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IS e 7200 (Part

3) - 1982

Indian Standard
PART 3 MANAGEMl?NT QUALITY INFORMATION CONTROL

( Reaffirmed 2004 )

PRESENTATION OF STATISTICAL DATA


SYSTEMS LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

.(First Reprint JUNE 1993)

UDC 519925 ( 083.4 ) : 6581562 : 659.24

0 Copyright 1983 BUREAU


MANAK

OF
BHAVAN,

INDIAN

STANDARDS
ZAPAR MARG

9 BAHADUR SHAH NBW DRLHI 110002

Gr 11

August 1983

IS : 7200 ( Part 3 ) = 1982

lndian Standard
PRESENTATION OF STATISTICAL DATA
PART 3 MANAGEMENT 1NFORMATlON QUALITY CONTROL Statistics Sectional SYSTEMS LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

Quality

Control and Industrial

Committee,

EC 3

Chairman
DR P. K. BOSE

Representing
Indian Association for Productivity, Reliability ( IAPQR ), Calcutta Quality and

Members
SHRI B. HIMATSINQKA ( Alternate to Dr P. K. Bose ) National Productivity Council, New Delhi SERI B. ANANT~ KRISENANAND SHRI R. S. GUPTA ( Alfernatc ) Tata Iron and Steel Co Ltd, Jamshedpur SHBI M. G. BBADE National Institute of Occupational Health, DB S. K. CHATTERJEE Ahmadabad SHBI P. K. KULKARNI ( Alternate ) TheBT;fboanv Textiles Export Promotion Council, SEBI C. A. CBASTO DIBECZOB DR S. S. PILLAI ( Alfernafe ) SHRI Y. GHOUSE KHAN SHBI C. RAJANNA ( Alternate ) Sri111 A. LAHIItI SHBI IJ. DUTTA ( Alternate ) SHRI R. N. MONDAL DB S. P. MUKHEBJEE Sanr A. N. NANKANA SERI M. K. V. NARAYAN SEBI P. N. GUPTA ( dlternate ) SBBI T. R. Pns~ Indian A&cultural Statistics ( ICAR ), New Delhi NGEF Ltd, Bangalore Indian Jute Calcutta Industries Research Association, Research Institute

Tea Board, Calcutta University of Calcutta, Calcutta Indian Statistical Institute, Calcutta The Indian Tube Co Ltd, Jamshedpur Army Statistical Organization, Defence, New Delhi Calcutta Ministry of Ministry of

SHBI R. D. AQBAWAL ( Alternate ) National Test House, SHEI E. K. RAMAOHANDARAN SRRI S. MONDAL ( Alternate ) SHBI RAYESH SHANKED Directorate Defence, SHRI N. S. SEN~AR ( Alternate )

General of Inspection, New Delhi

( Contitwud on @age 2) @
BUREAU CoQyrighf 1983

OF INDIAN

STANDARDS

This publication is protected under the Indian CoQfight Act ( XIV of 1957 ) and reproduction in whole or in part by any means except with written permission of tha publisber :hall be deemed to be an infringement of copyright under the said Act.

ISr72OO(Part3)-1982
( Contintudfimn

fklg61 )
Rcjmsmting South India Textile Research Association, Coimbatore Defence Research & Development Organization, Ministry of Defence, New Delhi Indian Telephone Industries Ltd, Bangalore ) The

Members SHRI T. V. RATNAY DR D. RAY SHRI G. SANEION SHRI P. V. RAO ( Ahnnale SHRI A. SANJEEVA Rko S~BI R. SETHUBAWAN SHBI N. SRINIVASAN SHRI S. SHIVARAX DR S. S. SBIVASTAVA SH~I S. SUBRAMKI SHRI Y. K. BHAT, Director ( Stat )

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

Shriram Fibres Limited, Madras Electronics Trade and Technology Corporation Ltd, New Delhi The

Development

(.hmatc

State Trading Corporation of India New Delhi Central Statistical Organization, New Delhi Steel Authority of India Ltd, New Delhi Director General, IS1 ( Ex-oficio Member )

Ltd,

SHRI P. K. GAMBI~II~ Assistant Director ( Stat ), IS1

Industrial

Statistics

Subcommittee,

EC 3 : 7

DR P, K. BOEE

Indian Association for Productivity, Reliability ( IAPQR ), Calcutta Indian A ricultural Statistics ( ICA% ), New Delhi

Quality

and

Members DIBECTO~ Research Institute

DR B. B. P. S. GOEL ( All6ffWt6 ) Calcutta University, Calcutta DR S. P. MUKHERJEE National Sample Survey Organization, New Delhi DR M. PADMANABHA~ Ministry of Army Statistical Sanx T. R. &RI Defence 3 New D%~izationy SHRI R. D. A~RAWAL ( Ahnate ) NGEF Ltd, Bangalore SURI C. RAJANNA SERI Y. GHOUSE KH~ET ( Aitcrnak ) Defence Research and Development Organization, DR D. RAY Ministry of Defence, New Delhi Indian Statistical Institute, Calcutta SHRI B. K. SARKAR Delhi Cloth Mills ( DCM ), Delhi SHRI D. R. SEN Central Statistical Organization, New Delhi DE S. S. SBIVASTAVA

IS t 7200 ( Part 3 ) - 1982

Indian Standard
PRESENTATION OF STATISTICAL DATA
PART 3 MANAGEMENT INFORMATION SYSTEMS QUALITY CONTROL
LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

0. 0.1This

FOREWORD

Indian Standard ( Part 3 ) was adopted by the Indian Standards Institution on 10 August 1982, after the draft finalized by the Quality Control and Industrial Statistics Sectional Committee had been approved by the Executive Committee. 0.2 Part 1 of this standard dealing with tabulation and summarization of with a view to drawing valid inferences from a data had been prepared Part 2 of the standard deals with diagrammatic large amount of data. presentation of the numerical data in the form of graphs and diagrams to facilitate quick understanding of the contents of the data including pattern of variation and bring out inter-relationships and other essential details. The present Part 3 contains the various charts and proformae which would be helpful to the management in organizing quality control activity and installing quality control.system in their organization. 0.3 The charts and proformae, as suggested, modified to suit the needs and requirements may have to be suitably authorized. may have to be appropriately of an individual industry and

0.4 The term (chart is used &here the information given is complete without the addition of any numerical data, otherwise the term proforma is used.

1. SCOPE 1.1 This standard ( Part 3 ) deals with management information charts and proformae used in the organization of a quality control system in an industry. The various charts and proformae covered under this standard are grouped under the following heads:

a) Cl

Organization Control

chart, equipments, 3

b) Matrix

of quality, on inspection

LS t 7200( Part 3). 1982


d) Vendor e) Control g) Customer h) Quality j) Utilization k) Inventory, m) Suggestion schemes, and n) Training and education. 2. CHARTS surveillance, of incoming complaint cost analysis,
LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

material, analysis,

f) Process control,

of resources,

AND PROFORMAE INFORMATION SYSTEMS

FOR MANAGEMENT

2.1 Organization Charts ( Appendix A, Charts I, 11, III and IV ) These charts describe the broad structure of organization usually found effective in an industry. It would be convenient for any industry to have an The organizaorganization chart indicating the areas of responsibilities. tion charts covered in this standard are for four types of industry, namely small ( Chart I ), medium (Chart II ), large ( Chart .III) and multiplant ( Chart IV ).
2.2 Chart of Typical Matrix of Quality Functions and Responsibilities ( Appendix B ) -The matrix describes the extent and degree of involvement of various departments in different quality functions fcr achieving the quality objectives of the organization. 2.3 Control on Inspection Equipments ( Appendix 0, Proformae I, II and III ) -The proformae covered under this appendix are for the registration of different measuring equipments ( Proforma I ), the day-today inspection report on the maintenance of various gauges ( Proforma II ) and the consolidated monthly report on maintenance ( Proforma III ) for reviewing the progress. 2.4 Vendor Development ( Appendix R, Proformae I, 11, III and appliIV) - Under this is given the pcoforma for vendors registration cation ( Proforma I I giving all the necessary information on the equipment roformae consist and capability of the vendor, The two supplementary of list of items for which registration is applied for ( Pro rp orma II ) and list of machines in operation ( Proforma III ). Proforma IV is meant for the overall assessment of the vendor capability. 2.5 Vendor History ( Appendix E ) - This proforma helps in maintaining complete histroy of vendors performance item-wise. 2.6 Vendors Performance Evaluation ( Appendix F )-This helps us in the evaluation of vendors performance. proforma

IS : 7200 ( Part 3 ) - 1982


2.7 Vendor Rating ( Appendix G, Proformae I and II ) - In the vendor rating, the proforma is provided for quality rating of a vendor for each of items supplied ( Proforma I ). Proforma II provides the comparative ratings of vendors on an item on various aspects, such as quality, delivery, price, attitude and potential which help in arriving at the overall rating, The weightages for overall index depend upon the criticality of components and their urgency on production schedule to be decided by the user. 2.9 Incoming Material Inspection ( Appendix H, Proformae I, IJ, for recording the inspection III and IV ) - Under this, the proformae results of incoming material for measurable characteristics ( Proforma I ) as also for attributes type ( checked by go and no-go gauges ) characteristics ( Proforma II ) are given. Proforma III is intended for studying the non-conformance of various attributes type of characteristics with causewise details. Proforma IV is provided for recording the deviation of incoming material from the specifications. 2.9 Vendors Corrective Action ( Appendix J ) - This proforma helps in getting feed back information on corrective actions taken by the vendor. 2.10 Inprocess Control - First Off Inspection ( Appendix K ) - This proforma is used for the purpose of first offinspection at the start of a new job on a machine with the object of prevention of defects. The first off inspection is made before the machine is ready to go for production. This ensures the right setting of the machine and/or process. Any deviation on the nominal dimension is immediately detected and rectified by proper adjustments. 2.11 Inprocess Control - Patrol Inspection (Appendix L, Proformae I, II, 111, IV, V, VI,. VII and VIII ) - The various proformae given under this appen,dix relate to the data sheets and control charts mostly used in a machine shop engaged in the production of components and parts. These charts are used for control purposes at the shop floor. The control chart data sheet may be for moving range ( that is, in cases where only one sample is tested from a batch/control unit ) ( Proforma I ), variable type of characteristics ( Proforma II ), attributes type of characteristics ( Proforma III ), inspection by gauging ( Proforma IV ), number of defects type of characteristics ( Proforma V ), demerit score when the data is classified according to seriousness of defects ( Proforma VI ) and daily summary of inprocess inspection report ( Proforma VII ). The Proforma VIII on summary of machine suitability and capacity (job-wise or characteristic-wise ) is meant for periodic review of the suitability of the various machines for doing different types of jobs. 2.12 Customer Complaints ( Appendix M, Proformae I and II ) Proforma I is meant for collection of data on customer complaints, whereas

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

1S I 7200 ( Part 3 ) - 1982 Proforma II is meaut and follow up action. for summarizing these complaints for proper review

2.13 Quality Cost Analysis ( Appendix N ) - The proforma provides for quarterly comparison of quality costs in different categories, like prevention, appraisal and failure for identifying areas for priority attention. 2.14 Utilization of Resources ( Appendix P, Proformae I, II, III and IV ) - Quality control in its total aspect implies customer satisfaction at minimum cost. This necessitates optimal utilization of all resources. Proformae I, II and ,111 are provided for recording and reviewing of productivity data pertaining to equipments, raw materials and manpower to enable necessary steps for effecting improvements wherever feasible. Proforma IV is meant for recording and overall summary of inputs and outputs for assessment of true growth. 2.15 Inventory ( Appendix Q ) - Optimal utilization of capital resources is also a very important aspect. Major part of capital resources is blocked in inventory of raw materials, semi-finished and finished goods. This proforma provides for comparison of actual inventory with minimum achievable for corrective action whenever necessary. 2.16 Suggestion Schemes for recording the information as also the ultimate impati.
( Appendix

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

on number

R ) - This proforma provides of suggestions made, their review

2.17 Training Programvnes ( Appendix S ) - This proforma is meant for recording the information regarding the various training programmes conducted for personnel of different levels, such as executives, supervisors, op-rators and other personnel from various departments. The proforma would be helpful in reviewing the training activities from time to time. 3. INFORMATION
TO TOP

MANAGEMENT

.3.1 All the proformae given in the standard need not go to the top management. It is desirable that the top management may be kept informed about the organization charts ( see 2.1 ), matrix of quality functions and responsibilities (see 2.2 ), consolidated monthly report on maintenance of inspection equipments ( Proforma III of 2.3 ), comparative overall rating of vendors ( Proforma II of 2.7 ), summary of customer complaints ( Proforma II of 2.12 ), quality cost analysis (see 2.13 ) and training programmes ( see 2.17 ). The remaining proformae may bc dealt with at the appropriate levels.

18 I tioo ( Part 3 ) - 1982

APPENblk

A
CHART

( Clawc 2.1 )
ORGANIZATION CHART Manager I SMALL SIZE COMPANY -Vendors -Incoming Inspection --IDroccss Control -End Product Testing -Precision Measurement Laboratory -Preservation and Storage -Packanine I

I
-------Quality Control

-I I

Admi&ation Finance

Prod&tin

s&

CHART

II

MEDIUId General

SlZE COMPANY

Manager

I
Technical -R&D -Work

Quality -Quality Process -Quality -Quality -Quality Engineering Control-

Production

Finance

Marketing /-;a,,, -servce

Administrat; pzci

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

3end;;rsg ~~~c~~u~_ -Inprocess

j--Accounts --Prchast

Data Analysis Improvement

-End Product --Instrumentation -Preservation and storage -Packaging

CHART

III

LARGE

SIZE COMPANY

Managing

Director

Central Technical Service

Central

Adminisrratio Service

Product

Group

I
Product Group II

-Finance -R&D I-Personnel -Standardization -Control Purchasing . . . . .._._...._.... ( co-ordination) -Quality...

-Marketing -Production -Maintenance . . . . . . . . . . . . -Quality Control------Incoming

I
Plsnni~g

_--__ I

---.~

___-__I____. Irqertion

---~ --.__-..

--I npOCCSS --End Product

( Vendor )

-Test Equipments -Test Procedures -Sampiig Ilnns -Manual or Systems & Procedures

-- Snlvage Qlmlity Impvwrmcnt A3surancc .-(:ustomcr -- lrvvcvation & Data Analysis Packaging -1nstrummt and Gauge -Education end Training Complaints --Maintenance -Quality Cost & I7.conomic and Failure Studies - O_u.7lity I.nhs (Testing Analysis --hudit and Crrtitication ) --Procrss Capability Studies -Trouble Shooting -Check Inspection & -Design of Experiments Accuracy of Inspectors -Market Quality Determination -Executive Reports on Quality

and

CHART

1V

MULTIPLANT

COMPANY

CORPORATE

LEVEL

, I

President or Chairman or Manrgir Director

Director I-Corporate

Director II-Corporate

Executive Director Plant I

Executive Director Plant II

Executive Director Plant III

Corporate Quality Assurance...

. . . . . ._.

Quality
ASSlWaC.5 & I I I

Quality Control

General Manager I

General Manager II

GCCIZJ Manager III

- -

x -T -i- ITf

P .:

I 2.

-I

- -

!-

mmagement

7-

-Sales

T-

i 1 I -r

I
-1 Finance -1 -;tamhrds -1 hign -1 Ianring -_ I 1 -_ 1 -_

L-

I -.

i -

T i

I -

v -

--

I -

c?

-i-

I I L I I - l- i I-

0 -

T-

I -

I I - I - - I I I

n -

++

I - - -

I w -

l/7,
-_ -_ -_ --

I -

c c
MetrolagylCalibration Lab

/n/ ! -I+-

T I

,zuality *,,urance
Tool Roam

-Maintenance

r -

-1 -_ <

I-

1 I -

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

Suppliers

APliENDIX (CZuuse 2.3 )


CONTROL PROFORMA Name of Company: I ON INSPECTION

EQUIPMENTS EQUIPMENTS Department:


LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

REGISTRATION -

OF MEASURING

lk.

DATEOF
RB@IBPIUTIOIZ

)ATE

or

:EOICIPT

DESCBIPTlON

SIZE
__

1 RANGE

:HEOKEI 3Y

REQISTBA TIoN*/

--DATEOX
ISSUE

~BDEX

No.

ISSUED TO

SIGNA- FIEMARK~3 TURE


_a-

*Give code number depending

size, range, number available, location, etc. ( Conhued

5:
) E

upon its description,

A P P E ND IX
CONTROL PROFORMA Name of Company: Gauge Number: Description: Type: Date Received:
DATE 1. Nominal... DIMENSIONS

C-

contd
LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

ON INSPECTION REPORT

EQUIPMENTS OF GAUGES

BI-INSPECTION

ON MAINTENANCE

Department: Location: Section: Date of Issue: Approved:


INSPECTED BY REMARKS NEXT DUE DATE BOB 'NSPECTION+ Shelf:

Tolerance Actual

..... _....

2. Nominal . .._.... Tolerance . .._Actual

3. Nominal...__... Tolerance . . . . . Actual

4. Nominal.. . . . . . Tolerance...-. Actual

I 1

*Maintain

cardex and file in the order of due date.

tS:72OO(Part3)-1362

A P P E N D I X
C@NTROL ON INSPECTION

C - Contd
EQUIPMENTS ON

PROFORMA III MONTHLY REPORT GAUGE MAINTENANCE Name of Company: Month:


a) Total number of measuring instruments/gauger b) Total number of measuring instruments/gauges covered in tfrecrlibration-programma c) Percentage covered ( yo of b/a2 ) al) Available a2) In use

Date:

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

Tool Cribs d) Expected --e) Controlled -f ) Percentage g9 within tolerance cont.rollcd ( o/o of e/d ) Number Percentage Number h) Rework Percentage Number j ) Scrapped Percentage k) Received earlier to schedule m) Total available Number Percentage _------. -----_-_---_-----_I_-_____-_--

4
---

-52_

-----

__---- I
_-----I L--L_

Number

11

fS-r7200~ Pprt3).1982

APPENDIX ( Chse 2.4 )


VENDOR PROFORMA
,-

DEVELOPMENT REGISTRATION APPLICATION

VENDORS

Name of Company:
Name of vendor:

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

Date: Address-Workshop/Godown

Trade

Name: Address-Head Office

Telephone 3rams

number:

Ielex number

:
on matters concerning bid*, contracts ( if agents, so specify ) number

Persona to contact Name

Official capacity

Telephone

Type a) b) c) d)

of organization Individual Partnership Joint stock company Co-operative

Particulars of registration such as Indian company/Indian partnership act/Indian factory act/any other

supplies, Indicate classes of equipment, interested to register with us in Proforma Are you on the list of approved vendors/contractors on DGS & D, Railways or Government undertakings ? If so, give registration number, date & items for which registered ( copy of registration/rate contract may he furnished ) Have you ever been banned or removed from any list of approved government csuitractors/vendors ? If so, give details

material II.

and/or

services

in which

you are

12

IS, 7200( tart3) - 1982

AP PEN D I X
VENDOR PROFORMA I VENDORS

D-

Contd

DEVELOPMENT REGISTRATION APPLICATION


)/Trader

Conrd

Xegory of vendors: Manufacturer/Agent ( authoriaed [f Manufacturer, give following particulars:


a) Duration b) Production for which capacity factory in production: per annum:

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

c) Percentage capacity organization: d) Facilities for testing

available

for our

and inspection: Range I Least count

Description of instruments and gauges available

e) Details of machines
( in Proforma III )

in operation

f ) Number

of emplc byees Status _

Graduate Nontechnical

Diploma

Skilled

Nonskilled

\ Division
Production Qrality control

Technical . I \--

g) Source

of raw materials Type Source

h). Do you inspect

the bought

out materiala

Yes/No Yes/No ? Yes/No Yes/No

j) Do you have testing facilities for bought out materials, if not, what is done for testing ? k) Is process inspection m) Do you have finished done during product manufacture inspection set up ?

&t92OO(Part3)-1982

A P P E N D I X
VENDOR PROFORMA I VENDORS n) Can you comply

D - Contd
APPLICATION-Contd
Yes/No ? Yes/No authorization.

DEVELOPMENT

REGJSTRATION
wherechecked copy.of

with the quality certificate ever called for ? p) Are gauges/instruments in use periodically f Agents, give particulars of agencies Use give the following information: 4re you mits ? no&s: a) b) c) d) inancial with true

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

already doing business with us or our sister If so, give following details for the last 12 Registration Total value Total value Total value Status: number, if of matersals of purchase of material registered with us tendered orders tendered supplied -

a) Value of current assets as on date: b) Value of current liabilities as on date: ( Attach balance sheets for last 3 years ) c) Value of total sales during the previous year: d) Value of orders in hand: e) Value of total capital employed: f) Bankers name and address: g) Sales tax registration number: Excise registration number: h) Amount up to which supply can be made at one time: j) Have you obtained incame tax clearance certificate? If so, state number & date, and enclose a copy of the same showing detatls of income assessed, tax demanded and paid for the last 3 years: List of enclosures: ( Catalogues, technical price list, etc ) Evaluation of vendor Any special literature, I certify that the information herein ( including all pages is correct Signature Name Designation Place Date information:

supplied attached )

14

IS : 7200 ( Part 3 ) - 1982

APPENDIX
VENDOR PROFORMA II

D-contd

DEVELOPMENT

ITEMS FOR WHICH REGISTRATION IS APPLIED


LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

Name of Company:
SL No.
Is/oTHEU

SlZR
( RANQE )

SPECll~IOATIOb

NUBIBEB

TRADE MAI@ BEAND

AVEUAQE STOCE MAINTAINED

Quantity

Value

Conlinucd )

15

IS : 7206 ( Part 3 ) - 1982

A PPE NDIX
VENDOR PROFORMA Name of Company: III

D - Contd

DEVELOPMENT IN OPERATION

LIST OF MACHliES

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

SL No.

DESCEIPTION AND SPECIPICATIONS OB MAOHIN~PWITE MAKE

NUIdBEROB MAOHINES

GBADE OP ACCUBAOY ATTAINABEE

SPARE CAPACITY AVAILABLE

REMARK,

16

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

I8 : 7200 ( Part 3 ) - 1982

AP PEN D IX

D - contd

VENDOR DEVELOPMENT PROFORMA IV VENDOR CAPABILlTY SURVEY Rating c) Is incoming inspection well equipped with instruments ? d) How much of acceptance rampling is followed ? e) Is there a defect feed back system to vendors ? f) Is inspection planning done ? g) Is there a procedure for disposal of nonconforming itemr ? h) Who decides on non-conforming items ? NOTEAttach a list of documenta, No -Poor Satinfactory Good

Contd

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

if any in use.

I&PROCESS &3 FINISHED PRODUCT QUAUTr ( Strike whicheverir not applicable )


a) b) c) d) e) Process inspection done Is inspection planning done ? Who decides on disporal of rejection ? Who inrpects and certifies the first off? Is there a system to use quality control charts ( zand R, p, c-chart j for control during production ? Is there a defect analysis and feed back system ? How outgoing products are inspected ? Is there facilities for i) Type tests ? ii) Routine tests ? Can inspection stop machine or process if defectives are made ? Aro check lists available for finished goeds ? ( If so, enclose a specimen )

CONTROL
No inspection/Set up/Patrol/Last 08 No/Poor/Satisfactory/Cc& .-- . . . .. . . . . . . . .. . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . . No body/Shop/Inspector No/Poor/Satisfactory/Good

f) g) h) j) k)

No/Poor/Satisfactory/Good Sampling/100 percent No/Poor/Satisfactory/Good No/Poor/Satisfactory/Good Yes/No Yes/No Yes/No

m) Can the firm comply with all the requiremen!, of quality certificates ? NOTE - Attach 0 THER FACILITIES a list of documents,

if any, in use. No/Poor/Satisfactory/Good

a) Are the gauges in use periodically

controRed? ( If so, please enclose a copy of procedure ) b) Is there a tool inspection and maintenance system ?

Yes/No

IS t 7200 ( Part 3 ) - 1982


A P P E N D I X D Contd

VENDOR PROFORMA
c) Are

DEVELOPMENT CAPABILITY SURVEY


Yes/No Yes/No Yes/No

IV

VENDOR

Contd

machine and process capability studies conducted periodically ? d) Is regular maintenance of machines done ? e) Is there a procedure regarding effecting changes in drawings ? f) Is there a procedure regarding handling of complaints ?

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

Yes/No

PERFORMANCE a) How is the performance


i) Product ii) Tools of: store ) Poor/Satisfactory/Good Poor/Satisfactory/Good ( calibration give areas ) Poor/Satisfactory/Good

( in finished in use

iii) Instruments b) If unsatisfactory,

for improvement:

OVERALL

RATING

ON THE

TECHNICAL

CAPAbILITY

OF THE

FIRM

REMARKS

AND RECOMMENDATIONS:

19

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIE

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BO

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BO

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

A P P E N D I X INCOMING PROFORMA Name of Company: Component: Inspected By:


SL No. CHARAC- AQL TERISTIC

H -

Contd

MATERIAL

INSPECTION CHARACTERISTICS
LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

III

FOR OTHER

ATTRIBUTE

Supplier: Order Number:SAMPLE SIZE ACCEPTANCE NUMBER*

Drawing Number: Lot Number:


NUMBER OF ITEMS
CONFORWINQ -

Date Indented: Lot Size: I


CAUSE-WISE DETAILS+ OF NONA,O;y;;;;._
-

Date Received: Date:


LOT ACCEPxEL LOT
DIS-

NUMBEB OF ITEMS NON-CONBORMRW Rzzp,k-

RE-

I MARKE j

1 Scrap/

Total

;I:

*Refer to IS : 2500( Part I )-1973. tCauses codes are listed below ( to be listed by the company

):

Code
ii

Causes

Code
c

GZUSCS

TLor disposal _

Code

Code
1 1-1 Material to be reworked

D Cods
Material sent to production on deviation

Code

Material to be returned to vendor

I-.

( Contrnued

fS:7290(Ptrrt 3).1982 A P P E N D I X

H - cod

INCOMING MATERIAL INSPECTIONfi PROFORMA


Name

IV

DEVIATION

OF INCOMING MATERIAL

of Company: Number: Date: Quantity: Challan Particulars Number: of Vendor:


LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

Reference Item:

Specification: Drawing Supplier: SL No. CJIABACTERIBTIO

Number:

NATUBE AND EXTENT OB DEVIATION

- _

Deviation Details

quantity of rework:

requested:

Effect on final product: Corrective Existing action stock: with the supplier:

Remarks of assembly/production: ( using department > 26

APPENDIX ( Clause 2.9 )


VENDORS CORRECTIVE
Name Vendor: Purchase The material item: The inspection
LTE

ACTION

of Company: Reference Order referred Number: in above purchase Date: order has been found substandard Number:
LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

QUANTITY
REOEIVED

results are given below: QUANTITY QUANTITY

INBPEOTED

REJECTED

DETAILS OB REJEOTION ( MEABUREYENT-WISE BOB MEASURABLE AND CAUSEWISE FOR ATTIUBUTE~ CRARAOTEBIBTIOB )

._

VENDORS

REPORT

a) I agree and accept the defects. I am taking avoid recurrence of such incidence in future. b) I do not agrea with defects pointed

following

steps to

for the following

reasons:

i)
ii) iii) c) If (b) is true, the vendor such differences on quality may suggest measures that will avoid between vendor and vendee, 27

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BO

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

Com#tah*on :

LetGe7,

xc

u E E

and

a-c+o

where k is the number

of samples and d = c + a as foi the

1. The control limits for ( c + u ) is same defectivea ( SW Proforma III ). 2. The control limits for (c CL-Z-Z _ LCL=-(c-a)-3 _ V UCL=(G-:a+3 (;+a)2/ I (F+ u-j _ (C-

aumk

of

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

(I ) are as follows:

;;)I n

(C?-G)S n

NOTE - Gauging is not limited to the engineering industry. It is a general It may be concept when the data is classified as within two limits or beyond that. applied to weight, resistance value, percent residue, etc.

33

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

lSr7200(

PartS)-1982

Compulation : Let ai, 61, cl be the number of defects of category A, B and C rerpectively in the i-th sample, and so
LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

~1, ws, ws be the weights of category of A, B and C respectively that IQ+ wl + ws = 1 Then Dl, the demerit score for the i-th rample ia-wlai+w&i+u.+ct and 07 the average demerits score

where < ; and Fare the average number

of defects

of category

A, B-and C respectively and k is the number of ramples.

The control limits are as follows: CLCB

( CWiwcf

36

A P P EN D IX
INPROCESS PROFORMA Name of Company: ~ACEIINI E!

L -

contd

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

CONTROL SUMMARY

PATROL

INSPECTION INSPECTION REPORT

VII

DAILY

OF IN-PROCESS Date:

Shop/Department:

3EIF' T
fDPE R .ATO

JUMBEB
- _ _-

JOB No. -

ITEM

TAO

I!nMRF.R ProIns)ectel

SOURCE-WISEDETAILSOFNOT

.OK lperator Machins Tool daterial

OK
T

RE6ARKI

Others

NOTE -

Make a monthly summary

for review for improvements.

IS I 7200 ( Part 3 ) - 1982

A P PE N D I X
PROCESS PROFORMA CONTROL -

L-

Contd

PATROL INSPECTION

VIII SUMMARY OF MACHINE SUITABILITY AND CAPACITY (JOB-WISE) YEARLY/ANNUAL )


LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

( PERIODIC REVIEW - QUARTERLY/HALF Name of Company:


MACHINE

NUMBER

I
I A I B

CHABACTERIBTIO JOB

2 ____3

5 6 -7

-9 .. . NOTE the capacity Leave the cell blank if a machine otherwise. io not suitable ,for a job and enter

38

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

As in the Original Standard, this Page is Intentionally Left Blank

APPEND
CUSTOMER PROFORMA II SUMMARY

IX

M-Contd

COMPLAINTS OF CUSTOMER COMPLAINTS


LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

Name of Company: Size: Brand:


EXTENT 01 SE! 1om3Nti I
P

Product ( Item ): Period:

SEaIOUB I Total No. of Defects Percent*

MAJOR I Total tie. of Defects Percent*

MINOB I Percent+

TOTAL

PEECENT PkEVIOVe YEAB


l

Total

Percent

SOUltOE DRFE~T~

OI

Customer%

fault fault &

Manufacturing Transport pilferage Others Overall

damages

*It is the reference.

percentage

of defectives

or defects

per

100 items

of the total items supplied

during

the period

under

J 3

18 t 7200 ( Part 3 ) - 1982

APPENDIX N ( Clause 2.13 )

QUALITY

COST ANALYSIS Year:


&ARTERLY
COST IN

Name of Company: _
COST CATEOORIES

QUALITY Rs

FOTAL

I COSTS and of Calibration Acceptance of of

-Ii

III

iv-

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

1. PREVENTION 1.1 Quality 1.2 Maintenance Equipments 1.3 Development Standards 1.4 Vendor 1.5 Obtaining of Quality 1.6 Quality TOTAL 2. APPRAISAL

Engineering

Development a Third Party Guarantee -

Training

COSTS
of the Incoming of

2.1 Inspection/Testing Materials 2.2 In-Process Product 2.3 Quality 2.4 Qrality Evaluation

of Quality

Audit on In-Process Audit on Finished

Products Products in of

2.5 Materials/Services Inspection 2.6 Calibration Inspection 2.7 Evaluation TOTAL

Consumed

and Maintenance Equipments of Inspection Data

( colltinud )

42

18 t 7200 (Part 3 ) - 1982

APPENDIX
QUALITY
COST CATEGORIES

N-Contd

COST ANALYSIS
QUARTERLY QUALITY COST IN Rs

TOTAL

I -.---_ 3. FAILURE 3.1 Internal COSTS

II

III

IV

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

Failure

Costs in Course Requirements Non-conforming and Re-testing of

3.1 .l Scrap Incurred Meeting Quality 3.1.2 Re-work 3.1.3 Analysis Materials 3.1.4 3.1.5 Re-inspection of

and Repair

Loss Due to Down Grading of the Materials as Seconds ---_* TOTAL ----.-

3.2 External

Failure

Costs Complaints of for of

3.2.1 Dealing Failures 3.2.2 Handling Rejected

with

and Accounting Products Repairing

and 3.2.3 Analysing Rejected Products 3.2.4 Replacement the Warrantee

of Failures Period

Within Due to -----

3.2.5 Replacement of Products Marketing Error TOTAL

----Grand Total of Quality Costs --p-v %Over Sales Turn Over or Total Expenditure of Company

43

I9 I 7200 ( Part 3 ) - 1982

APPENDIX ( Clause 2.14 )


UTILIZATION PROFORMA Name of Company:

OF RESOURCES I EQUIPMENTS Year:


LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

__--3~ No. ~~ERATI~N

-I-

-7-

NUMBER PRODUCED

I:PRODUCTION
Current

PEB HOUR Past Best

I;

REMARXS

( Continued )

44

B3r7100 (h-t!+1982

APPENDIX
UTILIZATION PROFORMA Name of Company:
ITEM ;o. QUANTITY CONSUMED VL;;;~~ --

P-Contd

OF RESOURCES RAW MATERIALS Year:


RATIO TO TOTAL OUTPUT (%) Quantity Value Best Year REMARKS

II

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

( Continued )

45

A P P E N D I X

P -

Contd
LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

UTILIZATION PROFORMA Name of Company:


SL VO. TOTAL NUMBER OF WORKINQ
DAYb

OF RESOURCES III MAN POWER Year:

MAN. DAYS Maximum Available Actual Worked

PERCENTAQE WORKED Last Year Current Year

RATIO TO OUTPUT Last Year Current Year Best Year

REMARKI

IS I 7200 (Parts)-1992 APPENDIX UTILIZATION PROFORMA Name of Company:


LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

P-Cod OF RESOURCES OF INPUT AND OUTPUT

IV

SUMMARY

1. INPUT
YEAB Last Year Current Year Percentage Increase BeIt Year

Equipments

( Rs )

Labora.toria

( Rs )

NOTE-The separately.

details

of equipment,

toola

and laboratories

should

be

provided

2. OUTPUT

2.

IQuantity

G~~OWTB

1 [TBpUS+

-Last

YEAU

-Produced

krent

PERCENTAO~ INCREASE/ DEOREA~~D

BEST
YEAB

8
b
C

d Turn-Over (Total ) Inflation Profits Cornction

*Major

items only.

47

IS:

72OO(Part3).1382

APPENDIX ( ChJe 2.15 )

INVENTORY Name of Company:


SL
JO. -ITEMS QUANTITY VALW IN RUPEES

Year:
RATIO TO IOTAL VALUE OB OUTPUT ( y0 ) Last Year huant Best Year Minimum Possible _---_ RElbAl%Kl

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

48

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

APPENDIX ( Clause 2.16 )

SUGGESTION Name of Company:

SCHEMES

Year:

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

As in the Original Standard, this Page is Intentionally Left Blank

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

BUREAU
Headquarters :

OF

INDIAN

STANDARDS

Manak Bhavan, 9 Bahadur Shah Zafar Marg, NEW DELHI 110002 Telephones : 331 01 31 Telegrams Regional Central * Eastern Northern Southern Western Branch 331 13 75 Offices :

: Manaksanrthe

(Common to all Offices) Telephone 331 01 31 i 331 13 75 37 86 62

: Manak Bhavan. 9, Bahadur Shah Zafar Marg.


NEW DELHI 110002 : 1114 C.I.T. Scheme VII M. V.I.P. Road, Maniktola. CALCUTTA 700054 : SCG 445-446, Sector 35-C, CHANDIGARH 160036 : C.I.T. Campus, IV Cross Road, MADRAS 600113 : Manakalaya. E9 MIDC. Marol, Andheri (East), BOMBAY 400093 Offices

LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

21843 41 29 16 6 32 92 95

:
380001 2 63 46 39 49 55 55 40 21 5 36 27 2 67 05 6-71 19 96 3 31 77 231083 6 34 71 21 68 76 5 55 07 6 23 05 Maiden. 8 21 04

Pushpak, Nurmohamed Shaikh Marg, Khanpur, AHMADABAD t Peenya Industrial Area, 1st Stage, Bangalore-Tumkur Road. BANGALORE 560058 Gangotri Complex, 5th Floor, Bhadbhada Road. T.T. Nagar. BHOPAL 462003

Plot No. 82/83, Lewis Road, BHUBANESHWAR 751002 Kalai Kathir Building, 6/48-A Avanasi Road, COIMBATORE 641037 Quality Marking Centre, N.H. IV, N.I.T., FARIDABAD 121001 Savitri Complex, 116 G. T. Road, GHAZIABAD 201001 5315 Ward No. 29, R.G. Barua Road, 5th By-lane, GUWAHATI 781003 58-56C L. N. Gupta Marg. ( Nampally Station Road ) HYDERABAD 500001 R14 Yudhister Marg, C Scheme, JAIPUR 302005 117/418 B Sarvodaya Nagar, KANPUR 208005 Plot No, A-9, House No. 561/63, LUCKNOW 226005 Patliputra Industrial Estate, PATNA District Industries Centre Complex. SRINAGAR 190011 Sindhu Nagar. Kanpur Road. 800013 Bagh-e-Ali

T. C. No. 14/1421, University P. 0.. Palayam. THIRUVANANTHAPURAM 695034 fnspection Offices (With Sale Point)

:
52 61 71 5 24 35

Pushpanjali. First Floor, 205-A West High Court Road. Shankar Nagar Square, NAGPUR 440010 Institution of Engineers (India) Building, 1332 Shivaji Nagar. PUNE 411005 Sales Office Calcutta is at 5 Chowringhee P. 0. Princep Street, CALCUTTA t $ Sales Office is at Unity Building. BANGALORE Approach

27 68 00 89 65 28 22 39 71

Sales Office is at Novelty Chambers, Grant Road, BOMBAY Narasimharaja Square.

Printed 61 Dee Kay Prrnters. New Delhi. India

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