KPM Reviewed & Approved By

QUALITY PROCEDURES
(Procedure For Quality Control - QP01)
-Page 1 of 6 Management Representative
Rev. 00/ 01-01-18
Purpose: To establish a procedure for Quality Control Dept. and to ensure that:
 The confirmed products are dispatched to next process/ customer.
 The dispatches are met as per the customer requirement.
Scope:
 Applicable to all items under the scope of Incoming inspection.
 Applicable to all stage inspections and final inspection.
Responsibility:
 Quality Control Head
System:
S No Activity Reference
Record/W.I Cl.n
o.
1.0 INCOMING INSPECTION
1 The incoming material are inspected as per the Incoming Inspection plan/work KPM/QC/01 8.6
instruction .4
2 After completion of inspection, the disposition status (Reject (or) O.K (or) Under
deviation) is communicated to Purchase dept. and Store dept. for necessary 8.6
KPM/QC/02
actions. .4
KPM/QC/26
After performing the necessary inspection activity, the incoming inspection 8.7
report is prepared and accordingly final decision is taken for the material.
2.0 SET UP APPROVAL
1 Whenever new set up is performed or change in tooling/ die or after major
overhaul in the machines which has been identified for change in set up. After
getting the approval from the Quality dept. for set up approval, only then the KPM/QC/07 8.5
production dept. continue the further production. The records are maintained in .1.
first piece inspection record. In first piece inspection, for result of first piece 3
inspection and last piece inspection is maintained. The requirement for the set up
approval is established in the control plan for that specific product. KPM/QC/06
2 During the die setting, die setting preparation report is maintained by the quality KPM/QC/25 8.5
control incharge so to ensure die is set accurately in the machine .1.
3
3.0 INPROCESS & FINAL INSPECTION
All the products are inspected as per the respective control plans and records of KPM/QC/06 8.6
its inspection are maintained. KPM/QC/27 .1
During the In-process as well as in Final Inspection, the Inspection is carried as KPM/QC/28 8.6
per the sampling basis/ as per the control plan, the Acceptance Level of critical KPM/QC/08 .6
and major defect is zero. As in any case, when any single defect is found recd., KPM/QC/23
whole the lot is rejected and re-inspected for those specific parameters 100%. KPM/QC/17
The document for final inspection is either as per customer specific requirement,
if customer not provides such information, then, company’s own format is
implemented. In case of Minor defect, the acceptance level is set as per the
sampling plan.
1) Critical Defects: Those which are the customer’s special characteristics.
2) Major Defects: All dimensions as specified in the customer drawing and
functional performance defects
 KPM Reviewed & Approved By
QUALITY PROCEDURES
(Procedure For Quality Control - QP01)
-Page 2 of 6 Management Representative
3) Minor Defects: Any defect of aesthetic look/ visual defects not affecting
the overall performance of product.
4.0 CALIBRATION
Ensure all instruments, which are used for different stages of process, are
calibrated. - 7.1
1
.5.
2
Maintain a list of Instruments & gauges with calibration status. KPM/QC/15 7.1
2
.5
Based on the calibration status of instruments, the instruments are sent to the KPM/QC/16
Standard Room and then send to authorized calibration agency for calibration as 7.1
3
per the schedule of calibration and record of calibration is maintained .5.
2
5.0 REVIEW OF PROCESS DOCUMENTS
1 Based on the monthly non-conformances, review & revise the FMEA and amend 9.1
the control plan accordingly. -
6.0 CONTROL OF NON-CONFORMING PRODUCTS
1 When the product is not meeting dimensionally (or) visual requirements it is
segregated and placed in identified area. - 8.7
2 If the Q.C Incharge could not arrive to disposition of the same, it is presented to
Partner (Works) & disposition action is taken as per Management’s decision by 8.7
Q.C Incharge.
3 Daily Non conformances during all the processes are monitored in Non 8.7
conformance register (In-process).
For the incoming material, if any non conformity is recd., the same is entertained
in the minutes of meeting (for non conforming incoming material)
4 Using daily non-conformance report of quality dept. and production dept.,
monthly-consolidated rejection and rework report is made. 8.7
5 All reworked products are re-inspected as per the control plan and recorded in the
rework inspection report. 8.7
6 If the product is accepted under deviation, customer approval is received prior to
release of the product, wherever required by the customer rest reject and scrap 8.7
7.0 CORRECTIVE ACTION
1 Q.C Incharge reviews the inspection records, when rejection due to a particular
cause is significant (Critical and Major), calls the MDT (Multi Discipline Team) 10.
for discussion & initiates Corrective Action Report. 1
2 Based on discussions, corrective action is planned; the nature of corrective action
could be modification in process, plant equipment, tool, die or fixture etc. as 10.
relevant. 2
3 While taking the corrective action, the appropriate problem solving technique 10.
like FISH bone diagram, WHY-WHY analysis will be used & effectiveness of 2.3
corrective action is reviewed.
4 After deciding the causes, the same is implemented for non-recurrence and 10.
records are maintained in the register. Wherever applicable in the process, 2.3
mistake proofing techniques as Poke-Yoke is applied to permanently cure the
occurrence of problem.
 KPM Reviewed & Approved By
QUALITY PROCEDURES
(Procedure For Quality Control - QP01)
-Page 3 of 6 Management Representative
5 After implementing the actions decided, the effectiveness of the implementation
of the same is verified. - 10.
2
6 CORRECTIVE ACTION IMPACT
After taking the corrective actions, if the actions taken are effective, the same is - 10.
applied in similar processes and products, wherever possible. 2

8.0 PREVENTIVE ACTION

1 A monthly preventive action meeting is organized by Q.C Incharge chaired by KPM/QC/21
Plant Head and Management. & attended by all departmental heads.
2 In Preventive action meeting overall rejection records, product non conforming KPM/QC/21
reports, customer complaints are reviewed, analysed and causes of potential non
conforming and necessary preventing actions are decided along with MDT.
3 The effectiveness of preventive action taken is reviewed in the subsequent KPM/QC/21
preventive action meeting and presented during the management review meeting.
9.0 RETURNED PRODUCT ANALYSIS
1 If the customer has returned the product, the appropriate reasons for the same KPM/QC/22
such as technical, non-technical, commercial, inadequate documentation etc. is --
analyzed and records are maintained in the Customer Complaint Analysis Sheet.
10.0 LAYOUT INSPECTION
1 Layout inspection is carried out for all the items at customer defined frequency. If
the customer has not defined any frequency, the layout inspection is carried out KPM/QC/09 8.6
six monthly. .2
Layout inspection schedule is prepared in which consideration to cover at least
one product from each category of product. KPM/QC/10
After the layout inspection, report of layout inspection is maintained.

11.0 MARKING INSPECTION

2 For specific products (If customer required), marking dimensions are verified as
per the sketches referred in the control plan & the results are recorded in the - 8.6
marking inspection sheet .2
12.0 FINAL PRODUCT AUDIT
Final product audit is carried out for all the packaged products before dispatch &
after packing. A plan for the final product audit is prepared and frequency is KPM/QC/11 8.6
established based on the results of the final product audit at least once in a year. .1
Final product inspection schedule is prepared in which consideration to cover at
least one product from each category of product.
After the Final product Audit process, report of final product audit is prepared KPM/QC/12
and suitable actions are taken based on the result of report.
13.0 PACKAGING
The packaging is carried out as per the packaging work instructions, - 8.5
.1
14.0 DISPATCH OF PRODUCTS FROM Q.C
1 Based on the dispatch plan, the dispatched quantities are monitored. - 8.5
.5
2 Products are dispatched with all required records like test certificates & 8.5
 KPM Reviewed & Approved By
QUALITY PROCEDURES
(Procedure For Quality Control - QP01)
-Page 4 of 6 Management Representative
dimensional reports. - .5
15.0 INSPECTION AND TEST STATUS
1 White tags identify products under in-process , non-conforming products are kept KPM/QC/04 8.5
in a separate area and/or with red tag. Products for rework are identified by KPM/QC/05 .2
yellow tag, the products with green tags are treated as conforming products.
Status tags of sky blue colour are used where all the above mentioned tags failed
to show the status.

16.0 SUSPECT PRODUCT OR MATERIAL

1 Any material or product in shop floor, where inspection & test status is not 8.7
known by anybody, that particular material (or) product is considered as a .1.
suspect product. The same will be re-inspected as per the control/quality plan to - 3
find out the test status.

2 Process capability for the critical operations & Critical machinery is accessed
using run charts. - 9.1
For one of the critical parameter as Forge Size as thickness and Width, for that
SPC is carried at least of two products in a year.
17.0 MEASUREMENT SYSTEMS ANALYSIS
1 Measurement systems analysis is done as per the plan. MSA Plan
MSA is carried out for the key measurement systems defined in the control plans MSA 7.1
in co-ordination with P.D.D Analysis .5.
1
18.0 MANUFACTURING PROCESS AUDIT
1 Manufacturing Process audit is carried out for any product in production stage KPM/QC/13
and ensure that product is in all stages of its process. Refer the control plan for 9.2
that product for its process audit. A plan for the Manufacturing Process Audit is .2.
prepared and frequency is established based on the results of the Process audit at 3
least once in a year.
Manufacturing Process Audit schedule is prepared in which consideration to
cover at least one product from each category of product.
After the Manufacturing Process Audit process, report of Manufacturing Process KPM/QC/14
audit is prepared and suitable actions are taken based on the result of report.
19.0 SAMPLE MANAGEMENT
 KPM Reviewed & Approved By
QUALITY PROCEDURES
(Procedure For Quality Control - QP01)
-Page 5 of 6 Management Representative
1 After the approval of prototype sample from the customer at the initial stage of
product development, the same sample is retained by the QC dept for the 8.5
reference purpose. .1
KPM/QC/18
In this, unique identification is mark over the sample and same is listed in the list
of customer provide drawings with complete details of drawing also. KPM/QC/19
Periodically all the samples are inspected for its condition. Frequency of sample
inspection is once in six months and in this sample is checked for its condition. If
the sample is found not suitable, then prepare the new sample, get it again
approve from the customer and then retain it. KPM/QC/20

Samples label is affixed on all the samples, where the complete identification of
sample is provide as sample no., sample name, related to customer.

20.0 PROCESS OBJECTIVES

1 To reduce rejection of Forged Automotive Products less than 2500 ppm each. (on
monthly basis). 6.2
-
2 Based on the data, the analysis on the same is carried out for not meeting the set 9.1
objectives and initiates actions for the same to improve the efficiency. /
-
10.
1
21.0 RESOURCE MANAGEMENT
a. Ensure the cleanliness of premises is maintained in the state of order and
repair of working places. Resource
b. Ensure appropriate lighting is provided in all the working places. Reqt Form 7.1
c. Ensure competent personnel perform work affecting product quality.
d. Any new resource (new equipment, new test & inspection facilities &
manpower etc.), requirement identified is raised to Plant Head. All resources
are recommended by Plant Head & sanctioned by Management.
22.0 CONTROL OF QUALITY RECORDS
1 1) Incoming inspection plan: KPM/QC/01 List of
2) Incoming inspection report: KPM/QC/02 Quality 7.5
3) Minutes of meeting (for non conforming incoming material) : KPM/QC/03 records .1
4) Identification Card (incoming/ final) : KPM/QC/04
5) Identification Card (rework) : KPM/QC/05 KPM/MR/01
6) Control Plan: KPM/QC/06
7) First piece inspection report : KPM/QC/07
8) Final / PDI inspection report: KPM/QC/08
9) Layout inspection schedule: KPM/QC/09
10) Layout inspection record: KPM/QC/10
11) Product audit schedule: KPM/QC/11
12) Product audit report: KPM/QC/12
13) Process audit schedule: KPM/QC/13
14) Process audit report: KPM/QC/14
15) List of IMTE and gauges: KPM/QC/15
16) Calibration record (external) : KPM/QC/16
17) MPI inspection report : KPM/QC/17
18) List of customer supplied drawings: KPM/QC/18
19) Periodic inspection of customer samples: KPM/QC/19
20) Sample label: KPM/QC/20
 KPM Reviewed & Approved By
QUALITY PROCEDURES
(Procedure For Quality Control - QP01)
-Page 6 of 6 Management Representative
21) Non conformance register (in-process) : KPM/QC/21
22) Customer complaint analysis sheet: KPM/QC/22
23) Coining section inspection report : KPM/QC/23
24) Rework Inspection Report: KPM/QC/24
25) Die setting preparation report : KPM/QC/25
26) Hardness inspection report (incoming): : KPM/QC/26
27) Cut weight inspection report : KPM/QC/27
28) In-process inspection report : KPM/QC/28
2 The identification, storage, protection, retrieval, retention and disposition of ….
records are established in the list of quality records and maintained. 7.5
.1