents the Customer & Product wise delivery performance report
in Management review meetings.
 Production planning
 Manager Marketing shall prepared tentative production plan on the basis of customer
schedule, pending order and order received from OEM in consultation with M.D. and G.M.
(Operation).
 On the basis of tentative production plan and availability of the material, PPC I/c & Production
I/c. shall prepared production plan on monthly basis.
 Make monthly production plan of components before the starting of month in 'Monthly
Production Schedule Cum Production Performance Monitoring.'

Page 16 of 23
 Daily production status review against plan in daily meeting and take appropriate action and
priority as per instruction from Vice President.
 Based on orders and stock, component planning is carried out than release P.O. to supplier.
 Daily and monthly production PPC I/c reviewed through ‘Monthly Production Schedule cum
Production performance Monitoring’ & Production S.H. reviewed through ‘Week wise
Production Schedule Cum Date & Operation wise Production Monitoring’ - monitor the
progress of daily production against the commitment
8.5.2 Identification and traceability/8.5.2.1 Identification and traceability - supplemental
 Company utilizes Identification Tag for effective component identification and trace ability.
The responsibility for identification of the product by suitable means throughout product
realization is as per the defined below.
S. N. Type of Product Responsibility

1 Raw material, Bought out material and packing material Receiving Material Stores I/c.
2 In process material Prod. S.H. / Inspector

3 Finished components Dispatch Incharge
Product Identification at Incoming Stage:
1. Stores: Material received and pending for inspection shall be kept in identified area mentioning
“Pending for Inspection”. Rejected Material shall be kept in Rejected Area. All other material
available in the stores shall be treated as “Conforming Material” and at all the stages, material
shall be identified with Tags / No. mentioned on racks.
2. Raw Material Store (Green Tag): Con Rod available in the Raw Material Stores shall be
identified by Green Tag. With details of Part Description, Op. Completed, Supplier, Ch. No. & Dt.,
Qty., Sign. and Date.
3. Product Identification at Inprocess Stage:
1. The semi-finished product shall be kept in identified area bins with details of Item No.,
Operation completed and test status. Inprocess Identification as below
Color code of Tags

Type Tag
OK Green tag
Pending for Inspection Yellow Tag
Rework Blue Tag
Master Piece Orange Tag
Rejection Red Tag
Deviation White Tag

Page 17 of 23
Product Identification at Final Stage:
The Company identifies the product status with respect to monitoring and measurement
Requirements. Tags or color provided by customer on the product which indicates
the following Information
Color code of Tags

Type Tag
OK Green tag
Pending for Inspection Yellow Tag
Rework Blue Tag
Master Piece Orange Tag
Rejection Red Tag
Devotion White Tag
 All the products which are to be rejected are identified so and kept in separate location. All the
products which can be corrected are identified so and kept in separate location.
 Company has the following coding system for traceability for components since traceability is
a specific requirement,
Part Traceability System:
Sr. No. / Month Code / Year Code / AI (Amul Industries)
e.g. xxxx/A/9/AI
8.5.3 Property belonging to customer or external providers
 Customer drawings or sample are protected it from lost or damages. Manager Marketing
reports the customer representative if the drawings are lost, damaged or unsuitable for use.
 Company does not possess any customer – owned production tooling; hence the standard
requirement on customer – owned production tooling is not applicable.
8.5.4 Preservation/8.5.4.1 Preservation - supplemental
 Company has established a system to preserve the conformity of product during all the
stages of production. Established system mentioned below includes identification, handling,
packaging, storage and protection of the product
 Company preserves the conformity of product during internal processing and delivery to the
intended destination.
Handling:
 Stores Incharge, Section head and Asst. Manager Quality shall ensures that material /
product is carefully handled at all stages of production to prevent damage or deterioration of
the material / product. Where required specific instructions for handling / transportation shall
be given which provides appropriate precautions to be taken for this activity.General part
specific trolly use for part handling.

Page 18 of 23
Packaging:
 Packaging for manufactured products is designed in consultation with customer, to the extent
necessary to ensure conformance to specified requirements. Production Manager and
marketing manager shall ensure that packing of final product is carried out as per schedule.
 Raw material is stored at designated storage area and details of stock are noted down in
stock register,
 Inventory turns over time (Sales value/Inventory value) are monitored at every month &
review Every Six Month and also in the management review meeting. Stock rotation (lying in
various areas) is ensured by following the Stock Register.
 Obsolete products are controlled in a similar manner to nonconforming product.
 Consumable material stock and issue – receipt details are noted down in Stock register.
 Packing, shipping & labeling requirement add in control plan.
8.5.5 Post delivery activities
 Presently post delivery activities are not a requirement, hence not addressed.
 Company not binding or not contract with customer for warranty provisions, contractual
obligation such as maintenance services, and supplementary services such as recycling or
final disposal.
8.5.5.1 Feedback of information from service/8.5.5.2 Service agreement with customer
Since no customer requirement of after service, the requirements on these clauses are not defined &
documented. However, on requirement from the customer, system shall be defined
8.5.6 Control of changes/8.5.6.1 Control of changes - supplemental
 Company has a process to control and react to changes that impact product realization. For
any process changes (including during new product introduction) occur due to following
situations PPAP is initiated through ENGINEERING CHANGE TRACKING FORM.
o Product or process changes related to the components to production parts and

manufacture internally that impact fit, form, function (including performance and /or
durability).
o When customer requires additional verification / identification
o Change in supplier for parts that affect fit, form, and function (including performance and /
or durability).
 The results (from the inspection/test records, SPC records etc.) after the process changes are
verified and validated to see whether the product meet customer specific requirements or not.
These results are communicated to the customer if required by the customer through Part
submission warrant (PSW).
8.5.6.1.1 Temporary change of process controls
Prepared 4M change sheet which include all the alternate method use for change. Alternate method
decided on basis of risk analysis or PFMEA.

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Before shipping product that was inspected or tested using the alternate methods, if required, the
organization shall obtain approval from the customer. The organization shall maintain and periodically
review a list of approved alternate process control methods that are referenced in the control plan.
Standard work instructions available for each alternate process control method. The organization
review the operation of alternate process control on a daily basis, at a minimum, to verify
implementation of standard work with the goal to return to the standard process as defined by the
control plan as soon as possible.
Daily review method as per following

1)Daily quality meeting
2)Daily leadership meeting
Maintained traceability of all product produced while any alternate process control devices or
processes are being used. (e.g. verification and retention of first piece and last piece from every shift)
8.6Release of products and service/8.6.1 Release of products and service-supplemental
 During the In-process & final stage, products are inspected as per the frequency defined in
the Control plan and recorded in the First Piece Approval Cum Inprocess Inspection report
(Process wise) and Final inspection report respectively.
 Inspection reports are indicated with the person(s) authorizing release of product.
 In case, if the planned inspection arrangements are not completed at any of the production
stages, they are not released to the customer, unless they give the approval.
 Various parts of Con Rods are inspected and results are noted down in First Piece Approval
Cum In process Inspection report (Process wise) for in process stage and Final inspection
reports for final stage.
8.6.2 Layout inspection and functional testing
 Quality Manager ensures that a layout inspection is carried out for all the parts as per Layout
inspection plan and recorded in the Layout Inspection report.
 Quality Manager ensures that the results of the Layout inspection is made available for the
customer review, if require by them.
8.6.3 Appearance items
 No products have been designated as ‘Appearance items’ by any of the customers. Hence
the requirements on appearance items are not defined & documented. However, on
requirement from the customer, system shall be defined.
8.6.4 Verification and acceptance of conformity of externally provided products and

service8.6.5 Statutory and regulatory conformity
 Upon the receipt of the materials from the suppliers, they are verified as per the control plan/
Specification chart for each raw material and results are recorded in Receiving Inspection
Report and Material Test Report.
 Frequency of receiving inspection and control method, which are addressed in control plans
are decided based on the following

Page 20 of 23
o Suppliers’ statistical data (Inspection/test reports etc.)

o Suppliers’ performance.
o Designated laboratory part evaluation results
 When materials are released for further processing prior to verification they are identified so
and are not dispatched till the verification is completed.
 Those lots which have been given concession to the supplier are identified with the
Identification tag.
 Release of externally provided products into its production flow , the company confirm and
able to keep evidence that externally provided processes, product and services conform to
the latest applicable statutory, regulatory or other requirements in the countries.
 Where the Company or its customer intends to perform verification at the supplier’s premises,
the Company states the intended verification arrangements and method of product release in
the Purchase order.
8.6.6 Acceptance Criteria
Acceptance criteria are defined in the control plans. If required it is sent to the customer for its
approval before the PPAP lot submission. For the attribute data sampling, acceptance level is taken
as zero defects and are mentioned in the control Plans.
8.7 Control of nonconforming outputs / 8.7.1.2 Control of nonconforming product-customer

specified process/ 8.7.1.3 control of suspected product /8.7.1.4 Control of reworked product /
8.7.1.5 Control of repaired product 8.7.1.6 Customer notification / 8.7.1.7 Nonconforming
product disposition.
Description:
 Quality Manager ensures that Non-conforming products (including the product with
unidentified or suspect status) found at any stage (i.e. receiving, in-process and final) are
identified as non-conforming product and are kept at separate location to prevent its
unintended use.
 After maintaining the record of the non-conformity, QA Manager shall dispose of the
Non-conforming Material.
 Quality Manager reviews the non-conforming products and initiates any of the following
actions, but not limited to,
o Rework the nonconforming product to meet specified requirements
 Reject the nonconforming product QA Incharge shall take the decision to dispose the
Nonconforming material:
By taking action to eliminate the detected non-conformity.

Release or Accept under concession, if required by the customer.
Reject or scrap.
Rework.
Based on above points, Quality Incharge shall take corrective and / or preventive actions.
QA Incharge shall review the non-conformity analysis, once in a month and take corrective
and / or preventive action in area where major problem observed.

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The responsible person shall identify non-conformity products by keeping non-conforming

product in specified area / bins / labels. Where contractually mentioned by the customer, the
use of repaired / reworked product, which does not conform to the specified requirement,
shall be informed to customer or customer’s representative.
 Re-verification is done as per the control plan for the products, which have been corrected.
 In case, if it is found that any nonconforming products are found to have already delivered to the
customer, Quality Manager takes any of following actions based on the effects or potential effects
of the nonconformity.
o Inform Manager Marketing to inform the customer regarding the detected

nonconformity.
o Inform Manager Marketing to offer replacement to the customer. (If it is functionally

affected)
 Production Section Head & Quality Manager analyses the nonconforming products and
summarize it in the N. C. Register and make the graphical presentation in the management
review meeting.
 Training provide to Inspector regarding non conforming and suspected product.
 If any customer specific control for non conforming product that step follow.
 All reworked product at any stage shall be re-inspected as per respective control plan
and Drawing and record after rework re verification maintained with traceability.
 Risk analysis include in rework process decision.
 At present company will not include in repaired product activity with customer.
8.7.1.1 Customer authorization for concession
Incase, the product deviates from the currently approved product, prior customer authorization is
obtained & details including the expiration date or quantity authorized & the identification mark are
note down in the Engineering approval product authorize.
If, any verbal approval given by customer regarding above matter then note down the customer
authorized person name and time of tele talk & other details in the Engineering approval product
authorization form.
Copy of Engineering approval product authorization form is given to dispatch person.
Material stripped on any authorization is identified on each package and a copy of Engineering
approval product authorization form is sent along with the dispatch.
8.7.1.6 Customer notification
 In case, if it is found that any nonconforming products are found to have already delivered to the
customer, Quality Manager takes any of following actions based on the effects or potential effects
of the nonconformity.
o Inform Manager Marketing to inform the customer regarding the detected

nonconformity.
o Inform Manager Marketing to offer replacement to the customer. (If it is functionally

affected)

Page 22 of 23
Procedure for request for change : VHV/P/8/01
Procedure for customer order : VHV/P/8/02
Procedure for Supplier selecton evaluation : VHV/P/8/03
Procedure for store : VHV/P/8/04
Procudure for tooling management : VHV/P/8/05
Procedure for production planning : VHV/P/8/06
Procedure for Inspection : VHV/P/8/07
Procedure for Preventive and breakdown maint : VHV/P/8/08
Procedure for ECN : VHV/P/8/09
Procedure for development of new product : VHV/P/8/10
Procedure for PPAP : VHV/P/8/11
Procedure for supplier development : VHV/P/8/12

Page 23 of 23
Quality Manual Performance Evaluation
Purpose :-
Production Manager : - For the performance evaluation of the product and process.
Marketing Manager:- For the performance evaluation of customer satisfaction.
MR : For performance evaluation of internal audit.
MD: Responsible for conduct the Management review meeting.
NPD Manager: Responsibility for identification of statistical concepts.
Description:-
9.1 Monitoring, measurement, analysis & evaluation
 The company monitors and measures the quality management system processes in the
internal quality audits. In the Internal quality audits, it is verified that the planned results of the
quality management system processes are achieved.
 When planned results are not achieved, correction and corrective action is taken, as
appropriate, to ensure conformity of the product.
 Studies all the new manufacturing processes (like during new product development) to verify
process capability & to provide additional input for process control.
 Production manager ensures that the Control plan and process flow charts are implemented,
including adherence to the specified.
o Acceptance criteria, and

o Reaction plans when acceptance criteria are not met
 On occurrence of change in any processes, relevant documents (like flow process chart,
Control / Quality plans etc) are changed to know the effective dates of process changes.
 Company ensures that planning of product & service is consistent with the requirements of
the other processes of the quality management system.
9.1.1 Monitoring and measurement of manufacturing processes
 The company monitors and measures the quality management system processes in the
internal quality audits. It is verified that the planned results of the quality management system
processes are achieved.
 When planned results are not achieved, correction and corrective action is taken, as
appropriate, to ensure conformity of the product.
 CFT studies all the new manufacturing processes (like during new product development) to
verify process capability & to provide additional input for process control.
Prepared by . Approved by .
Page 1 of 9
 Production Manager ensures that the Quality (control) plan and process flow charts are
implemented, including adherence to the specified.
o Measurement techniques
o Sampling plan
o Acceptance criteria
o Records of actual measurement value and test result for variable data.
o Acceptance criteria, and
o Reaction plans when acceptance criteria are not met
 Control charts (X & R chart) are used for the special characteristics as identified in the Control
plan(s). Where the customer requires for a certain level of capability of any processes (like Cp
>=1.33 / Cpk >= 1.67 etc), they are maintained. Process capability is measured for such
product characteristics in the Process capability study sheet.
 Significant process events, such as tool change or machine repair, shall be recorded in X-R
chart.
 Production Manager initiates a reaction plan ( 100 % inspection) from control plan for
characteristics that are found either not statistically capable or unstable from the Process
capability study / X &R Chart (Control chart).
 In such cases, Production Supervisor & Quality Inspector Ensures 100% inspection or
containment of product as appropriately.
 Production manager And Quality Manager takes appropriate actions to ensure that the
process becomes stable and capable.
 On occurrence of change in any processes, relevant documents (like flow process chart,
Control plans etc) are changed to know the effective dates of process changes.
9.1.1.2 Identification of statistical tools
 Cross function team determines appropriate statistical tools including process stability &
capability studies, measurement system analysis etc during advance quality planning and
includes it in the control plan.
 During the process of taking of corrective action, following statistical tools may be used
o Brainstorming
o Cause & effect diagram
o Pareto analysis
o Histograms
o Mistake Proofing
9.1.1.3 Application of statistical concepts
 Basic statistical concepts, such as variation, control (stability), process capability and over-
adjustment are understood and utilized throughout the organization as applicable and
employee are involved in the collection, analysis and management of statistical data.
Page 2 of 9
9.1.2 Customer satisfaction/ 9.1.2.1 Customer satisfaction -supplemental
 Marketing Manager conducts survey on customer satisfaction on 12 Month basis in the

Customer satisfaction survey form, to know whether the company has met the customer
requirements.
 Following points are covered in the satisfaction survey
o Delivered part quality performance
o Customer disruptions
o Field return, recalls and warranty
o Delivery schedule performance(including incidents of premium freight)
o Customer notification of quality or delivery issues,including special status
 M.D. compares the customer satisfaction survey results received from the customer with that of
the objective data available in the company.
 Apart from the survey, company also takes into consideration the following aspects to know
the satisfaction level of its customers
o Customer ratings / On site customer assessment scores, delivery ratings, customer

notifications/portal data
o Customer complaints (No. of customer complaints, Nature & severity of the customer
complaints, Repetitive complaints etc, Product returns)
o Information received during the direct interaction with the customers
o Trend in the dependency on the company (new source development etc)
 Customer satisfaction study results (in the graphical manner, as appropriately) are analyzed
in the Management review meetings, which is an indication of the performance of the quality
management system
9.1.3 Analysis and evaluation/9.1.3.1 Prioritization
 To demonstrate the suitability and effectiveness of the quality management system following
are analyzed in the Management Review meetings as per the frequency depending on the
events.
o Results of the customer satisfaction surveys
o Customer complaints trend
o Customer ratings
o Trends in the rejections
o Cost of poor quality
o M/c breakdown% MTTR/MTBF trend
o Inventory turnover ratio
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o Company’s delivery adherence
o Overall equipment effectiveness (OEE)
o Results of the Internal audits (no. of non conformities and the severity of the
nonconformities)
o Performance of the suppliers etc.
 In the Management review meetings, trends in quality and operational performance (like
rejection%, cost of poor quality, no. of customer complaints, delivery performance, inventory
turnover ratio, m/c breakdown% etc) are compared with progress toward objectives and lead
to support the following
o Development of priorities for prompt solutions to customer-related problems;
o Determination of key customer-related trends and correlation for status review,

decision-making and longer term planning;
o Information system for the timely reporting of product information arising from usage
 In the graphical trends, objectives are shown with thicker dotted lines for the easy comparison
of the progress.
9.2 Internal audit / 9.2.2.1 Internal audit programme /9.2.2.2 Quality management system audit /
9.2.2.3 manufacturing process audit .
Procedure description:
 Company selects the auditors based on the training given to them on ISO 9001:2015 , Internal
Audit Training and list of qualified auditors is made. Scope of the auditors in the internal audits is
defined in it, considering that the auditors do not audit their own work.
 Management representative prepares Yearly Internal audit plan for ISO 9001:2015 to conduct
internal audits of all the functions once in Six months.
 Apart from the quality management system, internal audits cover following points also, as
applicable
o Manufacturing process audit to determine its effectiveness.
 Management representative releases the Internal Audit Schedule For ISO 9001:2015 to the
Auditors and the Audit representatives to ensure that the auditors as well as the auditees are
aware of the plan/schedule date.
 Auditors communicate the time of the audit to the respective auditees before commencement of
the audits.
 Auditor audits the function to be audited (Auditee) as per the Plan. Quality management system
documents like Quality manuals, Procedures, Processes, Control plans, Work instructions are
used as audit checklist. Specific checklists (Mfg. process audit check list.) may also be used if
required for the Auditors.
 Auditors issue Nonconformity cum corrective action reports to the auditee for all the
nonconformities observed during the audit.
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 Audit Observation recorded in Audit Observation Report.
 Auditee takes the disposal action / corrective action (as appropriate) to eliminate the non-
conformity identified during the audit and submits the completed Nonconformity cum corrective
action reports to the Auditor.
 Auditor verifies the corrective action / disposal action taken in the follow-up audit.
 Auditor verifies the effectiveness of the corrective action taken during the follow-up audits and he
notes down his comments in the Nonconformity cum corrective action reports.
 Auditors submit the Nonconformity cum corrective action reports to Management Representative,
after closing the nonconformities.
 Auditor reports to Management Representative, if actions are not found completed during Follow-
up audit.
 MR may in-turn rearrange the Follow-up audit to ensure that the actions are taken without undue
delay to eliminate detected nonconformities and their causes. Auditors also see during the audit
whether any of the NCs of the previous audits are pending with the Auditee.
 Management Representative evaluates the audit results and prepares Summary of non-
conformity based on IQA for the management review.
 If more nonconformity is received in any of the areas, MR updates audit plan, by increasing the
frequency of the audits in that particular area.
Note: For the easy understanding of the internal audit procedure, refer Quality System Procedure
Internal audit.
9.2.2.4 Product audit
 Product audits are conducted at various stages (After completion of all processes) to verify
conformance to all specified requirements, such as product dimensions, functionality,
packaging and labeling. Product Audit conducted as per Mfg. process cum product check
sheet.
9.3 Management review
9.3.1/9.3.1.1 General
 Management reviews the organization’s Quality Management System after every 6 months to
ensure its continuing suitability, adequacy and effectiveness.
 This review includes assessing opportunities for improvement and the need for changes to
the Quality Management System including Quality policy and Quality objectives.
 MRM frequency increase on based on risk to compliance with customer requirements

resulting from internal or external changes impacting the quality management system and
performance related issue.
 Records from management reviews shall be maintained.
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9.3.2 Review Input:-
The input to management review includes information on :-
1 The status of actions from previous management review

2 Changes in external & internal issues that are relevant to the QMS.
3 Information on the performance and effectiveness of the QMS including
1) Customer satisfaction & feedback from relevant interested parties
2) Quality objective
3) Process performance & conformity of products and services
4) Nonconformities and corrective actions
5) Monitoring and measurement results
6) Audit results
7) The performance of external provider (Job work).
8) Cost of poor quality
9) Measures of process effectiveness
10) Measures of process efficiency
11) Product conformance
12) Assessment of manufacturing feasibility made of changes to existing operations and for
new facilities or new product
13) Customer satisfaction
14) Review of performance against maintenance objective
15) Warranty performance
16) Review of customer scorecard
17) Identification of potential field failure identified through risk analysis
18) Actual field failure and their impact on safety or the environment.
4 The adequacy of resources
5 The effectiveness of actions taken to address risk & opportunities
6 Opportunities for improvement
9.3.3 Review Output :-
The output form the management review includes any decision and actions related to:
1 Improvement of the effectiveness of the Quality Management System and its processes
2 Improvement of product related to customer requirements, and
3 Resources needs
Minutes of meeting shall circulated to all functional heads and get the target date of completions of
actions decided in management review.
Customer performance target not met then top management shall make & implement action plan.
Procedure for the internal audit : VHV/P/9/01

Procedure for MRM : VHV/P/9/02
Mfg. Process and product audit : VHV/P/9/03
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Quality Manual Improvement
Purpose :-
Production Manager: - Responsible for the error proofing system.
Quality Manager : Responsible for customer complaint and field failure including any returned parts
and shall initiate problem solving and corrective action /Warranty failure /no trouble found.
CFT: Responsible for problem solving & continual improvement.
Description:-
10.0 Improvement
10.1 General
Company has determined the opportunities for improvement and implement necessary actions to
meet customer requirements.
Organization shall include
a)Improvement in products to meet requirements as well as to address future needs and

expectations.
b) correcting, preventing or reducing undesired effects
c)improving the performance and effectiveness of the quality management systems.
Improvement can include correction, corrective action, continual improvement, breakthrough change,
innovation & re-organization.
10.2 Nonconformity and corrective action
10.2.1/10.2.2
Non-conforming products found at any stage (i.e. receiving, in-process and final) are identified
as non-conforming product and are kept at separate location to prevent its unintended use.
Details including reason of non-conformity are recorded in the Batch card or production report
as per the documented procedure for Control of Non-conforming product.
In-charge Production review the non-conforming products and initiates any of the following
actions, but not limited to:
Rework the non-conforming product to meet specified requirements,

Reject the non-conforming product,
Accept the non-conforming product under concession
Actions taken are also noted down in the Batch card or production report as per the
documented procedure for control of Non-conforming products.
Re-verification is done as per the drawing/control plan for the products, which have been
corrected.
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In case, if it is found that any non-conforming products are found to have already delivered to
the customer, In-charge production takes any of following actions based on the effects of
potential effects of the non-conformity.
Informs the In-charge marketing to inform the customer regarding the detected nonconformity.
Informs the in-charge marketing to offer replacement to the customer (It is functionally
affected).
In-charge production analyses the non-conforming products and summarize it and make the
graphical presentation in the management review meeting (If non-conformity is more).
Company has a documented procedure for taking action to eliminate the cause of non
conformities in order to prevent recurrence. Corrective actions are taken considering the
effects of the non-conformities encountered.
Concern function reviews the non-conformities in the following areas, but not limited to,
Customer complaints
Internal rejection
Product or process non-conformance
Supplier failure with respect to the quality and delivery
Any failure which has resulted in the customer dissatisfaction based on the Customer
satisfaction cum expectation survey
Based on the effects of the non-conformities, corrective actions are initiated in the form of
8D report as per the documented procedure for Corrective action by various functional heads to the
person responsible for corrective actions.
Person who is responsible for the corrective action determines the root cause of the non
conformities and noted down in the Corrective actions report as per the documented
procedure.
Person who is responsible for the non-conformity evaluates the need for action to ensure that
the non-conformity does not occur.
Concern function determines the action needed and are recorded in the corrective action
report as per the documented procedure.
Concern function ensures that the actions identified in the Corrective action report are
implemented.
M.R. reviews the results of the action taken in the Management Review Meeting and are
recorded in the Corrective action report as per the documented procedure.
Update risk and opportunities on basis of action.
10.2.3 Problem solving
 Company has defined process for problem solving leading to root cause identification and
elimination in the following situations
o Customer complaints
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o Customer delivery failures
o New product development problem
o Current manufacturing issues,
o Filed failure, audit findings
o Rejections etc
 Company uses following problem solving methods in the corrective actions (Corrective action
report), as appropriately
o Brainstorming
o Cause & effect diagram
o Pareto analysis
o Histograms
o Mistake proofing
o Poka Yoke
o 8D Methodology
 Systematic Corrective action implement to similar parts/process.

 Effectiveness of corrective action monitoring by same issue not occurs in next supply.
 PFMEA & control plan are update related to action.
 When external non-conformances occur, the company responds in a manner prescribed by
the customer.
10.2.4 Error-proofing
Company uses error-proofing methods in their corrective action process actions (Corrective action
report) to a degree appropriate to the magnitude of the problems and commensurate with the risks
encountered
Details of the method used shall be documented in the process risk – PFMEA and test frequencies
recorded in control plan.
Error proofing device test for failure and result recorded in Preventive maintenance report
Challenge parts of error proof device identified ,controlled, verified and calibrated where feasible
.Error proofing failure reaction plan defined in control plan.
10.2.5 Warranty management systems
At time of product development. standard term and condition sign. with customer for warranty failure.
Warranty issue handled as per procedure for warranty handling.
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10.2.6 Customer Complaint & field Failure test analysis
Enter the complaint details OR Field failure OR Returned parts detail in the Customer Complaint
Monitoring Register.
Analyze the root cause of the complaint, and take necessary corrective actions by using disciplined
problem solving methods (5Why,Ishikawa) & error proofing (as appropriately) in the Corrective action
plan analysis OR 8D Report.
If any customer need to specific time line for containment action ,root cause and corrective closer
same shall follow by Quality manager. Complaint closer time line mentioned in CSR matrix.
Apply the corrective action to eliminate the cause of nonconformity and note down the details in 8D
Report. Action communicate to the customer
10.3 Continual Improvement
Company has established systematic approach for continually improve the quality
management system through the use of quality policy, quality objectives, audit results,
analysis of data, corrective and preventive actions and management review etc.
Progress of quality objectives are monitored and reviewed in every management review
meeting and may be revised if necessary.
Audit results are analyzed for the No. of non-conformities received in various functions and
the severity of the non-conformities received during the internal quality audits.
Corrective actions may be taken by reviewing the existing systems and training may be
identified and given to the concern personnel.
Following point consider in Continual improvement
Identification of the methodology used , Objective , measurement, effectiveness and documented

information.
Manufacturing process improvement action plan with emphasis on the reduction of process variation
and Risk analysis.
Procedure for corrective & Preventive Action : VHV/P/10/01

Non conforming product : VHV/P/10/02
Procedure for customer complaint : VHV/P/10/03
Procedure for Continual Improvement : VHV/P/10/04
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QUALITY SYSTEM MANUAL

This manual and information contained therein is a

VHV PRECISION ENGINEERING

Prepared by: MR Approved by :-MD

We Are Committed to Provide Quality

1st June. 2022

4 Context of the organization

4.1 Understanding the organization and its context.

SWOT Analysis in QM/G of this manual.

4.2 Understanding the needs & expectation of interested parties.

A) Government department –VAT, Excise Department

Prepared by . Approved by.

4.3 Determining the scope of the quality management system

a) The external and internal issue as define in SWOT analysis.

Scope statement are define as per below :

Not applicable and Justifications:-

Clause 8.3: - Design & Development

4.4 : Quality management system and its processes :

 The company has established, documented, implemented and maintained a quality

o Ensures the availability of resources and information necessary to support the

o Company done outsource process like turning, Heat treatment, Calibration

Prepared by . Approved by.

o Monitors, measures and analysis these processes. Process capability, customer

o Implement actions necessary to achieve planned results and continual improvement

4.4.1.1 Conformance of products and processes

4.4.1.2 Product safety

Following product safety point consider in design of product :

 Identification of statutory & regulatory requirement of product safety.

Prepared by . Approved by.

4.4.2 To extent necessary, the organization shall :

1) SWOT Analysis –VHV/QM/G

Prepared by . Approved by.

To provide evidence of management commitment to the development and implementation of the

Responsibility and Authority :

 Management commitment demonstrates by Quality policy. Quality policy communicates

 Communicating to the organization the importance of meeting customer as well as

5.1.1.1 Corporate responsibility

5.1.1.2 : Process effectiveness & efficiency

 Top management has appoint competent person as process owner.

5.1.2 : Customer focus

Fronts Received from

5.2.1 : Establishing the Quality Policy

Quality policy shall communicate by following means:

 Quality policy shall document in Annexure I of this manual.

5.3 Organizational roles, Responsibility & Authorities :-

 Ensuring the promotion of awareness of customer requirements throughout the organization

5.3.1. Organizational roles, responsibilities & authorities

Setting quality objective Vice President

Related training HR Manager

Corrective and preventive

Capacity Analysis Production Manager

Logistic information Dispatch Manager

Customer Portal Marketing Manager

Quality policy – Annexure I

6.1 Action to address risks and opportunities

Management of Company ensures that:-

a) Action to address these risks and opportunities

6.1.2.1 Risk Analysis

Prepared by . Approved by.

Summary of corrective and preventive actions is submitted in management review.

6.1.2.3 Contingency Plans

 Contingency plan shall define on following basis:

Prepared by . Approved by.

6.2 Quality objective and planning to achieve them