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AKP Engg.

& Fabricators QUALITY SYSTEM DOCUMENTS


Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. ; QD / 01 PAGE : 1 OF 2


REV NO : 00 DOCUMENT NUMBERING SYSTEM
DATE OF REV : 01/ 05/ 09

AKPEAF follows the undermentioned ‘Document Numbering System’ for all its
internally generated Quality System Documents ( QDs ) & Forms & Formats ( QFs )
throughout the organization :

 QUALITY SYSTEM DOCUMENTS [ QDs ]


[ as Standard Operating Procedures (S.O.Ps), Work Instructions, Flowcharts, Checklists, Specifications,
Maintainance Schedules, Quality Assurance Plans, Project Schedules, Approved Supplier List etc. ] :

HEADER [ on each page ];

DOC. NO. ; QD / S.N. DOCUMENT TITLE PAGE : OF


REV NO :
DATE OF REV :

FOOTER [ on each page ] :

Prepared by M.R. Approved by M.P. - I

NOTE :

1. Standard Operating Procedures [S.O.Ps] are generally flow charted with


responsibility for the activity given.
2. Work Instructions [ W.I. ] are generally given in the following format :

S.N. ACTIVITY DOCUMENT REF. OF THE


SEQUENCE & DESCRIPTION REF. RECORDING RESPONSIBILITY
[ if any ] FORMAT
/
REGISTER
[ if applicable ]

CONTROLLED COPY OF THIS DOC. HAS BEEN DISTRIBUTED TO :

1.

2..

Prepared by M.R. Approved by M. P. - I


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AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

3.

Prepared by M.R. Approved by M. P. - I


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AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. ; QD / 01 PAGE : 2 OF 2


REV NO : 00 DOCUMENT NUMBERING SYSTEM
DATE OF REV : 01/ 05/ 09

 FORMS & FORMATS [ QFs ]

All QMS FORMS & FORMATS have the following printed / typed / stamped as
appropriate, on the document :

Name Of The Company at top left hand corner

Format No. [ QF / S.N. Rev. No. ] at top right hand corner

Date Of Issue. at top right hand corner


below the format no.

Form / Format Title at top centre

DOCUMENT APPROVALS :

NOTE : All internally generated documents are prepared and approved by the
following functions :

Internally Generated Documents Prepared By Approved By

Quality Manual Sections - M.R. M.P. - I


QMs
Quality System Documents - QDs M.R. M.P. - I
Quality System Forms / Formats - QFs M.R. M.R.

DOC. NO. ; QD / 02 PAGE : 1 OF 2


REV NO : 00 MASTER LIST OF RECORDS & THEIR CONTROL
DATE OF REV : 01/ 05/ 09

Prepared by M.R. Approved by M. P. - I


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AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

S.N. ISO 9001 ALL RECORDS RELATED TO FORMAT NOS. RETENTION TIME RESPONSIBILITY FOR
CLAUSE NO. [ QFs ] UPKEEP & RETRIEVAL

1 4.2.3 DOCUMENTS OF EXTERNAL ORIGIN 01 ONE YEAR FROM DATE M.R


[ EXTINGUISHED PERMITS / LICENCES OF EXPIRY
ETC ]

2 5.6 MANAGEMENT REVIEW MEETINGS 15, 16 TILL NEXT RE – M.R.


CERTIFICATION AUDIT

3 6.2.2 TRAINING 17, 18 TILL EMPLOYEE’S M. P. - I


SERVICE PERIOD

4 7.2.1 / 7.2.2 MARKETING 19,20,21, TWO YEARS M. P. - II

5 7.2.3 CUSTOMER COMPLAINTS 22, 23 TWO YEARS M. P. - II


& FEEDBACKS

6 7.3.2/ 7.3.4/ DESIGN 30, 31, 32, 33,34 THREE YEARS M. P. - I


7.3.5/ 7.3.6/ [ INPUT / REVIEW / VERIFICATION /
7.3.7 VALIDATION/ DESIGN CHANGE ]

7 7.1 PRODUCTION PLANNING 35 TILL COMPLETION OF M. P. - I


THE JOB

8 7.4.1 SUPPLIER CAPABILITY & 25, 26 TWO YEARS M. P. - I


PERFORMANCE EVALUATIONS

9 7.4.2 PURCHASE INDENTS / ORDERS 28,29, TWO YEARS M. P. - II

10 7.4.3 PURCHASE VERIFICATIONS 59 ONE YEAR Q.C. I/C

11 8.2.4 INSPECTION AND TEST REPORTS 37, 38, 39, 40, 41,42, THREE YEARS Q.C.I/C
43,43,
44,45,48,49,50,51,

12 7.5.1 CONTROL OF PRODUCTION 52,54,55,56 TWO YEARS M. P. - I


PROVISION

13 7.5.4 CUSTOMER PROPERTY 58 ONE YEAR STORES I/C

14 7.5.5 PRESERVATION OF MATERIAL STOCK 60, 61,62, ONE YEAR OF STORES I/C
COMPLETION OF WORK

15 7.6 CALIBRATION OF MEASURING 53 TWO YEARS Q.C. I/C


EQUIPMENTS

Prepared by M.R. Approved by M. P. - I


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Rabale [ Draft For Discussion D1 dated 17/08/09 ]

16 8.2.2 INTERNAL AUDITS 07,08, 09,10 & 11 TILL NEXT RE – M.R.


CERTIFICATION AUDIT

17 8.3 N.C. PRODUCT DISPOSITIONS 24, 59, 66 TWO YEARS M. P. - I

18 8.5.2 / 8.5.3 CORRECTIVE ACTIONS / 12, 13, 22 TWO YEARS M.R.


PREVENTIVE ACTIONS

19 5.4.1, 8.5.1, RECORDS RELATED TO 02, 03, 04, 05 & 06 THREE YEARS M.R.
8.4 MEASUREMENT OF Q. OBJECTIVES

DOC. NO. ; QD / 02 PAGE : 2 OF 2


REV NO : 00 MASTER LIST OF RECORDS & THEIR
DATE OF REV : 01/ 05/ 09 CONTROL

NOTE : 1. DISPOSITION INSTRUCTIONS [ as destroy, retain further for knowledge preservation / legal purposes etc ] FOR
EACH RECORD SHALL BE GIVEN BY THE M. P. - I AT THE END OF THE RETENTION PERIODS ON CASE
TO CASE BASIS.

2. * THE RETENTION PERIOD SHALL BE CALCULATED FROM THE END OF THE CALENDER YEAR ON
WHICH THAT PARTICULAR RECORD HAS BEEN GENERATED.

3. RECORDS IN THE COMPUTORS SHALL BE PROTECTED BY A ‘PASSWORD CONTROL SYSTEM’ TO BE


EXERCISED BY THE M.P. - I OR BY PERSON AUTHORISED BY THE M.P. - I

4. ALL RELEVANT DATAS / RECORDS IN THE COMPUTORS SHALL HAVE BACK – UPS RETAINED IN
COMPACT DISCS [ C.Ds ] AND THESE C.Ds SHALL BE KEPT WITH THE M. P. - I. THESE DATA
BACK – UPS SHALL BE DONE AT LEAST ONCE A WEEK.

5. ALL HARD COPIES OF RECORDS SHALL BE APPROPRIATELY FILED AND DULY LABELLED.
THESE FILES SHALL BE KEPT IN CUPBOARDS WITH MOTHBALLS OR SUBJECT TO PERIODIC
TREATMENTS FROM PEST CONTROL AGENCIES.

6. DATAS / RECORDS GENERATED OR KEPT AT THE SHOPFLOOR SHALL BE PUT IN PLASTIC ENVELOPS
TO PROTECT THEM AGAINST LUBRICANTS, DUST, OIL AND OTHER MATERIALS.

FOR ‘PROCEDURE FOR CONTROL OF QUALITY RECORDS’ – VIDE SECTION NO. 18 OF THE QUALITY MANUAL.

Prepared by M.R. Approved by M. P. - I


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Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. ; QD / 03 PAGE : 1 OF 1


REV NO : 00 APPOINTMENT OF MANAGEMENT
DATE OF REV : 01/ 05/ 09 REPRESENTATIVE

I AM PLEASED TO APPOINT MR R. PRAVEEN SUNDER [ Q.C. I/C ] - AS THE


MANAGEMENT REPRESENTATIVE FOR THE PURPOSE OF ISO 9001 : 2008
WITH EFFECT FROM 1ST MAY 2009.

IRRESPECTIVE OF OTHER RESPONSIBILITIES HE SHALL NOW HAVE THE


RESPONSIBILITY AND AUTHORITY THAT INCLUDES :

 ENSURING THAT PROCESSES NEEDED FOR THE Q.M.S. ARE


ESTABLISHED, IMPLEMENTED AND MAINTAINED.

 REPORTING TO THE TOP MANAGEMENT ON THE PERFORMANCE OF


THE Q.M.S. AND ANY NEED FOR IMPROVEMENT, AND

 ENSURING THE PROMOTION OF AWARENESS OF CUSTOMER


REQUIREMENTS THROUGHOUT THE ORGANIZATION THROUGH
PERIODIC TRAINING PROGRAMS

HE WILL LIASON WITH WITH EXTERNAL PARTIES ON MATTERS


RELATING TO THE Q.M.S.

MANAGING PARTNER - II

ACCEPTANCE

I , R. PRAVEEN SUNDER, MOST HUMBLY ACCEPT THE ABOVE ASSIGNMENT.

DATE : 01/ 05/ 09 R. PRAVEEN SUNDER

Prepared by M.R. Approved by M. P. - I


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AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. ; QD / 04 PAGE : 1 OF 1


REV NO : 00 LIST OF HUMAN RESOURCES
DATE OF REV : 01/ 05/ 09

S.N. NAME OF THE DATE OF QUALIFICATION TOTAL QUALIFICATION REMARKS


PERSON AND JOINING / YEARS SKILL / [ if no longer in
DESIGNATION AKPEAF EDUCATION OF EDUCATION service – date of
EXPERI CERTIFICAT leaving ]
ENCE E REF.
PRIOR
TO
JOININ
G
AKPEA
F

10

Prepared by M.R. Approved by M. P. - I


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AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

11

12

DOC. NO. : QD / 05 FLOWCHART FOR TRAINING PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09

IDENTIFY YEARLY TRAINING NEEDS OF EMPLOYEES IN THE RESPECTIVE M.P - I


EMPLOYEE TRAINING CARD AND SEND TO M.R. [ Vide Format No. QF / 18 ]
ACTIVITY RESPONSIBILITY

PREPARE YEARLY TRAINING PLAN [ Vide Format No. QF / 17 ] M.P - I

ARRANGE FOR TRAINING [ intimating date, time, venue, trainees ] – DESIGNATE TRAINER M.R.

CONDUCT TRAINING [ on the job / in house / external ] DESIGNATED


TRAINER

DETERMINE WHETHER TRAINING GIVEN TO THE CONCERNED


EMPLOYEE IS EFFECTIVE [ Vide Format No. QF / 18 ] SECTIONAL I/C

NO
INFORM M.R. & ARRANGE FOR EFFECTI
RE - TRAINING VE

YES

RECORD TRAINING DATE, DURATION AND FACULTY [ Vide Format No. QF / 18 ] M.R.

Prepared by M.R. Approved by M. P. - I


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VERIFY PERFORMANCE ON QUARTERLY BASIS AGAINST THE SET TARGET AND ANALYSE M.R.

PRESENT RESULT OF THE ANALYSIS AT THE SUBSEQUENT MRM M.R.


AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

CONSOLIDATE HOURS OF TRAINING GIVEN [ EMPLOYEEWISE AND MONTHWISE ] CONCERNED


[ Vide Format No. QF / 04 - Quality Objective – Training ] SECTIONAL I/C

DOC. NO. : QD / 06 PAGE : 1 OF 1


REV NO : 00 MINIMUM COMPETENCY MATRIX
DATE OF REV : 01/ 05/ 09

AKPEAF have set the following minimum competence criterias while assigning
functional designations to personnel doing quality related jobs :

S.N. FUNCTIONAL MIN. REQD. MIN. REQD. YEARS OF MIN. SKILL ANY OTHER
DESIGNATION QUALIF. EXPERIENCE REQUIREMENT EXTRAORDINARY
/ EDUCATION IN SIMILAR REQUIREMENTS
POST / JOB REQUIRED
[ if reqd.]
NOT APPLICABLE NOT APPLICABLE MANAGEMENT SKILL / AWARENESS OF THE
1 MANAGING PARTNER - II NEGOTIATION SKILL / COMPANY LAWS
SKILL TO RUN THE
BUSINESS
NOT APPLICABLE NOT APPLICABLE MANAGEMENT SKILL / AWARENESS OF THE
2 MANAGING PARTNER - I NEGOTIATION SKILL STATUTORY &
REGULATORY
REQUIREMENTS
GRADUATE INTERPERSONNEL THOROUGH
3 MANAGEMENT SKILL / UNDERSTANDING OF
REPRESENTATIVE COMMUNICATION REQUIREMENTTS OF
SKILL / THE ISO STANDARDS
TRAINING SKILL
COMMUNICATION
4 Q.C. I/C LEVEL II ONE YEAR SKILL/
MEASUREMENT SKILL

5 PRODUCTION I/C GRADUATE THREE YEARS OF SHOP INTERPERSONNEL


FLOOR EXPERIENCE SKILL /
COMMUNICATION
SKILL

6 PRODUCTION SUPERVISER S.S.C ONE YEAR OF SHOP FLOOR INTERPERSONNEL


EXPERIENCE SKILL /
COMMUNICATION
SKILL

7 STORE KEEPER S.S.C. ONE YEAR

8 WELDER PASSED WELDER ONE YEAR WELDING SKILL

Prepared by M.R. Approved by M. P. - I


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AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

QUALIFICATION
TESTS.

9 FITTER ELEMENTARY ONE YEAR MEASUREMENT SKILL


EDUCATION

10 CRANE OPERATOR CERTIFIED CRANE ONE YEAR OPERATING E.O.T.


OPERATOR CRANES

11 HELPER NONE NONE

NOTE : If any person is appointed without satisfying the above criterias, for any reason,
the management arranges for his / her training and is made to qualify before being
inducted to the job.

DOC. NO. : QD / 07 PAGE : 1 OF 1


REV NO : 00 CUSTOMER DATA BASE
DATE OF REV : 01/ 05/ 09

S.N. NAME OF THE ADDRESS OF THE PHONE FAX EMAIL REMARKS


CUSTOMER CUSTOMER /
MOBILE

* NOTE : THE CUSTOMERS MARKED IN ASTERISK ARE OUR ESTEEMED CUSTOMERS.

Prepared by M.R. Approved by M. P. - I


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AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

Prepared by M.R. Approved by M. P. - I


RPS : PK :
AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. : QD / 08 PROCEDURE FOR ORDER PROCESSING PAGE : 1 OF 2


REV NO : 00
DATE OF REV : 01/ 05/ 09

1. PURP0SE :
To establish a standard procedure for handling all customer enquiries till the

confirmation of the receipt of the orders and ensure adherence to the QMS during

this process.

2. SCOPE :
All activities from enquiry to order from customers.

3. RESPONSIBILITY AND AUTHORITY :


Responsibility to implement this procedure in the organization : M.P. - II
Authority to change / modify this control system if & when required : M.P. - II

4. ABBREVIATIONS :
QMS = Quality Management System.

5. PROCEDURE :

 All customer enquiries received verbally / mail / email / fax or by any other means
are initially recorded in the ‘Enquiry cum Quotation Register’
( Vide Register No. REG / 03 )
 M.P. – II reviews all enquiries and decides whether to submit an offer against the
enquiry.
The M.P. – II prepares and sends offer proposals / regret letters, as applicable, to the
customer against the enquiries.
All offer proposals / quotations are approved by the M.P. - II
prior to submission to the customers.
 All offers / quotations submitted to the customers are uniquely numbered and are
referenced in the ‘Enquiry cum Quotation Register’
 To maintain traceability all quotations / offers refer to the customer enquiries against
which these are sent.
 Follow up of an offer proposal / quotation with the customer is done by the M.P. - II
till the enquiry is ‘alive’.
 On receipt of the customer order, M.P. – II reviews the same and issues an ‘Order
Ackwoledgement’[vide Form No.QF / 20 ] .
 In case of customer supplied design, Job Order [vide Form No.QF / 21 ] is prepared
by the M.P. - II and issued to M.P. - I for design & execution. The customer orders
are referenced in the respective Job Order to maintain traceability.

Prepared by M.R. Approved by M. P. - I


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AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. : QD / 08 PROCEDURE FOR ORDER PROCESSING PAGE : 2 OF 2


REV NO : 00
DATE OF REV : 01/ 05/ 09

 The M.P. - II monitors the ‘Customer Order’at all stages of the project and
communicates with the customer for the job status till the completion of the order
execution.
 The acknowledgement / endorsement of the relevant commissioning report by the
customer against the order on installation constitutes the ‘closure of the order’

6. RECORDS :
 Internal Job Order : Format No. QF / 21
 Order Acceptance : Form No.QF / 20
 Enquiries cum Quotation Register : Register No. REG / 03
7. REFERENCES :

Quality Manual : Section No. 15

Prepared by M.R. Approved by M. P. - I


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DOC. NO. : QD / 09 FLOWCHART FOR HANDLING CUSTOMER PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 COMPLAINTS

ACTIVITIES RESPONSIBILITIES

Customer Complaint [ verbal, written or telephonic ] M.R.


made to any Compay personnel
[ Enter in Complaint Handling Register ( REG 04 )and assign a Complaint No. ]

Reply to the customer why NO


the complaint cannot be Complaint required to M.P. - II
entertained. be addressed

YES

Assign responsibility for redressal & setting target date . M.P. - II


Fill the CAR [ QF/ 12 ] or PAR [ QF/ 13 ] Form as appropriate

Take appropriate Remedial Action to redress the complaint & PERSON


revert to M.P. - II DESIGNATED
BY M.P. - II

Communicate to the Customer after taking the neccessary remedial action TOP MGTM

Close the complaint in the Customer Complaint Handling Register - REG 04 M.P. - II

Analyse the customer complaints over a review period and present the result of M.R.
analysis at the MRM

To minute appropriate Corrective / Preventive Action to be taken TOP MGTM


- assign responsibility and target date

Verify on completion that the Corrective / Preventive Action M.R.


taken is effective

DOC. NO. ; QD / 10 FLOWCHART FOR MONITORING CUSTOMER PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 SATISFACTION
Prepared by M.R. Approved by M. P. - I
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AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

RESPONSIBILITIES

In the month of April of each year to send the Customer Satisfaction Survey Form M.R.
[ Form No. QF / 23 ] by registered post / fax / email. to all the customers who
have placed orders in the previous financial year and keep a record

ACTIVITIES

Follow – up [ if neccessary ] with the customer for the feedback M.R.

On recept of the filled forms from the customers, calculate the Customer Satisfaction M.R.
Index [ C.S.I. ] by the formula given in Doc. No. QD / 11, for each Customer

Make entry in Form No. QF/ 05 – titled Measurable Quality Objective - for the financial year under ref. M.R.

Calculate the average C.S. I . in Form No. QF/ 05 M.R.

Evaluate the significant trend in customer dissatisfaction and present the same M.R.
at the subsequent MRM

NOT O.K.
TOP MGTM
Take corrective /
Review at MRM the
preventive action as
C.S.I. against target
neccessary

TOP MGTM
Revise upwards the Average C.S.I. target
for the next financial year

Prepared by M.R. Approved by M. P. - I


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Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. : QD / 11 PROCEDURE FOR CALCULATING PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 CUSTOMER SATISFACTION INDEX [ C.S.I. ]

FORM S.N. :- DATE : REVIEW PERIOD :-

CUSTOMER :-

CUSTOMER’S RATING DURING THE REVIEW PERIOD :-

i. Customer’s rating under criteria of WORKMANSHIP :-

ii. Customer’s rating under criteria of COMMUNICATION SYSTEM :-

iii. Customer’s rating under criteria of RESPONSE TO INQUIRIES :-

iv. Customer’s rating under criteria of INFRASTRUCTURE :-

v. Customer’s rating under criteria of TECHNICAL EXPERTISE :-

vi. Customer’s rating under criteria of STAFF BEHAVIOUR :-

vii. Customer’s rating under criteria of HANDLING OF COMPLAINTS :-


WEIGHTAGE :

S.N. CRITERIA WEIGHTAGE

i WORKMANSHIP
50 %
ii COMMUNICATION SYSTEM 20 %
iii RESPONSE TO INQUIRIES 10 %
iv INFRASTRUCTURE 5%
v TECHNICAL EXPERTISE 5%
vi STAFF BEHAVIOUR 5%
vii HANDLING OF COMPLAINTS 5%

CUSTOMER SATISFACTION INDEX :-

[i x 50] + [ ii x 20 ] + [ iii x 10 ] +[ iv x 5 ] + [ v x 5] +[ vi x 5 ] + [ vii x 5]


100

NOTE : REFER FORM FOR ‘CUSTOMER SATISFACTION SURVEY [ Format No. QF / 23 ]

Prepared by M.R. Approved by M. P. - I


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DOC. NO. : QD / 12 FLOWCHART FOR THE PURCHASING PAGE : 1 OF 2


REV NO : 00
DATE OF REV : 01/ 05/ 09 PROCESS

Any other Production


Function Function

RESPONSIBILITIES

Identify Need & prepare TDS / Specification [ QF / 27 ] Concerned Sectional I/C

Prepare Indent[ QF / 28 ] Concerned Sectional I/C

Send Indent to Purchase Section Concerned Sectional I/C

Check stock levels, determine purchase quantity & intimate M.PBUY


-I PURCHASE ASST.

In - House
Fabricate in – house M.P. - I
To the assigned section or Buy Decision
/ person

Buy
1. Send Inquiries to suppliers from the ASL[ QD / 13 ] for the existing product PURCHASE ASST.

2. Send Inquiries to new / existing suppliers for new product

Float
Headfresh
[ Admn.]
inquiries to M.P. - II
Assess quotations for technicality
other & commrrcial terms & select
suppliers supplier
from ASL

NOTE : ASL = Approved Suppler List Prepare P.O. [ QF / 29 ] PURCHASE ASST.


P.O. = Purchase Order

Check P.O. for its completeness & ‘sign off ’ M.P. - II

Supplier
Send P.O. to the supplier PURCHASE ASST.
[ cont. in
page 2 ]

Prepared by M.R. Approved by M. P. - I


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DOC. NO. : QD / 12 FLOWCHART FOR THE PURCHASING PAGE : 2 OF 2


REV NO : 00
DATE OF REV : 01/ 05/ 09 PROCESS

Supplier

Expediting, surveillance

Receive Goods & Enter in G.R.N [ QF / 59 ]


OK

Retain status
Verify Annually
of ASL
conformance $ Evaluate
[ QD / 13 ]
Supplier
Compliment
Performance
Supplier *
[ QF /
26 ]@
Vide NonConformance Control Accep NOT OK
Procedure [ QM 18 ] NO t
Delete from Approved
Supplier List [ QD / 13 ]
Warn Supplier*

YES

Process Invoice Stores Inventory


[ REG /
05 ]

NOTE :

1. * RESPONSIBILITY TO AMMEND ASL = M.P. - I


2. @ RESPONSIBILITY TO EVALUATE SUPPLIER PERFORMANCE = M.P. - I
3. $ RESPONSIBILITY TO VERIFY CONFORMANCE = Q.C. I/C

DOC. NO. : QD / 13 PAGE : 1 OF 2


Prepared by M.R. Approved by M. P. - I
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REV NO : 00 LIST OF APPROVED SUPPLIERS AND


DATE OF REV : 01/ 05/ 09
SERVICE PROVIDERS

1. SUPPLIERS OF MATERIALS

S.N. ITEMS APPROVED ADDRESS *CLASS OF REMARKS


SUPPLIERS OF THE
SUPPLIERS SUPPLIERS

A. S.S. PLATES / PIPES / TUBES/ RODS


1. 1. 1.

2. 2. 2.

B. C.S. PLATES / PIPES / TUBES/ RODS


1. 1. 1.

2. 2. 2.

C. FASTNERS
1. 1. 1.

2. 2. 2.

D. GASKETS
1. 1. 1.

2. 2. 2.

E. FLANGES
1. 1. 1.

2. 2. 2.

F. WELDING RODS
1. 1. 1.

2. 2. 2.

G. FORGINGS
1. 1. 1.

2. 2. 2.

H. CASTINGS
1. 1. 1.

2. 2. 2.

DOC. NO. : QD / 13 LIST OF APPROVED SUPPLIERS AND PAGE : 2 OF 2

Prepared by M.R. Approved by M. P. - I


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AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

REV NO : 00 SERVICE PROVIDERS [ CONT. ]


DATE OF REV : 01/ 05/ 09

2. SERVICE PROVIDERS

S.N. SERVICE APPROVED ADDRESS CONTACT *CLASS OF REMARKS


SUPPLIERS OF NUMBERS THE
SUPPLIERS ( Ph / Fax / SUPPLIERS
Email )

A CALIBRATING MEASURING EQUIPMENTS


1.
2.
3.

B SAND BLASTING
1.
2.
3.

C HEAT TREATMENT
1.
2.
3.

D COLD FORMING
1.
2.
3.

E MACHINING / DRILLING
1.
2.
3.

F PAINTING
1.
2.
3.

F STATUTORY CALIBRATION OF COMPRESSORS / LIFTING TACKLES / CRANES / SLINGS ETC


1.
2.
3.

*NOTE :
CLASS A : ISO 9000 CERTIFIED & DEMONSTRATED CAPABILITY.
[ The Organisation has done business with the Supplier before for a long time ]
CLASS B : DEMONSTRATED CAPABILITY.
[ The Organisation has done business with the Supplier for a long time though the Supplier is not ISO 9001 certified ]
CLASS C : CAPABLE WITH ADDITIONAL ASSURANCE.
[ First time Supplier – need to impose certain requirements for confidence ]
CLASS D : UNACCEPTABLE PERFORMANCE , BUT CAN’T BE AVOIDED. NEEDS CONSTANT MONITORING.
[ Sole Supplier of the product / service ]

Prepared by M.R. Approved by M. P. - I


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DOC. NO. ; QD / 14 DESIGN & DEVELOPMENT PROCESS PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09

S.N. STAGES OF THE DESIGN AND DEVELOPMENT TIME PERIOD RESPONSIBLE REMARKS
PROCESS FUNCTION

1 REVIEWING THE CUSTOMER REQUIREMENTS ON WITHIN 3 DAYS OF M.P. - I


RECEIPT OF TECHNICALLY CLEAR CUSTOMER RECEIVING THE CLEAR
ORDER. CUSTOMER ORDER.

2 REVIEWING THE STATUTORY, REGULATORY AND M.P. - I


ANY OTHER REQUIREMENTS RELATED TO THE
PRODUCT.

3 SENDING THE COMPLETE DESIGN INPUTS WITHIN 2 DAYS AFTER THE M.P. - I
TO THE DESIGNER [ OUTSOURCING ] FOR THE ABOVE REVIEW
DESIGN & SUBMISSION OF THE DRAWINGS.

4 REVIEWING THE DRAWINGS AND CALCULATIONS WITHIN 2 DAYS OF RECEIPT Q.C. I/C &
RECEIVED FROM THE DESIGNER. FROM THE DESIGNER M.P. - I

5 SENDING THE DRAWINGS AND CALCULATIONS TO WITHIN 2 DAYS AFTER THE M.P. - I
THE CUSTOMER / THIRD PARTY FOR APPROVAL. ABOVE REVIEW

6 REVIEWING THE CHANGES ( if any ) IN THE WITHIN 2 DAYS AFTER THE M.P. - I
DRAWINGS / CALCULATIONS MADE BY THE RECEIPT OF THE DRAWINGS
CUSTOMER / THIRD PARTY AND SENDING THE SAME FROM THE
TO THE DESIGNER FOR AMMENDMENT. CUSTOMER / THIRD PARTY

7 APPROVING THE AMMENDED DRAWINGS IN WITHIN 2 DAYS OF RECEIPT M.P. - I


CONSULTATION WITH THE CUSTOMER / THIRD FROM THE DESIGNER
PARTY AND RELEASING FOR FABRICATION.

8 OFFERING FOR STAGEWISE CUSTOMER / THIRD WITHIN 3 DAYS OF M.P. - I


PARTY INSPECTIONS. SATISFACTORY INTERNAL
INSPECTION OF EACH STAGE

9 OFFERING FOR FINAL PERFORMANCE TRIALS WITHIN 3 DAYS OF THE M.P. - I


[ HYDRAULIC / PNEUMATIC TESTS ETC ] WITH COMPLETE ASSEMBLY
WATER.

Prepared by M.R. Approved by M. P. - I


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10 GETTING THE VALIDATION RECORD FROM THE WITHIN 3 MONTHS OF M.P. - I


CUSTOMER AFTER COMMISSIONING AT SITE. DESPATCH

11 MAINTAINING THE DESIGN CALCULATIONS, ON GOING Q.C I/C


DRAWING / DESIGN CHANGE RECORDS AND THE
FINAL ‘AS BUILT’ DRAWINGS IN THE COMPANY.

Prepared by M.R. Approved by M. P. - I


RPS : PK :
AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. ; QD / 15 FLOWCHART FOR THE PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 MANUFACTURING PROCESS

RECEIPT INSPECTION [ INTERNAL ] and / or THIRD PARTY INSPECTION

MATERIAL UNLOADING
FOLLOW
NONCONFORMING MATERIAL APPROVED
PROCEDURE
TAKE IN STORE STOCK

ISSUE FOR PRODUCTION

SIZING, CUTTING , BENDING, and / or ANY OTHER MACHINING OPERATIONS [ AS APPLICABLE ] /


OUTSOURCE [ AS APPLICABLE ]

STAGEWISE INSPECTION [ INTERNAL and / or THIRD PARTY INSPECTION ]

FOLLOW
NONCONFORMING STAGE APPROVED
PROCEDURE
WELDING and OTHER APPLICABLE OPERATIONS

INTERNAL INSPECTION and / or THIRD PARTY INSPECTION

FOLLOW
NONCONFORMING APPROVED
PROCEDURE

COMPLETE FABRICATION

FINAL INSPECTION, PRESSURE TEST, RUNNING TRIAL [ as applicable ] BY CUSTOMER or THIRD PARTY

RECTIFY AND
RETEST TO
ORIGINAL FINAL APPROVAL
SPECIFICATION

BLANKING, PACKING [ AS APPLICABLE ] AND DESPATCH

Prepared by M.R. Approved by M. P. - I


RPS : PK :
AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. ; QD / 16 QUALITY ASSURANCE PLAN PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09

S.N. PRODUCT CHARACTERISTICS TYPE OF CHECK SAMPLING REF. RESPONS


DESCRIPTION [ AS APPLICABLE ] [ AS APPLICABLE ] PLAN DOC. TOLERA IBILITY
[ typical ] /
STD
NCES

A INCOMING 100% INSP. AS PER AS PER


MATERIALS PURCHASE RELEVANT
1. Surface 1. Surface Finish SPEC. I.S. STD STORES I/C
Defects 2. Burrs,
3. Tearing of
threads,
4. Buffing
(marks &
scratches),
5. Clear
impression for
stampimg.
6. Blowholes
7. Laminations

2. Dimensions Dimensional Q.C. I/C

3. Identificatio Visual STORES I/C


n [ Lot No. ]

4. Quantity Count / Weight / Vol. STORES I/C

5. Test 1 Chemical analysis, 2. Q.C. I/C


Certificates Physical properties,
3. Identification,
4. Signature / date
5.Heat Treatment Temp.
& Control
6.Accredited lab.

B IN PROCESS 1. Dimensions 100 % AS PER AS PER PRODN. I/C


2. Intermediate INSP. W.I. APPROVED
Testing / DRAWING
Inspections

FINAL 1. Marking N.A. AS PER N.A. Q.C. I/C


C INSPECTION 2. Blanking CUSTOMER
3. Test / ORDER
inspection
Certificates
4. Loading

NOTE : QUALITY ASSURANCE PLAN SPECIFIC TO THE INDIVIDUAL JOB, IF REQUIRED , IS ALSO PREPARED AND
FOLLOWED IN CONSULTATION WITH THE INDIVIDUAL CUSTOMER .

Prepared by M.R. Approved by M. P. - I


RPS : PK :
AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

Prepared by M.R. Approved by M. P. - I


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Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. ; QD / 17 LIST OF PRODUCTION EQUIPMENTS PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 AND MACHINERIES

AKPEAF have the following equipments on which its process capabilities depend
and makes all arrangements for upkeepment of these equipments :

S.N. EQUIPMENT EQUIPMENT MODEL *MANUFACTURER *LOCATION OF ESSENTIAL


DESCRIPTION IDENTIFICATION / [ if available ] OPERATIONAL SPARES
NUMBER CAPACITY MANUAL
[ to be given /
M/S AKPEAF ] MAINTENANCE
MANUAL
[ if available ]

Prepared by M.R. Approved by M. P. - I


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*NOTE : WRITE N.A. WHEREVER NOT AVAILABLE

Prepared by M.R. Approved by M. P. - I


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Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. ; QD / 18 WORK INSTRUCTION FOR PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 HYDRAULIC TESTING

S.N. ACTIVITY DOCUMENT REF. OF THE


SEQUENCE & DESCRIPTION REF. RECORDING RESPONSIBILITY
[ if any ] FORMAT
/
REGISTER
[ if applicable ]

CONTROLLED COPY OF THIS DOC. HAS BEEN DISTRIBUTED TO :

1.

2..

3.

Prepared by M.R. Approved by M. P. - I


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AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. ; QD / 19 WORK INSTRUCTION FOR PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 PNEUMATIC TESTING

S.N. ACTIVITY DOCUMENT REF. OF THE


SEQUENCE & DESCRIPTION REF. RECORDING RESPONSIBILITY
[ if any ] FORMAT
/
REGISTER
[ if applicable ]

CONTROLLED COPY OF THIS DOC. HAS BEEN DISTRIBUTED TO :

1.

2..

3.

Prepared by M.R. Approved by M. P. - I


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AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. ; QD / 20 WORK INSTRUCTION FOR PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 SAND BLASTING

S.N. ACTIVITY DOCUMENT REF. OF THE


SEQUENCE & DESCRIPTION REF. RECORDING RESPONSIBILITY
[ if any ] FORMAT
/
REGISTER
[ if applicable ]

CONTROLLED COPY OF THIS DOC. HAS BEEN DISTRIBUTED TO :

1.

2..

3.

Prepared by M.R. Approved by M. P. - I


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Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. ; QD / 21 WORK INSTRUCTION FOR RADIOGRAPHY PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09

S.N. ACTIVITY DOCUMENT REF. OF THE


SEQUENCE & DESCRIPTION REF. RECORDING RESPONSIBILITY
[ if any ] FORMAT
/
REGISTER
[ if applicable ]

CONTROLLED COPY OF THIS DOC. HAS BEEN DISTRIBUTED TO :

1.

2..

3.

Prepared by M.R. Approved by M. P. - I


RPS : PK :
AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. ; QD / 22 WORK INSTRUCTION FOR COLD FORMING PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09

S.N. ACTIVITY DOCUMENT REF. OF THE


SEQUENCE & DESCRIPTION REF. RECORDING RESPONSIBILITY
[ if any ] FORMAT
/
REGISTER
[ if applicable ]

CONTROLLED COPY OF THIS DOC. HAS BEEN DISTRIBUTED TO :

1.

2..

3.

Prepared by M.R. Approved by M. P. - I


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AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. ; QD / 23 WORK INSTRUCTION FOR LIQUID PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 PENETRATING TESTING

S.N. ACTIVITY DOCUMENT REF. OF THE


SEQUENCE & DESCRIPTION REF. RECORDING RESPONSIBILITY
[ if any ] FORMAT
/
REGISTER
[ if applicable ]

CONTROLLED COPY OF THIS DOC. HAS BEEN DISTRIBUTED TO :

1.

2..

3.

Prepared by M.R. Approved by M. P. - I


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AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. ; QD / 24 WORK INSTRUCTION FOR PAINTING PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09

S.N. ACTIVITY DOCUMENT REF. OF THE


SEQUENCE & DESCRIPTION REF. RECORDING RESPONSIBILITY
[ if any ] FORMAT
/
REGISTER
[ if applicable ]

CONTROLLED COPY OF THIS DOC. HAS BEEN DISTRIBUTED TO :

1.

2..

3.

DOC. NO. : QD / 25 CONSOLIDATED LIST OF MONITORING AND PAGE : 1 OF 1


REV NO : 00

Prepared by M.R. Approved by M. P. - I


RPS : PK :
AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DATE OF REV : 01/ 05/ 09 MEASURING EQUIPMENTS

Prepared by M.R. Approved by M. P. - I


RPS : PK :
AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

S.N. UNIQUE UNIQUE EQUIPMENT MODEL FREQUENCY # CALIBRATION *JUSTIFICATION


EQUIPMENT EQUIPMENT TYPE / OF CARD NO. FOR NOT
IDENT. NO. IDENT. NO. RANGE CALIBRATION [ say C.C. / S.N. ] REQUIRING
GIVEN BY OF THE CALIBRATION
AKPEAF MANUFACTURER [ if any ]
[ if any ]

10

11

12

NOTE :

1. THE Q.C. I/C GETS THE MEASURING EQUIPMENTS CALIBRATED ON SCHEDULE AND MAINTAINS THE
CALIBRATION CERTIFICATES.
2. * MEASURING EQUIPMENTS WHICH ARE NOT RELATED TO PRODUCT / PROCESS MEASUREMENTS &
SAFETY ARE NOT REQUIRED TO BE CALIBRATED.
3. # VIDE FORM NO. QF/ 53 – CALIBRATION CARD OF MEASURING EQUIPMENTS.

Prepared by M.R. Approved by M. P. - I


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Rabale [ Draft For Discussion D1 dated 17/08/09 ]

S.N. TYPE OF UNIQUE MODEL CAPACITY COMPETENT CERTIFICATE NEXT


EQUIPMENT EQUIPMENT AUTHORITY NO. CALIBRATION
NO. [ with [ IN FORM DUE ON
Registration NO 12/13
No. ] UNDER RULE 64
OF MFR ]

1 HOISTS 1. 1. 1. 1. 1.

2. 2. 2. 2. 2.

3 3 3 3 3

3 AIR RECEIVERS 1. 1. 1. 1. 1.
FOR
COMPRESSORS 2. 2. 2. 2. 2.

3 3 3 3 3

4 CHAIN PULLEY 1. 1. 1. 1. 1.
BLOCKS
2. 2. 2. 2. 2.

3 3 3 3 3

5 SLINGS 1. 1. 1. 1. 1.

2. 2. 2. 2. 2.

3 3 3 3 3

DOC. NO. : QD / 26 LIST OF ITEMS REQUIRING CALIBRATION PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 UNDER REGULATORY STATUTES

NOTE : THE M.P. - I ARRANGES FOR THE CALIBRATION OF THE ABOVE EQUIPMENTS FROM THE COMPETENT
AUTHORITIES.

Prepared by M.R. Approved by M. P. - I


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DOC. NO. : QD / 27 LIST OF FIRE EXTINGUISHERS AND THEIR PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 CONTROL

S.N. NAME OF THE WHERE UNIQUE CAPACITY FREQUENCY TESTCERT. NO.


FIRE FIGHTING LOCATED IDENTIFICATION OF & DATE
EQUIPMENT NO. TESTING

1 SAND BUCKETS 1. 1. 1. EVERY 1.


MONTH FOR
2. 2. 2. CLEAN AND 2.
DRYNESS OF
3. 3. 3. THE SAND 3.
.

2 FIRE 1. 1. 1. EVERY SIX 1.


EXTINGUISHER MONTHS
[ CARBON – 2. 2. 2. 2.
DI - OXIDE ]
3. 3. 3. 3.
.

3 FIRE 1. 1. 1. EVERY SIX 1.


EXTINGUISHER MONTHS
[ DCP ] 2. 2. 2. 2.

3. 3. 3. 3.
.

NOTE : M.P – I ARRANGES FOR THE CALIBRATION FROM THE APPROVED SERVICE PROVIDERS.

Prepared by M.R. Approved by M. P. - I


RPS : PK :
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Rabale [ Draft For Discussion D1 dated 17/08/09 ]

Prepared by M.R. Approved by M. P. - I


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Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. : QD / 28 LIST OF CRITICAL MATERIALS & PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 ENGINEERING ITEMS AND THEIR MINIMUM
STOCK LEVELS

S.N. ITEMS SPECIFICATION MINIMUM RE – ORDERING


STOCK LEVEL QTY

1 ELECTRODES

2 GRINDING WHEELS

3 FASTNERS

Prepared by M.R. Approved by M. P. - I


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Rabale [ Draft For Discussion D1 dated 17/08/09 ]

Prepared by M.R. Approved by M. P. - I


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DOC. NO. : QD / 29 LIST OF ITEMS WITH SHELF LIVES PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09

S.N. ITEMS HAVING SHELF LIVES REMARKS PERSON RESPONSIBLE FOR


LIMITED SHELF [ months from the date [ if any ] RE – VALIDATING THE ITEMS
LIVES of manufacture ] AFTER EXPIRY OF THEIR SHELF
LIVES

VEE BELTS

ELECTRODES

PAINTS

CHEMICALS FOR
LIQUID PENETRANT
TES

CHEMICALS FOR
LIQUID PENETRANT
TESTS

NOTE : 1. THE EXPIRY DATES ARE PUT ON THE LABELS OF ALL ITEMS HAVING LIMITED SHELF LIVES.

2. REVALIDATING THE SHELF LIVES AFTER THE EXPIRY DATE IS DONE BY A COMPETENT PERSON.

Prepared by M.R. Approved by M. P. - I


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Rabale [ Draft For Discussion D1 dated 17/08/09 ]

DOC. NO. : QD / 30 FLOWCHART FOR MONITORING PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 BUSINESS TURNOVER

ACTIVITY

PREPARE BUSINESS PLAN & SET BUSINESS TURNOVER TARGET FOR THE SUBSEQUENT M.P. - II
FINANCIAL YEAR IN THE MONTH OF MARCH EACH YEAR [ Vide Format No. QF / 03 ]

INTIMATE TURNOVER TARGET TO THE CONCERNED FUNCTIONS / FIELD STAFF M.P. - II

FORMULATE YEARLY ACTION PLAN TO ACHIEVE TARGET FOR THE M.P. - II


REFERRED FINANCIAL YEAR

FORMULATE MONTHWISE ACTION PLAN TO ACHIEVE TARGET FOR M.P. - I


THE REFERRED FINANCIAL YEAR AND IMPLEMENT

ENTER VALUES OF THE MONTHWISE BUSINESS EXECUTED FOR THE REFERRED ACCOUNTANT
FINANCIAL YEAR IN DESIGNATED FORMAT [ Vide Format No. QF / 03 ]

M.P. - II
QUARTERLY REVIEW OF THE BUSINESS PERFORMANCE

NOT O.K.

TAKE REMEDIAL ACTION


/
REVISE BUSINESS PLAN
O.K.

PREPARE YEARLY BALANCE SHEET / PROFIT – LOSS ACCOUNT ACCOUNTANT

REVIEW YEARLY PERFORMANCE AGAINST THE SET TARGET AND ANALYSE M.P. - I
Prepared by M.R. Approved by M. P. - I
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PRESENT RESULT OF THE ANALYSIS AT THE SUBSEQUENT MRM M.P. - I

DOC. NO. : QD / 31 LIST OF OUTSOURCING ACTIVITIES AND PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 THEIR CONTROL

THE M.P. - I IS RESPONSIBLE FOR ALL OUTSOURCING ACTIVITIES. HE REVIEWS ALL OUTSOURCING CONTRACTS
PRIOR TO THEIR RELEASE.

S.N. OUTSOURCED TYPE OF CONTROL EXERCISED CURRENT REMARKS


ACTIVITIES SERVICE
PROVIDERS

1. EQUIPMENT  DESIGNING IS CONTRACTED TO AN ESTABLISHED QUALIFIED


DESIGNING DESIGNER OF CHEMICAL PROCESS EQUIPMENTS.
 COMPLETE CUSTOMER REQUIREMENTS ARE COMMUNICATED TO
THE DESIGNER
 DESIGN CALCULATIONS AND THE FABRICATION DRAWINGS ARE
VERIFIED AND APPROVED BY THE CUSTOMERS PRIOR TO THE
MANUFACTURE.

2. INTERNAL INTERNAL AUDITING IS CONTRACTED TO A COMPETENT QMS


AUDITING AUDITOR EXTERNAL TO THE ORGANIZATION.
INTERNAL AUDIT REPORT IS REVIEWED BY THE M.P. - I PRIOR TO
APPROVAL

3. HEAT  HEAT TREATMENT IS CONTRACTED TO BONAFIDE HEAT


TREATMENT TREATERS WHO HAVE A MARKET REPUTATION.
 CAPABILITY OF THE HEAT TREATERS ARE ASSESSED
 AKPEAF APPROVES THE HEAT TREATMENT PROCESS PRIOR TO
ITS EXECUTION.
 THERMO GRAPHS OF THE PROCESSING IS VERIFIED BY
AKPEAF.
 SURFACE HARDNESS OF THE EQUIPMENT AFTER THE
TREATMENT IS CHECKED BY AKPEAF ON RECEIPT.

4. COLD FORMING  COLD FORMING IS CONTRACTED TO BONAFIDE COLD FORMERS


[ DISHEND FABRICATORS ]
 CAPABILITY OF THE COLD FORMERS ARE ASSESSED PRIOR TO
PLACING THE ORDER.
 DISH ENDS ARE DIMENSIONALLY CHECKED BY AKPEAF AS PER THE
APPROVED DRAWINGS WITHIN THE LIMITS OF TOLERANCES
MENTIONED THERIN.

5. SAND BLASTING  SAND BLASTING IS CONTRACTED TO BONAFIDE SAND BLASTING


AGENCIES GIVING THE FULL TECHNICAL REQUIREMENTS
 AKPEAF APPROVES THE SAND BLASTING PROCESS PRIOR TO ITS
EXECUTION
 INSPECTION IS CARRIED OUT BY AKPEAF AT THE SAND BLASTER’S
SITE ON A CASE TO CASE BASIS.

6. PAINTING OF  PAINTING IS CONTRACTED TO EXPERIENCED PAINTING


EQUIPMENTS CONTRACTORS WITH SKILLED WORK FORCE.

Prepared by M.R. Approved by M. P. - I


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 THE CONTRACTOR CARRIES OUT THE PAINTING AS PER THE WORK


INSTRUCTIONS GIVEN BY AKPEAF.
 STAGEWISE INSPECTION IS CARRIED OUT BY AKPEAF.

7. MACHINING  OCCASSIONALY MACHINING IS OUTSOURCED TO MACHINING


AGENCIES HAVING APPROPRIATE MACHINING FACILITIES.
 MACHINING DIMENSIONS ALONGWITH THE LIMITS OF TOLERANCES
ARE COMMUNICATED THRU APPROVED DRAWINGS.
 THE ITEMS ARE CHECKED FOR DIMENSIONS BU AKPEAF PRIOR TO
APPROVAL

DOC. NO. : QD / 32 ACTION PLAN TO MEET QUALITY PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 OBJECTIVE ON ‘ON TIME DELIVERY’

A. QUALITY OBJECTIVE : TO ACHIEVE ATLEAST 90% FOR ‘SUCCESS RATE’ FOR ‘ON TIME DELIVERY’ OF THE
CONTRACTED GOODS TO OUR CUSTOMERS FOR THIS FINANCIAL YEAR.

B. DESCRIPTION OF THE ACTION PLAN :

S. N. SEQUENTIAL ACTIVITIES TO ACHIEVE THE OBJECTIVE PERSON


RESPONSIBLE

1 ESTABLISH BASE LEVEL OF THE DELIVERY ‘SUCCESS RATE’ ACHIEVED IN LAST M.R
FINANCIAL YEAR
2 ESTABLISH THE MAIN REASONS FOR DELAYS IN DELIVERY IN THE LAST FINANCIAL M.R
YEAR
3 CONDUCT MEETINGS WITH THE CONCERNED SECTIONAL I/Cs – M.R, PRODUCTION I/C , M.P. - I
Q.C. I/C TO DISCUSS THE DELAYS AND ESTABLISH A CORRECTIVE / PREVENTIVE PLAN
4 MINUTE THE MEETINGS AND SEND TO THE CONCERNED INCHARGES M.R
5 TAKE THE NECESSARY ACTIONS CONCERNED I/C
6 RECORD THE DELIVERIES IN FORM NO. QF / 02 DESPATCH I/C
7 CONDUCT MEETINGS WITH THE CONCERNED SECTIONAL I/Cs EVERY QUARTER M.R, M.P. - I
PRODUCTION I/C , Q.C. I/C TO ANALYSE AND MAKE MID – COURSE CORRECTIONS
[ IF REQD ]
8 MINUTE THE MEETINGS AND SEND TO THE CONCERNED INCHARGES M.R.
9 TAKE THE NECESSARY ACTIONS CONCERNED I/C
10 EVALUATE ON A QUARTERLY BASIS WHETHER THE TARGET FOR THE OBJECTIVE HAS M.R.
BEEN MET
11 PRESENT AT THE SUSEQUENT MRM M.R.
12 REVIEW TARGET FOR THE OBJECTIVE M.P. - I

C. EVALUATION PROCEDURE : AS ABOVE

D. TRAINING REQUIREMENTS : NONE

E. ACTION PLAN START DATE : 01/ 05/ 09 ACTION PLAN DEADLINE : 31/ 03/ 10

M.R. M.P. - I

COMMENTS OF THE M.P. - I [ on closure ] :

DATE : M.P. - I :

Prepared by M.R. Approved by M. P. - I


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DOC. NO. : QD / 33 ACTION PLAN TO MEET QUALITY OBJECTIVE PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 ON ‘INCREASING BUSINESS TURNOVER’

A. RESOURCE ALLOCATION :

ALLOCATED BUDGET : TEAM MEMBERS : TEAM LEADER : M.P. - II

B. PROCESS OBJECTIVE : TO INCREASE BUSINESS TURNOVER BY ATLEAST 10% EACH YEAR OVER THE
PREVIOUS FINANCIAL YEAR.

C. DESCRIPTION OF THE ACTION PLAN :

S. N. SEQUENTIAL ACTIVITIES TO ACHIEVE THE OBJECTIVE PERSON ACTUAL


RESPONSIBLE COMPLETION
DATE
[ TO BE FILLED
BY M.R. ]
1 ESTABLISH THE BUSINESS TURNOVER FOR THE LAST M.P. - II
FINANCIAL YEAR [ VIDE FORM QF / 03 ]
2 ASSESS THE MARKETING INPUTS & DEVELOP A MARKETING M.P. - II
STRATEGY TO INCREASE BUSINESS
3 EVALUATE CURRENT RESOURCES IN TERMS OF M.P. - II
INFRASTRUCTURE / PERSONNEL / PLANT & MACHINERIES AND
TAKE SUITABLE ACTION
4 REVIEW THE STRENGTHS / ADEQUACY OF MARKETING M.P. - II
PERSONNEL AND TAKE SUITABLE ACTION
5 SET APPROPRIATE BUSINESS ACHIEVEMENT TARGETS M.P. - II
6 EXPAND THE MARKETING NETWORK, IF NECCESSARY M.P. - II
7 MONITOR TURNOVER ON QUARTERLY BASIS IN M.P. - II
FORM NO. QF/ 03
8 TAKE MID – TERM CORRECTIVE ACTIONS , IF REQUIRED M.P. - II

D. EVALUATION PROCEDURE :

THE M.P. - II WILL EVALUATE THE TARGET DEADLINES ON A QUARTERLY BASIS. APPROPRIATE CORRECTIVE /
PREVENTIVE ACTION WILL BE TAKEN AFTER ANALYSING THE ROOT CAUSE.

E. TRAINING REQUIREMENTS :

F. ACTION PLAN START DATE : 01/ 05/ 09 ACTION PLAN DEADLINE : 31/ 03/ 10

M.R. M.P. - II

Prepared by M.R. Approved by M. P. - I


RPS : PK :
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Rabale [ Draft For Discussion D1 dated 17/08/09 ]

COMMENTS OF THE EVALUATOR [ on closure ] :

DATE : EVALUATOR :

DOC. NO. : QD / 34 ACTION PLAN TO MEET QUALITY OBJECTIVE PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 ON ‘ENHANCING AVERAGE C.S.I.’

A. RESOURCE ALLOCATION :

ALLOCATED BUDGET : NIL TEAM MEMBERS : TEAM LEADER : M.R.

B. PROCESS OBJECTIVE : TO ENHANCE THE SATISFACTION LEVEL OF OUR CUSTOMERS BY INCREASING THE
CUSTOMER SATISFACTION INDEX [ C.S.I. ] BY ATLEAST 1. 0 % OVER THE BASE LEVEL
ESTABLISHED FOR THE PREVIOUS YEAR.

C. DESCRIPTION OF THE ACTION PLAN :

S. N. SEQUENTIAL ACTIVITIES TO ACHIEVE THE OBJECTIVE PERSON ACTUAL


RESPONSIBLE COMPLETION
DATE
[ TO BE FILLED
BY M.R. ]
1 ESTABLISH BASE LEVEL OF THE C.S.I. FOR THE PREVIOUS M.R.
FINANCIAL YEAR
2 REVIEW THE ADVERSE FEEDBACKS RECEIVED FROM THE M.R.
CUSTOMERS FOR THE PREVIOUS FINANCIAL YEAR
3 PRIORTISE THESE FEEDBACKS M.R.
4 CARRY OUT THE ROOT CAUSE ANALYSIS M.R.
5 TAKE THE APPROPRIATE CORRECTIVE ACTIONS / PREVENTIVE M.P. - I
ACTIONS
6 REVERT TO THE CUSTOMERS ON THE CORRECTIVE ACTIONS / M.P. - I
PREVENTIVE ACTIONS TAKEN
7 SEND THE CUSTOMER SATISFACTION SURVEY FORM M.R.
[ VIDE QF / 23 ] TO THE CONCERNED CUSTOMERS IN THE MONTH OF
APRIL EACH YEAR
8 CALCULATE THE C.S.I. OF EACH CUSTOMER AS PER THE M.R.
PROCEDURE QD / 11 AND FIND OUT THE AVERAGE C.S.I.
9 ENTER DATA IN FORM NO. QF/ 05 AND ANALYSE M.R.
10 PRESENT THE RESULT OF THE ANALYSIS AT THE MRM. M.R.

D. EVALUATION PROCEDURE :

THE M.R WILL REGULARLY EVALUATE ALL TARGETS ON A MONTHLY BASIS. NONCONFORMANCE WITH RESPECT
TO THE ACTION PLAN WILL BE REPORTED TO THE M.P. - I WHO WILL TAKE THE APPROPRIATE CORRECTIVE /
PREVENTIVE ACTION.

E. TRAINING REQUIREMENTS : TO TRAIN THE MARKETING / FIELD STAFF TO APPROPRIATELY CAPTURE THE
CUSTOMER REQUIREMENTS.

F. ACTION PLAN START DATE : 01/ 05/ 09 ACTION PLAN DEADLINE : 31/ 03/ 10

M.R. M.P. - I
Prepared by M.R. Approved by M. P. - I
RPS : PK :
AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

COMMENTS OF THE EVALUATOR [ on closure ] :

DATE : EVALUATOR :

DOC. NO. : QD / 35 ACTION PLAN TO MEET QUALITY OBJECTIVE PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 ON ‘TRAINING’

A. RESOURCE ALLOCATION :

ALLOCATED BUDGET : TEAM MEMBERS : TEAM LEADER : M.R.

B. PROCESS OBJECTIVE : TO IMPART ATLEAST 12 HOURS OF TRAINING PER YEAR TO EACH PERMANENT
EMPLOYEE DOING QUALITY RELATED WORK, TO RETAIN / ENHANCE THE EMPLOYEE’S
COMPETENCY LEVEL ON THE JOB.

C. DESCRIPTION OF THE ACTION PLAN :

S. N. SEQUENTIAL ACTIVITIES TO ACHIEVE THE OBJECTIVE PERSON ACTUAL


RESPONSIBLE COMPLETION
DATE
[ TO BE FILLED
BY M.R. ]
1 IDENTIFY THE TRAINING NEEDS OF EACH PERMANENT EMPLOYEE FOR CONCERNED I/Cs
THE CURRENT FINANCIAL YEAR AND SEND TO THE TEAM LEADER
[ VIDE FORM QF / 18 ]
2 PREPARE AN ANNUAL TRAINING PLAN FOR THE FINANCIAL YEAR GIVING TEAM LEADER
- TOPIC OF TRAINING / SCHEDULE MONTH / MODE OF TRAINING /
DURATION OF TRAINING / TRAINING CONTENTS [ VIDE FORM QF / 17 ]
3 IDENTIFY THE INTERNAL TRAINERS FOR EACH TRAINING TOPIC M.P. - I
4 ARRANGE FOR IMPARTING TRAINING TO THE INTERNAL TRAINERS, IF M.R.
NECCESSARY
5 PREPARE A TRAINING SCHEDULE FOR EACH PERSON FOR THE CURRENT TEAM LEADER
FINANCIAL YEAR GIVING – PROPOSED DATE OF TRAINING / TOPIC OF
TRAINING / SHEDULED TIME PERIOD OF TRAINING / TRAINING FACULTY[
VIDE FORM QF / 69 ]
6 IMPART TRAINING TO THE CONCERNED PERSON DESIGNATED
TRAINER
7 RECORD THE TRAINING DATE & TIME PERIOD IN FORM NO. QF / 69 TEAM LEADER
AND SEND TO M.R. FOR REVIEW & RETURN.
8 RECORD THE CONSOLIDATED TIME PERIOD IN FORM NO. QF / 04 M.R.
9 VERIFY EFFECTIVENESS OF THE TRAINING GIVEN CONCERNED I/Cs
10 TO PRESENT TRAINING DATAS IN THE MRMs FOR ANALYSIS M.R.

D. EVALUATION PROCEDURE :

THE M.R WILL REGULARLY EVALUATE ALL TARGETS ON A QUARTERLY BASIS. NONCONFORMANCE WITH
RESPECT TO THE ACTION PLAN WILL BE REPORTED TO THE M.P. - I WHO WILL TAKE THE APPROPRIATE
CORRECTIVE / PREVENTIVE ACTION.

E. TRAINING REQUIREMENTS : TRAINING THE ‘ TRAINERS ’

F. ACTION PLAN START DATE : 15/ 06/ 09 ACTION PLAN DEADLINE : 31/ 03/ 10

Prepared by M.R. Approved by M. P. - I


RPS : PK :
AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

M.R. M.P. - I

COMMENTS OF THE EVALUATOR [ on closure ] :

DATE : EVALUATOR :

DOC. NO. : QD / 36 ACTION PLAN TO MEET QUALITY OBJECTIVE PAGE : 1 OF 1


REV NO : 00
DATE OF REV : 01/ 05/ 09 ON ‘REDUCTION IN REJECTION LEVELS’

A. RESOURCE ALLOCATION :

ALLOCATED BUDGET : TEAM MEMBERS : TEAM LEADER :

B. PROCESS OBJECTIVE : TO MAINTAIN AND CONTINUALLY REDUCE FIRST – TIME REJECTION .[ RATIO OF THE
NO. OF REWORKS / REJECTIONS TO THE NUMBER OF IN – HOUSE INSPECTIONS
CARRIED OUT ] LEVELS TO LESS THAN 1.0 % DURING THE
IN – PROCESS FABRICATIONS.

C. DESCRIPTION OF THE ACTION PLAN :

S. N. SEQUENTIAL ACTIVITIES TO ACHIEVE THE OBJECTIVE PERSON ACTUAL


RESPONSIBLE COMPLETION
DATE
[ TO BE FILLED
BY M.R. ]
1 FOR EACH JOB RECORD THE NO. OF REJECTIONS / REWORKS CARRIED Q.C. I/C
OUT FOR EACH OPERATIONS - DURING SEAM SET – UPS, WELDING,
DIMENSIONAL CHECKS AND PERFORMANCE TRIALS . THESE ARE TO BE
LOGGED IN FORMAT NO. QF / 06
2 CALCULATE THE PERCENTAGE REJECTION / REWORK LEVELS AT Q.C. I/C
QUARTERLY INTERVALS.
3 ESTABLISH THE SIGNIFICANT ROOT CAUSES FOR SUCH PRODN I/C
NONCONFORMANCES.
4 TAKE SUITABLE CORRECTIVE / PREVENTIVE ACTION M.P. - I
5 IMPART TRAINING TO THE OPERATORS M.P. - I
6 CHECK FOR IMPROVEMENTS M.P. - I

D. EVALUATION PROCEDURE :

THE M.R WILL REGULARLY EVALUATE ALL TARGETS ON A QUARTERLY BASIS. NONCONFORMANCE WITH
RESPECT TO THE ACTION PLAN WILL BE REPORTED TO THE M.P. - I WHO WILL TAKE THE APPROPRIATE
CORRECTIVE / PREVENTIVE ACTION.

E. TRAINING REQUIREMENTS : SYSTEMATIC TRAINING TO THE SHOPFLOOR OPERATORS ON THE VARIOUS


ASPECTS OF SHOPFLOOR OPERATIONS.

F. ACTION PLAN START DATE : 15/ 06/ 09 ACTION PLAN DEADLINE : 31/ 03/ 10

M.R. M.P. - I

Prepared by M.R. Approved by M. P. - I


RPS : PK :
AKP Engg. & Fabricators QUALITY SYSTEM DOCUMENTS
Rabale [ Draft For Discussion D1 dated 17/08/09 ]

COMMENTS OF THE EVALUATOR [ on closure ] :

DATE : EVALUATOR :

Prepared by M.R. Approved by M. P. - I


RPS : PK :