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INTERNAL

QUALITY SYSTEM PROCEDURE


TITLE
1 PURPOSE: TO ENSURE THAT THE PURCHASED PRODUCTS CONFORM TO SPECIFIED REQUIREMENTS. 2 SCOPE : APPLICABLE TO RAW MATERIAL, PRODUCTION CONSUMABLES , PACKING MATERIALS, CATALOGUE ITEMS , BOUGHT OUT PARTS , TOOLS AND GAUGES , SERVICES FOR CALIBRATION , JOB - WORK AND CONTRACTS. 3 3.1 3.2 3.3 3.4 ABBREVIATION AND DEFINITION : BOP VD SUB-CONTRACTOR SUPPLIER BOUGHT OUT PARTS VENDOR DEVELOPMENT A SUPPLIER / VENDOR / JOB - CONTRACTOR.

PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4

INDIVIDUAL / ORGANISATION , WHO SUPPLIES RA MATERIALS, CATALOGUE ITEMS , PACKING MATER PRODUCTION CONSUMABLES TOOLING & GAUGES.

3.5

VENDOR

INDIVIDUAL / ORGANISATION , WHO SUPPL COMPONENTS TO RICO AUTO INDUSTRIES LIM AGAINST RICO AUTO INDUSTRIES LIMITED DRAWIN SPECIFICATIONS.

3.6

JOB-CONTRACTOR

ANY OUT SIDE AGENCY WHICH PERFORMS / PROVID JOB / SERVICES AS PER RICO AUTO INDUSTR REQUIREMENT EITHER AT HIS PLACE OF WORK INSIDE RICO AUTO INDUSTRIES PREMISES INCLUD JOB - WORK ON COMPONENTS. ANY ORDER RAISED FOR MATERIALS / BOUGHT OUT CONSUMABLES.

3.7

PURCHASE ORDER

SUPPLY OF RA PARTS / PRODUCT

3.8

JOB ORDER / WORK ORDER

ANY ORDER RAISED FOR PROCESSING , REPAIR A MAINTENANCE AT SUB-CONTRACTOR'S PLACE RICO AUTO INDUSTRIES LIMITED PREMISES.

3.9

PRODUCTION CONSUMABLE

MATERIALS WHICH ARE USED DIRECTLY IN T PROCESS OF PRODUCT MANUFACTURING SUCH WELDING ROD / BRAZING WIRE , FLUX AND GASES E

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QUALITY SYSTEM PROCEDURE


TITLE
3.10 CATALOGUE ITEMS

PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4

MATERIALS FOR WHICH MANUFACTURER PUBL THEIR CATALOGUE / LITRATURE INDICATING SPECIFICATION AND ARE AVAILABLE IN THE MARK THROUGH THEIR DISTRIBUTION NETWORK.

ORGANISATION CHART AND RESPONSIBILITY

E.D.(FINANCE)

PLANT MANAGER ALUMINIUM FACILITIES

D.G.M. MATERIALS (CORPORATE) HOD (MATERIALS)

SECTION HEAD (MATERIALS) DHARUHERA

MATERIALS ENGR. MISC ITEM

MATERIALS SR. ENGR. BOP

MATERIALS ENGR. BOP

MATERIALS ENGR. MISC ITEM

PURCHASE ASSISTANT

4.1

OVER ALL RESPONSIBILITY FOR IMPLEMENTATION OF THIS PROCEDURE LIES WITH HOD (MATERIALS). OTHER RESPONSIBILITIES ARE AS INDICATED AGAINST EACH ACTIVITY.

4.2

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QUALITY SYSTEM PROCEDURE


TITLE
5 PROCESS APPROACH PROCESS MAP AND INTERACTIONS (REFER TURTLE DIAGRAM - MATERIALS) 6 SL.NO 6.1 6.1.1 DESCRIPTION ACTIVITY PURCHASE ORDER PREPARE THE ORDER INDICATING ALL THE REQUIREMENTS LIKE , DESCRIPTION OF MATERIAL SPECIFICATION / DRAWING, QUANTITY, INSPECTION INSTRUCTIONS, OTHER DELIVERY TERMS AND CONDITIONS INDICATE APPLICABLE GOVERNMENT REGULATION IN THE COUNTRY OF PURCHASE AND SALES ON SAFETY , TOXIC AND HAZARDOUS SUBSTANCES , AS REQUIRED IN THE PURCHASING DOCUMENT. REVIEW THE PURCHASING DOCUMENT FOR ADEQUACY AND COMPLETENESS AND FORWARD TO PLANT MANAGER / HOD MATERIALS (CORP.) FOR APPROVAL. REVIEW AND APPROVE THE PURCHASING SECTION HEAD (MATERIALS) RESPONSIBILITY

PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4

6.1.2

ENGINEER MATERIALS

6.1.3

SECTION HEAD (MATERIALS) / ENGINEER MATERIALS PLANT MANAGER /

6.1.4

DOCUMENT 6.1.5 RECEIVE AND ENTER THE DETAILS IN P.O. CONTROL REGISTER.

HOD (MATERIALS) SECTION HEAD (MATERIALS) / ENGINEER MATERIALS

6.2 6.2.1

RAW MATERIAL & BOUGHT OUT PARTS IDENTIFY THE NEED ON THE BASIS OF PRODUCTION PLAN , INTERNAL REVIEW AND DEVELOPMENT PLAN IN CONSULTATION WITH HOD (MATERIALS) IDENTIFY FOR THE CAPABLE SUB-CONTRACTOR SECTION HEAD (MATERIALS)

6.2.2

SECTION HEAD (MATERIALS)

INTRODUCTION FOR NEW COMPONENT. ENGG. CHANGES IN DRAWING. SECOND SOURCE / ALTERNATIVE SOURCE FOR EXISTING COMPONENTS.

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QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.2.3 ACTIVITY ALLOCATE THE VENDOR FOR DEVELOPING THE COMPONENTS FROM THE LIST OF APPROVED SUB-CONTRACTOR. CO-ORDINATE FOR INSPECTION / TRIAL OF TOOLS , JIG AND FIXTURE WITH SUPPLIER.

PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4
RESPONSIBILITY HOD (MATERILS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) SECTION HEAD(QA)

6.2.4

6.2.5

RECEIVE THE SAMPLES ALONG WITH THE DOCUMENTS AND CARRY OUT INSPECTION AND PREPARE INSPECTION REPORT AND FORWARD TO HOD (QA) FOR REVIEW AND COMMENTS. REVIEW THE INSPECTION REPORT AND IF FOUND "O.K." RECOMMEND FOR SUPPLYING PILOT SUPPLY & SEND THE INSPECTION REPORT TO HOD (MATERIALS) / SECTION HEAD (MATERIALS) .

6.2.6

HOD (QA)

6.2.7

RECEIVE THE PILOT LOT SUPPLY AND INSPECT FOR CONFORMANCE . IF MATERIAL ARE ACCEPTABLE ALLOW FOR REGULAR SUPPLY AFTER APPROVAL OF PILOT LOT SUPPLY RELEASE REGULAR DELIVERY SCHEDULE.

SECTION HEAD RECEIPT (QA)

6.2.8

HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS)

6.2.9

AFTER THE STARTING OF REGUAR SUPPLY CARRY OUT THE VENDOR PERFORMANCE EVALUATION QUARTERLY. EXAMINE VENDOR PERFORMANCE RATING ON QUARTERLY BASIS AND TAKE NECESSARY ACTIONS. FOR HIGH IMPACT PARTS IDENTIFIED IN APPROVED VENDOR LIST, ARRANGE MIS DATA FROM VENDOR ON MONTHLY BASIS FOR KEY INDICATORS OF PROCESS / PRODUCTS OF SUPPLIER AS APPROPRIATE e.g. - Cpk DATA, INTERNAL REJECTION DATA, DELIVERY PERFORMANCE, R.M. STOCK ETC.

6.2.10

6.2.11

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QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.3 6.3.1 ACTIVITY CATALOGUE ITEMS, CONSUMABLES & MISC. ITEMS RECEIVE THE PURCHASE REQUISITION OR MONTHLY REQUIREMENT DULY APPROVED. HOD (MATERIALS) / SECTION HEAD (MATERIALS) PURCHASE ENGR.

PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4
RESPONSIBILITY

6.3.2

PREPARE PURCHASE ORDER MENTIONING THE ITEM DESCRIPTION, REFERENCE / SPECIFICATION GIVEN IN THE CATALOGUE,

ANY OTHER REQUIREMENT LIKE TRANSPORTATION METHOD AND OTHER DELIVERY TERMS AND CONDITIONS. 6.4 6.3.3 JOB WORK ITEMS REVIEW THE PURCHASING DOCUMENT FOR ADEQUACY AND COMPLETENESS AND FORWARD TO PLANT MANAGER / HOD MATERIALS (CORP.). INCASE OF MATERIAL / COMPONENT TO BE SENT FOR JOB WORK FROM RICIO AUTO INDUSTRIES LIMITED, ADVISE STORE TO ISSUE THE MATERIAL / COMPONENTS TO THE SUB-CONTRACTORS FOLLOW STEP 5.3.3 TO 5.3.4 SCHEDULING OF SUB-CONTRACTOR BASED ON PPC REQUIREMENT, RELEASE THE PART WISE / VENDOR WISE SCHEDULE TO CONCERN VENDOR. IF SCHEDULING IS REQUIRED ON DAILY / WEEKLY / FORTNIGHTLY BASIS AND MENTION IT IN DELIVERY SCHEDULE (SPECIFICALLY IN SCHEDULE). MONITOR THE SCHEDULE ON DAILY BASIS AND TAKE ACTION ACCORDINGLY IN ORDER TO MAKE SUPPLIES 100% ON TIME. IF SUPPLIES ARE RECEIVED EXCEEDING 10% LIMIT NORMS OF SCHEDULE QTY HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / MATERIALS ENGR.

6.4.1

HOD (MATERIALS)

6.4.2 6.5 6.5.1

CONCERN PERSON

6.5.2

6.5.3

HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS)

6.5.4

6.5.5

TAKE CORRECTIVE ACTION ACCORDINGLY

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QUALITY SYSTEM PROCEDURE


TITLE
PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4

SL.NO 6.6 6.6.1

ACTIVITY SUPPLIER VERIFICATION AT SUBCONTRACTOR END ARRANGE AND SPECIFY THE VERIFICATION OF PURCHASED PRODUCT AT SUBCONTRACTOR END AND INDICATE THE REQUIREMENT ALONG WITH PURCHASE ORDER

RESPONSIBILITY

HOD (MATERIALS) / SECTION HEAD (MATERIALS)

6.7 6.7.1

CUSTOMER VERIFICATION OF SUBCONTRACTED PART FIND OUT FROM APQP LEADER WHEATHER CUSTOMER VERIFICATION AT SUBCONTRACTOR END IS REQUIRED OR NOT. IF REQUIRED BY CUSTOMER INDICATE THE REQUIREMENT IN THE SUBCONTRACTOR PURCHASE ORDER AND ARRANGE ACCORDINGLY TO CUSTOMER REQUIREMENT HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS)

6.7.2

6.8

PART APPROVAL PROCESS (APPLICABLE IF CUSTOMER SPECIFIC PROCEDURE DOES NOT EXIST FOR TIER 2) RECEIVE SAMPLES ALONG WITH RELEVENT DOCUMENTS FROM SUBCONTRACTOR AS PER DEVELOPMENT REQUIREMENTS FILL THE SAMPLE EVALUATION REQUEST AND SUBMIT TO Q.A. DEPARTMENT FOR INSPECTION ENSURE THAT ALL APPROPRIATE DOCUMENTS ARE SUBMITTED ALONG WITH SAMPLES AS AGREED WITH Q.A. ARRANGE THE INSPECTION AND DO VENDOR VISIT FOR PROCESS IF REQUIRED SUBMIT THE REPORT TO HOD (Q.A.) FOR APPROVAL AND FURTHER ACTION. IF SAMPLE O.K. , ARRANGE PILOT LOT AS PER INSTRUCTION OF Q.A. DEPARTMENT RECORD THE SAMPLE DETAILS i.e. O.K. / REJECT & DATES ETC IN PART APPROVAL LOG SHEET HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS)

6.8.1

6.8.2

6.8.3

6.8.4

HOD (Q.A.) / SECTION HEAD (Q.A.)

6.8.5

SECTION HEAD (Q.A.)

6.8.6

SECTION HEAD (PURCHASE) SECTION HEAD (Q.A.)

6.8.7

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PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.8.8 ACTIVITY IF PILOT LOT O.K. , RECORD THE DATE OF INTRODUCTION OF PART IN PRODUCTION LINE IN PART APPROVAL LOG SHEET FOLLOW THE CUSTOMER SPECIFIC REQUIREMENT FOR PART APPROVAL (IF ANY) PART APPROVAL PROCESS (FOR REGULAR BOP ITEMS) RECEICVE THE CHANGE APPROVAL REQUEST FORM DULY FILLED ALONG WITH SAMPLES AND RELATED DOCUMENTS SEND THESE SAMPLES TO HOD (Q.A.) FOR ANALYSIS DO THE INSPECTION OF SAMPLES AND DO FOLLOW UP WITH CHANGE APPROVAL REQUEST FORM. INFORM TO PURCHASE DEPTT REGARDING STATUS OF THE SAMPLES COMMUNICATE VENDOR. THE FINAL APPROVAL TO HOD (MATERIALS) / SECTION HEAD

PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4
RESPONSIBILITY SECTION HEAD (Q.A.)

6.8.9

SECTION HEAD (Q.A.)

6.10 6.9.1

6.9.2

HOD (MATERIALS) / SECTION HEAD

6.9.3

SECTION HEAD (Q.A.) ENGINEER (Q.A.)

6.9.4

HOD (Q.A.) / SECTION HEAD (Q.A.) SECTION HEAD (MATERIALS) / ENGINEER (MATERIALS)

6.9.5

6.9.6

DO FINAL CUSTOMER NOTIFICATION AS APPROPRIATE (AS PER CUSTOMER SPECIFIC REQUIREMENTS)

HOD (Q.A.) / SECTION HEAD (Q.A.)

6.10 6.10.1

PREMIUM FREIGHT RECORD THE PREMIUM FREIGHT PAID BY EITHER US OR BY VENDOR IF ANY. AND INTIMATE TO MANAGEMENT ON MONTHLY BASIS FOR REVIEW & ACTION. HOD (MATERIALS) / SECTION HEAD (MATERIALS)

6.11 6.11.1

CUSTOMER APPROVED SOURCES WHERE SPECIFIED BY THE CONTRACT, ENSURE THAT PRODUCT / MATERIAL / SERVICES ARE SOURCED FROM APPROVED SOURCES. HOD (MATERIALS)

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QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.12 6.12.1 ACTIVITY SUPPLIER MONITORING DO SUPPLY MONITORING THROUGH FOLLOWING INDICATORS (A) DELIVERY PERFORMANCE (B) QUALITY PERFORMANCE (C) QUALITY RATING CONSIDERING FIELD FAILURES (D) ANY OTHER CUSTOMER SPECIFIC INDICATORS HOD (MATERIALS)

PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4
RESPONSIBILITY

6.13

CUSTOMER SPECIFIC REQUIREMENTS FORD (NOV 2003)

RESP. - HOD (MATER

4.27 Subcontractor Development (ISO/TS 16949:2002 7.4.1.2) 4.28 Customer approved sources (ISO/TS 16949:2002 cl. 7.4.1.3) 4.30 Scheduling subcontractors (ISO/TS 16949:2002 cl. 7.4.3.2)

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QUALITY SYSTEM PROCEDURE


TITLE
7 7.1 DOCUMENTS : RICO 08 QSP 02 PROCEDURE FOR ASSESSMENT AND SELECTION OF SUB-CONTRACTORS PROCEDURE FOR INVENTORY CONTROL

PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4

7.2 7.3 7.4 7.5

RICO 14 QSP 04 RICO 06 QSP 01 RICO 16 QSP 02 RICO 06 QWI 03

PROCEDURE FOR INCOMING MATERIAL INSPECTION AND TES PROCEDURE FOR ISSUE OF MATERIAL FOR JOB-WORK. WORK INSTRUCTION FOR ASSESSMENT OF VENDOR RATING SYSTEM.

RECORDS : RECORD DESCRIPTION FORM NO TITLE PURCHASE ORDER HOD LOCATION

RETENT PERIO

RICO 08 QFO 01

5 YEA

(MATERIALS) RICO 08 QFO 02 DELIVERY SCHEDULE HOD (MATERIALS) HOD (MATERIALS) HOD (Q.A.) HOD (MATERIALS) HOD (MATERIALS) HOD (PURCHASE) HOD (MATERIALS)

1 YEA

RICO 08 QFO 03

LIST OF APPROVED SUB-CONTRACTOR

ON GO

RICO 08 QFO 06

CHANGE APPROVAL REQUEST FORM

2 YEAR

RICO 08 QFO 07

PURCHASE REQUISITION

1 YEA

RICO 08 QFO 08

P.O.CONTROL REGISTER

1 YEA

RICO 08 QFO 09

RECEIPT MONITORING

1 YEA

RICO 08 QFO 10

SAMPLE EVALUATION REQUEST

1 YEA

NOTE :-

FORMATS ARE COMMON FOR BOTH PLANTS HENCE EITHER OF THE CONFIGURATION NUMBER PRINTED ON FORMAT CAN BE USED.

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QUALITY SYSTEM PROCEDURE


TITLE
9

PURCHASING
Ref ISO-TS 16949 , MMOG , QM Sec. 7.4

BRIEF DESCRIPTION OF AMENDMENT DETAIL :

REVISION NO.

DATE

NATURE OF CHANGE / DESCRIPTION

06

25-06-2003

Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements

07

25-12-2003

MIS Data requirement added for high impact parts identified in approved list

08

15-04-2004

Procedure reviewed for Ford specific requirements NOV 2003

08

15-04-2004

Procedure reviewed for Ford specific requirements NOV 2003

09

05-05-2004

MS-9000 System requirements added as per Ford Q1 Programme

10

25-01-2006

MS-9000 System upgraded to MMOG

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DOC. NO. ISSUE NO ISSUE DATE

RICO 08 QSP 01 10 25-01-2006

EQUIREMENTS.

MATERIALS, RVICES FOR

- CONTRACTOR.

N , WHO SUPPLIES RAW TEMS , PACKING MATERIAL, ES TOOLING & GAUGES.

N, WHO SUPPLIES UTO INDUSTRIES LIMITED STRIES LIMITED DRAWING'S

CH PERFORMS / PROVIDES RICO AUTO INDUSTRIES T HIS PLACE OF WORK OR TRIES PREMISES INCLUDING

UT

SUPPLY OF RAW PARTS / PRODUCTION

PROCESSING , REPAIR AND ONTRACTOR'S PLACE OR ITED PREMISES.

USED DIRECTLY IN THE MANUFACTURING SUCH AS IRE , FLUX AND GASES ETC

COPY STATUS

SHEET 01 OF 10

DOC. NO. ISSUE NO ISSUE DATE

RICO 08 QSP 01 10 25-01-2006

MANUFACTURER PUBLISH TURE INDICATING THE AVAILABLE IN THE MARKET ION NETWORK.

E.D.(FINANCE)

D.G.M. MATERIALS (CORPORATE) HOD (MATERIALS)

SECTION HEAD (MATERIALS) HPDC GURGAON

MATERIALS ENGR. MISC ITEM

MATERIALS ENGR. BOP

PURCHASE ASSISTANT

COPY STATUS

SHEET 02 OF 10

DOC. NO. ISSUE NO ISSUE DATE

RICO 08 QSP 01 10 25-01-2006

RESPONSIBILITY

REF.DOC

SECTION HEAD (MATERIALS)

RICO 08 QFO 01

ENGINEER MATERIALS

SECTION HEAD (MATERIALS) / ENGINEER MATERIALS PLANT MANAGER /

HOD (MATERIALS) SECTION HEAD (MATERIALS) / MATERIALS RICO 08 QFO 08

SECTION HEAD (MATERIALS)

SECTION HEAD (MATERIALS)

COPY STATUS

SHEET 03 OF 10

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY HOD (MATERILS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) SECTION HEAD(QA)

RICO 08 QSP 01 10 25-01-2006 REF.DOC

HOD (QA)

SECTION HEAD RECEIPT (QA)

HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS)

COPY STATUS

SHEET 04 OF 10

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY

RICO 08 QSP 01 10 25-01-2006 REF.DOC

HOD (MATERIALS) / SECTION HEAD (MATERIALS) PURCHASE ENGR.

RICO 08 QFO 07

RICO 08 QFO 01

HOD (MATERIALS) / MATERIALS ENGR.

HOD (MATERIALS)

CONCERN PERSON

HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS)

HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) COPY STATUS SHEET 05 OF 10

DOC. NO. ISSUE NO ISSUE DATE

RICO 08 QSP 01 10 25-01-2006

RESPONSIBILITY

REF.DOC

HOD (MATERIALS) / SECTION HEAD (MATERIALS)

HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS)

DOES NOT

HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (MATERIALS) / SECTION HEAD (MATERIALS) HOD (Q.A.) / SECTION HEAD (Q.A.) SECTION HEAD (Q.A.)

SECTION HEAD (PURCHASE) SECTION HEAD (Q.A.)

COPY STATUS

SHEET

06 OF 10

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY SECTION HEAD (Q.A.)

RICO 08 QSP 01 10 25-01-2006 REF.DOC

SECTION HEAD (Q.A.)

HOD (MATERIALS) / SECTION HEAD

HOD (MATERIALS) / SECTION HEAD SECTION HEAD (Q.A.) / ENGINEER (Q.A.)

HOD (Q.A.) / SECTION HEAD (Q.A.) SECTION HEAD (MATERIALS) / ENGINEER (MATERIALS) HOD (Q.A.) / SECTION HEAD (Q.A.)

HOD (MATERIALS) / SECTION HEAD (MATERIALS)

HOD (MATERIALS)

COPY STATUS

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DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY

RICO 08 QSP 01 10 25-01-2006 REF.DOC

HOD (MATERIALS)

RESP. - HOD (MATERIALS)

COPY STATUS

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DOC. NO. ISSUE NO ISSUE DATE

RICO 08 QSP 01 10 25-01-2006

SELECTION OF

L INSPECTION AND TESTING. FOR JOB-WORK.

NT OF VENDOR RATING

RETENTION PERIOD 5 YEAR

DISPOSAL AUTHORITY HOD (MATERIALS)

1 YEAR

HOD (MATERIALS)

ON GOING

HOD (MATERIALS)

2 YEARS

HOD (Q.A.)

1 YEAR

HOD (MATERIALS)

1 YEAR

HOD (MATERIALS)

1 YEAR

HOD (PURCHASE)

1 YEAR

HOD (MATERIALS)

COPY STATUS

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DOC. NO. ISSUE NO ISSUE DATE

RICO 08 QSP 01 10 25-01-2006

W.e.f.

APPROVED BY Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp.

25-06-2003

25-12-2003

15-04-2004

15-04-2004

Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp.

05-05-2004

25-01-2006

COPY STATUS

SHEET 10 OF 10

DOCUMENTS :

DOCUMENTS :

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

QUALITY SYSTEM DOCUMENT

INTERNAL

QUALITY SYSTEM PROCEDURE


TITLE
1 PURPOSE: To establish and implement control measures for development and review of systems at sub-controctor's end. SUPPLIER QUALITY MANAGEMENT DEVELOPMENT

Ref ISO-TS 16949 , MMOG , QM Sec. 7.4

SCOPE : This procedure is applicable to identified sub-contractors of bought out parts (H, Q, C, R Class) and carrying out job work (JW Class) on components.

3 3.1 3.2

ABBREVIATION AND DEFINITION : BOP H-Class (High Impact Supplier) Brought Out Parts

Supplier come in the High Impact supplier category, If it falls in any of flollowing criteria (a) New Supplier (b) New part with existing supplier (c) New technology to supplier (d) Monthly Quality PPM is higher than standard target for consecutiv 3 months (e) Environmental, Health, Safety Risk Involved in the process (f) Others as specified by CFT Quality Class i.e. Item important w.r.t. Form, Fit, Function, Safety, Government & Apperanace C-Class i.e. Item not much important w.r.t. end use Properiery Class Raw Material Class Raw Material Properiery Class

3.3

Q-Class Supplier

3.4 3.5 3.6 3.7

C-Class Supplier P-Class Supplier R-Class Supplier RP-Class Supplier

3.8 3.9 3.10

JW-Class Supplier CSP CFT

Job Work Class Customer Supplied Product Cross functional team

Note : Any supplier which is supplying multiple part no. The supplier will be designated accordingly to the most severe class of Part no, supplying to RICO i.e. any supplier having parts within C-Class and Q-Class. Supplier will come in Q-Class category.

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
4 SUPPLIER QUALITY MANAGEMENT DEVELOPMENT

Ref ISO-TS 16949 , MMOG , QM Sec. 7.4

ORGANISATION CHART AND RESPONSIBILITY For organisation please refer organisation chart

Plant Manger (s)

HOD-Corp. Quality

HOD-Material Plants

Section Head

Section Head

Engineers (Quality)

Engineers

Typical Audit Team (CFT Team)

Typical Audit Team (CFT Team)

4.1 4.2

Hod (materials) is over all responsible for implementation of this procedure. Hod (Corp.- Quality) is over all responsible for reviewing of implementation of corrective and preventive actions Identified audit teams are responsible for carrying out systems audits. Other responsibilities are as mentioned against each activity

4.3 4.4

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 5 ACTIVITY PROCESS APPROACH PROCESS MAP AND INTERACTIONS (REFER TURTLE DIAGRAM - MATERIALS) 5.1 SUPPLIER QUALITY MANAGEMENT DEVELOPMENT

Ref ISO-TS 16949 , MMOG , QM Sec. 7.4

Process Input
Sl.No

Process Input
Supplier selection criteria EHS specific requirements Specification of the material to be procured Customer specific requirement.

Source / Supplier
HOD QA MR Process Owner HOD QA

1 2 3 4

5.2

Process Output
Sl.No Process Output

Sl.No 1 2 5.3

Process Output Timely procurement of the material conforming to customer specified requirement, user specification, all other applicable specifications. Quality System Complying Vendors

Process Effectiveness And Efficiency Measurable


Sl.No 1 2 Measurables Supplier delivery schedule V/s Actual Vendor Rating trend

6 SL.NO 6.1

DESCRIPTION ACTIVITY Classify the Bought Out Parts and Job Work Components according to end use , status of supplier performance. viz - H, Q, C, P, R, RP and CSP Class Prepare list of approved sub-contractor for bought out parts as well as sub contractors doing job work on components for development of system.

6.2

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.3 ACTIVITY Review and update sub-contractor list for H, Q, C, P, R, RP and CSP Class after every three months Identify resource requirements for sub-contractor development e.g. visit expenses, training to suppliers etc and get it sanctioned through yearly budget review committee. Bifurcate the vendor on the basis of present quality system status and nature of supplier in the following category 1H - Class Category Supplier (a) New Supplier (b) New part with existing supplier (c) New technology to supplier SUPPLIER QUALITY MANAGEMENT DEVELOPMENT

Ref ISO-TS 16949 , MMOG , QM Sec. 7.4

6.4

6.5

(d) Monthly Quality PPM is less than standard target for consecutive 3 months (e) Environmental, Health, Safety Risk Involved in the process (f) Others as specified by CFT (Annual Auidit as per RICO 06 QFO 88) 2Q - Class Category Supplier Minimum ISO 9001:2000 Certified suppliers supplying Quality Product (Annual Auidit as per RICO 06 QFO 23) C - Class Category Supplier
Minimum ISO 9001:2000 Certified suppliers supplying Parts having relatively less important on Quality

3-

(Annual Auidit as per RICO 06 QFO 23, but these C-Class items are not Audited during Audit) 4P - Class Category Supplier Suppliers supplying Proprietary items (Not in Audit Scope) R - Class Category Supplier Minimum ISO 9001:2000 Certified suppliers supplying Quality Product (Annual Auidit as per RICO 06 QFO 23) JW - Class Category Supplier Minimum ISO 9001:2000 Certified suppliers carrying Job Works. (Annual Auidit as per RICO 06 QFO 23) RP - Class Category Supplier Raw Material Properiery Supplied Product (Not in Audit Scope) CSP - Class Category Supplier Customer Supplied Product (Not in Audit Scope)

5-

6-

7-

8-

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO ACTIVITY SUPPLIER QUALITY MANAGEMENT DEVELOPMENT

Ref ISO-TS 16949 , MMOG , QM Sec. 7.4

FOLLOWING IS THE CRITERIA FOR DECIDING THE AUDIT CHECK LIST S.NO
1 H - Class Category Supplier

CATEGORY

2 3 4 5 6 7 8 9

Q - Class Category Supplier R - Class Category Supplier Q - Class Category Supplier Become H - Class Category Supplier H - Class Category Supplier Become Q - Class Category Supplier R - Class Category Supplier Become H - Class Category Supplier H - Class Category Supplier Become R - Class Category Supplier JW - Class Category Supplier Become H - Class Category Supplier H - Class Category Supplier Become JW - Class Category Supplier

6.6

Get Quality System Certificate i.e. ISO 9001:2000, ISO TS 16949:2002 & other applicable system certificate as per requirement

6.7

Prepare Annual Audit Schedule in consultation with HOD (Corp.-Quality). The Audit Plan consists of H-Class Suppliers & Q-Class Suppliers

6.8

Intimate the Supplier for audit in advance as per Annual Audit Schedule. Decide Date & Time in consultation with supplier to be audited

6.9

6.10

Perform Audit as per Rico Defined Check List. (1) H-Class Category Supplier (2) Q-Class Category Supplier

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO ACTIVITY SUPPLIER QUALITY MANAGEMENT DEVELOPMENT

Ref ISO-TS 16949 , MMOG , QM Sec. 7.4

6.11

Appraise the supplier with system conformances & non-conformances and Hand over the audit report to supplier for taking action at their end and submission of short term & long term action plan for issues raised by RICO Submit the audit report to HOD (Corp.-Quality) / Hod (Plant Quality) and HOD (Plant Purchase) for Review Do follow up with supplier for getting feed back regarding corrective and preventive action submission. Perform Audit at least once in a year for each supplier unless other wise waived by HOD (Quality Corporate) Do the audit of supplier based on the supplier status (Class / Category) of that month receive the corrective and preventive action report from supplier Review the effectiveness of counter measure taken by supplier . Visit the supplier for checking the effectiveness and implementation if required Q-Class Category Supplier becomes H-Class category Supplier, if its Monthly PPM for consecutive 3 Months is more than 100 PPM & H-Class Category Supplier becomes Q-Class Category supplier, if its Monthly PPM for consecutive 3 Months is less than 100 PPM Review the Sub-supplier list at three month frequency and reallocate the supplier in H-Class Category & Q-Class Category based PPM Performance. Re-schedule the supplier audit plan based on this changed category

6.12

6.13

6.14

6.15

6.16

6.17

6.18

6.19

6.20

6.21

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.22 ACTIVITY Inform to Vendor Development Department / Plant material Department so as to taken action in case of supplier quality rating is going lower in continuous months plan for alternative source development & re-scheduling of supply Minimum 60% Rating as per Risk & Quality assessmenet check list is to be achieved to become RICO Poitential Supplier or to Continue business to RICO. SUPPLIER QUALITY MANAGEMENT DEVELOPMENT

Ref ISO-TS 16949 , MMOG , QM Sec. 7.4

6.23

NOTE :

Customer designated sub-supplier / Quality system developed by customer. So it will not come under perview of Rico sub-supplier system development Depending upon the subcontractor size certain sub element can be waived by Audit Team. Properietary part & c-class items are not included in the subcontractor system development and audit. In case of customer specific requirement, follow the customer advise for sub-contractor development. Minimum 60% quality rating must be achieved in the assessment to become potential supplier to Rico or To be continued as supplier to RICO.

2 3

7 7.1 7.2 7.3 7.4

DOCUMENTS : RICO 08 QSP 01 RICO 08 QSP 02 RICO 06 QWI 02 RICO 06 DOC 02 Procedure for Purchasing. Procedure for Assessment and selection of Sub-Supplier Work Instruction For Assessment of Vendor Rating System Classification of Boughtout Parts

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
8 RECORDS : RECORD DESCRIPTION FORM NO Vendor Audit Schedule RICO 06 QFO 07 Vendor Quality Audit Report RICO 06 QFO 23 Quality & Risk Assessment check list RICO 06 QFO 88 Section Head (QA) Section Head (QA) TITLE LOCATION Section Head (QA) SUPPLIER QUALITY MANAGEMENT DEVELOPMENT

Ref ISO-TS 16949 , MMOG , QM Sec. 7.4

BRIEF DESCRIPTION OF AMENDMENT DETAIL :

REVISION NO.

DATE

NATURE OF CHANGE / DESCRIPTION

05

25-06-2003

Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements

06

05-05-2004

MS-9000 System requirements added as per Ford Q1 Programme

07

25-01-2006

MS-9000 System upgraded to MMOG

08

05-09-2006

Procedure re-designed for selection & initial development of subsupplier

08

05-09-2006

Procedure re-designed for selection & initial development of subsupplier

PREPARED BY QUALITY SYSTEM DOCUMENT

APPROVED BY

ISSUED BY

MENT

.4

DOC. NO. ISSUE NO ISSUE DATE

RICO 08 QSP 03 08 05-09-2006

H, Q, C, R Class)

t supplier category, If it falls in

r than standard target for consecutive

y Risk Involved in the process

w.r.t. Form, Fit, Function, Safety,

tant w.r.t. end use

cordingly to the most d Q-Class. Supplier

COPY STATUS

SHEET 01 OF 08

MENT

.4

DOC. NO. ISSUE NO ISSUE DATE

RICO 08 QSP 03 08 05-09-2006

orrective and

COPY STATUS

SHEET 02 OF 08

MENT

.4

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY

RICO 08 QSP 03 08 05-09-2006 REF.DOC

ource / Supplier

When To Collect The Input (Frequency Of Collection) Before vendor development and procurement of the engineering goods

HOD QA MR Process Owner HOD QA

User / Customer

User / Customer HOD (Materials Plant) HOD (Materials Plant)

mer specified cifications.

Unit % Age Rating

RESPONSIBILITY Section Head (Plant Material)

REF.DOC ___

Section Head (Plant Material)

___

COPY STATUS

SHEET 03 OF 08

MENT

.4

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY Section Head (Quality Assurance) HOD (Plant Materials)

RICO 08 QSP 03 08 05-09-2006 REF.DOC RICO 06 DOC 02

HOD (Plant Materials)

___

ely less important on Quality

re not Audited during Audit)

COPY STATUS

SHEET 04 OF 08

MENT

.4

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY

RICO 08 QSP 03 08 05-09-2006 REF.DOC

CHECK LIST REQUIRED


RICO 06 QFO 88

RICO 06 QFO 23 RICO 06 QFO 23 RICO 06 QFO 88 RICO 06 QFO 23 RICO 06 QFO 88 RICO 06 QFO 23 RICO 06 QFO 88 RICO 06 QFO 23

y Supplier

y Supplier

y Supplier

y Supplier

ory Supplier

ory Supplier

Section Head (VDD) / Section (Plant Quality)

Section Head (Plant Quality) / Section Head (Plant Materials)

HOD (Plant Materials)

Section Head (Plant Quality) / Section Head (Plant Materials) Section Head (Plant Quality) / Section Head (Plant Materials)

COPY STATUS

SHEET 05 OF 08

MENT

.4

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY

RICO 08 QSP 03 08 05-09-2006 REF.DOC

Section Head (Plant Quality) / Section Head (Plant Materials)

Section Head (Plant Quality) / Section Head (Plant Materials) Section Head (Plant Manterials)

Section Head (Plant Quality) / Section Head (Plant Materials) Section Head (Plant Quality) Section Head (Plant Quality) Section Head (Plant Quality) Section Head (Plant Quality) Section Head (Plant Quality)

Section Head (Plant Quality)

Section Head (Plant Quality)

COPY STATUS

SHEET 06 OF 08

MENT

.4

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY HOD (Corp.- Quality)

RICO 08 QSP 03 08 05-09-2006 REF.DOC

HOD (Corp.- Quality)

eloped by customer. So it will not

ment can be waived by Audit Team. subcontractor system

tomer advise for

sessment to become

election of Sub-Supplier t of Vendor Rating System

COPY STATUS

SHEET 07 OF 08

MENT

.4

DOC. NO. ISSUE NO ISSUE DATE

RICO 08 QSP 03 08 05-09-2006

LOCATION Section Head (QA)

RETENTION PERIOD 1 Year

DISPOSAL AUTHORITY HOD(QA)

Section Head (QA)

1 Year

HOD(QA)

Section Head (QA)

1 Year

HOD(QA)

CRIPTION

W.e.f.

APPROVED BY Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp.

S 16949 : 2002 & FORD

25-06-2003

r Ford Q1 Programme

05-05-2004

25-01-2006

development of sub-

05-09-2006

development of sub-

05-09-2006

Management Representative QEHS Corp.

COPY STATUS

SHEET 08 OF 08

DOCUMENTS :

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

QUALITY SYSTEM DOCUMENT

INTERNAL

QUALITY SYSTEM PROCEDURE


TITLE
1 PURPOSE : TO MAKE A PRODUCTION PLAN SO AS TO MEET THE CUSTOMER DEMANDS AND PROPER UTILISATION OF MAN , MATERIAL AND MACHINES AND ALSO GIVE GUIDE LINES FOR THE ACTIVITIES OF THE SUPPORTING DEPARTMENTS. 2 SCOPE : IT COVERS ALL THE PRODUCTION ACTIVITIES AS WELL AS THE ACTIVITIES OF THE SUPPORTING DEPARTMENTS TO MEET THE CUSTOMER REQUIREMENT FOR COMPONENTS AND JOB WORK. 3 ABBREVIATION & DEFINITIONS : PPC MP&L DI SYSTEM CMMS3 CFT 4 PRODUCTION PLANNING AND CONTROL. MATERIAL PLANNING & LOGISTICS DELIVERY INSTRUCTION SYSTEM - MUL COMMON MATERIAL MANAGEMENT SYSTEM CROSS FUNCTIONAL TEAM( MP&L,MKT.,Q.A,PURCHASE,DEVELOPMENT)

PRODUCTION PLANNING & CONTROL


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

ORGANISATION CHART AND RESPONSIBILITY


PLANT MANAGER

HOD (MKT - EXPORT)

HOD(HPDC)

HOD (MP&L)

HOD(M/C SHOP-I)

HOD(M/C SHOP-II)

SECTION HEAD (HPDC)

SECTION HEAD (MP&L)

4.1 4.2

PLANT MANAGER IS RESPONSIBLE TO RECEIVE THE CUSTOMER PRODUCTION SCHEDULE. HOD (MP&L ) / SECTION HEAD (MP&L) IS RESPONSIBLE TO CONVERT THE CUSTOMER PRODUCTION / DELIVRY SCHEDULE IN TO RICO AUTO INDUSTRIES LIMITED PRODUCTION PLAN. OTHER RESPONSIBILITIES ARE AS INDICATED AGAINST EACH ACTIVITY.

4.3

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
5 PROCESS APPROACH PROCESS MAP AND INTERACTIONS (REFER TURTLE DIAGRAM - PPC) 6 SL.NO 6.1 DESCRIPTION ACTIVITY RECEIVE THE ANNUAL / MONTHLY DESPATCH SCHEDULE FROM CUSTOMER / MARKETING / HEAD OFFICE. INFORM AND DISCUSS WITH PLANT MANAGER FOR PRODUCTION PLANNING AS PER SCHEDULE (S) RECEIVED AND PREPARE AGREED DISPATCH PLAN TO FEED IN COMPUTER BASED ON CUSTOMER SCHEDULE PREPARE MONTHLY DESPATCH SCHEDULE (IF REQUIRED), INCORPORATE IN FLASH REPORT AND INTIMATE TO ALL CONCERNED INCLUDING PURCHASE DEPARTMENT FOR RAW MATERIAL PLANNING & PROCUREMENT BASED ON DESPATCH SCHEDULE PREPARE MONTHLY BOP REQUIREMENTS AND GIVE COPY TO PURCHASE AND STORE DEPTT. HOD (MP&L) / SECTION HEAD (MP&L) HOD (MP&L) / SECTION HEAD (MP&L)

PRODUCTION PLANNING & CONTROL


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.2

6.3

HOD (MP&L) / SECTION HEAD (MP&L)

6.4

HOD (MP&L) / SECTION HEAD (MP&L)

6.5 6.5.1 6.5.1.1

ON TIME DELIVERY
FOR HHML DHARUHERA & GURGAON / AUTOFIT TAKE DAY'S PRODUCTION PLAN FROM HHML BY MEANS OF PHONE / E-MAIL ETC ON DAILY BASIS. TAKE PHYSICAL STOCK DATA OF OUR PARTS BY MEANS OF PHONE / E-MAIL OR VIA PHYSICAL UNDERTAKING AT CUSTOMER END BY OUR REPRESENTATIVE. DECIDE DESPATCH PLAN (IN CONCSULTATION WITH PLANT MANAGER) FOR DAY AND INTIMATE TO ALL CONCERNED.

S.H. (MKT.) / HOD (MP&L) / SECTION HEAD (MP&L

6.5.1.2

S.H. (MKT.) / HOD (MP&L) / SECTION HEAD (MP&L

6.5.1.3

HOD (MP&L) / SECTION HEAD (MP&L)

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.5.1.4 ACTIVITY DO MINIMUM 4HRLY DESPATCH MONITORING IN ORDER TO MAINTAIN JUST IN TIME AND ON TIME DELIVERY AND APPRAISE THE STATUS TO PLANT MANAGER. KEEP TRACK WITH CUSTOMER REPRESENTATIVE FOR NECESSARY FEED BACK AND ALTERATIONIN DESPATCH (IF ANY.) ENSURE 100% ON TIME DELIVERY.

PRODUCTION PLANNING & CONTROL


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

HOD (MP&L) / SECTION HEAD (MP&L) HOD (PRODN.) / S.H. (MARKETING)

6.5.1.5

HOD (MP&L) / SECTION HEAD (MP&L) HOD (PRODN.)

6.5.1.6

HOD (MP&L) / SECTION HEAD (MP&L) HOD (PRODN.)

6.5.2 6.5.2.1

FOR MARUTI UDYOG LIMITED RECEIVED THE "DI" FROM THE CUSTOMER / MARKETING BY FAX / E-MAIL HOD (MP&L)

6.5.2.2

INTIMATE TO ALL CONCERNED WELL IN ADVANCE FOR "DI" REQUIREMENT OF MUL. ARRANGE THE "DI" REQUIREMENT PARTICULAR DAY IN ADVANCE APPROPRIATE OF AS

HOD (MP&L)

6.5.2.3

HOD (PRODN.)

6.5.2.4

ARRANGE THE DESPATCH AS PER "DI" REQUIREMENT IN ORDER TO REACH SUPPLY ON REQUIREMENT DATE AND TIME AS WELL AS AT REQUIRED LOCATION OF MARUTI STORES. KEEP TRACK WITH CUSTOMER FOR CHANGE IN "DI" SCHEDULE / NON "DI" SCHEDULE FOR NECESSARY ACTION AT OUR END. ENSURE 100% ON TIME DELIVERY AS PER DI GIVEN BY MUL.

HOD (PRODN.)

6.5.2.5

HOD (MP&L) / HOD (PRODN.)

6.5.2.6

HOD (MP&L) / HOD (PRODN.)

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.5.3 6.5.3.1 ACTIVITY FOR EXPORT CUSTOMERS RECEIVED CUSTOMER REQUIREMENT PLANNING, INFORMATION & SHIP SCHEDULE THROUGH CMMS3/EDI DISCUSS THE CUSTOMER SCHEDULE WITH PRODUCTION TEAM AND PLANT MANAGER TAKING INTO CONSIDERATION THE PLANTS CAPACITY & TIME REQUIRED FOR PRODUCTION.

PRODUCTION PLANNING & CONTROL


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

HOD (MP&L) / SECTION HEAD(MP&L)

6.5.3.2

HOD (MP&L) SECTION HEAD(MP&L)

6.5.3.3

PREPARE PRODUCTION PLAN / DESPATCH PLAN FOR INHOUSE PRODUCTION , RAW MATERIAL PLANNING & PROCUREMENT & SCHEDULING OF SUB-CONTRACTORS & VENDORS FEED THE DESPATCH PLAN IN THE ERP SYSTEM, WHICH WILL TAKE CARE OF UNAUTHORISED SHIPMENTS TO CUSTOMER

HOD (PRODN.) / SECTION HEAD(MP&L)

6.5.3.4

SECTION HEAD(MP&L)

6.5.3.5 6.5.3.6

MP&L PROCESS TO AVOID POTENTIAL PROBLEM REVIEW THE CMMS3 ON DEFINE INTERVAL DISCUSS THE PRODUCTION REQUIREMENT IN PRODUCTION MEETING MAKE SURE THE PRODUCTION AS PER PLAN , IF ANY ABNORMALITY INFORM TO HOD FOR NECESSARY ACTION. INCASE OF POTENTIAL FAILURE IN MP&L SERVICES , INFORM TO CUSTOMER WELL IN ADVANCE SO THAT POSSIBLE ACTION CAN BE TAKEN BY CUSTOMER KEEP TRACK WITH CUSTOMER FOR CHANGE IN "CMMS3 / EDI" SCHEDULE / NON "CMMS3 / EDI" SCHEDULE FOR NECESSARY ACTION AT OUR END. ENSURE 100% ON TIME DELIVERY AS PER CMMS3 / EDI GIVEN BY EXPORT CUSTOMER.

SECTION HEAD(MP&L)

HOD (MP&L) / SECTION HEAD(MP&L) SECTION HEAD (PRODN.)

6.5.3.7

6.5.3.8

HOD (MP&L)

6.5.3.9

HOD (MP&L) / HOD (PRODN.)

6.5.3.10

HOD (MP&L) / HOD (PRODN.)

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.5.4 6.5.4.1 ACTIVITY QUANTITY VERIFICATION PROCESS FOR CUMULATIVE SHIP (BETWEEN RICO INDIA & WAREHOUSES) UPDATE THE DESPATCHES IN THE PIPE LINE

PRODUCTION PLANNING & CONTROL


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

SECTION HEAD (MP&L

FORMAT ON WEEKLY BASIS 6.5.4.2 SEND THE PIPE LINE DETAIL TO WAREHOUSE AT LEAST ONCE IN A MONTH ARRANGE RECONCILING WITH THE WAREHOUSE PERSONNEL INCASE OF DISAGREEMENT, DETECT THE CAUSE AND TAKE CORRECTIVE ACTION AS PER ADVICE OF HOD (MP&L)

SECTION HEAD (MP&L

6.5.4.3

SECTION HEAD (MP&L

6.5.4.4

SECTION HEAD (MP&L

6.5.4.5

(BETWEEN WAREHOUSES & CUSTOMER) REVIEW THE CMMS3 IN THE FIRST WEEK OF MONTH FOR LAST QTY. RECEIVED FOR PREVIOUS MONTH AND TOTAL SHIP QTY. TO CUSTOMER RECONCILE IT IF THERE IS DISCREPANCY, DISCUSS WITH CUSTOMER AND FIND OUT THE ROOT CAUSE IMPLEMENT THE CORRECTIVE ACTION IN ADVICE WITH DIRECTOR WARE HOUSE. FOR OTHER CUSTOMER RECEIVED THE SCHEDULE FROM MARKETING FOR DISPATCH INTIMATE TO ALL CONCERNED ACCORDINGLY VIA FLASH REPORT ARRANGE DESPATCH AS PER SCHEDULE

WARE HOUSE INCHARGE

6.5.4.6

WARE HOUSE INCHARGE

6.5.4.7

WARE HOUSE INCHARGE

6.5.5 6.5.5.1

PLANT MANAGER / HOD(MP&L) HOD (MP&L)

6.5.5.2

6.5.5.3

HOD (MP&L) / HOD (PRODN.)

6.5.5.4

KEEP TRACK WITH MARKETING FOR ANY ALTERATION IN DESPATCH PLAN AND INTIMATE TO ALL CONCERNED (IF APPLICABLE) ENSURE 100% ON TIME DELIVERY.

HOD (MP&L) / SECTION HEAD (MP&L) HOD (PRODN.)

6.5.5.5

HOD (MP&L) / SECTION HEAD (MP&L) HOD (PRODN.)

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE

TITLE
SL.NO ACTIVITY

PRODUCTION PLANNING & CONTROL


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.6

PLANNING AMENDMENT RECEIVE THE AMENDMENT DETAIL FROM CUSTOMER / HEAD OFFICE BY WRITTEN MEDIA OR VERBALLY PREPARE THE AMENDMENT NOTE AS PER INFORMATION RECEIVED INDICATING SOURCE DETAIL OF AMENDMENT REVIEW THE AMENDMENT FOR VALIDITY

SECTION HEAD (MP&L)

6.7

SECTION HEAD (MP&L)

6.8

HOD (MP&L)

6.9

ENSURE THAT AMENDMENT ARE IN-CORPORATED IN FLASH REPORT

HOD (MP&L) / SECTION HEAD (MP&L) HOD (STORES) HOD (MP&L) / SECTION HEAD

6.10

CARRY OUT MONTHLY PHYSICAL INVENTORY AND INTIMATE TO ALL CONCERN REGARDING PLAN AND MACHINE LOADING INLINE WITH INVENTORY STOCK. DISCUSS AND REVIEW THE FLASH REPORT IN DAILY PRODUCTION MEETING ALONG WITH ALL CONCERN HODS AND DECIDE ACTION ON IMPROVING DELIVERY PERFORMANCE. PREPARE MONTHLY FLASH SUMMARY REPORT INDICATING THE REASON OF DELIVERY FAILURE AND IDENTIFY THE AREA / CUSTOMER WHERE DELIVERY PERFORMANCE NEED IMPROVEMENT. MAKE CORRECTIVE ACTION PLAN IN CASE OF DELIVERY FAILURE.

6.11

HOD (MP&L) / SECTION HEAD (MP&L)

6.12

HOD (MP&L) / SECTION HEAD (MP&L)

6.13

HOD (HODC) / HOD (M/C SHOP) / HOD (MP&L) HOD (MP&L) / SECTION HEAD (MP&L)

6.14

INTIMATE TO CUSTOMER WELL IN ADVANCE WITH REGRET, IN CASE OF SUPPLIES CAN NOT BE MADE ON DUE DATE AND TIME. PREMIUM FREIGHT RECORD THE PREMIUM FREIGHT PAID BY EITHER US OR BY VENDOR IF ANY. AND INTIMATE TO MANAGEMENT ON MONTHLY BASIS FOR REVIEW & ACTION.

6.15 6.15.1

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO ACTIVITY ONGOING CAPACITY MONITORING & CAPACITY ENHANCEMENT SYSTEM EVALUATE EFFECTIVENESS OF EXISTING OPERATIONS BY TRACKING "OEE" , CYCLE TIMES, NON-VALUE ADDED ACTIVITIES ETC. RECEIVE THE FORE CAST PRODUCTION PLAN OR CAPACITY ENHANCEMENT REQUIREMENT DETAIL FROM CUSTOMER. CALL CFT MEETING FOR REVIEW & ANALYSE OF THE CAPACITY ENHANCEMENT / FORECAST SCHEDULE WITHIN A WEEK AFTER RECEIPT OF CUSTOMER REQUIREMENT. ANALYZE THE CAPACITY REQUIREMENT BASED ON CUSTOMER OPERATING PATTERN. DECIDE THE WEEKLY AND MONTHLY REQUIREMENT AND FIX THE GAPS FOR MAN, MACHINES, METHODS, MATERIALS, MP&L AND PLANT FACILITIES AS APPLICABLE. DECIDE ACTION PLAN TO FILL THE GAP TO ACHIEVE THE REQUIRED CAPACITY. COMMUNICATE TO CUSTOMER FOR CONFORMANCE & TIMINGS & ESTABLISH THE AGREEMENT ON SUPPLIES IN CASE OF INABILITY TO MEET THE SCHEDULE (INCLUDING SUB-SUPPLIER REQUIREMENT) INFORM TO CUSTOMER WITH IN ONE WEEK TIME.

PRODUCTION PLANNING & CONTROL


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.16

PLANT TEAM

6.17

MKT. / MP&L

6.18

CFT

6.19

CFT

6.20

MKT. / MP&L

6.21

MKT. / MP&L

6.22

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
7 7.1 7.2 DOCUMENTS RICO 08 QSP 01 ----------PROCEDURE FOR PURCHASING CUSTOMER PLAN

PRODUCTION PLANNING & CONTROL


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

CAPACITY UTILIZATION PLAN

RECORDS : RECORD DESCRIPTION LOCATION TITLE PRODUCTION PLAN AMENDMENT MP&L

FORM NO RICO 09 QFO 01

RICO 09 QFO 02

DELIVERY CORRECTIVE ACTION PLAN

MP&L

RICO 09 QFO 03

FLASH REPORT

MP&L

RICO 09 QFO 04

PHYSICAL INVENTORY STATUS -HPDC

MP&L

RICO 09 QFO 05

PHYSICAL INVENTORY STATUS - CNC

MP&L

RICO 09 QFO 06

DESPATCH PLAN FOR THE MONTH OF . CONTAINER LOADING PLANS

MP&L

------

MP&L

-------

CAPACITY UTILIZATION PLAN (SOFT COPY)

MP&L

-------

WEEKLY SHIP SCHEDULE CMMS3 (SOFT COPY) DAILY SHIP SCHEDULE CMMS3 (SOFT COPY)

MP&L

-------

WARE HOUSE

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
9

PRODUCTION PLANNING & CONTROL


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

BRIEF DESCRIPTION OF AMENDMENT DETAIL :

REVISION NO.

DATE

NATURE OF CHANGE / DESCRIPTION

06

25-06-2003

Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements

07

05-05-2004

MS-9000 System requirements added as per Ford Q1 Programme

08

11-11-2004

Ongoing capacity monitoring & Capacity enhancement system added

09

25-01-2006

MS-9000 System upgraded to MMOG

10

16-03-2006

Capacity Enhancement Process of Suppliers & Subsupplier on the basis of Customer Requirement added.

10

16-03-2006

Capacity Enhancement Process of Suppliers & Subsupplier on the basis of Customer Requirement added.

PREPARED BY

APPROVED BY

ISSUED BY QUALITY SYSTEM DOCUMENT HOME

ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 09 QSP 01 10 16-03-2006

.5

NDS AND PROPER E LINES FOR THE

TIES OF THE SUPPORTING NENTS AND JOB WORK.

Q.A,PURCHASE,DEVELOPMENT)

HOD (MATERIALS)

HOD(M/C SHOP-II)

SECTION HEAD PAINT SHOP

SECTION HEAD MATERIALS

DUCTION SCHEDULE.

HE CUSTOMER PRODUCODUCTION PLAN.

COPY STATUS

SHEET 01 OF 09
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 09 QSP 01 10 16-03-2006

.5

RESPONSIBILITY HOD (MP&L) / SECTION HEAD (MP&L) HOD (MP&L) / SECTION HEAD (MP&L)

REF.DOC

RICO 09 QFO 06

HOD (MP&L) / SECTION HEAD (MP&L)

RICO 09 QFO 03

HOD (MP&L) / SECTION HEAD (MP&L)

S.H. (MKT.) / HOD (MP&L) / SECTION HEAD (MP&L) S.H. (MKT.) / HOD (MP&L) / SECTION HEAD (MP&L)

HOD (MP&L) / SECTION HEAD (MP&L)

COPY STATUS

SHEET 02 OF 09
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY HOD (MP&L) / SECTION HEAD (MP&L) / HOD (PRODN.) / S.H. (MARKETING) HOD (MP&L) / SECTION HEAD (MP&L) / HOD (PRODN.) HOD (MP&L) / SECTION HEAD (MP&L) / HOD (PRODN.)

RICO 09 QSP 01 10 16-03-2006 REF.DOC

.5

HOD (MP&L)

HOD (MP&L)

HOD (PRODN.)

HOD (PRODN.)

HOD (MP&L) / HOD (PRODN.)

HOD (MP&L) / HOD (PRODN.)

COPY STATUS

SHEET 03 OF 09
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY

RICO 09 QSP 01 10 16-03-2006 REF.DOC

.5

HOD (MP&L) / SECTION HEAD(MP&L)

HOD (MP&L) SECTION HEAD(MP&L)

HOD (PRODN.) / SECTION HEAD(MP&L)

SECTION HEAD(MP&L)

SECTION HEAD(MP&L) HOD (MP&L) / SECTION HEAD(MP&L) SECTION HEAD (PRODN.)

HOD (MP&L)

HOD (MP&L) / HOD (PRODN.)

HOD (MP&L) / HOD (PRODN.)

COPY STATUS

SHEET 04 OF 09
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY

RICO 09 QSP 01 10 16-03-2006 REF.DOC

.5

SECTION HEAD (MP&L)

SECTION HEAD (MP&L)

SECTION HEAD (MP&L)

SECTION HEAD (MP&L)

WARE HOUSE INCHARGE

WARE HOUSE INCHARGE

WARE HOUSE INCHARGE

PLANT MANAGER / HOD(MP&L) HOD (MP&L) RICO 09 QFO 03

HOD (MP&L) / HOD (PRODN.) HOD (MP&L) / SECTION HEAD (MP&L) / HOD (PRODN.) HOD (MP&L) / SECTION HEAD (MP&L) / HOD (PRODN.) COPY STATUS SHEET 05 OF 09
ALUMINIUM PLANTS

DOC. NO.

RICO 09 QSP 01

.5

ISSUE NO ISSUE DATE RESPONSIBILITY

10 16-03-2006 REF.DOC

SECTION HEAD (MP&L)

SECTION HEAD (MP&L)

RICO 09 QFO 01

HOD (MP&L)

HOD (MP&L) / SECTION HEAD (MP&L) HOD (STORES) HOD (MP&L) / SECTION HEAD (MP&L) HOD (MP&L) / SECTION HEAD (MP&L)

RICO 09 QFO 01 RICO 09 QFO 03

RICO 09 QFO 04 RICO 09 QFO 05

RICO 09 QFO 03

HOD (MP&L) / SECTION HEAD (MP&L)

HOD (HODC) / HOD (M/C SHOP) / HOD (MP&L) HOD (MP&L) / SECTION HEAD (MP&L)

HOD (MP&L) / SECTION HEAD (MP&L)

COPY STATUS

SHEET 06 OF 09
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY

RICO 09 QSP 01 10 16-03-2006 REF.DOC

.5

PLANT TEAM

RICO 14 QSP 03

MKT. / MP&L

CFT

CFT

MKT. / MP&L

MKT. / MP&L

MKT. / MP&L

COPY STATUS

SHEET 07 OF 09
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 09 QSP 01 10 16-03-2006

.5

LOCATION

RETENTION PERIOD 1 YEAR

DISPOSAL AUTHORITY HOD (MP&L)

MP&L

MP&L

1 YEAR

HOD (MP&L)

MP&L

1 YEAR

HOD (MP&L)

MP&L

1 YEAR

HOD (MP&L)

MP&L

1 YEAR

HOD (MP&L)

MP&L

1 YEAR

HOD (MP&L)

MP&L

3 MONTHS

HOD (MP&L)

MP&L

1 YEAR

HOD (MP&L)

MP&L

3 YEARS

HOD (MP&L)

WARE HOUSE

3 YEARS

WARE HOUSE INCHARGE

COPY STATUS

SHEET 08 OF 09
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 09 QSP 01 10 16-03-2006

.5

CRIPTION

W.e.f.

APPROVED BY Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp.

S 16949 : 2002 & FORD

25-06-2003

r Ford Q1 Programme

05-05-2004

ancement system

11-11-2004

25-01-2006

s & Subsupplier on the

16-03-2006

s & Subsupplier on the

16-03-2006

Management Representative QEHS Corp.

COPY STATUS

SHEET 09 OF 09

MENT

DOCUMENTS :

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

QUALITY SYSTEM DOCUMENT

INTERNAL

QUALITY SYSTEM PROCEDURE


TITLE
1 PURPOSE : TO PROVIDE EFFECTIVE METHODS OF HANDLING OF PRESERVATION SO AS TO PREVENT DAMAGE OR DETERIORATION OF MATERIALS AND PRODUCTS. 2 SCOPE : IT COVERS UNLOADING OF MATERIAL AT RECEIPT , TRANSFER TO DIFFERENT SHOPS AND THEIR STORAGE DURING THE PROCESS. 3 ABBREVIATION & DEFINITIONS : R.M. FIFO 4 RAW MATERIAL FIRST IN FIRST OUT

MATERIAL HANDLING AND PRESERVATION


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

ORGANISATION CHART AND RESPONSIBILITY FOR ORGANISATION, PLEASE REFER ORGANISATION CHART.

4.1 4.2

OVER ALL RESPONSIBILITY LIES WITH PLANT MANAGER. HOD'S ARE RESPONSIBLE FOR MATERIAL HANDLING, PRESERVATION AND MOVEMENT IN THEIR RESPECTIVE AREA. HOD (STORES) IS RESPONSIBLE FOR HANDLING, PRESERVATION AND MOVEMENT OF MATERIAL IN MAIN STORES, RECEIPT STORE AND FEEDING TO PRODUCTION LINES. OTHER RESPONSIBILITIES ARE INDICATED AGAINST EACH ACTIVITY. PROCESS APPROACH PROCESS MAP AND INTERACTIONS (REFER TURTLE DIAGRAM - STORES, MATERIL HANDLING & INVENTORY)

4.3

4.4 5

6 SL.NO 6.1

DESCRIPTION ACTIVITY RECEIPT OF RAW MATERIAL

6.1.1

ARRANGE TO PUT CARRIER LOADED WITH RAW MATERIAL IN THE ALLOCATED AREA. UNLOAD THE MATERIAL AT APPROPRIATE LOCATION BY ANY OF FOLLOWING METHOD AS APPLICABLE. FOR RICO DHARUHERA (I) RAW MATERIAL > 10 TONS USE HEAVY DUTY CRANE. (II) RAW MATERIAL > 3 TONS USE CHAIN PULLY BLOCK. (III) RAW MATERIAL > 20 KG BUT < 3 TONS USE FORK LIFT. (IV) RAW MATERIAL < 20 KG MANUAL / FORK LIFT / PALLET ETC.

6.1.2

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO ACTIVITY FOR HPDC DIV. GURGAON (I) RAW MATERIAL > 3 TONS USE FORK LIFT OR MANNUALY. (II) RAW MATERIAL > 20 KG BUT < 3 TONS USE FORK LIFT OR MANUAL TROLLY. (III) RAW MATERIAL < 20 KG MANUAL / FORK LIFT / PALLET ETC. 6.1.3 PROVIDE RAW MATERIAL IDENTIFICATION AND TRACEABILITY DETAIL AS PER REQUIREMENT. TRANSFER THE RAW MATERIAL TO ALLOY MAKING SECTION BY MEANS OF FORK LIFT / HAND PALLET / MANUAL ETC. HANDLE THE PRODUCT (RAW MATERIAL) WITH PROPER SAFETY. RECEIPT OF BROUGHT OUT PARTS, CONSUMABLES , SPARES , TOOLING , GAUGE, INSTRUMENTS AND SAFETY ITEMS. UNLOAD THE MATERIAL MANUALLY AND KEEP

MATERIAL HANDLING AND PRESERVATION


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.1.4

6.1.5

6.2

6.2.1

THEM ON HAND PALLET / TROLLEY TRANSFER THEM TO RECEIPT AREA. 6.2.2

AND

PROVIDE IDENTIFICATION TAG ON INCOMING AREA. PROTECT THE MATERIAL KEPT IN STORES FROM RUST AND DAMAGES FOLLOW FIRST IN FIRST OUT (FIFO) FOR ITEM HAVING LIMITED SELF LIFE. TRANSFER THE MATERIAL FROM STORE TO THE RESPECTIVE SHOPS. TRANSFER THE REQUIRED RAW MATERIAL TO RESPECTIVE SHOP (HPDC, MACHINE SHOP, PAINT SHOP & ASSY. LINES) BY MEANS OF HAND PALLETS OR MANUALLY. SUPPLY BOUGHT OUT PARTS TO MACHINE SHOP BY MEANS OF HAND PALLETS OR MANUALLY.

6.2.3

6.3

6.3.1

6.3.2

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.3.3 ACTIVITY SUPPLY THE PRODUCTION CONSUMABLES, MACHINERY , SPARES, TOOLINGS , GAUGES, INSTRUMENTS AND SAFETY ITEMS ETC. MANUALLY OR ON TROLLEY DEPENDING UPON SIZE , WEIGHT AND QUANTITY TO RESPECTIVE DEPARTMENT. MOLTEN METAL HANDLING IN HPDC POURING METAL FROM MELTING FURNACE TO TRANSFER LADDLE MANUALLY. MOVE THE TRANSFER LADDLE ON RAIL UP TO EOT CRANE LEVEL.

MATERIAL HANDLING AND PRESERVATION


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.4 6.4.1

6.4.2

6.4.3

LIFT THE LADDLE BY CRANE.

6.4.4

MOVE THE LADDLE UP TO HOLDING FURNACE FOR POURING. DO CROSS MOVEMENT UP FURNACE FOR POURING. TO HOLDING

6.4.5

6.4.6

POUR THE METAL IN TO HOLDING FURNACE BY CROSS WHEEL. PICK UP THE METAL WITH SPOON. POUR THE METAL IN SLEEVE.

6.4.7 6.4.8

6.5 6.5.1

HANDLING OF MATERIAL DURING PROCESS HANDLE THE MATERIAL DURING PROCESS IN BINS / TROLLEYS WITH HAND PALLET.

6.5.2

KEEP THE PARTS IN SUCH A WAY THAT THEIR MACHINED SURFACE SHOLD NOT TOUCH EACH OTHER DURING PROCESS / MATERIAL HANDLING. APPLY RUST PREVENTIVE OIL ON THE MATERIAL IN RAINY SEASON ON UNPAINTED MATERIAL / SURFACES (IF REQUIRED).

6.5.3

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.6 ACTIVITY TRANSFER OF MATERIAL FROM MACHINE SHOP TO PAINT SHOP AND DESPATCH SECTION TRANSFER THE MATERIAL FROM MACHINE SHOP TO PAINT SHOP BY MEANS OF BINS / TROLLEY NEAR PAINT SHOP LOADING AREA OR NEAR CONVEYOR.

MATERIAL HANDLING AND PRESERVATION


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.6.1

6.6.2

ENSURE UTMOST PRODUCT SAFETY DURING HANDLING LOAD THE PART ON THE CONVEYOR HANGER CAREFULLY AFTER THE PAINT TRANSFER THE MATERIAL TO NEXT OPERATION / FINAL INSPECTION & PACKAGING. PACK THE PARTS AS PER PACKAGING WORK INSTRUCTION

6.6.3

6.6.4

6.6.5

6.6.6

DESPATCH THE MATERIAL TO CUSTOMER IN SPECIAL TROLLEYS , BINS & CONTAINERS PACKED IN CORRUGATED BOX & WOODEN BOX AS APPLICABLE. FOLLOW THE WORK INSTRUCTION FOR STORAGE , HANDLING AND DESPATCH OF FINISHED GOODS.

6.6.7

6.6.8

DO PRESERVATION OF MATERIAL BY MEANS AS PER APPLICABILITY.

6.7 6.7.1

CONTROL OF CONTAINER & DUNNAGE STORE CONTAINER & DUNNAGE IN ALLOCATED AREA TO AVOID DAMAGE ASSUME THAT RETURNABLE CONTAINER AND DUNNAGE ARE RETURNED IN TIMELY MANNER AND IN ACCEPTABLE CONDITION.

6.7.2

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
7 DOCUMENTS :

MATERIAL HANDLING AND PRESERVATION


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

7.1 7.2

RICO 14 QSP 02 RICO 14 QWI 01

PROCEDURE FOR PACKAGING AND DELIVERY OF PRODUCT

WORK INSTRUCTION FOR STORAGE , HANDLING AND DESPAT FINISHED GOODS.

RECORDS : RECORD DESCRIPTION FORM NO ___ TITLE ____ LOCATION ___

___

____

___

___

____

___

PREPARED BY

APPROVED BY

ISSUED BY

INTERNAL

QUALITY SYSTEM PROCEDURE


TITLE
9

MATERIAL HANDLING AND PRESERVATION


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

BRIEF DESCRIPTION OF AMENDMENT DETAIL :

REVISION NO.

DATE

NATURE OF CHANGE / DESCRIPTION

07

25-06-2003

Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements

08

05-05-2004

MS-9000 System requirements added as per Ford Q1 Programme

09

05-08-2004

Material handling guidelines for operator provided for machining parts in process and in handling in column 6.5.2

10

25-12-2004

Control of Containers & Dunnage in Column 6.7

11

25-01-2006

MS-9000 System upgraded to MMOG

TURTLE DIA
DOCUMENT NO. : INTERFACE
- ALL EMPLOYEE OF ORGANISATION - PURCHASE DEPT. - QUALITY ASSURANCE DEPT. - PRODUCTION, PLANNING & CONTROL DEPT. - HPDC SHOP - M/C SHOP - PAINT SHOP - HR & TRAINING DEPT.

- INTERNAL & EXTERNAL CUSTOMERS REQUIREMENTS ON HANDLING AND STORAGE - BOP'S - RAW MATERIAL - RECEIPT OF MATERIAL FROM SUPPLIER - CUSTOMER SPECIFIC REQUIREMENTS

PROCEDURES
RICO 16 QSP 01 / QSP/RICO GGN/ 15.1 RICO 16 QSP 02 RICO 14 QSP 04 / QSP/RICO GGN/ 15.3 RICO 15 QSP 01 / QSP/RICO GGN/ 18.1 PROCEDURE FOR STORES PROCEDURE FOR ISSUE OF MATERIAL FOR JOB WORK PROCEDURE FOR INVENTORY MANAGEMENT PROCEDURE FOR TRAINING

PROCESS OWNER : HOD (STORES) / SECTION HEAD (STORES)

ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 14 QSP 01 11 25-01-2006

.5

SO AS TO PREVENT

FERENT SHOPS AND

AND MOVEMENT IN

MOVEMENT OF CTION LINES.

RESPONSIBILITY

REF.DOC

SECTION HEAD RECEIPT STORE SECTION HEAD RECEIPT STORE

COPY STATUS

SHEET 01 OF 06
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY

RICO 14 QSP 01 11 25-01-2006 REF.DOC

.5

SECTION HEAD RECEIPT STORE OPERATOR

OPERATOR

SECTION HEAD

RECEIPT STORE

SECTION HEAD RECEIPT STORE HOD (STORES)

SECTION HEAD (STORES)

SECTION HEAD (STORES)

COPY STATUS

SHEET 02 OF 06
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY SECTION HEAD (STORES)

RICO 14 QSP 01 11 25-01-2006 REF.DOC

.5

MELTING FURNACE OPERATOR MELTING FURNACE OPERATOR

MELTING FURNACE OPERATOR MELTING FURNACE OPERATOR MELTING FURNACE OPERATOR M/C OPERATOR

M/C OPERATOR M/C OPERATOR

SECTION HEAD (PRODN.) / SECTION HEAD (STORES) OPERATOR

SECTION HEAD (PRODN.) / SECTION HEAD (STORES)

COPY STATUS

SHEET 03 OF 06
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY

RICO 14 QSP 01 11 25-01-2006 REF.DOC

.5

SECTION HEAD (M/C SHOP)

HOD'S

OPERATOR

OPERATOR

OPERATOR

RICO 14 QSP 02

SECTION HEAD DESPATCH

OPERATORS/ HELPERS IN RESPECTIVE DEPARTMENTS OPERATORS/ HELPERS IN RESPECTIVE DEPARTMENTS

RICO 14 QWI 01

HOD (MP&L)

HOD (MP&L)

COPY STATUS

SHEET 04 OF 06
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 14 QSP 01 11 25-01-2006

.5

G AND DELIVERY OF PRODUCT

ORAGE , HANDLING AND DESPATCH OF

LOCATION ___

RETENTION PERIOD ___

DISPOSAL AUTHORITY ___

___

___

___

___

___

___

COPY STATUS

SHEET 05 OF 06

ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 14 QSP 01 11 25-01-2006

.5

CRIPTION

W.e.f.

APPROVED BY Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp.

S 16949 : 2002 & FORD

25-06-2003

r Ford Q1 Programme

05-05-2004

vided for machining .5.2

05-08-2004

6.7

25-12-2004

25-01-2006

TURTLE DIAGRAM - STORES, MATERIAL HANDLING & I


ISSUE NO. / REV NO. : 01

STORES , HANDLING & INVENTORY

SUE OF MATERIAL FOR JOB WORK VENTORY MANAGEMENT

L HANDLING & INVENTORY


EFFECTIVE DATE : COMPETENCE AND SKILL
- MANAGERIAL SKILLS - AWARENESS ABOUT STORE LAYOUT PLAN - STORE FUNCTION SKILL - INVENTORY MANAGEMENT FUNCTION SKILL - MATERIAL HANDLING SKILL & KNOWLEDGE - KNOWLEDGE OF QUALITY SYSTEM

1. STORE MANAGEMENT AS PER SYSTEM REQUIREMENT 2. IMPROVEMENT IN STORAGE CONDITION TO AVOID DAMAGE AND DETERIOTATION

PERFORMANCE
EFFECTIVENESS (1) INVENTORY TURN OVER RATIO (2) MONTHLY INVENTORY TREND VS SALES (3) TREND IN OBSOLETE / NON MOVING STOCK IN INR (4) NO OF TIMES FIFO FAILURE (5) TREND IN REJECTION FOLLOWING PERIODIC STOCK VARIATION (6) TRENDS IN ACCIDENTS RELATING TO HAZARDOUS MATERIAL HANDLING EFFICIENCY (1) REDUCING TREND IN INVENTORY IN RUPEES

DOCUMENTS :

EFFICIENCY CING TREND IN TORY IN RUPEES

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

QUALITY SYSTEM DOCUMENT

INTERNAL

QUALITY SYSTEM PROCEDURE


TITLE
1 PURPOSE : TO ESTABLISH A SYSTEM FOR PACKAGING & DELIVERY OF FINISHED PRODUCTS. 2 SCOPE : ALL FINISHED PRODUCTS. 3 ABBREVIATION & DEFINITIONS : HOD 4 HEAD OF DEPARTMENT

PACKAGING AND DELIVERY OF PRODUCT


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

ORGANISATION CHART AND RESPONSIBILITY FOR ORGANISATION, PLEASE REFER ORGANISATION CHART.

4.1 4.2

HOD (MP&L) IS OVER ALL RESPONSIBLE TO IMPLEMENT THIS PROCEDURE. HOD (HPDC) / HOD (M/C SHOP) / SECTION HEAD (PAINT SHOP) / HOD (MP&L) IS RESPONSIBLE FOR DAY TO DAY MONITORING OF THE ACTIVITIES OF THE DEPARTMENT. OTHER RESPONSIBILITIES ARE INDICATED AGAINST EACH ACTIVITY. PROCESS APPROACH PROCESS MAP AND INTERACTIONS (REFER TURTLE DIAGRAM - )

4.3 5

6 SL.NO 6.1

DESCRIPTION ACTIVITY RECEIVE THE PARTS FOR PACKAGING.

6.2

REMOVE THE BURR CHIPS AND OTHER FORIGN PARTICLES CLEAN THE PARTS PROPERLY.

6.3

6.4

DO PACKAGING & LABELLING AS PER WORK INSTRUCTION AND / OR AS CONFIRMED BY CUSTOMER DURING PPAP. INCASE OF CUSTOMER HERO HONDA MOTERS LIMITED , PUT THE PARTS IN BINS / TROLLEYS AS APPLICABLE. TRANSFER THE SAME TO FINISHED GOODS STORES.

6.5

6.6

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.7 ACTIVITY ENSURE THAT ONLY CONFORM PRODUCTS ARE PACKED. RECEIVE THE FINISHED GOODS FROM PRODUCTION ALONG WITH PRODUCTION SLIP. COUNT THE MATERIAL AFTER VERIFICATION OF PROPER DESCRIPTION. IF THERE IS ANY DESCREPENCY BRING IT TO THE ATTENTION OF HOD (EXCISE & DESPATCH) REFER THE MATTER TO CONCERNED PRODUCTION SHOP AND RESOLVE THE SAME. ENSURE THAT ONLY CONFORMING PRODUCT ARE TAKEN. ENSURE THAT EACH BIN / TROLLEY / RACK CONTAINING PRODUCT IS DULY IDENTIFIED BY PLATE / TAG. DO THE STACKING OF THE PRODUCT IN THE BIN / TROLLEY / WOODEN BOXES / PLLETS TO AVOID DAMAGE DURING STORAGE AND DESPATCH. PREPARE NECESSARY DOCUMENTS FOR

PACKAGING AND DELIVERY OF PRODUCT


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.8

6.9

6.10

6.11

6.12

6.13

6.14

6.15

DESPATCH OF MATERIAL TO CUSTOMER 6.16 SHIP THE MATERIAL AS PER THE REQUIREMENT OF THE CUSTOMER. ALSO CONSIDER THE TRANSPORTATION MODE, ROUTING DEFINED BY THE CUSTOMER. RECEIVE ACKNOWLEDGEMENT FROM THE CUSTOMER FOR MATERIAL SUPPLIED AS A TOKEN OF RECEIPT OF MATERIAL. PREPARE THE DAILY STOCK STATEMENT INDICATING MATERIAL RECEIVED , MATERIAL DESPATCHED, STOCH IN HAND MONITOR DELIVERY PERFORMANCE AGAINST SCHEDULE / PLAN ON DAILY BASIS.

6.17

6.18

6.19

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.20 ACTIVITY INCASE OF DESCREPENCY, TAKE NECESSARY CORRECTIVE AND PREVENTIVE ACTION TO IMPROVE DELIVERY PERFORMANCE. INCLUDING COMMUNICATION TO CUSTOMER WHERE REQUIRED. COMMUNICATE THE DETAILS OF SHIPMENT TO THE CUSTOMER AT THE TIME OF DESPATCH OF MATERIAL BY FAX, LETTER, OR ON TELEPHONE. WHEN COMMUNICATION SYSTEM BY ELECTRONIC MEDIA , IN THE EVENT OF ITS FAILURE, INTIMATE ADVANCE SHIPMENT DETAILS, BY LETTER / FAX / PHONE. REVIEW DELIVERY PERFORMANCE AT LEAST ONCE IN A MONTH AND INFORM CUSTOMER ON CORRECTIVE AND PREVENTIVE ACTION TAKEN TO IMPROVE DELIVERY PERFORMANCE WHERE DISCREPENCY EXISTS.

PACKAGING AND DELIVERY OF PRODUCT


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.21

6.22

6.23

6.24 6.24.1

EXPORT SHIPPING PREPARE CONTAINER / VEHICLE LOADING PLAN TO ENSURE DAMAGE FREE TRANSIT NOTIFY TO CONCERN AGENCIES PREPARE PACKING LIST FOR MATERIAL TO BE DESPATCH ENSURE EACH BOX CONTAINING PRODUCTS IS IDENTIFIED BY LABEL / TAGS PREPARE / ARRANGE EFFICIENTLY THE NECESSARY DOCUMENTS FOR DESPATCH OF THE MATERIAL TO THE CUSTOMER AS PER CUSTOMER STANDARD BIZ. EXPORT INVOICE, PACKAGING LIST , EXCISE INVOICE, LABELS, SHIPPING BILL , FUMIGATION CERTIFICATE & INSURANCE CERTIFICATE. LOAD THE CONTAINER / VEHICLE AS PER PACKAGING LIST / CONTAINER LOADING PLAN

6.24.2

6.24.3

6.24.4

6.24.5

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.24.6 ACTIVITY SHIP THE MATERIAL & WHEN CONTRACTULLY SPECIFIED BY CUSTOMER, COMMUNICATE TRANSPORTATION ROUTING (CARRIER , MODE ETC). TRACK THE CONTAINER / CONSIGNMENT TILL IT REACHES THE DESTINATION DO PACKAGING AUDIT AT LEAST ONCE IN A YEAR INFORM TO ALL CONCERNED IF THERE IS ANY

PACKAGING AND DELIVERY OF PRODUCT


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.24.7

6.24.8

6.24.9

DEVIATION FROM MATERIAL PLANNING & LOGISTIC INSTRUCTION 6.24.10 INVESTIGATE THE ROOT CAUSE & COMMUNICATE TO CUSTOMER & SUPPLIER AS WELL FOR IMPLEMENTATION

6.25

CUSTOMER SPECIFIC REQUIREMENTS FORD (NOV 2003)

4.34 Identification and traceability, preservation, storage and inventory


(ISO/TS 16949:2002 cl. 7.5.3, 7.5.4, 7.5.5, 7.5.5.1)

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
7 7.1 7.2 DOCUMENTS : RICO 14 QSP 01 RICO 06 QSP 15 (APPLICABLE TO RICO DHARUHERA) PROCEDURE FOR MATERIAL HANDLING AND PRESERVATION. PROCEDURE FOR INSPECTION AND TEST STATUS.

PACKAGING AND DELIVERY OF PRODUCT


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 7.20 7.21 7.22 7.23 7.24 7.25 7.26

RICO 14 QWI 01 RICO 10 QWI 14 RICO 10 QWI 17 RICO 10 QWI 24 RICO 10 QWI 30 RICO 10 QWI 31 RICO 10 QWI 32 RICO 10 QWI 33 RICO 11 QWI 01 RICO 11 QWI 02 RICO 11 QWI 03 RICO 11 QWI 04 RICO 11 QWI 05 RICO 11 QWI 08 RICO 11 QWI 09 RICO 11 QWI 11 RICO 11 QWI 12 RICO 11 QWI 13 RICO 11 QWI 14 RICO 11 QWI 25 RICO 11 QWI 27 RICO 11 QWI 41 RICO 11 QWI 42 RICO 11 QWI 44

WORK INSTRUCTION FOR STORAGE , HANDLING AND DESPAT FINISHED GOODS. WORK INSTRUCTION FOR PACKAGING OF SHROUD RADIATOR WORK INSTRUCTION FOR PACKAGING FOR MISC. COMPONEN ( M/S AMTEK AUTO & RICO GGN ) WORK INSTRUCTION FOR PACKAGING OF LIFTER PLATE P-40 WORK INSTRUCTION FOR PACKAGING OF OUTER CLUTCH (CD WORK INSTRUCTION FOR PACKAGING OF CENTRE CLUTCH (C WORK INSTRUCTION FOR PACKAGING OF PRESSURE PLATE (C WORK INSTRUCTION FOR PACKAGING OF LIFTER PLATE (CD 1 WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR FRONT HUB (HHML-I & HHML-II) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR REAR HUB (HHML-I & HHML-II) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR FRONT PANEL (HHML-I & HHML-II) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR REAR PANEL (HHML-I & HHML-II) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR CFD-CD (HHML-I) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR C - PLATE (HHML-I , HHML-II & FCC-GGN) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR FFD - ASSY (HHML-I & HHML-II) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR GSD (HHML-I & HHML-II) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR CLUTCH ASSY (HHML-I & HHML-II) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR PR- PLATE (HHML-I , HHML-II & FCC-GGN) WORK INSTRUCTION FOR PACKAGING & SPECIFICATION FOR L - PLATE (HHML-I , HHML-II & FCC-GGN) WORK INSTRUCTION FOR MARUTI COMPONENT PACKAGING OPERATOR WORK INSTRUCTION FOR CLEANING AND PACKAGING OPERA OF OIL PUMP YE - 2 WORK INSTRUCTION FOR PACKAGING OPERATOR OF H.S.P.P.L WORK INSTRUCTION FOR PACKAGING OPERATOR OF A.V.R. WORK INSTRUCTION FOR PACKAGING UPPER & LOWER BRACKET.

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE

TITLE
7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 7.20 7.21 7.22 7.23

PACKAGING AND DELIVERY OF PRODUCT


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

DOCUMENTS : (APPLICABLE TO RICO HPDC DIV. GURGAON) RICO 10 QWI 17 WORK INSTRUCTION FOR PACKAGING OF FCC RICO CASTING COMPONENTS RICO 10 QWI 18 WORK INSTRUCTION FOR PACKAGING OF CRANK CASE RIGHT RICO 10 QWI 34 RICO 10 QWI 35 RICO 10 QWI 36 RICO 10 QWI 37 RICO 11 QWI 06 RICO 11 QWI 07 RICO 11 QWI 08 RICO 11 QWI 09 RICO 11 QWI 10 RICO 11 QWI 11 RICO 11 QWI 12 RICO 11 QWI 13 RICO 11 QWI 14 RICO 11 QWI 15 RICO 11 QWI 16 RICO 11 QWI 17 RICO 11 QWI 18 RICO 11 QWI 19 RICO 11 QWI 20 RICO 11 QWI 21 RICO 11 QWI 22

W.I FOR PACKAGING OF FCC COMPONENTS ( CENTRE CLUTCH

W.I FOR PACKAGING OF FCC COMPONENTS ( OUTER CLUTCH) W.I FOR PACKAGING OF FCC COMPONENTS ( LIFTER PLATE)

W.I FOR PACKAGING OF FCC COMPONENTS ( PRESSURE PLAT

WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HUB FRONT WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HUB REAR WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF FRONT PANEL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF REAR PANEL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF FLANGE FINAL DRIVEN ASSY. WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF CIM 8086 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HLOF 8954 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF CIM 0551 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HFF 969 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HFF 331 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER REAR 1043 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER VALVE 404 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER VALVE 405 FOR TCL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER VALVE 404 / 405 FOR CUMMINS WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HFF 969 FOR CUMMINS WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF CIM 551 FOR CUMMINS WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF STRICKER LEFT FOR LGI

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
7 7.24 7.25 7.26 7.27 7.28 7.29 7.30 7.31 7.32 7.33 7.34 7.35 7.36 7.37 7.38 7.39 7.40 7.41 7.42 DOCUMENTS : RICO 11 QWI 23 RICO 11 QWI 24 RICO 11 QWI 25 RICO 11 QWI 26 RICO 11 QWI 27 RICO 11 QWI 39 RICO 11 QWI 42 RICO 11 QWI 43 RICO 11 QWI 44 RICO 11 QWI 45 RICO 11 QWI 46 RICO 11 QWI 47 RICO 11 QWI 48 RICO 11 QWI 49 RICO 11 QWI 50 RICO 11 QWI 51 RICO 11 QWI 52 RICO 11 QWI 53 RICO 11 QWI 54

PACKAGING AND DELIVERY OF PRODUCT


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF STRICKER RIGHT FOR LGI WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF FMD FOR FCC RICO WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF FORKS (6 TYPES) FOR MUL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER THERMO FOR HSCIL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER WATER OUTLET FOR HSCIL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF PANEL ASSY. FRONT FOR HMSI WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER CYLINDER HEAD F8D FOR MUL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER CYLINDER HEAD F10D FOR MUL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF CIM 1819 FOR CUMMINS WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF AIRCON BRACKET FOR JAGUAR / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF FAN IDLER BRACKET FOR JAGUAR / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF PAS BRACKET FOR JAGUAR / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF PQU 500022 BRACKET FOR LAND ROVER / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF PQU 500032 BRACKET FOR LAND ROVER / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF AUTO CLOSURE PLATE FOR LAND ROVER / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HOUSING TUNNEL ASSEMBLY FOR LAND ROVER / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF ALTERNATOR BRACKET FOR JAGUAR / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF ARC BRACKET FOR JAGUAR / FORD WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER GEAR SHIFT FOR HMSI

7.43 7.44 7.45 7.46

RICO 11 QWI 56 RICO 11 QWI 57 RICO 11 QWI 59 RICO 11 QWI 60

WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF HLOF FOR CUMMINS WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF CIM7069 FOR CUMMINS WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF STAY CHANGE WIRE FOR HSCIL WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF COVER COMPOUND WATER OUTLET FOR HSCIL

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
7 7.47 7.48 7.49 7.50 7.51 7.52 7.53 7.54 7.55 7.56 7.57 7.58 7.59 7.60 7.61 7.62 DOCUMENTS : RICO 11 QWI 61 RICO 11 QWI 73 RICO 11 QWI 79 RICO 11 QWI 80 RICO 11 QWI 82 RICO 11 QWI 83 RICO 11 QWI 84 RICO 11 QWI 85 RICO 11 QWI 87 RICO 11 QWI 88 RICO 11 QWI 93 RICO 11 QWI 95 RICO 11 QWI 97 RICO 11 QWI 98 RICO 11 QWI 101 RICO 11 QWI 105

PACKAGING AND DELIVERY OF PRODUCT


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

WORK INSTRUCTION FOR PACKAGING SPECIFICATION & DEVE OF CLUTCH ASSY FOR HHML WORK INSTRUCTION FOR PACKAGING OF PROTOTYPE OR PV TEST PARTS W.I. FOR PACKAGING OF PAS BRACKET ( AJ 42 / 44) W.I. FOR PACKAGING OF ALTERNATOR BRACKET ( AJ 42/44)

PACKAGING OF BASE AS FUEL FILTER (136-5017) FOR CATERP

PACKAGING OF BASE AS FUEL FILTER (141-5138) FOR CATERP

PACKAGING OF ADOPTER (ATM PRESS) (166-6693) FOR CATER PACKAGING OF MANIFOLD (168-0300) FOR CATERPILLER WORK INSTRUCTION FOR PACKAGING OF COVER REAR 3967200 FOR CUMMINS USA WORK INSTRUCTION FOR PACKAGING OF COVER INTAKE MANIFOLD (3965566 & 3957907) FOR CUMMINS USA WORK INSTRUCTION FOR PACKAGING OF TRANSFER BOX

WORK INSTRUCTION FOR PACKAGING OF ENGINE MOUNTING WORK INSTRUCTION FOR PACKAGING OF BKT SUPPORT AC

WORK INSTRUCTION FOR PACKAGING OF BKT AC ALTERNATOR (30731398) W.I. FOR CHECKING , WASHING OILING & PACKAGING OF CIM & COVER REAR WORK INSTRUCTION FOR PACKAGING OF ENGINE MOUNTING

7.63 7.64 7.65 7.66 7.67 7.68

RICO 11 QWI 111 RICO 11 QWI 112 RICO 11 QWI 114 RICO 11 QWI 117 RICO 11 QWI 119 RICO 11 QWI 120

WORK INSTRUCTION FOR PACKAGING OF COVER COMP. THRUST (HSCIL) WORK INSTRUCTION FOR PACKAGING OF EGR PLATE (HSCIL) WORK INSTRUCTION FOR CHECKING, WASHING,PACKAGING FOR PAS BKT - 6R83-3K738-BA WORK INSTRUCTION FOR PACKAGING OF 2.2 LTR PAS BKT

PACKAGING OF BASE AS FUEL FILTER (1N3789) FOR CATERPI

WORK INSTRUCTION FOR PACKAGING OF VOLVO BKT 3075732

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
7 7.69 7.70 7.71 7.72 7.73 7.74 7.75 DOCUMENTS : RICO 11 QWI 121 RICO 11 QWI 122 RICO 11 QWI 125 RICO 11 QWI 134 RICO 11 QWI 136 RICO 11 QWI 142 RICO 11 QWI 144

PACKAGING AND DELIVERY OF PRODUCT


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

WORK INSTRUCTION FOR PACKAGING OF VOLVO BKT STAY FR

WORK INSTRUCTION FOR PACKAGING OF VOLVO BKT FLY WHEEL SENSOR WORK INSTRUCTION FOR PACKAGING OF PAS BKT - 6R83-3K

WORK INSTRUCTION FOR PACKAGING OF CRANK CASE COVE WORK INSTRUCTION FOR PACKAGING OF BKT 683 WORK INSTRUCTION FOR PACKAGING OF OIL FILTE HEAD VERTICAL - PERKINS WORK INSTRUCTION OF PACKAGING - BACK PLATE

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
8 RECORDS : RECORD DESCRIPTION FORM NO ---TITLE -----LOCATION

PACKAGING AND DELIVERY OF PRODUCT


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

----

----

---

----

----

---

----

----

---

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
9

PACKAGING AND DELIVERY OF PRODUCT


Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

BRIEF DESCRIPTION OF AMENDMENT DETAIL :

REVISION NO.

DATE

NATURE OF CHANGE / DESCRIPTION

08

25-06-2003

Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements

08

25-06-2003

Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements

09

15-04-2004

Procedure reviewed for Ford specific requirements NOV 2003

10

05-05-2004

MS-9000 System requirements added as per Ford Q1 Programme

11

25-01-2006

MS-9000 System upgraded to MMOG

12

20-05-2006

New developed parts Packaging work instruction added to procedure

PREPARED BY

APPROVED BY

ISSUED BY

ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 14 QSP 02 12 20-05-2006

.5

P&L) IS RESPONSIBLE

RESPONSIBILITY OPERATOR (PACKAGING) HELPER

REF.DOC

HELPER

OPERATOR / HELPER

RELEVANT PACKAGING WORK INSTRUCTION

HELPER

HELPER

COPY STATUS

SHEET 01 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY SECTION HEAD (PRODN) SECTION HEAD EXCISE SECTION HEAD PPC / EXCISE SECTION HEAD EXCISE SECTION HEAD EXCISE SECTION HEAD EXCISE SECTION HEAD PPC

RICO 14 QSP 02 12 20-05-2006 REF.DOC

.5

HELPER

SECTION HEAD

EXCISE SECTION HEAD EXCISE / HOD(PRODN)

SECTION HEAD EXCISE

SECTION HEAD EXCISE / SECTION HEAD (PPC) PLANT MANAGER / HEAD (PP/LOGISTICS)

COPY STATUS

SHEET 02 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY PLANT MANAGER / HOD (MP&L)

RICO 14 QSP 02 12 20-05-2006 REF.DOC

.5

PLANT MANAGER / HOD (MP&L)

PLANT MANAGER / HOD (MP&L)

PLANT MANAGER / HOD (MP&L)

SECTION HEAD (MP&L)

SECTION HEAD (PRODN.)

SECTION HEAD (PRODN.)

SECTION HEAD (EXCISE) / SHOD (MP&L) / SECTION HEAD (MP&L)

SECTION HEAD (MP&L)

COPY STATUS

SHEET 03 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY SECTION HEAD (MP&L)

RICO 14 QSP 02 12 20-05-2006 REF.DOC

.5

SECTION HEAD (MP&L)

SECTION HEAD (PRODN.) SECTION HEAD (MP&L)

SECTION HEAD (MP&L)

RESP. - MP&L HOD

inventory

COPY STATUS

SHEET 04 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 14 QSP 02 12 20-05-2006

.5

HANDLING AND PRESERVATION. N AND TEST STATUS.

ORAGE , HANDLING AND DESPATCH OF

CKAGING OF SHROUD RADIATOR CKAGING FOR MISC. COMPONENT

CKAGING OF LIFTER PLATE P-40 CKAGING OF OUTER CLUTCH (CD 100) CKAGING OF CENTRE CLUTCH (CD 100) CKAGING OF PRESSURE PLATE (CD 100) CKAGING OF LIFTER PLATE (CD 100) CKAGING & SPECIFICATION FOR

CKAGING & SPECIFICATION FOR

CKAGING & SPECIFICATION FOR

CKAGING & SPECIFICATION FOR

CKAGING & SPECIFICATION FOR

CKAGING & SPECIFICATION FOR

CKAGING & SPECIFICATION FOR

CKAGING & SPECIFICATION FOR

CKAGING & SPECIFICATION FOR

CKAGING & SPECIFICATION FOR

CKAGING & SPECIFICATION FOR

RUTI COMPONENT PACKAGING

EANING AND PACKAGING OPERATOR

CKAGING OPERATOR

CKAGING OPERATOR

CKAGING UPPER &

COPY STATUS

SHEET 05 OF 11
ALUMINIUM PLANTS

DOC. NO.

RICO 14 QSP 02

.5

ISSUE NO ISSUE DATE

12 20-05-2006

CKAGING OF FCC RICO CASTING

CKAGING OF CRANK CASE RIGHT (HMSI)

COMPONENTS ( CENTRE CLUTCH)

COMPONENTS ( OUTER CLUTCH)

COMPONENTS ( LIFTER PLATE)

COMPONENTS ( PRESSURE PLATE )

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY OR CUMMINS CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

COPY STATUS

SHEET 06 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 14 QSP 02 12 20-05-2006

.5

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY 8D FOR MUL CKAGING SPECIFICATION & DEVELVERY 10D FOR MUL CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY GUAR / FORD CKAGING SPECIFICATION & DEVELVERY JAGUAR / FORD CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY R LAND ROVER / FORD CKAGING SPECIFICATION & DEVELVERY R LAND ROVER / FORD CKAGING SPECIFICATION & DEVELVERY OR LAND ROVER / FORD CKAGING SPECIFICATION & DEVELVERY BLY FOR LAND ROVER / FORD CKAGING SPECIFICATION & DEVELVERY OR JAGUAR / FORD CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY

CKAGING SPECIFICATION & DEVELVERY ER OUTLET FOR HSCIL

COPY STATUS

SHEET 07 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 14 QSP 02 12 20-05-2006

.5

CKAGING SPECIFICATION & DEVELVERY

CKAGING OF PROTOTYPE OR BRACKET ( AJ 42 / 44)

ERNATOR BRACKET ( AJ 42/44)

L FILTER (136-5017) FOR CATERPILLER

L FILTER (141-5138) FOR CATERPILLER M PRESS) (166-6693) FOR CATERPILLER

68-0300) FOR CATERPILLER

CKAGING OF COVER REAR

CKAGING OF COVER INTAKE 7) FOR CUMMINS USA CKAGING OF TRANSFER BOX

CKAGING OF ENGINE MOUNTING BKT (LH)

CKAGING OF BKT SUPPORT AC (3711584)

CKAGING OF BKT AC

NG OILING & PACKAGING OF

CKAGING OF ENGINE MOUNTING BKT (RH)

CKAGING OF COVER COMP.

CKAGING OF EGR PLATE (HSCIL)

ECKING, WASHING,PACKAGING

CKAGING OF 2.2 LTR PAS BKT

L FILTER (1N3789) FOR CATERPILLER

CKAGING OF VOLVO BKT 30757329

COPY STATUS

SHEET 08 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 14 QSP 02 12 20-05-2006

.5

CKAGING OF VOLVO BKT STAY FRONT

CKAGING OF VOLVO BKT FLY

CKAGING OF PAS BKT - 6R83-3K738-BA

CKAGING OF CRANK CASE COVER - HMSI

CKAGING OF BKT 683

CKAGING OF OIL FILTE HEAD

KAGING - BACK PLATE

COPY STATUS

SHEET 09 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 14 QSP 02 12 20-05-2006

.5

LOCATION

RETENTION PERIOD ---

DISPOSAL AUTHORITY ---

---

---

---

---

---

---

---

---

---

---

COPY STATUS

SHEET 10 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 14 QSP 02 12 20-05-2006

.5

CRIPTION

W.e.f.

APPROVED BY Management Representative QEHS Corp.

S 16949 : 2002 & FORD

25-06-2003

S 16949 : 2002 & FORD

25-06-2003

Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp.

ments NOV 2003

15-04-2004

r Ford Q1 Programme

05-05-2004

25-01-2006

ction added to

20-05-2006

COPY STATUS

SHEET 11 OF 11

DOCUMENTS :

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

HOME

QUALITY SYSTEM DOCUMENT

INTERNAL

QUALITY SYSTEM PROCEDURE


TITLE
1 PURPOSE : TO ESTABLISH A SYSTEM TO MAINTAIN OPTIMUM INVENTORY LEVEL AND STOCK ROTATION. 2 SCOPE : THIS PROCEDURE COVERS INVENTORIES AT INCOMING STORAGE , WORK IN PROGRESS , COMPONENTS , CONSUMABLES AND FINISH GOODS STOCKS. 3 ABBREVIATION & DEFINITIONS : MRR HOD FIFO 4 - MATERIAL RECEIPT REPORT - HEAD OF DEPARTMENT - FIRST IN FIRST OUT

INVENTORY CONTROL
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

ORGANISATION CHART AND RESPONSIBILITY FOR ORGANISATION , PLEASE REFER ORGANISATION CHART

4.1 4.2 4.3 5

PLANT MANAGER IS OVER ALL RESPONSIBLE TO IMPLEMENT THIS PROCEDURE. HOD PURCHASE IS RESPONSIBLE FOR PROCUREMENT OF MATERIAL REQUIRED. OTHER RESPONSIBILITIES ARE INDICATED AGAINST EACH ACTIVITY. PROCESS APPROACH PROCESS MAP AND INTERACTIONS (REFER TURTLE DIAGRAM - STORES, MATERIL HANDLING & INVENTORY)

6 SL.NO 6.1 6.1.1

DESCRIPTION ACTIVITY RECEIPT STAGE DECIDE THE MINIMUM & MAXIMUM LEVELS.THE LEVELS IS BEING MONITORED IN THE SYSTEM

ON DAILY BASIS BY THE PURCHASE DEPTT. ACCORDINGLY. NOTE : - NON CRITICAL HIGH VALUE SPARES WILL NOT BE HAVING ANY LEVEL. THESE WILL BE PROCURED AGAINST PURCHASE REQUISITION. 6.1.2 INITIATE THE ACTION FOR PROCUREMENT.

6.1.3

RECEIVE THE NECESSARY DOCUMENT OF MATERIAL RECEIPT AT SECURITY GATE OFFICE. ENTER THE RELEVANT DETAIL IN THE COMPUTOR FOR SCHEDULED QTY. TO BE RECEIVE FROM VENDOR.

6.1.4

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.1.5 ACTIVITY IF COMPUTOR INDICATES OVER SCHEDULED, THEN SEND BACK THE MATERIAL TO VENDOR. IF WITHIN SCHEDULED NORMS, ENTER THE RELEVANT DETAIL IN COMPUTOR. MAKE MATERIAL RECEIPT REPORT (MRR)

INVENTORY CONTROL
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.1.6

6.1.7

6.1.8

RECEIVE THE MATERIAL AND STORE IN SUCH A WAY THAT STOCK CAN BE ROTATED ON REGULAR BASIS AND FIFO CAN BE FOLLOWED IN CASE OF SELF LIFE ITEMS. DO MONTHLY PHYSICAL STOCK TAKING. UPDATE THE STOCK LEVELS AND INFORM TO HOD (PURCHASE) IN CASE THE STOCK VARIES WITH RESPECT TO LEVEL DECIDED BASED ON 5.1.9 ABOVE , REVIEW THE DELIVERY SCHEDULE & PASS ON NECESSARY INSTRUCTION TO THE CONCERN SUBCONTRAC-

6.1.9 6.1.10

6.1.11

TOR AS REQUIRED. 6.1.12 ISSUE THE MATERIAL TO CONCERN USER CONSIDERING THE FIFO / STOCK ROTATION.

6.2 6.2.1

WORK IN PROGRESS RECEIVE PRODUCTION PLAN DEPARTMENT MAINTAIN THE PRODUCTIVITY RESPECTIVE SHOPS FROM PPC

6.2.2

NORM

OF

6.2.3

GET THE MATERIAL ISSUED FROM THE STORES IN ADVANCE AS PER PLANNING. CARRY OUT PRODUCTION AS PER PLANNING SCHEDULE.

6.2.4

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.2.5 ACTIVITY INCASE ANY REVISION IN PRODUCTION PLAN FOLLOW STEP 5.2.3 TO ONWARDS. TRANSFER THE MATERIAL FOR FINAL INSPECTION AND PACKAGING AS PER CUSTOMER REQUIREMENTS. TRANSFER THE NON-CONFORMING MATERIAL TO RESPECTIVE SHOP THROUGH REWORK INTIMATION SLIP OR TO SCRAP YARD THROUGH REJECTION REPORT. ARRANGE TO CARRY OUT THE PHYSICAL VERIFICATION OF DOCUMENTED STOCK ON MONTHLY BASIS.

INVENTORY CONTROL
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.2.6

6.2.7

6.2.8

6.2.9

REVIEW THE INVENTORY REPORT AND TAKE NECESSARY CORRECTIVE / PREVENTIVE ACTION TO ELIMINATE OR MINIMISE THE VARIATION IN DOCUMENTED AND PHYSICAL STOCK. FINISHED GOODS STORES DECIDE THE INVENTORY LEVEL TAKING CUSTOMER REQUIREMENT IN CONSULTATION WITH PLANT MANAGER. RECEIVE THE CONFORMING MATERIAL AFTER FINAL INSPECTION. ARRANGE TO SEND THE MATERIAL CUSTOMER WITH RELEVANT DOCUMENT. TO

6.3 6.3.1

6.3.2

6.3.3

6.4

DO MONTHLY INVENTRY & FILL RG-1 FORM FOR INVENTORY ANALYSIS AND EXCISE PURPOSE. NOTE : DIRECT DATA LINK WHERE APPLICABLE AND CUSTOMER MENDATORY REQUIREMENT, RICO WILL USED INTERACTIVE INVENTORY MANAGEMENT SYSTEM E.G. DDL (DIRECT DATA LINK) & HOD (MP&L) WILL BE RESPONSIBLE TO ANSWER DAILY SHORTAGE AND NEW MODEL LAUNCH REQUIREMENT ACCURATELY AND IN ACCORDANCE TO THE FORD PROCEDURE. THIS DDL COVERAGE WILL BE PROVIDED TO CUSTOMER IN CUSTOMER OPERATING HOURS.

6.5

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
7 7.1 7.2 DOCUMENTS : RICO 08 QSP 01 RICO 16 QSP 01 PROCEDURE FOR PURCHASING PROCEDURE FOR STORES

INVENTORY CONTROL
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

RECORDS : RECORD DESCRIPTION FORM NO ------TITLE MONTHLY INVENTRY DATA FOR RM / BOP, WIP & FINISH STORE, EXCISE LOCATION

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
9

INVENTORY CONTROL
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

BRIEF DESCRIPTION OF AMENDMENT DETAIL :

REVISION NO.

DATE

NATURE OF CHANGE / DESCRIPTION

07

25-06-2003

Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements

08

05-05-2004

MS-9000 System requirements added as per Ford Q1 Programme

09

25-01-2006

MS-9000 System upgraded to MMOG

PREPARED BY

APPROVED BY

ISSUED BY

QUALITY SYSTEM DOCUMENT HOME

ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 14 QSP 04 09 25-01-2006

.5

ORK IN PROGRESS ,

RESPONSIBILITY

REF.DOC

PLANT HEAD / HOD (PURCHASE)

LEVEL. THESE WILL

HOD (PURCHASE) / SECTION HEAD (PURCHASE) SECTION HEAD (SECURITY) SECTION HEAD (SECURITY)

COPY STATUS

SHEET 01 OF 05
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY SECTION HEAD (SECURITY) SECTION HEAD (SECURITY) SECTION HEAD ( STORES) HOD (STORES)

RICO 14 QSP 04 09 25-01-2006 REF.DOC

.5

RICO 16 QFO 02

HOD (STORES) HOD (STORES)

HOD (PURCHASE) SECTION HEAD (PURCHASE)

HOD (STORE) SECTION HEAD (STORE)

RICO 16 QWI 04

RESPECTIVE SECTION HEAD RESPECTIVE SECTION HEAD RESPECTIVE SECTION HEAD RESPECTIVE SECTION HEAD

COPY STATUS

SHEET 02 OF 05
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY RESPECTIVE SECTION HEAD RESPECTIVE SECTION HEAD

RICO 14 QSP 04 09 25-01-2006 REF.DOC

.5

SECTION HEAD (QA)

PLANT MANAGER

PLANT MANAGER / HOD (PURCHASE)

HOD (MP&L)

SECTION HEAD (EXCISE) HOD (MP&L) / SECTION HEAD(EXCISE) SECTION HEAD (EXCISE)

HOD (MP&L) / SECTION HEAD (MP&L)

COPY STATUS

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RETENTION PERIOD 6 MONTH

DISPOSAL AUTHORITY PLANT MANAGER

STORE, EXCISE

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RICO 14 QSP 04 09 25-01-2006

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CRIPTION

W.e.f.

APPROVED BY Management Representative QEHS Corp. Management Representative QEHS Corp. Management Representative QEHS Corp.

S 16949 : 2002 & FORD

25-06-2003

r Ford Q1 Programme

05-05-2004

25-01-2006

COPY STATUS

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DOCUMENTS :

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

HOME QUALITY SYSTEM DOCUMENT DOC. NO : CHAPTER : RICO 01 QM 01 7.4

QUALITY MANUAL
PRODUCT REALIZATION PURCHASING

A : PURPOSE Documented procedures are established and maintained to ensure that products and services that directly affect quality are performed throughout the facility in a manner that conforms to the quality standards and specifications. Production operations are planned and verified to ensure that they are proceeding under controlled conditions in the specified manner and sequence. B : SCOPE Applicable for all purchased raw materials, bought out components, packing materials other consumable items and services which have bearing on the quality of the products made by RICO AUTO Dharuhera / HPDC Gurgaon

C : RESPONSIBILITY AND AUTHORITY Hod (Purchase) is responsible for ensuring the requirements of this chapter Hod (Q.A.) is responsible for verification and take corrective action in case of nonconformance. D : DESCRIPTION 7.4 PURCHASING 7.4.1 PURCHASING PROCESS RICO AUTO INDUSTRIES LIMITED ensures that purchased product conforms as per purchasing to specified purchase requirements. The type and extent of control applied to the supplier and the purchased product is depended upon the effect of the purchased product on subsequent product realization or the final product. The purchasing department selects suppliers on the requisites of quality, price, and delivery. The selection criteria is documented and based on one or more of the following: A inspection of final product at the sub-contractors facility. B inspection of final product upon delivery C historical performance of adherence to purchasing requirements D sub-contractors conformance to an international standard When there are mergers, acquisitions or affiliations associated with suppliers, the organization will verify the continuity of the suppliers quality system and its effectiveness. 7.4.1.1 REGULATORY COMPLIANCE All purchased products or materials used in product satisfy applicable regulatory requirements. 7.4.1.2 SUPPLIER QUALITY MANAGEMENT SYSTEM DEVELOPMENT RICO AUTO INDUSTRIES LIMITED has a defined procedure for development of subcontractor RICO AUTO INDUSTRIES LIMITED performs supplier quality management system development with the

goal of supplier compliance to this technical specification. 7.4.1.3 CUSTOMER- APPROVED SOURCES Where specified by the contract, RICO AUTO INDUSTRIES LIMITED purchases products, materials or services from approved sources. The use of customer-designated sources, including tool/gauge suppliers, does not relieve the RICO AUTO INDUSTRIES LIMITEDs responsibility for ensuring the quality of purchased products

PREPARED BY DOC. NO : CHAPTER :

APPROVED BY RICO 01 QM 01 7.4

ISSUED BY

REVISION NO. : 01 ISSUE DATE : 15-12-2003

EDITION - 04 SHEET 01 OF 03

QUALITY MANUAL
PRODUCT REALIZATION PURCHASING

7.4.2 PURCHASING INFORMATION Purchasing documents contain data that clearly describes the product ordered, including where applicable: Purchasing documents are reviewed and approved for adequacy of specified requirements prior to release. A The type class, grade, requirements, or other precise identification. B The title or other positive identification applicable to the issue of specifications, drawings, process requirements, inspection instructions, and other relevant technical data, including requirements for approval or qualification of personnel / or product. C Quality management system requirements. 7.4.3 VERIFICATION OF PURCHASED PRODUCT RICO AUTO INDUSTRIES LIMITED has established and maintained for the verification of purchased product upon receipt. Purchased product failing to meet requirements is documented and returned to the supplier. Records of purchased product verification are maintained as quality records. If so required by contract or agreement, the customer is afforded the right to inspect our subcontractors. The verification arrangements and product validation will be stated in purchasing documentation. The customers acceptance of the product does not absolve the company or the supplier from providing acceptable product or meeting specifications. 7.4.3.1 INCOMING PRODUCT QUALITY RICO AUTO INDUSTRIES LIMITED has a process to ensure the quality of purchased product utilizing one or more of the following methods: - Receipt of, and evaluation of, statistical data by the organization. - Receiving inspection and/or testing such as sampling based on performance. - Second or third party assessments or audits of supplier sites, when coupled with records of acceptable quality performance. - Part evaluation by a designated laboratory. - Another method agreed with the customer. 7.4.3.2 SUPPLIER MONITORING Supplier performance is monitored through the following indicators: - Delivered part quality performance. - Customer disruptions including field returns. - Delivery schedule performance (including incidents of premium freight).

- Special status customer notifications related to quality or delivery issues. RICO AUTO INDUSTRIES LIMITED promotes supplier monitoring of the performance of there manufacturing processes. E : RECORDS Records are maintained as described in the procedure.

PREPARED BY DOC. NO : CHAPTER : F : REFERENCES

APPROVED BY RICO 01 QM 01 7.4

ISSUED BY

REVISION NO. : 01 ISSUE DATE : 15-12-2003

EDITION - 04 SHEET 02 OF 03

QUALITY MANUAL
PRODUCT REALIZATION PURCHASING

FOR ALUMINIUM DIVISIONS RICO 08 QSP 01 RICO 08 QSP 02 RICO 08 QSP 03 RICO 06 QSP 01 RICO 18 QSP 01 RICO 06 QSP 06 RICO 06 QSP 07 RICO 06 QSP 09

Procedure for Purchasing Procedure for Assessment and selection of Supplier Procedure for Supplier development Procedure for Incoming material inspection and testing Procedure for product realization / advanced product quality planning Procedure for control on non-conforming product. Procedure for corrective and preventive action Procedure for control of quality records

FOR FERROUS FOUNDRY DIVISION QSP/RICO GGN/ 06.1 Procedure for Purchase specification QSP/RICO GGN/ 06.2 Procedure for Evaluation selection and development of sub contractors QSP/RICO GGN/ 06.3 Procedure for Purchase document release QSP/RICO GGN/ 10.1 Procedure for Receiving inspection and testing QSP/RICO GGN/ 02.1 Procedure for Advanced product quality planning ( apqp) QSP/RICO GGN/ 13.1 Control of non conforming product QSP/RICO GGN/ 14.1 Corrective & preventive action QSP/RICO GGN/ 16.1 Procedure for control of quality records

G : BRIEF DESCRIPTION OF AMENDMENT DETAIL EDITION NO. / REVISION NO.

DATE

NATURE OF CHANGE / DESCRIPTION

W.e.f.

EDITION NO. / REVISION NO.

DATE

NATURE OF CHANGE / DESCRIPTION

W.e.f.

04 / 01

15-12-2003

Merging of Al. Plant Quality manual with Ferrous Foundry Quality manual

15-122003

PREPARED BY

APPROVED BY

ISSUED BY

REVISION NO. : 01 ISSUE DATE : 15-12-2003

EDITION - 04 SHEET 03 OF 03

QUALITY SYSTEM DOCUMENT HOME QUALITY SYSTEM DOCUMENT DOC. NO : CHAPTER : RICO 01 QM 01 7.5

QUALITY MANUAL
PRODUCT REALIZATION PRODUCTION AND SERVICE PROVISION

A : PURPOSE Documented procedures are established and maintained to ensure that products and services that directly affect quality are performed throughout the facility in a manner that conforms to the quality standards and specifications. Production operations are planned and verified to ensure that they are proceeding under controlled conditions in the specified manner and sequence.

B : SCOPE Covers all customer supplied product , such as components , toolings, gauges & Consumables and returnable packaging. C : RESPONSIBILITY AND AUTHORITY Plant manager is responsible for ensuring control measures during different stages of operations. specific responsibilities are detailed in the relevant procedures It is the responsibility of all the employees to follow the procedure laid down specific responsibilities wherever applicable are referred to in the relevant procedures. HOD (Q.A.) / Respective Shop Heads are responsible for maintaining inspection and test status at different stages of operations.

D : DESCRIPTION 7.5 PRODUCTIONS AND SERVICE PROVISION 7.5.1 CONTROL OF PRODUCTION AND SERVICE PROVISION. A : production operations are planned and verified to ensure that they are proceeding under controlled conditions in the specified manner and sequence. B : documented work instructions, where necessary, define the specific methods to be used at operations where the absence of work instructions would be detrimental to product realization. C : production operations are accomplished with appropriately maintained tooling and machines, equipment. D : measuring and monitoring devices are utilized to evaluate the product in process, at various stages of production, and to evaluate the result of product realization. E : employees responsible for the individual operations as well as in-process inspection perform product monitoring by quality control personnel. Final product acceptance is the responsibility of the quality control department. F : defined processes are established, maintained, and responsibilities assigned, for product release, delivery, and applicable post-delivery activities such as customer complaint. 7.5.1.1 CONTROL PLAN RICO AUTO INDUSTRIES LIMITED develops control plans for pre-launch and productions that take into account the manufacturing process fmea outputs. The control plan does - List the controls used for the manufacturing process control - Include methods for monitoring of control exercised over special characteristics defined by both the customer and the organization, - Include the customer required information, if any, and - Initiate the specified reaction plan when the process becomes unstable or not statistically capable.

PREPARED BY DOC. NO : CHAPTER :

APPROVED BY RICO 01 QM 01 7.5

ISSUED BY

REVISION NO. : 01 ISSUE DATE : 15-12-2003

EDITION - 04 SHEET 01 OF 04

QUALITY MANUAL
PRODUCT REALIZATION PRODUCTION AND SERVICE PROVISION

Control plans shall be reviewed and updated when any change occurs affecting product, manufacturing process, measurements, logistics, supply sources or fmea. Customer will review control plan, if it is in agreement with customer at the time of contract 7.5.1.2 WORK INSTRUCTIONS RICO AUTO INDUSTRIES LIMITED prepares documented standard operating procedure, quality documents for various activities and works instructions for all employees having responsibilities for the operation of processes. These instructions are accessible for use of the workstation. These instructions are derived from sources such as the control plan and the product realization process. 7.5.1.3 VERIFICATION OF JOB SET-UPS Job set-ups are verified whenever performed, such as initial run of a job, material changeover, and job change. Work instructions are available for set-up personnel. RICO AUTO INDUSTRIES LIMITED uses statistical methods or verification where applicable. Last-off-part inspection is carried out to compare the first-piece approval part. 7.5.1.4 PREVENTIVE AND PREDICTIVE MAINTENANCE RICO AUTO INDUSTRIES LIMITED identifies key process equipment and provides resources for machine / equipment maintenance and has developed an effective planned total preventive maintenance system. The system includes following: - Planned maintenance activities - Packaging and preservation of equipment, tooling and gauging, - Availability of replacement parts for key manufacturing equipment, - Documenting, evaluating and improving maintenance objectives. RICO AUTO INDUSTRIES LIMITED utilizes predictive maintenance methods to continually improve the effectiveness and the efficiency of production equipment. 7.5.1.5 MANAGEMENT OF PRODUCTION TOOLING RICO AUTO INDUSTRIES LIMITED provides resources for tool and gauge design, fabrication and verification and activities. RICO AUTO INDUSTRIES LIMITED has established and implements a system for production tooling management including: - Maintenance and repair facilities and personnel. - Storage and recovery. - Set-up. - Tool-change programs for perishable tools. - Tool design modification documentation, - Tool modification and revision to documentation - Tool identification, defining the status, such as production, repair or disposal. RICO AUTO INDUSTRIES LIMITED has a system to monitor these activities if any work is out sources. 7.5.1.6 PRODUCTION SCHEDULING Production is scheduled in order to meet customer requirements, such as just in time supported by an information system that permits access to production information at key stages of the process and is order driven. 7.5.1.7 FEEDBACK OF INFORMATION FROM SERVICE This is not applicable since after sales service not applicable 7.5.1.8 SERVICING AGREEMENT WITH CUSTOMER This is not applicable since after sales service not applicable.

PREPARED BY DOC. NO : CHAPTER :

APPROVED BY RICO 01 QM 01 7.5

ISSUED BY

REVISION NO. : 01 ISSUE DATE : 15-12-2003

EDITION - 04 SHEET 02 OF 04

QUALITY MANUAL
PRODUCT REALIZATION PRODUCTION AND SERVICE PROVISION

7.5.2 VALIDATION OF PROCESSES FOR PRODUCTION AND SERVICE PROVISION RICO AUTO INDUSTRIES LIMITED do validation of the product at periodic intervals. Validation arrangements are defined and established and include, - Qualification of processes; - Qualification of equipment and personnel - Use of specific methods and procedures - Requirements for records - Re-validation 7.5.3 IDENTIFICATION AND TRACEABILITY The identification of the product is established and maintained for all products, to all applicable drawings, or other documentation during all stages of product realization and delivery. Where traceability is specified, the products have a recorded unique lot number. 7.5.4 CUSTOMER PROPERTY At RICO AUTO INDUSTRIES LIMITED customer supplied products are verified, stored and properly maintained. Lost or unsuitable property is reported to customer and records are maintained. 7.5.4.1 CUSTOMER OWNED PRODUCTION TOOLING At RICO AUTO INDUSTRIES LIMITED, all customer owned toolings are permanently marked with suitable means 7.5.5 PRESERVATION OF PRODUCT RICO AUTO INDUSTRIES LIMITED has established procedure for preservation during storage, process and finished product to prevent deterioration in the product quality RICO AUTO INDUSTRIES LIMITED has established procedure for packing, packaging , marking which also Takes care of customer packaging standard and labeling requirements. 7.5.5.1 STORAGE AND INVENTORY Designated storage area are provided for storage of material with required facilities for preventing damages and deterioration . Receipt and issue from stores is approved by authorized personnel . Item having limited shelf life are identified and first in first out (FIFO) procedure is followed for issuing those items. Provisions are also made to assess the condition of these items at a defined frequency. RICO AUTO INDUSTRIES LIMITED has established and implemented inventory management system at all stages and assures stock rotation. Obsolete products are also considered as non-conforming products. E : RECORDS Records are maintained as described in the procedure.

PREPARED BY DOC. NO : CHAPTER :

APPROVED BY RICO 01 QM 01 7.5

ISSUED BY

REVISION NO. : 01 ISSUE DATE : 15-12-2003

EDITION - 04 SHEET 03 OF 04

QUALITY MANUAL
PRODUCT REALIZATION PRODUCTION AND SERVICE PROVISION

F : REFERENCES FOR ALUMINIUM DIVISIONS RICO 10 QSP 01 RICO 11 QSP 01 RICO 19 QSP 01 RICO 09 QSP 01 RICO 16 QSP 01 RICO 06 QSP 15 RICO 06 QSP 10 RICO 06 QSP 14 RICO 13 QSP 01 RICO 12 QSP 01 RICO 14 QSP 04

Procedure for process control & production (HPDC) Procedure for process control & production (Machine shop & F.M.) Procedure for process control & production (Paint shop) Procedure for process control & production (PPC) Procedure for Stores Procedure for Identification and traceability Procedure for customer complaint resolution Procedure for Control of customer supplied product Procedure for Maintenance Procedure for Control plan Procedure for Inventory control

FOR FERROUS FOUNDRY DIVISION QSP/RICO GGN/ 09.0 Procedure for Procedure for process control QSP/RICO GGN/ 09.3 Procedure for Production of castings in foundry shop QSP/RICO GGN/ 09.4 Procedure for production ofcomponents in m/c shop QSP/RICO GGN/ 09.5 Procedure for paint shop QSP/RICO GGN/ 09.2 Procedure for Production planning & control QSP/RICO GGN/ 15.1 Procedure for Handling & storage QSP/RICO GGN/ 08.1 Procedure for Product identification and traceability QSP/RICO GGN/ 14.2 Procedure for Customer complaint handling & disposition QSP/RICO GGN/ 07.1 Procedure for Control of customer supplied product QSP/RICO GGN/ 09.1 Procedure for Maintenance QSP/RICO GGN/ 02.4 Procedure for Control plan ( cp ) establishment

QSP/RICO GGN/ 09.2

Procedure for Production planning & control

G : BRIEF DESCRIPTION OF AMENDMENT DETAIL EDITION NO. / REVISION NO.

DATE

NATURE OF CHANGE / DESCRIPTION

W.e.f.

04 / 01

15-12-2003

Merging of Al. Plant Quality manual with Ferrous Foundry Quality manual

15-122003

HOME QUALITY SYSTEM DOCUMENT DOC. NO : CHAPTER : A : PURPOSE Documented procedures are established and maintained to ensure that products and services that directly affect quality are performed throughout the facility in a manner that conforms to the quality standards and specifications. Production operations are planned and verified to ensure that they are proceeding under controlled conditions in the specified manner and sequence. B : SCOPE Covers all gauges & equipment used in RICO AUTO INDUSTRIES LIMITED. C : RESPONSIBILITY AND AUTHORITY HOD(Q.A.) is responsible for control and calibration of all equipments covered under calibration procedure. He is also responsible for measurement system analysis. D : DESCRIPTION 7.6 CONTROL OF MEASURING AND MONITORING DEVICES All measuring devices are maintained and established ensuring the suitability of measuring and monitoring devices. Measuring and monitoring devices are consistent with the degree of accuracy needed to evaluate conformity of the product during all phases of the manufacturing process. Measuring and monitoring devices are controlled as a numbering system for each device in use is maintained and periodic cleaning, re-calibration is conducted and results are recorded. A Measuring and monitoring devices are calibrated and adjusted at defined intervals to ensure continued accuracy and usability. Calibration activities, where applicable, are traceable to NPL / national equivalent. B Results of initial calibration and re-calibration or adjustment of measuring and monitoring devices is recorded. RICO 01 QM 01 7.6

QUALITY MANUAL
PRODUCT REALIZATION
CONTROL OF MONITORING AND MEASURING DEVICES

C All measuring and monitoring devices identify the calibration status. D All precision measuring and monitoring devices are maintained for protection from damage during handling, maintenance, and storage. E In the event a measuring and monitoring device is found to be out of calibration, corrective action is taken to validate previous results. 7.6.1 MEASUREMENT SYSTEM ANALYSIS Measurement system analysis is also carried out for all type of measurement system to analyze the variation, using statistical technique as per msa reference manual 7.6.2 CALIBRATION / VERIFICATION RECORDS Rico has identified measurements to be made and the accuracy required for measurement. accordingly, the inspection, measuring & test equipments selected. hardware and software used for inspection and testing that need calibration are also identified. Unique identification numbers are allocated to these equipments. This listing includes details of equipment type, identification number, location, frequency of check, check method and accuracy required, acceptance criteria and action taken when results are unsatisfactory. The calibration is carried out in accordance with the laid down procedure as per in house qualified lab which come under lab scope or otherwise done by calibration facilities accredited to iso/iec guide or national equivalent .

PREPARED BY DOC. NO : CHAPTER :

APPROVED BY RICO 01 QM 01 7.6

ISSUED BY

REVISION NO. : 01 ISSUE DATE : 15-12-2003

EDITION - 04 SHEET 01 OF 03

QUALITY MANUAL
PRODUCT REALIZATION
CONTROL OF MONITORING AND MEASURING DEVICES

The calibration records are maintained against each of such equipment coming under the calibration activity. The equipments coming under the calibration activity are identified to show the calibration status. The persons using the calibrated equipments are adequately instructed to store and handle them in such a way that the fitness for use and accuracy are maintained. Provision to safeguard the calibrated equipments from adjustment and setting are also made as and where applicable. The calibration is carried out under standard conditions, detailed in relevant procedures. During calibration of the equipment, if the equipment is found to be out of calibration , the validity of previous inspection and test results are assessed through the quality records /available product / customer complaint and documents. Customers are informed about the shipment of the suspected products. If an equipment is not conforming to the laid down acceptance criteria, it is identified and removed from the point of use. Calibration of inspection, measuring or test equipment is conducted in as per RICO'S laboratory scope matrix (calibration & testing) and laboratory quality system procedure as per lab scope. If required by customer RICO uses accredited lab for laboratory work perform from out side. From time to time, an assessment is made by HOD (Q.A.) in consultation with concerned heads of department, to identify the need for any new inspection, measuring and test equipments. RICO to ensure notification to the customer if suspect product or material has been shipped.

7.6.3 LABORATORY REQUIREMENTS 7.6.3.1 INTERNAL LABORATORY Rico has established and implemented all applicable laboratory requirements which come under laboratory scope. Rico has documented its policy,system procedure, of laboratory to assure that test result generated within lab scope. Rico have professionals with relevant background and experience for laboratory process decision making. Rico has established procedure for product identification and testing, products are being kept in lab as per requirements. Process control conditions are monitored and recorded that may influence quality. Rico has established all lab test method either agreed by customer or current issue of national / international standards. System has been established for verification of lab capability and appropriate statistical technique is used to verify the activities where applicable. The sampling norms for inspection if applicable, are indicated in the relevant procedures. Before dispatch of the products, it is ensured that inspection and testing has Carried out as per the relevant procedures and records are available clearly Indicating the authority responsible for release of product.

PREPARED BY DOC. NO : CHAPTER :

APPROVED BY RICO 01 QM 01 7.6

ISSUED BY

REVISION NO. : 01 ISSUE DATE : 15-12-2003

EDITION - 04 SHEET 02 OF 03

QUALITY MANUAL
PRODUCT REALIZATION
CONTROL OF MONITORING AND MEASURING DEVICES

7.6.3.2 EXTERNAL LABORATORY External / commercial / independent laboratory (if required) facilities used for inspection, test or calibration services by RICO AUTO INDUSTRIES LIMITED has defined laboratory scope that includes the capability to perform the required inspection, test or calibration, and the laboratory accredited to iso/iec 17025 or national equivalent, or there shall be evidence that the external laboratory is acceptable to the customer

E : RECORDS Records are maintained as described in the procedure.

F : REFERENCES

FOR ALUMINIUM DIVISIONS RICO 06 QSP 16 RICO 06 QSP 17 RICO 06 QSP 05 RICO 06 QSP 12 RICO 06 QSP 09

Procedure for Laboratory management Procedure for Laboratory process control & testing Procedure for Measurement system analysis Procedure for Control of inspection measuring and test equipment Procedure for Control of quality records

FOR FERROUS FOUNDRY DIVISION QSP/RICO GGN/ 10.5 Procedure for Laboratory management procedure QSP/RICO GGN/ 11.1 Procedure for Control of inspection, measuring and test equipment QSP/RICO GGN/ 11.2 Procedure for Measurement system analysis QSP/RICO GGN/ 16.1 Procedure for control of quality records

G : BRIEF DESCRIPTION OF AMENDMENT DETAIL EDITION NO. / REVISION NO.

DATE

NATURE OF CHANGE / DESCRIPTION

W.e.f.

04 / 01

15-12-2003

Merging of Al. Plant Quality manual with Ferrous Foundry Quality manual

15-122003

PREPARED BY

APPROVED BY

ISSUED BY

REVISION NO. : 01 ISSUE DATE : 15-12-2003

EDITION - 04 SHEET 03 OF 03

QUALITY SYSTEM DOCUMENT

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EDITION - 04 SHEET 01 OF 03

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EDITION - 04 SHEET 02 OF 03

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APPROVED BY

APPROVED BY Management Representative QEHS Corp.

EDITION - 04 SHEET 03 OF 03

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EDITION - 04 SHEET 03 OF 04

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APPROVED BY Management Representative QEHS Corp.

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APPROVED BY Management Representative QEHS Corp.

EDITION - 04 SHEET 03 OF 03

INTERNAL

QUALITY SYSTEM PROCEDURE


TITLE
1 PURPOSE : TO ESTABLISH A SYSTEM FOR RECEIPT, STORAGE, PRESERVATION AND ISSUE OF MATERIAL. & FINISH GOODS STORAGE MANAGEMENT. 2 SCOPE : APPLICABLE TO ALL MATERIAL RECEIVED , STORED AND ISSUED FROM MAIN STORE. THIS PROCEDURE ALSO INCLUDES CONTROL OF MATERIAL RETURNED FROM SHOPS. THIS PROCEDURE IS NOT APPLICABLE TO MISCELLANEOUS ITEM AND CUSTOMER SUPPLIED PRODUCT. THIS PROCEDURE IS ALSO APPLICABLE TO FINISH GOOD STORAGE MANAGEMENT. 3 3.1 3.2 ABBREVIATION & DEFINITIONS : MRR REWORK MATERIAL RECEIVED REPORT

STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

ACTION TAKEN ON NON-CONFORMING PRODUCT SO THAT IT WILL MEET SPECIFIED REQUIREMENT.

3.3

REPAIR

ACTION TAKEN ON NON-CONFORMING PRODUCT SO THAT THE PRODUC FUL FILL THE INTENDED USAGE, ALTHOUGH THE PRODUCT MAY NOT CO TO THE ORIGINAL REQUIREMENT. ANY OPERATION DONE BY THE OUT SIDE PARTY ON THE MATERIAL BELONGING TO RICO AUTO INDUSTRIES LIMITED , DHARUHERA.

3.4

JOB-WORK

3.5

RE-OFFER

OFFERING THE PREVIOUSLY REJECTED MATERIAL AFTER REWORK / RE ON CONCESSION.

3.6

MISSC. ITEM

ITEM NOT UNDER INVENTORY CONTROL ( LIKE PANTRY ITMS , STATIONA OFFICE EQUIPMENT AND OTHERS ) HAVING NO EFFECT ON OUT GO PRODUCTS.

ORGANISATION CHART AND RESPONSIBILITY FOR ORGANISATION , PLEASE REFER ORGANISATION CHART.

4.1

OVER ALL RESPONSIBILITY TO IMPLEMENT THIS PROCEDURE LIES WITH HOD (STORES) /

SECTION HEAD (EXCISE). 4.2 OTHER RESPONSIBILITIES ARE AS INDICATED AGAINST EACH ACTIVITY.

PROCESS APPROACH PROCESS MAP AND INTERACTIONS (REFER TURTLE DIAGRAM - STORES)

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
6 DESCRIPTION

STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

FOR RICO DHARUHERA


SL.NO 6.1 6.1.1 ACTIVITY GENERATING NEW ITEM CODE RECEIVE REQUEST FROM CONSUMING DEPARTMENT FOR ALLOCATION OF " ITEM CODE" FOR NEW ITEMS. GENERATE ITEM CODE AND COMPUTER. RECEIPTS OF GOODS RECEIVE THE SUB-CONTRACTOR'S DOCUMENT AT GATE AND COMPARE WITH PENDING SCHEDULE IN COMPUTER . IF QTY EXCEED AS PER SCHEDULE , DO NOT TAKE MATERIAL AND RETURN THE DOCUMENT. IF GOODS IS AS PER SCHEDULED QTY, PUT THE RECEIVING STAMP ON SUB-CONTRACTOR DOCUMENTS AND ENTER THE DETAILS IN THE COMPUTER. DO PHYSICAL QUANTITY VERIFICATION AND ATTACH PRODUCT IDENTIFICATION TAG TO ENTER IN THE

6.1.2

6.2 6.2.1

6.2.2

6.2.3

ALL INCOMING MATERIAL. 6.2.4 RECORD AND VALIDATE THE SUPPLIER'S DOCUMENT , DATA WITH PURCHASE ORDER ON STORE COMPUTER TERMINAL FOR THE PREPARATION OF MRR . IF THE DOCUMENT CONFORM THE PURCHASE ORDER REQUIREMENTS , GET MRR PRINTED FOR FURTHER PROCESSING. IF THE P.O. IS NOT AVAILABLE , PROVIDE UNIQUE CODE 9999 ON MRR AND SEND IT TO FURTHER PROCESS. AFTER RECEIPT OF MRR FROM CONCERN DEPARTMENT APPROVAL . ARRANGE THE P.O. FROM VENDORS / PURCHASE.

6.2.5

6.2.6

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.2.7 ACTIVITY IF STILL THE P.O. NOT AVAILABLE IN COMPUTER THEN THESE MRR WILL BE ISSUED TO PURCHASE DEPARTMENT FOR THEIR ACTION. OBTAIN DECISION ON QUALITY ASSURANCE / USER DEPARTMENT FOR ACCEPTANCE / REJECTION OF MRR UP DATE INSPECTION DATA OF MRR IN STORE COMPUTER TERMINAL. MOVE AND CONTROL REJECTION STORE. REJECTION IN THE

STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.2.8

6.2.9

6.2.10

6.2.11

MOVE ACCEPTED MATERIAL TO THE MAIN STORE TO THE RESPECTIVE BAYS AND BINS ALONG WITH PRODUCT IDENTIFICATION TAG . ONCE THE MATERIAL IS KEPT ON THE IDENTIFIED LOCATION , PRODUCT IDENTIFICATION TAG MAY BE REMOVED.

6.2.12 6.2.13

AUTHORISE THE MRR AFTER APPROVAL DESPATCH COPY OF MRR AND RELATED DOCUMENT TO ACCOUNTS DEPARTMENT THROUGH DESPATCH REGISTER. RE - OFFER MATERIAL PREPARE RE-OFFER MRR FOR SEGREGATION / REWORK / REPAIR OF MATERIAL FROM PURCHASE DEPARTMENT DULY APPROVED BY HOD (QA). RE-OFFER MRR WILL BE HAND OVER TO STORE DEPARTMENT AND TAKE MATERIAL ACCORDINGLY TAKE ACTION AND ENTER THE DETAILS IN RE-OFFER MRR AND SEND TO STORE SECTION

6.3 6.3.1

6.3.2

6.3.3

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.4 6.4.1 ACTIVITY STORAGE ENSURE THAT RELEVANT MATERIAL KEPT AT IDENTIFIED LOCATION. FOR ITEMS WITH SHELF LIFE (HAVING EXPIRY PERIOD) ISSUE ON THE MATERIAL ON FIRST IN FIRST OUT (FIFO) BASIS.REVIEW THE MATERIAL PERIODICALLY FOR ANY DETERIORATION AND EXPIRY, AS APPLICABLE AND FOLLOW THE WORK INSTRUCTION

STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.4.2

6.4.3

MATERIALS WHOSE QUALITY GETS AFFECTED DUE TO ENVIRONMENTAL CONDITIONS, ENSURE SUITABLE PRESERVATIVES ARE APPLIED. ENSURE THAT FRAGILE ITEMS ARE EASILY ACCESSIBLE TO AVOID DAMAGE IN HANDLING. PREPARE LIST OF ITEMS WHICH ARE OVER STOCKED ON MONTHLY BASIS. CHECK THE CONDITION OF STOCK, IF FOUND DETERIORATED, APPLY SUITABLE PRESERVATIVE ON THESE ITEMS OR INFORM TO HOD(QA) FOR DISPOSAL ( IF REQUIRED ).

6.4.4

6.4.5

6.5 6.5.1

LINE REJECTION MATERIAL RECEIVE THE LINE REJECTION ALONG WITH THE REJECTION REPORT. VERIFY THE DESCRIPTION AND QUANTITY GIVEN IN THE REJECTION REPORT MOVE THE LINE REJECTION TO REJECTION STORE AND TAKE FURTHER ACTION WHERE APPLICABLE. TREAT OBSELETE PRODUCT SIMILAR TO NON-CONFIRMING PRODUCT AND KEEP IN REJECRTION STORE IN PROPER MANNER.

6.5.2

6.5.3

6.5.3

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.6 6.6.1 ACTIVITY ISSUE OF MATERIAL RECEIVE ISSUE SLIP PERSON / DEPARTMENT. FROM CONCERN

STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.6.2

CHECK THE ISSUE SLIP FOR DESCRIPTION AND DETAIL DULLY FILLED. ISSUE THE MATERIAL TO CONCERN PERSON / DEPARTMENT. FOLLOW "FIFO SYSTEM" FOR ALUMINIUM ALLOY.

6.6.3

6.6.4

6.6.5

FOR BOUGHT OUT PART, ENSURE FIFO BY PROVIDING SEPARATION IN BETWEEN EACH LOT AND ISSUE THE OLD LOT FIRST. FINISH GOOD STORAGE MANAGEMENT LIST OF FINISHED GOODS LYING IN STOCK IS RECEIVED BY STORES FROM EXCISE DEPARTMENT IN THE BEGININGING OF EVERY MONTH. THE LIST IS RECEIVED OF FINISHED GOODS & STOCK LYING FOR MORE THAN ONE YEAR IS INTIMATED TO HOD (Q.A.) HOD (Q.A.) AFTER APPROPRIATE VERIFICATION, INTIMATES STORES THROUGH INSPECTION REPORT. (I) BASED ON DECISION, IF THE STOCK NEEDS TO BE REMOVED FOR 100% VERIFICATION / REPROCESSING, THE SAME IS CONVEYED TO EXCISE DEPARTMENT FOR FURTHER NECESSARY ACTION. (II) MOVE THE SUSPECTED QUARNTINE SEGREGATION SEGREGATION. STOCK TO AREA FOR

6.7 6.7.1

6.7.2

6.7.3

6.7.4

6.7.5

IF NO DETERIORATION IS REPORTED BY Q.A., THE STOCK IS RETAINED IN THE STORAGE AREA.

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
STORES

TITLE
SL.NO 6.7.6 ACTIVITY

Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

KEEP THE FINISH GOODS IN SUCH A WAY THAT STOCK CAN BE ROTATED REGULARLY AND "FIFO" CAN BE FOLLOWED

6.7.7

REVIEW THE STORAGE PROCESS / AREA FOR ANY WATER LEAKS, STACKING METHOD, HEIGHT, WALL CONDITION, TEMPERATURE AND ATMOSPHERIC REQUIREMENT AND MAINTAIN AS PER REQUIREMENT. ENSURE THAT PRODUCTS / IN PROCESS PARTS / BOP AND OTHER ITEMS ARE PROTECTED FROM RUST, CONTAMINATION, DUST ETC AND DO NOT STORE THE PRODUCT OUT SIDE. DO PACKAGING VARIFICATION / INSPECTION AT INCOMING STAGE FOR PACKAGING REQUIREMENTS

6.7.8

6.8

FOR RICO HPDC GURGAON


(A) RECEIPTS 6.1 DOCUMENTS OF MATERIAL RECEIVED FROM SUB-CONTRACTOR ARE SCRUTINISED SECURITY AGAINST MATERIAL RECEIVED AND DETAILS OF ALL THE MATERIAL RECEIVED DURING THE DAY ARE RECORDED IN COMPUTERISED GATE INWARD BOOK (GIB). MATERIAL FROM SUB CONTRACTOR IS RECEIVED, CHECKED AGAINST SUPPLIED DOCUMENTS FOR CORRECTNESS OF SUPPLY RECEIVED MATERIAL FOR INSPECTION ARE IDENTIFIED WITH THE TAG HAVING VANDOR NAME, QTY, GIB NO. & DESCRIPTION. RAW MATERIAL FOR PDC STORE. RAW MATERIAL UNLOADED AFTER GIVEN TAG TO Q.A. DEPTT. PDC MRR IS GENERATED & VARIFIED BY Q.A. ACTION TAKEN ACCORDINGLY.

6.2

6.2.1

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.2.2 ACTIVITY OTHER MATERIALS RECEIVED AGAINST REQUISITION OF USERS DEPTT. MRR IS GENERATED & INTIMATED TO CONCERN DEPARTMENT. MATERIAL LIKE TOOLS, OIL PAINTS, BEARING, PACKING, HARDWARE & ELECTRICAL MATERIAL KEPT IN STORES AFTER VISUAL INSPECTION. MRR GENERATED & VARIFIED BY USER, ACTION TAKEN ACCORDINGLY. MATERIAL RECEIPT REPORT (MRR) IS GENERATED AFTER CROSS CHECKING WITH RELATED GIB. THE Q.A. & OTHER DEPARTMENT WILL VARIFY MRR IN SYSTEM THROUGH GIB NO. & CLEARING OF MRR IN THE SYSTEM ONLY. ACCEPT & REJECTED QUANTITIES ARE ENTERED IN COMPUTER BY THE Q.A. & USER DEPARTMENT. BILLS IS SENT TO ACCOUNTS DEPTTS WITH MRR NO. (B) HANDLING, STORAGE & ISSUES 6.6 ACCEPTED MATERIAL RELATED TO PDC & DIE DIVISION IS STORED IN MAIN STORE i.e. PDC. REJECTED MATERIAL IS IDENTIFIED, RECORDED IN COMPUTER STORE IN DESIGNATED AREA IN MAIN STORES, PDC, THE REJECTIONS ARE RETURNED TO SUB CONTRACTOR. MATERIAL IS ISSUES TO USER DEPTT. AGAINST REQUISITION SLIP & REQUISITION SLIP IS

STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.2.3

6.3

6.4

6.5.

6.7

6.8

CONVERTED IN ISSUE SLIP IN THE SYSTEM ONLY

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.9 ACTIVITY EXCESS MATERIAL LEFT UNUSED IN DEPTT./ MATERIAL SENT FOR JOB WORK IS RECEIVED BACK AGAINST STORE RETURN NOTE IN SYSTEM. MATERIAL SENT FOR JOB WORK, MATERIAL DESPATCH ADVICE (MDA) TO BE PREPARED EITHER FROM SHOP OR STORE BY THE USER. MATERIAL REQUIRED FOR TEMPORARY USE ARE ISSUED AGAINST SIGNATURE OF RECEIVER IN A SEPARATE LOAN REGISTER. (NIGHT LOAN REGISTER) INVENTORY LEVELS ARE MONITORED AS PER PROCEDURE FOR INVENTORY CONTROL. MATERIAL SENT OUTSIDE FOR REPAIRS PROCESSING ARE SENT ON RGP. RETURN OF THESE MATERIAL IS FOLLOWED UP WITH SUBCONTRACTORS. BASED ON GIVEN SHELF LIFE FOR PRESERVATION, STOCK IS TO BE VARIFIED AND STATEMENT TO BE PREPARED ON MONTHLY BASIS. ENSURE THAT PRODUCTS / IN PROCESS PARTS / BOP AND OTHER ITEMS ARE PROTECTED FROM RUST, CONTAMINATION, DUST ETC AND DO NOT STORE THE PRODUCT OUT SIDE.

STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

6.10

6.11

6.12

6.13

6.14

(C) FINISH GOOD STORAGE MANAGEMENT 6.13.1 LIST OF FINISHED GOODS LYING IN STOCK IS RECEIVED BY STORES FROM EXCISE DEPARTMENT IN THE BEGININGING OF EVERY MONTH. THE LIST IS RECEIVED OF FINISHED GOODS & STOCK LYING FOR MORE THAN ONE YEAR IS INTIMATED TO HOD (Q.A.) HOD (Q.A.) AFTER APPROPRIATE VERIFICATION, INTIMATES STORES THROUGH INSPECTION REPORT.

6.13.2

6.13.3

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
SL.NO 6.13.4 ACTIVITY (I) BASED ON DECISION, IF THE STOCK NEEDS TO BE REMOVED FOR 100% VERIFICATION / REPROCESSING, THE SAME IS CONVEYED TO EXCISE DEPARTMENT FOR FURTHER NECESSARY ACTION. (II) MOVE THE SUSPECTED QUARNTINE SEGREGATION SEGREGATION. 6.13.5 STOCK TO AREA FOR

STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

IF NO DETERIORATION IS REPORTED BY Q.A., THE STOCK IS RETAINED IN THE STORAGE AREA. KEEP THE FINISH GOODS IN SUCH A WAY THAT STOCK CAN BE ROTATED REGULARLY AND "FIFO" CAN BE FOLLOWED

6.13.6

6.13.7

REVIEW THE STORAGE PROCESS / AREA FOR ANY WATER LEAKS, STACKING METHOD, HEIGHT, WALL CONDITION, TEMPERATURE AND ATMOSPHERIC REQUIREMENT AND

MAINTAIN AS PER REQUIREMENT. 6.13.8 ENSURE THAT PRODUCTS / IN PROCESS PARTS / BOP AND OTHER ITEMS ARE PROTECTED FROM RUST, CONTAMINATION, DUST ETC AND DO NOT STORE THE PRODUCT OUT SIDE. DO PACKAGING VARIFICATION / INSPECTION AT INCOMING STAGE FOR PACKAGING REQUIREMENTS

6.14

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
7 7.1 DOCUMENTS : RICO 06 QSP 06 RICO DHARUHERA RICO 16 QWI 01 RICO 16 QWI 02 RICO 16 QWI 03 RICO 16 QWI 04 RICO HPDC GURGAON RICO 16 QWI 01 RICO 16 QWI 02

STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

PROCEDURE FOR CONTROL OF NON - CONFORMING PRODUC

7.2 7.3 7.4 7.5

WORK INSTRUCTION FOR HANDLING OF SHELF LIFE ITEMS.

WORK INSTRUCTION FOR STORAGE OF MATERIAL IN STORES

WORK INSTRUCTION FOR RECEIPT OF MATERIAL AT RECEIPT WORK INSTRUCTION FOR FIFO SYSTEM OF RAW MATERIAL

7.6 7.7

WORK INSTRUCTION FOR HANDLING OF SHELF LIFE ITEMS.

WORK INSTRUCTION FOR STORAGE OF MATERIAL IN STORES

7.8 8

RICO 16 QWI 03 RECORDS

WORK INSTRUCTION FOR RECEIPT OF MATERIAL AT RECEIPT

RECORD DESCRIPTION FORM NO --------TITLE GOODS RECEIPT REPORT (GR)

LOCATION ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM

---------

REQUISITION SLIP

---------

TRANSFER POSTING

---------

RETURNABLE GATE PASS (RGP)

---------

NON RETURNABLE GATE PASS (NRGP)

RICO 06 QFO 13

RETURN DELIVERY ( M/C SHOP) (LINE REJECTION) RETURN DELIVERY ( HPDC) (LINE REJECTION)

RICO 10 QFO 02

PREPARED BY INTERNAL

APPROVED BY

ISSUED BY

QUALITY SYSTEM PROCEDURE


TITLE
9

STORES
Ref ISO-TS 16949 , MMOG , QM Sec. 7.5

BRIEF DESCRIPTION OF AMENDMENT DETAIL :

REVISION NO.

DATE

NATURE OF CHANGE / DESCRIPTION

07

25-06-2003

Procedures are upgraded in line with ISO TS 16949 : 2002 & FORD Q1 requirements

08

05-05-2004

MS-9000 System requirements added as per Ford Q1 Programme

09

25-01-2006

MS-9000 System upgraded to MMOG

PREPARED BY QUALITY SYSTEM DOCUMENT HOME

APPROVED BY

ISSUED BY

ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 16 QSP 01 09 25-01-2006

.5

ND ISSUE OF MATERIAL.

FROM MAIN STORE. RNED FROM SHOPS. EM AND CUSTOMER H GOOD STORAGE

PRODUCT SO THAT IT WILL MEET THE

PRODUCT SO THAT THE PRODUCT WILL UGH THE PRODUCT MAY NOT CONFORM

E PARTY ON THE MATERIAL S LIMITED , DHARUHERA. MATERIAL AFTER REWORK / REPAIR/

L ( LIKE PANTRY ITMS , STATIONARY , HAVING NO EFFECT ON OUT GOING

TH HOD (STORES) /

COPY STATUS

SHEET 01 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 16 QSP 01 09 25-01-2006

.5

RESPONSIBILITY

REF.DOC

HOD (STORES)

HOD (STORES)

SECTION HEAD (SECURITY)

SECTION HEAD (SECURITY)

RICO 16 QWI 03

SECTION HEAD (STORES)

RICO 16 QFO 03

SECTION HEAD (STORES)

SECTION HEAD (STORES)

SECTION HEAD (STORES)

COPY STATUS

SHEET 02 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY SECTION HEAD (STORES)

RICO 16 QSP 01 09 25-01-2006 REF.DOC

.5

SECTION HEAD (STORES)

CONCERN HOD

SECTION HEAD (STORES) SECTION HEAD (STORES)

HOD(STORES) HOD(STORES)

SECTION HEAD (PURCHASE)

SECTION HEAD (PURCHASE)

SECTION HEAD (PURCHASE)

COPY STATUS

SHEET 03 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY

RICO 16 QSP 01 09 25-01-2006 REF.DOC

.5

SECTION HEAD (STORES) SECTION HEAD (STORES) RICO 16 QWI 02 RICO 16 QFO 01

SECTION HEAD (STORES)

RICO 16 QWI 01

SECTION HEAD (STORES) SECTION HEAD (STORES)

SECTION HEAD (STORES) SECTION HEAD (STORES) SECTION HEAD (STORES)

SECTION HEAD (STORES)

COPY STATUS

SHEET 04 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY

RICO 16 QSP 01 09 25-01-2006 REF.DOC

.5

SECTION HEAD (STORES)

SECTION HEAD (STORES) SECTION HEAD (STORES) SECTION HEAD (STORES) SECTION HEAD (STORES) RICO 16 QWI 04

SECTION HEAD (EXCISE)

SECTION HEAD (EXCISE)

HOD (Q.A.)

HOD (EXCISE)

HOD (EXCISE)

HOD (EXCISE)

COPY STATUS

SHEET 05 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO

RICO 16 QSP 01 09

.5

ISSUE DATE RESPONSIBILITY SECTION HEAD (EXCISE)

25-01-2006 REF.DOC

HOD (EXCISE)

PLANT HEAD / HOD (EXCISE)

SECURITY INCHARGE

STORES ASST.

STORES ASST.

COPY STATUS

SHEET 06 OF 10
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY STORE ASSTT.

RICO 16 QSP 01 09 25-01-2006 REF.DOC

.5

STORE ASSTT.

STORE ASSTT.

STORE OFFICER

STORE OFFICER

STORE ASSTT.

STORE ASSTT.

STORE ASSTT.

COPY STATUS

SHEET 07 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY STORE ASSTT.

RICO 16 QSP 01 09 25-01-2006 REF.DOC

.5

STORE ASSTT.

STORE INCHARGE

STORE INCHARGE

STORES OFFICER

PLANT HEAD / STORE INCHARGE

SECTION HEAD (EXCISE)

SECTION HEAD (EXCISE)

HOD (Q.A.)

COPY STATUS

SHEET 08 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE RESPONSIBILITY HOD (EXCISE)

RICO 16 QSP 01 09 25-01-2006 REF.DOC

.5

HOD (EXCISE)

HOD (EXCISE)

SECTION HEAD (EXCISE)

HOD (EXCISE)

PLANT HEAD / HOD (EXCISE)

COPY STATUS

SHEET 09 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 16 QSP 01 09 25-01-2006

.5

OF NON - CONFORMING PRODUCT

NDLING OF SHELF LIFE ITEMS.

ORAGE OF MATERIAL IN STORES.

CEIPT OF MATERIAL AT RECEIPT SECTION.

O SYSTEM OF RAW MATERIAL

NDLING OF SHELF LIFE ITEMS.

ORAGE OF MATERIAL IN STORES.

CEIPT OF MATERIAL AT RECEIPT SECTION.

LOCATION ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM ON LINE SAP SYSTEM

RETENTION PERIOD
AS PER SAP SYSTEM

DISPOSAL AUTHORITY HOD (STORES)

AS PER SAP SYSTEM

HOD (STORES)

AS PER SAP SYSTEM

HOD (STORES)

AS PER SAP SYSTEM

HOD (STORES)

AS PER SAP SYSTEM

HOD (STORES)

AS PER SAP SYSTEM

HOD (STORES)

AS PER SAP SYSTEM

HOD (STORES)

COPY STATUS

SHEET 10 OF 11
ALUMINIUM PLANTS

DOC. NO. ISSUE NO ISSUE DATE

RICO 16 QSP 01 09 25-01-2006

.5

CRIPTION

W.e.f.

APPROVED BY Management Representative QEHS Corp.

S 16949 : 2002 & FORD

25-06-2003

r Ford Q1 Programme

05-05-2004

Management Representative QEHS Corp. Management Representative QEHS Corp.

25-01-2006

COPY STATUS

SHEET 11 OF 11

DOCUMENTS :

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

M.R. OFFICE

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