M.S.

PLASTICS QUALITY PROCEDURE

Date: 21/01/20
Document No.: MS/QP Issue No.: 00

QUALITY PROCEDURES -01

PROCEDURE FOR CONTROL OF DOCUMENTS REF.CLAUSE 4.2.3 OF ISO 9001:2015

1.0 Objective

To establish & maintain a system that ensures that all quality system documents are controlled.

2.0 Scope

This quality system procedure applies to all documents, which relates to the quality system, including documents
of the external origin. It covers approval prior to issue. Review, revision, & availability at point of use,
identifiably & irretrievability in addition to prevention of use of obsolete documents.

3.0 Responsibility

PROPRIETOR& MR

4.0 Procedure

4.1 Various documents /formats are numbered in the following manner

XX/FF/YY
Where-XX = Company Name.
FF= Format/ Record Type
YY = Relative Number of records (01, 02, 03,.. etc)

4.2 Preparation, review of adequacy, & control of various quality systems documents is conducted in the
following Table

S. Name of Document Prepared By Reviewed & Re- Change, Control

No. approved by by
1. Quality Management Manual M.R. Proprietor Proprietor
and Quality Procedure [QMM]
(Level-I)
2. Quality Assurance Plans, MR Proprietor Proprietor
Quality Formats & Work
Instructions (Level II)

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4.1.1. Section Incharges & MR are responsible for ensuring:

- Availability of correct documents & data

- Removal of obsolete documents &data.

4 1.2 Master copies of level I documents shall be maintained by PROPRIETORwith Original signature on
cover page & shall be stamped as: “MASTER COPY” in green ink at the back of each page

4.1.3 Documents of external origin shall be kept with a stamp of “Controlled Copy”. These shall not be
distributed to anybody and shall be retained by the PROPRIETOR.

4,1.4 Controlled copies shall be generated from the master copy with a stamp of “CONTROLLED COPY”
in Red Ink on each page. One Controlled copy will be issued to Certifying Body & distribution of
controlled document is done through controlled document issue register.

4.1.5 Master List of Documents for ensuring current status of the document

4.1.6 Any request for change in the existing system is processes as per “PROPOSED CHANGE NOTE”
format.

4.1.7 Quality system manual can be issued to any external agency only after Approval of PROPRIETOR&
it will be marked “INFORMATION COPY” in Black.

4.1.8 Whenever there is any revision in the Level & Level II documents, the old master copy shall be taken
out from the master file & to be stamped as “OBSOLETE COPY” & shall be recorded in Obsolete
Document Format. Along with this the Revised Format shall supersede the Obsolete Format at the
point of use. Current status of the revised document will be communicated to concerned Department
head through Controlled issue /change record.

4.1.9 With every twenty revisions there will be a change in respective issue number.

4.1 .10 The retention of obsolete copies shall be decided in the Master List of Formats.

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QUALITY PROCEDURES-02

PROCEDURE FOR CONTROL OF RECORDS REF CLAUSE 4.2.4 OF ISO 9001-2015

1.0 Objectives:
To maintain & Control quality records and ensure their easy retrieval and disposition

2.0 Scope:
This Quality Management system procedure applies to quality records generated by the company.

3.0 Responsibility
MR
4.0 Procedure:

4.1 Methodology for Control of records

4.1.1 MR is responsible for making and controlling of records.

4.1.2 The existing records are controlled through Master List of Documents.
4.1.3 If new records are to be made, M.R. ensures that unique identification is given to records so that
reviewing it from list of records does not duplicate it.
4.1.4 All the records which support the Quality Management System are referenced in the appropriate
procedure, work instruction, quality plan etc. List and various files maintained by each function head.
4.1.5 All personnel have been advised to fill the records legibly and identified to the product/process involved.

4.2 STORAGE:

Records are stored in suitably protected & secure facilities which are “termite, water and moisture” proof so as to:

 Be easily retrievable.
 Minimize deterioration.
 Protected from damage.
 Prevent loss! Authorized access or tempering such alteration.

4.3 Retention Period:

Retention Period of each record is maintained in the List of Records.

4.4 Disposition:
After expiry of the retention period quality records are destroyed, after approval
of PROPRIETORby any appropriate means preferably by shredding. A record of
records! Documents destroyed are maintained for reference! where required.

5 Changes due to revision: NIL

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QUALITY PROCEDURES-03

PROCEDURE FOR INTERNAL AUDIT REF CLAUSE 8.2.2 OF ISO 9001:2015

1.0 Objective:

To establish a documented system for planning and implementation of internal

Quality Audits

2.0 Scope:

To verify compliance of documented procedures and requirements of the standard.

3.0 Responsibility:

PROPRIETOR/ MR

4.0 Procedure:

4.1 Annual audit plan for each year is prepared.

4.2 Internal audits are conducted on six months based on importance of the activity and in such a way that
each area shall be covered.
4.3 Internal auditors could be selected internally or externally for conducting the quality audits. MR in
consent with PROPRIETORselect the internal auditor on the basis of their qualification, skills and
knowledge of all the intricacies of that particular department to conduct the audit.
4.4 The Internal audit matrix is circulated to the auditors and auditee to ensure their communication
regarding the audit programmes & scope and availability on the respective dates. Third party audits are
also acceptable.
4.5 Internal audits are organized and carried out through auditors with Audit
Check List. In case of any Non-Conformity of the system Corrective Action report Form is issued by
auditor as applicable. Auditee shall review NCR’s and take corrective/preventive action within
acceptable time period to the auditor. Constraints of resource required shall be put in MRM.
4.6 If any follow up audits is required, the same shall be indicated in the “Audit non-compliance report,”
Corrective action taken shall be verified and the auditor shall close NCR.
4.7 A summary report of audits is prepared based on NCR’s and a review is presented in MRM.
4.8 Changes in quality system, as a consequence of NCR’s are implemented with a view to remove
deficiencies in the quality system.

5.0 Changes due to revision: NIL

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QUALITY PROCEDURES-04

PROCEDURE FOR CONTROL OF NON CONFORMING PRODUCT REF CLAUSE 8.3 OF ISO 9001:2015

1.0 Objectives:

To establish a documented system for appropriate identification, segregation, evaluation, documentation

& disposition to prevent inadvertent use or mix up of non-conforming product.

2.0 Scope:

Applicable to all those departments where non-conformity is observed i.e. Control of non-conforming
material identified at any stage of process starting from incoming testing/inspection till final inspection.

3.0 Responsibility:

MR & Production Incharge

4.0 Procedure:

Materials and Products are being inspected at Incoming, In Process & Final stages as per the Quality
Plans.

Incoming Testing Stage

 Non- conforming material (NCM) is generated on the basis of incoming testing/inspections, recorded in
Incoming Inspection Record
 This rejected material is then returned back to the supplier for replacement.
 Store In-charge thus informs the supplier regarding its rejection and the NCM is kept separately at a
specified place.
 Care shall be taken during production if NCM is used that the material/ product can be traced out for
positive recall in case of any quality problem.

In-process testing stage

 NCM generated during the process is segregated & send to store to keep it separately. PROPRIETORis
the final authority to dispose it.

 Any product re-worked will be inspected as per inspection instruction and then recorded as a new
product both at in process and final stages.

Final inspection & testing stage

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 Since the final inspection is done, any defects observed during the final inspection are considered as the
non-conformity and are kept at designated place.
 If the defects are minor, the identified product is reworked and offered again for inspection.
 If the defects are major and product is rejected. Then the NCM are removed from the working place and
then offered again for review for its use, release or acceptance under concession the authority lies with
PROPRIETOR
 Any NCP arisen due to defect in any electrical or electronic part will be rectified by taking the
replacement from the supplier.

AT THE CUSTOMER END.

All the complaints against the manufacturing defect at customer’s end are rectified free at their end by our
technocrats and verified by the customer. If NCP is not rectified at their end then it is brought back to the
workshop and reworked at our end and after final inspection sent back to customer

Causes of the nonconformity shall be discussed in the MRM

References:
Control of NCP

5.0 Changes due to revision: Nil

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QUALITY PROCEDURES-05

PROCEDUREFOR CORRECTIVE ACTION REF CLAUSE 8.5 OF ISO 9001:2015

1. Objective
To eliminate the root cause of non-conformities related to product, process or quality system in order to
prevent its re-occurrence.

2. Scope
All non-conformities identified

3. Responsibilities
PROPRIETOR! MR

4 Procedure

 All non-conformities that are observed from various input reports (as mentioned above) are to be
considered for corrective action.
 The problem is thus analyzed for root cause identification and corrective actions are identified and
implemented.
 All the long term & short term actions are then reviewed in the management review meetings
 PROPRIETORanalyzes customer complaints.
 All the non- conformities are reviewed and compiled at least once in three months and on the basis of the
nature/gravity of problem, preventive action plan is prepared.
 Corrective action is taken immediately if any non-conformity is observed at any stage and is of high risk
and can affect the quality of the product! services. In such cases, PROPRIETORtakes the decision.
 To check the effectiveness of any corrective action a follow-up mechanism shall be followed and record
shall be maintained for review.
 All the records of corrective action and their follow-up observations shall be maintained.
 The MR monitors monthly all corrective actions and it would be a permanent input to MRM.

Reference:

CORRECTIVE & PREVENTIVE ACTION REPORT.

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QUALITY PROCEDURES-06

PROCEDURE FOR PREVENTIVE ACTION REF CLAUSE 8.5 OF ISO 9001:2015

1. Objective
To prevent the occurrence of any potential non-conformity

2. Scope

All potential non-conformities identified during internal audits, operation of QMS, feedback from
customers & customer complaints etc.

3. Responsibilities
PROPRIETOR/MR

4. Procedure

 All potential non-conformities identified out of recorded non-conformities.

 Potential causes of non conformities shall also be identified from trends of data, minutes of management
review and achievement of objectives.
 Root cause analysis will be done with the help of statistical technique or past experience.
 PROPRIETORand concerned HOD will evaluate the need for action to prevent occurrence of potential
NC.
The HOD will determine the appropriate action and implementation plan.
 These plans will be implemented as per plan.
 HOD will follow up for results
 MR will review on follow up
 MR will report in management review meeting
Record of preventive action and its implementation will be maintained by the MR.

Reference:

Corrective & preventive action report.

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QUALITY PROCEDURES-07

PROCEDURE FOR MANTANENCE AND BREAKDOWN REF CLAUSE 8.5 OF ISO 9001:2015

1.0 Objective

To provide & document the method Maintenance and up-keeping of plant & equipments for ensuring that

a) Process capability continue to be satisfactory,

b) Required data / records are maintained, and
c) Corrective actions / improvements are initiated.

2.0 Scope

This process covers

 Mechanical Maintenance of Plant and Machines
 Electrical Maintenance of Plant and Machines

3.0 Responsibility

Proprietor/M.R. are responsible for effective implementation of this process in their respective areas.

4.0 Procedure
Activity Responsibility
4.1 In puts for Maintenance
4.1.1 A comprehensive list of equipments / devices available with details such as M.R.
 Their Identification,
 Location,
 Range of Operation, and
 Maintenance requirements.
4.1.2 The maintenance requirements are normally identified using the operational & Proprietor/M.R.
maintenance manuals. Where maintenance manuals are not available, these are based on
knowledge and experience. For all new procured equipments / devices it is ensured that
these manuals are controlled through the control of External Origin Documents.
4.1.3 The requirements of maintenance is informed to respective maintenance areas by M.R.
concerned department / section.
4.1.4 The availability of necessary spares, consumables, tools and necessary materials are M.R.
ensured through standardization and /or advance planning, through Stores and guidance
by Head (Operations)
4.2 Maintenance Process
4.2.1 Preventive Maintenance
1 Preventive maintenance schedules are prepared based on manufacturer’s M.R.

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recommendations /review of History Card maintained. The intimation of preventive

maintenance is communicated in advance to the Plant Supervisor for release of
equipment.
2 Preventive maintenance is carried out using check points given in Maintenance Schedule M.R.
and Records . The M.R. checks the maintenance activities regularly.
3 After completion of maintenance (whether preventive or breakdown) the O K report is M.R.
taken from the user department.

4 All preventive maintenance jobs done are recorded in History Card maintained for each M.R.
equipment / devices
4.2.2 Breakdown Maintenance
1 Breakdown of an equipment or device is reported, Maintenance work is immediately M.R.
taken up for rectification and repair.
2 After completion of maintenance (whether preventive or breakdown) the O K report is M.R.
taken from the user department.
3 All preventive maintenance jobs done are recorded in History Card maintained for each M.R.
equipment / devices .
4.3 In-charges of Maintenance ensures that all safety and protective devices necessary are M.R.
used while breakdown or preventive maintenance are mounted and are functional all
time. These include fan/gear guards, correct fuses and ear thing etc.
4.4 Calibration of Devices
1 In case of process Instruments, maintenance include calibration where applicable. M.R.
2 Calibration of Instruments is done using work instructions in respect of the standard M.R.
used, environmental conditions, precautions, and the ranges & accuracies to be covered.
Standards meant for calibration should be stored properly along with their certificates
and trace ability records.

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QUALITY PROCEDURES-08

PROCEDURE FOR PRODUCTION PLANNING REF CLAUSE 8.5 OF ISO 9001:2015

1.0 Objective

To describe the process of PPC and Production for the following objectives ,
 Reduction of In Process Rejection
 Productivity Improvement
 Timely Dispatch of Products
2.0 SCOPE
This process covers all products made by company.

3.0 Responsibility:
Proprietor/M.R. is overall responsible for implementation of this procedure.
4.0 Procedure

Sl. # Activity ( in put / activity / output ) Responsibility

4.1.1 Marketing sends the requirements for monthly dispatch of component to head Proprietor/M.R.
Production
4.1.2 Production Head Collect data of finished good stock/WIP . Proprietor/M.R.
4.1.3 Requirements of Production for the month is calculated. Proprietor/M.R.
4.1.4 Production plan for the month is prepared on the basis of following inputs. Proprietor/M.R.
a) Machine Capacity
b) Production Capacity
4.1.5 Dispatch Plan is prepared on following basis.. Proprietor/M.R.
a) Production Plan
b) Data wise schedule if given by CG
4.1.6 Raw material planning is carried out and given to Purchase and its receipt status Proprietor/M.R.
monitored action as required are taken or timely procurement
4.1.7 Planning for consumables tools gauges is carried out on basis of completion data and Proprietor/M.R.
indents given to stores for procurement / Issue.

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4.1.8 Data of Production and dispatches are used as input for progress tracking and details . Proprietor/M.R.

4.1.9 Changes in production plan as required are carried out and details recovered Proprietor/M.R.
4.2 Production
4.2.1 Production of component is carried out on basis of following inputs Proprietor/M.R.
a) Manpower needed
b) Process Flow Sheet
c) Process Sheet/ Work Instruction
d) Consumable/ Tools/ Gauges required
e) Utility items such as electricity
4.2.2 Quality of work is checked as per control plan/ Quality plan for each stage. Records as Proprietor/M.R.
required.
4.3 Data base is maintained for following Proprietor/M.R.
a) Production Done
b) Quality results
c) Consumption of Tooling/ Consumables
4.4 Material Movement is done with the help of trolleys/ Bins as per guidelines. Proprietor/M.R.
Products are identified and inspection tests indicated as per WI.
Machine cleaning and housekeeping is carried out as per guidelines.

QUALITY PROCEDURES-09

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PROCEDURE FOR CALIBRATION REF CLAUSE 8.5 OF ISO 9001:2015

1.0 Objective
To establish, implement and maintain a system which ensures that effective control is exercised over all Inspection,
Measuring & Test Equipments.
2.0 Scope
This procedure is applicable to all inspection, measuring and test Equipments

3.0 Responsibility

Proprietor/ M.R. is responsible for implementation of this procedure

5.0 Procedure

Sl. No. Activity

Responsibility
4.1 Identification of measurements to be made and the accuracy required is documented in Proprietor/M.R.
Quality plan, or any other inspection/testing document.
4.2. A list of all inspection, measuring and test equipment requiring calibration to be Proprietor/M.R.
Maintained. List identifies the measurement instruments by name, type, serial number,
location, applicable calibration requirements ,date of calibration done and calibration due
date. The calibration status is updated continuously.
4.3 The indent for calibration is prepared and with relevant purchase order sent to the Proprietor/M.R.
calibration agency for calibration.
4.4 Calibration agency is provided with needed facilities and support for carrying out Proprietor/M.R.
calibration at our works place.
4.5 Such instruments that are to be calibrated at outside location are collected and sent to Proprietor/M.R.
identify calibration agency.
4.6 Whenever the calibration is got done, following is checked up Proprietor/M.R.
a) Physical condition of instrument /test equipment
b) Calibration report verification
c) Calibration certificate to be obtained from calibration agency and after verification
marked as O.K./Not O.K.
d) Sticking of calibration sticker
4.7 History of calibration is kept using format and calibration certificates filed. Proprietor/M.R.
4.8 The equipment’s are well maintained, to preserve their accuracy and fitness for use. If Proprietor/M.R.
equipment is out of calibration or is otherwise not fit for use, is withdrawn from use.

QUALITY PROCEDURES-10

PROCEDURE FOR TRAINING REF CLAUSE 8.5 OF ISO 9001:2015

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1.0 Objective
To provide guideline instructions & process of training with the aims that Training activities are well planned,
Training for developing the skills and knowledge needed to perform management and technical roles is provided,
Individual and groups receive training necessary to perform their roles, Training activities related to Quality
Management System & Environment Health And Safety related subjects is provided ,Customer satisfaction is enhanced
on continual basis .
2.0 Scope
It covers Trainings for
2.1 Quality Management System Documents
2.2 Control Plan
2.3 C.T.Q’s Parameters
2.4 .Environment Health & Safety Policy
2.5 Fire Fighting
2.6 First Aid
It should covers all employees of the company

3.0 Responsibility:
Proprietor/M.R. is responsible for effective implementation of this procedure

4.0 Procedure

Sl. Activity Responsibility

4.1 Policy For Training Needs
4.1.1 A documented policy for Training Needs is prepared and approved . The policy specifies
 The needed skills and knowledge for each role
 Training methods ( where needed ) which includes
1. Class room training
2. Facilitated videos
3. Formal apprenticeship & mentoring programs
4. Guided self study / computer aided instructions
5. Commercial available training courses
6. Professional conferences / seminars , etc
4.1.2 Reviewed for
 Training requirement
 Feedback to Employee
4.1.2 A group responsible for fulfilling training needs is developed , as part / full time ( with in
or external sources )
4.1.3 Adequate resources and funding are provided for implementing the training program ,
which include
1. Designated person responsible for implementing training program
2. Tools to support training program activities
3. Appropriate facilities to conduct training
4. Maintaining training records .
4.2 Training Plan

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4.2.1 A training plan is prepared which covers

 The set of skills / knowledge needed & whom these skills are needed
 The skills for which training is required & using this the skills would be obtained
 For each training , whom it is required & when it is required
 Measurement for effectiveness of training provided .
4.2.2 The training objectives is considered ( where required ) as different levels such as
A: Does not know, cannot do job
1. B : Know but cannot do job
2. C : Know and can do under supervisions.
3. D : Know well and can do independently
E: Know well, can do well and can train others
4.2.3 The training plan is reviewed by key responsibilities , and where required it is revised
4.2.4 Materials for training are reviewed.
4.2.5 Needs of training are identified either using Competence Matrix.
4.3 Trainings are conducted as per plan , the attendance and time of training are recorded .
4.4 All training attended by personnel are maintained in individual records of
 Qualifications
 Experience
 Knowledge
 Training attended
 Skills developed
 Proposed trainer for any training program

UALITY PROCEDURES-11

PROCEDURE FOR PURCHASE REF CLAUSE 8.5 OF ISO 9001:2015

1.0 Objective:
To provide & document the method purchasing for ensuring that
a) Purchased products conforms to specified purchase requirements ,

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b) Suppliers are selected, evaluated and re-evaluated based on specified criteria,

c) Needed actions are taken after evaluations / re-evaluations, and.
d) Required data / records are maintained.

2.0 Scope:

This process covers all purchases made by company.

3.0 Responsibility:
M/R and Proprietorare responsible for effective implementation of this process.

4.0 Procedure:

Sl. # Activity
4.1 Indenting
4.1.1 For proper Indenting and controlling, the inventory has been divided in to two category,
 Stocked items
 Non stocked items (Capital items and non production items etc)
4.1.2 For stocked items, the indents are raised by Production
1. Based on shortage list of items for delivery of customer order
2. When stocks falls below the minimum levels set, or
3. Based on inventory norms
4.1.3 For non stocked / capital items, the indents are raised by Supervisor
4.1.4 Indents are generated giving following details
 Indenting department
 Date of indent
 Material Code / description
 Material Supplier
 Quantity
 Delivery time/ date
 Dispatch instruction
 Packaging Instructions
 Any other remarks
Based on these indents are approved, reviewed and then approved as per purchase policy of
organization.
4.1.5 Indents for (stocked items) i.e production items are normally generated as per resource
requirements of organization. Records of all indents are maintained in soft file and further
follow up for required delivery.
4.1.6 Indents of Capital items / Non-stocked items are raised by concerned department.However,
for stock position in Stores is verified by Store Keeper.
4.1.7 An allocation requirement (reservation) is indicated in stores database for all indents raised.
NOTE: Stores bring to the notice of management if any item is received with out any indent
or / and Purchase order.
4.2 Issue Of Purchase Order
4.2.1 P.O is prepared based on comparative rate input in soft database or based on the quotations
from suppliers or rate contract with suppliers.
4.2.2 Based on approval of Indent, a Purchase Order is prepared or generated.
4.2.3 All PO related to Stocked Items are raised on approved supplier, reviewed and is sent for

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approval as per policy and copy is sent to Supplier.

Purchase orders of Non Stocked items or Capital Items are reviewed by concerned HOD and
sent to HOD (PUR) after approval by Proprietor,
I/C Purchase or Indenter ensures that requirements, commercial terms, inspection criteria etc,
all are appropriately mentioned in Purchase Orders.
NOTE: All purchase is made through approved supplier. A list of approved should be
maintained.
4.2.4 It is ensured that all technical details / specification, supplier’s reference, commercial terms
and acceptance criteria (on receipt) are written in the Purchase Orders where required.
4.3 Selection & Approval Of New Suppliers
4.3.1 Suppliers (both for Product and Services) are identified and asked to furnish details, such as
manufacturing / suppliers status, G.S.T. registration details, Quality assurance / control
facilities, manufacturing facilities, infrastructure available and regulatory act (where
applicable) being followed etc. using format Supplier’s Evaluation Form.
4.3.3 A list of all selection-evaluated supplier is maintained for each category of item / services and
is updated from time to time.
4.3.4 A trial order is raised and based on performance of supplies (quality and delivery); the
supplier is considered as approved supplier and is updated from time to time.
4.4 Evaluation Of Performance Of Suppliers
4.4.1 Performance of all suppliers is monitored by allocating marks for
 Quality.
 Delivery.
Once in a year.
4.4.2 Quality:
If material is rejected first time, supplier is informed verbally. For every rejection marks are
deducted.
On repeated rejection. The supplier is warned.
4.4.4 Delivery:
Supplier giving material in time is given full marks. For every 20 to 25 % more delays 5
marks are reduced further.
4.4.7 Based on Performance report of the supplier’s performance evaluation is carried out.
Suppliers, which are not considered acceptable, are deleted or marked suspect suppliers.
4.5 Verification Of Purchased Items
4.5.1 All purchased products are inspected, verified against their requirements / Standards / Quality
Plans, and then accepted
Records of verification (both acceptable and non-conforming) of all purchased parts are
maintained.
4.6 Re-evaluation of Suppliers
Re-evaluation of Suppliers (whose performance has not be evaluated) is taken up every 2
years of implementation of system. Suppliers are re-evaluated on same parameters based on
which approved. If any changes found, changes are evaluated and suitable decision is taken
accordingly.

ABBREVIATION

CA Corrective Action

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Date: 21/01/20
Document No.: MS/QP Issue No.: 00

CL Calibration
DC Document Controller
Doc Document
Dt Dated
IA Internal Audit
I/C In-Charge
MR Management Representative
ML Master List
NCP Non-Conformity Product
NCR Non-Conforming Report
PA Preventive Action
PM Production Manager
Prod Production
QAP Quality Assurance Plan
QA Quality Assurance
QC Quality Control
Rev Revision
QF Quality Format
QP Quality Procedure
TM Test Method
WI Work Instruction
IMTE Inspection, Measuring and Test Equipment.
Admn Administration
MP Proprietor

PREPARED BY: MR APPROVED BY: MANAGER P a g e | 46