FM/MR/02

JPSL
S.NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

MASTER LIST OF DOCUMENTS

DOCUMENT NAME Document and Data Control Control of quality records Management Review Internal quality audits Business Plan Continuous Improvement Resource Planning Determining customer satisfaction level & monitoring Contract Review for custom products Handling, storage, packaging, preservation & delivery Control of customer supplied products Handling of customer problems Contract Review for Export Products Handling, storage, packaging, preservation & delivery Handling of customer problems ( Exports ) Contract Review ( Repl. Mkt.) Handling, storage, packaging, preservation & delivery Quality Planning Design Control Prototype development Pre - launch quality planning Control of drgs / specifications & standards PFMEA study Sub contractor evaluation and approval Purchasing Receipt and Stores Sub contractor performance monitoring Purchasing ( Engg. Items ) Receipt Inspection and testing Inprocess Inspection Final Inspection Control of inspection, measuring and test equipment Statistical Techniques Sample Validation Inspection and test status Control of non conforming product Corrective and preventive action Product Identification and traceability Process control Heat treatment Shot peening Painting PPC Maintenance of production equipments Tool Control Training Environment Safety Quality Manual ISO NO. 4.5 4.16 4.1.3 4.17 4.1.4 4.1.1 4.1.2.2 4.1.1 4.3 4.15 4.7 4.14 4.3 4.15 4.14 4.3 4.15 4.2.3 4.4 4.4 4.2.3 4.5 4.4 4.6.2 (a) 4.6.3 4.15 4.6.2 (c) 4.6.3 4.10.2 4.10.3 4.10.4 4.11 4.20 4.6.2 (a) 4.12 4.13 4.14 4.8 4.9 4.9 4.9 4.9 4.9 4.9 4.9 4.18 4.9 DOC. NO REVISION DATE OP/MR/01 00 29.04.98 OP/MR/02 00 11.05.98 OP/MR/03 00 27.04.98 OP/MR/04 00 29.04.98 OP/MR/05 00 26.04.98 OP/MR/06 00 27.04.98 OP/MR/07 00 26.04.98 OP/MR/08 00 26.04.98 OP/MK/01 03 10.01.98 OP/MK/02 00 07.07.97 OP/MK/03 00 07.07.97 OP/MK/04 02 02.05.98 OP/ME/01 01 23.12.97 OP/ME/02 00 26.07.97 OP/ME/03 00 26.07.97 OP/MA/01 02 05.02.98 OP/MA/02 01 01.12.97 OP/RD/01 00 07.07.97 OP/RD/02 03 03.02.98 OP/RD/03 01 01.10.97 OP/RD/04 01 01.10.97 OP/RD/05 01 01.10.97 OP/RD/06 00 04.05.98 OP/MS/01 02 27.12.97 OP/MS/02 03 27.12.97 OP/MS/03 04 20.05.98 OP/MS/04 02 01.02.98 OP/MS/05 03 28.01.98 OP/QA/01 02 10.01.98 OP/QA/02 01 01.09.97 OP/QA/03 01 10.01.98 OP/QA/04 01 29.11.97 OP/QA/05 01 29.11.97 OP/QA/06 00 07.07.97 OP/QA/07 01 01.09.97 OP/QA/08 00 07.07.97 OP/QA/09 01 10.01.98 OP/QA/10 01 20.10.97 OP/PD/01 01 01.09.97 OP/PD/02 01 01.09.97 OP/PD/03 01 01.09.97 OP/PD/04 01 01.09.97 OP/PC/01 01 01.09.97 OP/MN/01 00 15.06.98 OP/TR/01 00 01.09.98 OP/HR/01 00 05.05.98 OP/MN/02 00 04.02.98 01

Deptt. :

FM/MR/02

JPSL
S.NO.

MASTER LIST OF DOCUMENTS

DOCUMENT NAME DOC. NO REVISION DATE

JPSL

S. No. 1 2 3 4

Doc. #

Doc. Name

Rev. 00 00 00 00

FM/MR/01 DOCUMENTS DISTRIBUTION SHEET Change RECIPIENTS Dir. GM MR Mkt. Exp. R&DMatr. QA Prod PPC Maint. T/C HRD

QP/QA/01 QUALITY PLAN - Raw Material QP/QA/02 QUALITY PLAN - Sampling QP/QA/04 QUALITY PLAN - Loose leaf QP/QA/05 QUALITY PLAN - Finish Product

FM/MR/07

FM/MR/07

JPSL
S.No. Department/Area 1 2 3 4 5 6 7 8 9 10 11 12 13 Management Rep. Marketing - OEM Marketing - Export Marketing - Repl. R&D Materials Quality Assurance Production - I Production - II PPC Maintenance Tool Control HRD April 98
W1 W2 W3 W4

INTERNAL
May 98 June 98 July 98 All procedures being modified / updated for QS9000. Department interactions in-process. Training for APQP, CP, GRR, FMEA completed. The system effective date is 01 July 98.

QUALITY AUDIT
Sep-98 Oct 98

PLAN
Nov 98 Dec 98 Jan 98 Feb 98 Mar 98

Aug 98 *

W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4

QS systems reviewed in September for implementation and on the basis of status the system effective date changed to 08 Sep 98. * Only follow up audit Approved by : Date : 05-09-98

FM/MR/05

JPSL

INTERNAL QUALITY AUDIT SCHEDULE

Deptt. / Area Audit Date OEM & Replac Exports 12/10/98 Time Auditor

MR

Marketing

9.0 am~10.30 am Ms Venu Kashyap 3.30 pm~4.30 pm Ms Venu Kashyap

R&D Materials Quality Assurance

Receipt Manufacturing Standard Room

12/10/98 13/10/98 13/10/98

2.0 pm~3.30 pm Ms Venu Kashyap 3.30 pm~5.0 pm Ms Venu Kashyap 9.0 am~11.00 am Ms Venu Kashyap Ms Venu Kashyap Ms Venu Kashyap 11.00 am 12.30 pm Ms Venu Kashyap 2.0 pm~3.30 pm Ms Venu Kashyap

Production

Processing & HT 13/10/98 Assembly 13/10/98

PPC Maintenance Tool Control HRD

12/10/98 10.30 am~11.30 am Ms Venu Kashyap 12/10/98 12/10/98 13/10/98 11.30 am~1.30 pm Ms Venu Kashyap 4.30 pm~5.30 pm Ms Venu Kashyap 12.30 pm 1.30 pm Ms Venu Kashyap

Remarks

Date

5/10/1998

Approved by

FM/MR/05

Auditee Mr. Ajay Sharma Mr. Hemant D. Mr Paritosh Kumar Mr. Sudhir Singh Mr. R.K.Khanna

Mr. Ashwani Mehta Mr. Rajwinder S. Mr. Permish Mr. Jaspreet Singh Mr. Amardeep S. Mr. R.S.Nanda

FM/MR/03

JPSL
S.No.

LIST OF QUALITY RECORDS

Name of Quality Record Number Retention

Deptt. : ........................................

Approved by :

FM/MR/06

JPSL

NON CONFORMITY REPORT

Ref. : NCR / /

Audit Area :.............................. .............................. Auditor :.... .............................. Details of Non conformity :

Audit date :.............................. Auditee :..............................

Auditor's sign Counter measures :

Auditee's sign

Date : Verification of counter couter measures measures taken taken : : NCR :

Auditee's sign Closed / Continue

Auditor's sign

Date :

Auditee's sign

JPSL

MANAGEMENT REVIEW - ANNEXURE

17.09.97

PARTICIPANTS : Director operations, GM(O), AKS, MR, HKS, SSG, VK, AW, GJS, AS, LPS, SUDHIR, KS. S.NO. ACTIVITY 1 Internal Quality Audits performance & External Audit reports : 1.1 The NCRs which were 127 in no. after 1st internal audit, came down to 95 in the 2nd audit. In the follow up audit it reached down to 32 ( Still 25 % of NCRs are open ). The concerning poits are : Completion of control plans Completion of D&D plans Unidentified material at receipt stage area must be controlled. The identification & test status of raw material in unit - 2 to be streamlined. All the products must be identified ( Unit - 1 ). All the stacks of products must have inspection & test status ( Unit - 2 ). Workers need more training to make them understand of ISO 9000 systems ( Unit - 1 ) Disposition of accomulated rejections to be cleared ( Unit - 1 ). To get temp. indicators installed on HT of Unit - 2. Traceability up to HT to be implemented. Installation of safety boards. Sales projections must be provided to PPC by 25 th of each month. House keeping of FG godown - Repl. Market to be streamlined. House keeping of FG godown - OEM. Market to be streamlined. Company level quality performance data : To evolve data of rework at HT stage for Jul & Aug. Hence forth start data collection on regular bases. To evolve data of rework in processing stage wise also. And to start data collection on regular bases. The target for St. pass of loose leaf should be taken 100 %. 18.09.97 18.09.97 19.09.97 RKK RKK RKK 18.09.97 18.09.97 18.09.97 18.09.97 20.09.97 20.09.97 20.09.97 18.09.97 20.09.97 19.09.97 19.09.97 25.09.97 30.09.97 18.09.97 AW VK LPS SSG SSG SSG SSG SSG SSG RKK GJS HKS AS HKS TARGET RESPONS. STATUS

1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.1.10 1.1.11 1.1.12 1.1.13 1.1.14 2 2.1 2.2 2.3

JPSL

MANAGEMENT REVIEW - ANNEXURE

S.NO. ACTIVITY TARGET RESPONS. 2.4 The data on MUL Car defects attribute the major contributer - Eye tight. The analysis of this contributer 18.09.97 RKK should be done using quality tools. 3 3.1 3.2 4 4.1 5 5.1 Preventive actions - continuos improvement : Effectiveness of the countermeasures taken to control problem of low camber in MUL Car should be 17.09.97 detailed by way of collecting data before & after improvement. R&R study and productivity improvement in the above action to be done using QS formats. 17.09.97 Sales : The average sale of the past five months is 87% against the Business Plan targets. The fall has come due to 22.09.97 slash down of production of major customers. Hence the Business plan needs review & updation. Customer Complaints : The data needs corrections. It should be jointly signed by Mkt., QA, Prod. The implementation date & data 17.09.97 showing its effectiveness to be prepared. Breakdowns : 18.09.97 keeping the actual data of previous months of parabolic in view, the target needs to be reduced to 4%. Also review the target of HT. 16.09.97 At Parabolic, the data shows that the major contribution of breakdown is Hydraulic Problem. Hence, 17.09.97 analyse the problem & prepare action plan. Inventory : The actual inventory against target is quite high. The details of surplus / dead stocks to be prepared section 19.09.97 wise for taking decisions. Productivity : Three months data of productivity & variable cost should be prepared and presented. 01.10.97 SSG SUDHIR GJS GJS GJS RKK RKK RKK

STATUS

GM(O)

6 6.1 6.2 6.3 7 7.1 8 8.1

JPSL
S.NO.

MANAGEMENT REVIEW - ANNEXURE

ACTIVITY TARGET RESPONS. STATUS

9 9.1 10

Training : To prepare matrix of training imparted topic wise. Also prepare data of compliace with target. Business Plan : 22.09.97 GM(O) 18.09.97 AM

10.1 Business plan needs to be up dated as per changing Scenario of the Market. 11 Quality System :

11.1 In view of the suggestion for material deptt. reporting system on performance monitoring , it is felt by deptt. that ORG system will require some changes. 12 Others : 18.09.97 18.09.97 18.09.97 RKK RKK AW

12.1 Disposition of nonconforming lies with QA. 12.2 NCP report needs to be discussed daily with GM(O) during production meeting. 12.3 Since rework after tempering is considered a part of process, it should be incorporated into flow chart . 13 Previous Review :

13.1 Previous review was conducted only to see the progress of quality systems.

BUSINESS
1997 -

PLAN
98

JAI PARABOLIC SPRINGS LTD. , MOHALI

ANNEXURE
WORK
S.No.

INSTRUCTIONS
Doc. No.

DISPLAY

STATUS
Location

Document Name

SUMMARY OF 9th INTERNAL QUALITY AUDIT NCs SUMMARY DEPTT / AREA

Previous Fresh Total

ISO CLAUSE

MARKETING ( OEM ) MARKETING ( Exp. ) MARKETING ( Repl. ) R&D

MATERIALS

* Clamps in receipt area unidentified. * Qty mismatch on bin card.

4.8 4.5 4.9

PRODUCTION

* Ist piece approval missing *Daily maintenance checksheet not filledup.

QA

*Measurement before & after cleaning to be added * Non-conforming product register incomplete

4.11 4.5 4.9 4.1

MAINTENANCE

* All breakdowns to be recorded on history cards * Organisation structure to be updated

PPC

* Procedure to be amended

4.5

TOOL CRIB

* WI for machines to be made & displayed.

4.9

HRD

MR

FM/MR/08

List of Internal Quality Auditors Issue 00

S.No. 1 2 3 4 5 Name Ms. Venu Kashyap Mr. RK Khanna Mr. Ajay Sharma Mr. Sudhir Singh Mr. Rajwinder Singh Rev. 01 Department QS QA Marketing Materials Production

Approved by

Date

Doc #

Work Instruction

Issue # Rev # Date Page

Prepared by

Approved by

Letter to MUL 15-Mar-98 KA : Mr. SS Gore

Subject : Approval of Drawings of Special gauges

Sir, Enclosed please find the drawings for the bar gauges for your approval. This is as per the requirement of ISO9001 and was advised in the final registration audit. We shall consider the drawings approved if no response is received by 15th of April 1998, as the supply lots being sent are made/checked as per these fixtures.

Venu Kashyap Management Representative

MASTER LIST OF QUALITY RECORDS

Format # Issue # Rev. # Page Date

FM/MR/03 01 01 01 / 01 15-06-98
Remarks

DEPARTMENT : S.NO. Document Description

MR
Form No. Identification Indexing Method Location Deptt. Retention Period Disposition

1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17

Document distribution sheet Masterlist of documents List of quality records Management Review Internal Quality audit schedule Non conformity Report Internal Quality audit plan List of Internal quality Auditors Reports of External Audits Customer Satisfaction Survey Resource request form Document request form Agenda for management review Internal Audit summary report Audit observation sheet Business plan agenda

FM/MR/01 FM/MR/02 FM/MR/03 FM/MR/04 FM/MR/05 FM/MR/06 FM/MR/07 FM/MR/08 FM/MR/09 FM/MR/10 FM/MR/11 FM/MR/12 FM/MR/13 FM/MR/14 FM/MR/15

FL/MR/01 FL/MR/02 FL/MR/02 FL/MR/04 FL/MR/03 FL/MR/05 FL/MR/03 FL/MR/02 FL/MR/06 FL/MR/07 FL/MR/08 FL/MR/09 FL/MR/04 FL/MR/10 FL/MR/05 FL/MR/11

Datewise Depttwise Depttwise Datewise Datewise Depttwise Datewise Datewise Datewise Datewise Datewise Datewise Datewise Datewise Depttwise Yearwise

RK/MR/01 RK/MR/01 RK/MR/01 RK/MR/01 RK/MR/01 RK/MR/01 RK/MR/01 RK/MR/01 RK/MR/01

All concerned deptts.

Permanent Permanent Permanent one year+1 one year+1 one year+1 one year+1 Permanent one year+1 one year+1 one year+1 one year+1 one year+1 one year+1 one year+1 one year+1

Burning do do do Burning do do do do do do do

External audit agency

All concerned deptts. All concerned deptts. All concerned deptts.

RK/MR/01 Customer RK/MR/01 RK/MR/01 RK/MR/01 RK/MR/01 RK/MR/01 RK/MR/01

All concerned deptts.

Made by

Approved by