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Project on ISO

Presented to:
Prof. Ahmad Usman

Presented by:
Mahboob HAssan 322
Munir Ahmad 339
Hafiz Abu Baker Usman 354
Farrukh Shehzad 308

Section: B.com (Hons.)


6TH Sem. (D) Morning program

Hailey College of commerce


University of the Punjab

INSTAPLAST
Established in Pakistan, INSTAPLAST is one of the world’s most advanced PET
Preform manufacturing facilities. The company offers exceptional value for customers
through market insight and latest technology by some of the most recognized global
brands in their respective industries.

Since its inception, INSTAPLAST has successfully evolved into a dynamic and most
recognized PET Preform supplier for the beverage industry in the region.

At a Glance
INSTAPLAST was established with the vision of setting new standards of quality in the
PET industry with major focus on the PET preforms business with large multi-national
and national organizations on dedicated manufacturing lines concept.

Our state-of-the-art preform plant is located in the heart of Pakistan – Lahore, with very
easy access to all major business centers. Our Plant is very well connected through easily
approachable network of Motorways/Highways. By virtue of this convenient location and
our highest quality standards find no match in the local industry and make us No. 1
choice for bulk preform consumers in the region.

Key Facts
• Housed in a lush green expanse of 6 acres
• Vast premises with more than 75,000 sq. ft of built up area
• Ample production and storage facilities built in steel structure
• World’s latest injection molding technology agreement with Husky
• Hi-tech in-house preform quality testing facility
• ISO certifications 9001 and 14001
• Internationally approved by PEPSI Cola
• Corporate centre: Lahore, Pakistan
• Internet address: www.instaplast.com

Contact of INSTAPLAST
Quality Department Functions

Comprehensive Quality Control & Quality Assurance Programmes


Carbonated Soft Drink (CSD) PET Containers made from INSTAPLAST preforms allow
brand owners to obtain a safer product with longer shelf life than the preforms typically
provided by competitors.

INSTAPLAST follows a comprehensively designed Quality Assurance Programme that


sets forth personnel and operational guidelines to assist the employees with operational
responsibilities at all levels. Mainly it comprises of two areas where a complete Quality
Control department independently takes charge to ensure best quality during process and
later Quality re-check and reassurance during storage and before final dispatch of
finished goods.

Preforms Quality Testing Facility

The QC department at INSTAPLAST provides;


• Pakistan’s Most Modern QC Lab Facility
• Latest equipments including fully automatic AA and I.V. tests
• Full compliance of Food Packaging Safety Rules
• Strict Quality Control measures for Incoming Raw Materials
• Rejection of Out of Specification Materials
• Storage & Safety of Stored Raw Materials
• Process Controls.
• Machine parameter are recorded every 30-60 mins. with co-relation to standard
performance data
• Visual Inspection of preforms is recorded every two hrs. with co-relation to process
parameters

QC lab performs number of physical, visual and chemical tests on routine basis to keep a
strict check on the quality of manufactured products. Proper record keeping is done for
all the tests and reports generated for critical analysis. QC lab has the facility to perform
following major and number of other minor tests;

• Visual Inspection Test


• Polarized Light Inspection of Preforms
• Preform Dimension Test
• Perpendicularity Test
• Preform Weight Test
• Acetaldehyde Test
• Intrinsic Viscosity Test

INSTAPLAST is certified by ISO 9001 and also 14000


The Certifications are:
IMPLEMENTATION
CONTRACT
Firstly the INSTAPLAST make a contract with SGS to get certification of International
organization of standardization (ISO). SGS made general survey of InstaPlast and review
the existing system, then provide standards to InstaPlast in July 2008 which were
completely implemented in December 2008.
The duration of implementation was only 6 month because of the severe demand from
our quality conscious customers NESTLE and PEPSI.

DURATION
This certification is given for 3 years then after the survey and audit of system this
certification is renovate due to good performance.
Top management allocates time and resources with full cooperation. Cross functional
team was established, task was given, dead line was given and maintain the standards.

ISO STANDARDS
Special guidelines, standards, and training is given by the ISO to the organization
employees for a particular quality improvement process, for example proper employees
uniforms, gloves, safety measures, hair cap, mask, medical treatment after process, air
filtration plant in double glass environment to avoid germs.

MANAGEMENT
Member of management team is responsible for ensuring that QMS processes are
established, implemented and maintained.
Reporting performance of the QMS to management, including any need for
improvement.

INFRASTRUCTURE
ISO made survey and check the Infrastructure and its maintenance to achieve product
conformity:
Building, work place and facilities.
Process equipment (hardware and software)
Supporting services (Transport, communication etc.)

ORGANIZATION
Organization identified the process needed. Determined the sequence and interaction of
these processes. Determined the criteria and methods for effective operation and control.
Made supporting resources and information available. Measured, monitored and analyze
these processes. Acted to achieve planned results and continual improvement of these
processes.

INTERNAL COMMUNICATION
Internal communications processes established including effectiveness of QMS.

MANAGEMANT REVIEW
Top management reviews the QMS at planned interval for following reasons: To ensure
continual stability, adequacy and effectiveness. To asses improvement opportunities and
the need for changes to the QMS, policy and objectives. To maintain the record.

REVIEW INPUT
Organization Review the input include information from audit result, customer feedback,
process performance and product conformity, preventive and corrective actions, follow
up from previous reviews, and changes.

REVIEW OUTPUT
Organization Review the Output Including decision and actions for:
Improved effectiveness of the QMS and processes improved product related to customer
requirements.

CONTROL OF RECORD
Records are maintained to provide evidence of the effective operation of QMS in
accordance with a Documented Procedure.

ISO provide training to the employees for successful implementations of the provided
standards in the organization.

ISO provide training to the employees for successful implementations of the provided
standards in the organization.

Problems in Implementation
Our top management was fully committed, organizational structure is almost compatible
but there were some minor problems occur to change the culture because the standards,
processes, policies and methods adopted by employees were challenging to them, they
were little resisting, then they were provided proper training and education. But the
continual training were very costly for each employee, it was also a financial problem.

DOCUMENTATION
The following documents are required by ISO to be maintained in INSTAPLAST
Policy and Objectives
Quality Manual
Required Documented Procedures
Process related documentation
Operating Procedures
Quality Policy Statement, company Objectives, Goal, Plans. Action plan and record
keeping.

QUALITY MANUAL
Quality manual defines the scope of quality management system (products and
processes). Documented QMS procedure or reference to them. Description of the
interaction between the processes of QMS.

QUALITY POLICY
Include appropriate to the purpose of organization. Commits to comply with requirements
and continually improved the effectiveness of QMS.
It provides a framework for establishing and reviewing quality objectives. Communicated
and understood within the organization. Review for continuing stability.

QUALITY OBJECTIVES
Objectives established at relevant functions and level and product requirements. These
are measurable.

Audit
Interim and annual audit are conducted by SGS according to the pre given dates, to check
the quality. If they find that firm is exercising the provided standard successfully, they
renew their certification and if they find short comings in implementations they provide
extra guidelines to improve the process.

Certification can be cancelled by SGS if the firm does not fulfill the requirements.
Customers complaints team also exist which conduct monthly meetings to handle the
customer complaints and quality requirements in a proper way

AUDIT RESULTS
Audit results are used to continually improve the QMS effectiveness. To monitoring and
measurement of processes.

ANALYSIS OF DATA
Customer’s satisfaction,
Conformity to products requirements,
Process and product characteristics,
Trends and preventing actions opportunity,
Supplier information

Actions are taken (appropriate to the effects of non conformity encountered) to


eliminate causes of non conformity.

Cost and Benefit Analysis


INSTAPLAST is providing Bottles and closure to its customers NESTLE and PEPSI at
international level. It had to purchase new modern technological automatic machines for
both Multinational Companies separately, (NESTLE and PEPSI) for the manufacturing
of bottles and closure. The machine was purchased from JERMANY for Rs. 130 Million
from Husky Modeling Company.

Air filtration plant, double glasses were erected to cover this machine from dirty air and
germs. And the cost born by the company for this purpose was RS. 5000000.
Workers uniform, mask, glasses, socks, worker hand and body wash system, changing
cloth room and employees medical treatments.

All these standards and actions are taken to fulfill both the requirements of ISO and
INSTAPLAST quality conscious customers as well.
Our Customers are fully satisfied with our quality product.

It’s our Pleasure that the International Companies NESTLE and PEPSI made contract
only with us in Whole Asia due to the implementation of ISO quality standards.

Our profitability has increased and customers are satisfied due to use of cost conscious
machines.

Our processes are improved on continually basis and our internal customers are also
satisfied now.
ISO. The International Organization for Standardization (ISO) is an international
federation of national standards involving more than 140 countries. ISO 9000 is a
well-known family of guidelines and standards developed by the ISO. It has become
popular worldwide for its role in setting up quality management systems within
organizations.

What is ISO?
The International Organization for Standardization (ISO) is an international federation of
national standards involving more than 140 countries. A non-governmental organization
it was set up in 1947. The motto of ISO is to endorse the growth of standardization
worldwide to promote international trade and services. ISO promotes mutual
collaboration between various organizations in the scientific, technology and economic
related activities.
• An internationally accepted management model that makes a company
Document their processes to maintain consistent practices
• Method that dictates how a company should produce their products
• through a rigorous documentation process
• This prevents repetitive errors from occurring and allows for improvement
• Focuses on ensuring a quality product

A Brief History
International standardization was first initiated in the electro technical area. The
International Electro Technical Commission (IEC) was established in 1906. The
International Federation of the National Standardizing Associations (ISA), established in
1926, put in groundbreaking efforts in other areas. ISA focused mainly on mechanical
engineering. But with the start of World War II ISA operations was put on hold in 1942
After the war in 1946, representatives from 25 countries convened in London and decided
to form a new international organization, in order to “make possible the international
coordination and integration of organizational standards". The new organization, ISO,
formally became operative on 23 February 1947.

The reasons for international standards are:

• A cheaper product
• Less waste
• Greater interoperability between products
• Improved usability
• Ease of maintenance
What Is ISO 9000?

Founded in 1946 in Geneva, Switzerland.

• The goal of any organization is to constantly accrue benefits through product


innovation and efficiency in the use of resources. The critical aspect to achieve this is to
attain all round quality performance. Quality is a basic consumer requirement. A
customer prefers organizations reliable as far as its quality performance is concerned.
Consistently manufacturing products and offering services of superior quality is the need
of the hour worldwide. This is a critical aspect in sustaining customer loyalty and
retaining the market base.
• In order to attain this, organizations have to comply with a set of procedures that
are not only acknowledged and accepted within a country but also internationally. ISO
9000 standards serve this purpose.
• ISO 9000 is a well-known family of guidelines and standards developed by the
ISO. ISO 9000 standards for a Quality Management System handles the processes
concerned with the design, development and delivery of a product or service.
• The standard stipulates specifications for the control and assessment of a process
for attaining quality performance.
• The 1987 version of ISO 9000 standard, (originally published as BS5750 by the
British Standards Institute) emphasized on quality control by means of effective checking
and corrective actions. Quality control (QC) is a management function that controls the
quality of raw materials, products, components, and services concerned with production
and inspection activities. It aims to prevent defects in the products or services.
• The 1994 version of the ISO 9000 standard focused on quality assurance via
preventive actions, and stipulated the need for documented procedures. Quality assurance
(QA) comprises all measures taken to ascertain that the standards and procedures are in
conformity and that the products or services meet the performance requirements.
• An ISO 9000 certification indicates that the management is effectively
controlling the processes that are ‘critical to quality’ with respect to the customer. ISO
9000 is not just about service or product quality; it's about quality in management.
• These standards address aspects related to process management. This requires
organizations to identify, document and control processes ranging from executive
management to the production of different items.
• An organization could be successfully certified to ISO 9000 if it adhered to the
specifications of the standard. In order to be certified, an organization must submit to an
accredited assessor’s examination. The assessor interviews staff members to ensure that
they are aware of their roles and responsibilities in complying with the ISO 9000
standard. The assessor also examines the organization's paperwork to check on ISO 9000
compliance. When all issues are addressed, the organization is deemed for certification.

ISO 9000 series

ISO 9000:94 family is a set of international quality standards and guidelines that have
become popular worldwide for their role in setting up quality management systems
within organizations.
In the past, organizations preferred to implement any of the three ISO 9000:94
requirement standards i.e. the ISO 9001, ISO 9002 and ISO 9003. Moreover, there was a
notion that ISO standards are applicable only in the manufacturing sector.
ISO in a move to change this perception drafted some more guidelines that cater to the
requirements of the service sector, small and medium scale industries and software
companies. Given below is a list of ISO 9000:94 guidelines and standards.

ISO 8402
Quality management and quality assurance – Vocabulary: Defines the essential terms
used in the ISO 9000 family, which is necessary for avoiding misinterpretations.

ISO 9000-1
Quality management and quality assurance standards – Part 1: Sets the guidelines for
selection and use of specific standards. Provides the scope for understanding and
selecting the appropriate standards.

ISO 9000-2
Quality management and quality assurance standards –Part 2: Provides basic guidelines
for the application of ISO 9001, ISO 9002 and ISO 9003. Helps in interpreting ISO 9001,
ISO 9002 and ISO 9003.

ISO 9000-3
Quality management and quality assurance standards –Part 3: Sets guidelines for the
application of ISO 9001 1994 in the development, delivery, installation, and maintenance
of computer software. Also provides a specific interpretation of the requirements of ISO
9001 for computer software development applications.

ISO 9000-4
Quality management and quality assurance standards –Part 4: Provides guidance on how
to plan, organize and control resources to produce reliable and sustainable products.

ISO 9001
Quality systems – Model for quality assurance in design, development, production,
installation and servicing.
This is a requirement standard used to ascertain the process capabilities for the design and
development of the product or service, as well as for installation and servicing.
ISO 9002
Quality systems – Model for quality assurance in production, installation and servicing.
This standard is used to ascertain process capabilities for production, installation and
servicing (identical to ISO
9001except for design control requirement).

ISO 9003
Quality systems – Model for quality assurance in final inspection and testing. This is a
requirement standard used to control product or service through final inspection and
testing.

ISO 9004-1
Quality management and quality system elements –Part 1: Guidelines for
implementation. This optional standard provides guidelines to implement a quality
system to satisfy the customers’ and organizational requirements.

ISO 9004-2
Quality management and quality system elements –Part 2: Sets guidelines for services.
This standard is analogous to ISO 9004-1, but the guidelines are designed specifically to
suit the requirements of the service sector.

ISO 9004-3
Quality management and quality system elements –Part 3: Sets guidelines for processed
materials.

ISO 9004-4
Quality management and quality system elements –Part 4: Sets guidelines for quality
improvement. Provides guidelines for implementing continual quality improvement
within the organization using tools and techniques based on information compilation and
evaluation.

ISO 10005
Quality management –Sets guidelines for quality plans. This standard provides guidance
on how to prepare quality plans for the control of specific products, and projects.

ISO 10006
Sets guidelines to quality in project management

ISO 10007
Quality management –Sets guidelines for configuration management. Provides guidelines
to ensure that a complex product continues to work in the desired manner even when
certain parts are modified
ISO 10011-1
Sets guidelines for auditing quality systems – Part 1: Provides guidelines for auditing a
quality system, and verifying the system’s capability to achieve set quality goals. It can
be used within the organization or for auditing the suppliers.

ISO 10011-2
Sets guidelines for auditing quality systems – Part 2: Qualification criteria for quality
systems: auditors.
Provides guidance on the education, training, know-how, personal traits and management
capabilities needed to carry out an audit.

ISO 10011-3
Sets guidelines for auditing quality systems – Part 3: Management of audit programmes.
Provides basic guidelines for managing quality system audit programmes.

ISO 10012-1
Quality assurance requirements for measuring equipment – Part 1: It is a metrological
confirmation system for measuring equipment. Provides guidelines on the key
characteristics of a calibration system to ensure that measurements are done with the
projected accuracy.

ISO 10012-2
Quality assurance for measuring equipment – Part 2:
Sets guidelines for control of measurement processes. Provides additional guidance on
the application of statistical process control whenever it is apt for achieving the
objectives of Part 1.

ISO 10013
Sets guidelines for developing quality manuals. Provides guidelines for the setting up,
organising and
Controlling quality manuals customised to specific needs.

ISO 14000 Series

Standard Title / Description


Guide to Environmental Management Principles,
14000
Systems and Supporting Techniques
Environmental Management Systems - Specification
14001
with Guidance for Use
Guidelines for Environmental Auditing - General
14010
Principles of Environmental Auditing
Guidelines for Environmental Auditing - Audit
14011 Procedures-Part 1: Auditing of Environmental
Management Systems
Guidelines for Environmental Auditing - Qualification
14012
Criteria for Environmental Auditors
Guidelines for Environmental Auditing - Audit
14013/15
Programmes, Reviews & Assessments
14020/23 Environmental Labeling
Environmental Labeling - Practitioner Programs -
14024 Guiding Principles, Practices and Certification
Procedures of Multiple Criteria Programs
14031/32 Guidelines on Environmental Performance Evaluation
Life Cycle Assessment General Principles and
14040/43
Practices
14050 Glossary
Guide for the Inclusion of Environmental Aspects in
14060
Product Standards

Bibliography

[1] ISO 9004:—1), Managing for the sustained success of an organization — A quality
management approach
[2] ISO 10001:2007, Quality management — Customer satisfaction — Guidelines for codes of
conduct for organizations

[3] ISO 10002:2004, Quality management — Customer satisfaction — Guidelines for complaints
handling in organizations

[4] ISO 10003:2007, Quality management — Customer satisfaction — Guidelines for dispute
resolution external to organizations

[5] ISO 10005:2005, Quality management systems — Guidelines for quality plans

[6] ISO 10006:2003, Quality management systems — Guidelines for quality management in
projects

[7] ISO 10007:2003, Quality management systems — Guidelines for configuration management

[8] ISO 10012:2003, Measurement management systems — Requirements for measurement


processes and measuring equipment

[9] ISO/TR 10013:2001, Guidelines for quality management system documentation

[10] ISO 10014:2006, Quality management — Guidelines for realizing financial and economic
benefits

[11] ISO 10015:1999, Quality management — Guidelines for training

[12] ISO/TR 10017:2003, Guidance on statistical techniques for ISO 9001:2000

[13] ISO 10019:2005, Guidelines for the selection of quality management system consultants and
use of their services

[14] ISO 14001:2004, Environmental management systems — Requirements with guidance for
use

[15] ISO 19011:2002, Guidelines for quality and/or environmental management systems auditing

[16] IEC 60300-1:2003, Dependability management — Part 1: Dependability management


systems

[17] IEC 61160:2006, Design review

[18] ISO/IEC 90003:2004, Software engineering — Guidelines for the application of ISO
9001:2000 to computer software

[19] Quality management principles 2), ISO, 2001

[20] ISO 9000 — Selection and use 2), ISO, 2008

[21] ISO 9001 for Small Businesses — what to do; Advice from ISO/TC 176 3), ISO, 2002
1) To be published. (Revision of ISO 9004:2000)

2) Available from website: http://www.iso.org.

3) To be updated and aligned with ISO 9001:2008.

[23] Reference web sites:

http://www.iso.org
http://www.tc176.org
http://www.iso.org/tc176/sc2
http://www.iso.org/tc176/ISO9001AuditingPracticesGroup
http://www.scribd.com/doc/19501552/ISO-9000
http://www.iso.org/iso/iso_catalogue/management_standards/iso_9000_iso_14000/iso_9000_ess
entials.htm
http://en.wikipedia.org/wiki/ISO_9000
http://www.scribd.com/doc/2414046/ISO9000
http://instaplast.projects.mags.net.pk

Personal Visit

INSTAPLAST Head Office