quality manual rr gears

7/25/2019 Quality Manual RR GEARS

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Doc: QM-RRG-01 Issue: 1.0

Rev: 0 Date: 01.06.15

QUALITY MANUAL

RR GEARS PVT LTD

CONTENTSSECTION TITLE PAGE NO.


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RR GEARS PVT LTD DOC QM-RRG-01PAGE : 2 of 31ISSUE : 1.0

DATE :01.06.15QALIT! MANAL

1

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#

$4.14.25

5.15.25.35.4

5.56

6.16.26.36.4%

7.17.27.37.47.57.6&

8.18.28.38.48.5

Annex-IAnnex-IIAnnex-IIIAnnex-IV

Title pageContentsQalit! "anal At#o$isationInt$o%&tion to Co'pan!($pose) *&ope + Cont$ol of Qalit! "anal"anal ,ist$ition ist// A/* (VT T,) Qalit! (oli&!// A/* (VT T,) Qalit! e&tiesQua'(t) Ma*a+e,e*t S)ste,Q"* "o%el at // A/* (VT T,Q"* ,o&'entationMa*a+e,e*t Reso*s(('(t)"anage'ent &o''it'ent) poli&! + oe&tiesCsto'e$ fo&sQ"* planning/esponsiilit!) at#o$it! + &o''ni&ation

"anage'ent $eieResou/ce Ma*a+e,e*t($oision of $eso$&es'an $eso$&esInf$ast$&t$eo$ eni$on'entP/ouct(o* Rea'(at(o*(lanning of ($o%&tion $eali9ationCsto'e$-$elate% p$o&esses,esign + %eelop'ent($asing($o%&tion p$oisionCont$ol of 'onito$ing + 'eas$ing %ei&esMeasu/e,e*t2 A*a')s(s 3 I,/ove,e*tene$al"onito$ing + 'eas$e'entCont$ol of non-&onfo$'ing ($o%&tionAnal!sis of %ataI'p$oe'ent$ganisation *t$&t$e/esponsiilities + At#o$ities of e! (e$sonnel($o&ess ,eplo!'ent "at$ix"anal A'en%'ent /e&o$% *#eet

123

4-5678;1011121314

15-161718

1;2021212222232324242424252626272728282;303132

PREPARED BY: REVIEWED &

APPROVED

MANAGEMENT REPRESENTATIVE MANAGING

DIRECTOR


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1.# QALIT! MANAL AT4ORISATION

1. T#is "anal %es&$ies t#e a&tiities t#at a$e essential fo$ 'eeting t#e 'anage'ent s!ste'$e


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A reputed name, RR GEARS (P) Ltd. is a professionally managedorganization, engaged in manufacturing Transmission gears, safts and

!nduction ardening ,Gear "orging, #ase $ardening !nduction $ardening,TougeningAll our products are of supreme %uality and are e&tremelydura'le in nature. e ere incorporated in *++ , it te aim tomanufacture precision engineering components catering to te tractor andgeneral automo'ile industry. Today, e are te leaders in our field. -urmanufacturing line consists of te most modern foundry and macinesop to produce intricate components for -E/s. !t employs latesttecnology and process for 'etter and faster production. e a0e a teamof igly trained and dedicated personnel o practice stringent %ualitycontrols to ensure te ig standards. -ur commitment to %uality andcustomer satisfaction as elped us in earning a large clientele, ic

spreads all across te orld.

e offer to our clients ide range of precision engineered parts for tractor1 oter ligt, medium and ea0y 0eicles. Te range offered 'y usincludes2

Our products:1. Shaft Forging2. Gear Forging3. Case Hardening4. Induction Hardening5. Toughening

!ant and "achiner#

1. Gas Car$uri%ing furnace

2. Induction Hardening "achine

3. Shot $!asting

4. &or'a!i%ing Furnace

5. (p setter 'achine

Our "a)or Custo'ers :

H"T

*a)a Gears + , -td


APPROVED


DIRECTOR


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PRPOSE2 SCOPE 3 CONTROL O7 QALIT! MANAL

1. Pu/ose

T#is @Qalit! "anal= #as een eole% fo$ fo$'lating t#e o$ganisation) $esponsiilities) +poli&ies of //) fo$ i'ple'enting a Qalit! "anage'ent *!ste' >Q"*? fo$ 'eeting t#e &ontent +p$pose of %epa$t'ent=s Qalit! (oli&! + oe&ties an% fo$ setting p a %is&ipline + %i$e&tion fo$ all'e'e$s of t#e o$ganisation fo$ t#e sa'e.

". ScoeT#is 'anal + t#e Q"* %es&$ie% in t#is 'anal in&l%e t#e folloing s&ope:o$ging of T$ans'ission ea$s) *#afts + Axles + #eat t$eat'ent ($o&ess

>i? a$%ening>ii? In%&tion #a$%ening>iii? Tog#ening

a? o&ation:Locat(o*s A/ess 7u*ct(o*s

"ain *ite // A/* (VT T,381) (#ase I In%st$ialA$ea)(anlaA/BAA

o$ging of T$ans'ission ea$s) *#afts + Axles + #eatt$eat'ent ($o&ess

>i? a$%ening>ii? In%&tion #a$%ening>iii? Tog#ening

ffsite one

? *tan%a$%: ISO see o$ganisational st$&t$e of // Annex-I of t#is'anal? fo$ %e&i%ing t#e &ontents + poli&ies %es&$ie% in t#is 'anal. T#e effo$t fo$ eoling t#is'anal is &o-o$%inate% ! t#e "anage'ent /ep$esentatie >"./.? #i is finall! $eiee% + app$oe%! t#e "AAI ,I/CT/on e#alf of t#e exe&tie 'anage'ent.


APPROVED


DIRECTOR


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$. Issue 3 D(st/(ut(o* Co*t/o'

T#e 'anal #as een %ii%e% into a$ios se&tions &onsi%e$ing t#e a$ios ele'entsE&lases of t#e I*stan%a$%. T#e title page of t#e 'anal gies t#e 'anal ,o&'ent o.) Isse o.) an% its %ate of isse.T#e "anage'ent /ep$esentatie >"./.? is $esponsile fo$ 'aintaining t#e 'aste$ &op! of t#is 'anal%l! i%entifie% ! t#e o$iginal signat$es of t#e app$oing at#o$it! on ea page.o$ t#e p$pose of ope$ation of t#e Q"* %es&$ie% in t#is 'anal) t#e &opies a$e 'a$e% it# %istin&t&op! nos. + isse% to t#e $e//? n%e$ t#e sa'e Isse o.

MANAL DISTRI>TION LIST


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DIRECTOR


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T#e "anage'ent /ep$esentatie >"./.? is $esponsile to ens$e t#at &$$ent + p%ate% isses of t#is@Qalit! "anal= a$e isse% to all t#e &op! #ol%e$s as gien elo. All &opies gien elo a$e &ont$olle%an% a$e 'a%e aailale to se$=s t#$o= $ea%-onl! a&&ess.

Alt#og#) possessions of &opies of t#e 'anal a$e $est$i&te% to t#e folloing pe$sonnel) an! e'plo!ee oft#e %epa$t'ent is eligile to #ae a&&ess fo$ se f$o' t#ese #ol%e$s. A sepa$ate /efe$en&e &op! is alsoaailale it# t#e "./. o &op! is) #oee$) pe$'itte% to e $e'oe% f$o' t#e %epa$t'ent=s p$e'isesit#ot t#e p$io$ app$oal f$o' t#e "./.

T#e $efe$en&e &op! + 'aste$ &op! a$e aailale as #a$% &opies an% a$e $etaine% + 'aintaine% ! t#e"./.

Co) Nu,e/ COP! 4OLDER

1.

2.

Maste/ co)

"AAI ,I/CT/

/efe$en&e Cop!Ce/t(8(cat(o* >o);

Ma*a+e,e*t Re/ese*tat(ve


APPROVED


DIRECTOR


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QUALITY POLICY

RR GEARS PVT LTD & its staff is committe

To ac!ie"e c#stome$ Satisfactio% t!$o#! its

e%ea"o#$s of '#a(it) se$"ice *) committi% itse(f

to '#a(it) ma%aeme%t s)stem a% to

fo((o+ t!e ,at! of co%ti%#a( im,$o"eme%t.

Q(-//-0101.08.2014 "AAI ,I/CT/


APPROVED


DIRECTOR


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APPROVED


DIRECTOR


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$. QALIT! MANAGEMENT S!STEM

4.1 QMS Moe' at RR GEARS PT LTD

T#e %epa$t'ent #as estalis#e% + %o&'ente% a /E//E"TCE04?.

All ($o&esses s#on on t#e siness p$o&ess flo a$t a$e pe$fo$'e% inte$nall! ! t#e o$gani9ation.


APPROVED


DIRECTOR


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$.1.1 >SINESS PROCESS MAP

Co/e P/ocesses

Ma*a+e,e*t 3 I,/ove,e*t P/ocesses


APPROVED


DIRECTOR

Cont$ol of,o&'ents

$%e$ /eie

($aseCont$ol of $e&o$%s

*to$e

/ + T$aining*F((I/>*?

CF*T"/

($o%&tion

"aintenan&eQFAITB CC

Cali$ationFT*F/C, ,ispat

($o%&tion ($o&ess on-&onfo$'ities Cont$ol

,ata Anal!sisCsto'e$

Co'plaints

Csto'e$*atisfa&tion

"eas$e'ent

Co$$e&tie A&tion

($eentie A&tion

Inte$nal A%its

"anage'ent /eie


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$." QMS Docu,e*tat(o*

$.".1 Ge*e/a'

T#e %epa$t'ent=s Q"* %o&'entation &onsists of t#e folloing:

a? Leve' 1: state'ents of ?ua'(t) o'(c)2 ?ua'(t) o9ect(vesan% t#e Qua'(t) ,a*ua')? Leve' ": %o&'ente% /oceu/es$efe$$e% in t#is 'anal)&? Leve' #: all ot#e$ %o&'ents $efe$$e% in t#is 'anal o$ $elate% p$o&e%$e fo$ effe&tie ope$ation +

&ont$ol of Q"* p$o&esses) in&l%ing 'a*s2 @o/ (*st/uct(o*s2 sta*a/s) et&.%? Leve' $: fo$'s) an%e? Leve' 5: $e&o$%s $e


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All $eleant fn&tions of t#e %epa$t'ent 'aintain t#e $e&o$%s as $e


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5.1 Ma*a+e,e*t co,,(t,e*t

Top 'anage'ent of t#e Co'pan! an% t#e fn&tional #ea%s is &o''itte% to t#e %eelop'ent +i'ple'entation of a Q"* an% &ontinall! i'p$oing its effe&tieness. o$ t#is p$pose) t#e folloing'eas$es a$e taen:

a? a ?ua'(t) o'(c)#as een %efine%) %o&'ente% + &o''ni&ate% to all &on&e$ne% in t#e o$ganisation#i &one!s 'anage'ent &o''it'ent to t#e i'po$tan&e of 'eeting &sto'e$ an% ot#e$I''ig$ation an% e$seas %&ation ($o%&tion ($oi%e$ $elate% $e


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T#e o$ganisational st$&t$e of t#e Co'pan!=s e! fn&tions $esponsile fo$ a$ios p$o&esses #as een%o&'ente% as gien in Annex$e-I of t#is 'anal.

T#e $esponsiilities + at#o$ities of t#e a$ios *taff "e'e$s in t#e %epa$t'ent #ae een %efine% inAnnex - II of t#is 'anal. oee$) t#e %etaile% $esponsiilities + at#o$ities of all pe$sonnel inole%in e.g. p$o&e%$es) inst$&tions) et&.)? %efine t#e t!pe + 'et#o% of t#is info$'ation flo. Apa$t f$o' t#is)a$ios info$'al 'eans of &o''ni&ation lie) &i$&la$s) 'e'os) inte$nal pli&ations) le&t$e sessions)'eetings) et&. a$e se% ! t#e "/ to &o''ni&ate t#e effe&tieness of Q"* t#$og#ot t#eo$ganisation.

5.6 Ma*a+e,e*t /ev(e@

5.6.1 Ge*e/a'A 'anage'ent $eie &o''ittee >"/C? fo$ &on%&ting t#e $eie of t#e //=s Q"*)


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a? $epo$ts of inte$nal C*I?)&? %ata on p$o%&tion + p$o&ess non-&onfo$'ities)%? %etails of &o$$e&tie + p$eentie a&tion taen + t#ose $e


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// A/* (VT T, #as p$oi%e% all $e


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a? Apa$t f$o' t#is app$op$iate offi&e spa&e) f$nis#ings a$e p$oi%e% fo$ an% is ti'e to ti'e$eiee% ! t#e Top "anage'ent.

An! anges $e


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/eali9ation p$o&ess flo s#on in Hsiness lo C#a$t >(age 2 of 4? t#e planning of a$ios ($o&esses.T#e %o&'ente% p$o&e%$es $efe$$e% t#e$e in an% ot#e$ $elate% %o&'ents e.g. Qalit! (lans) Qalit!'anal et&. %efine t#e folloing %etails as app$op$iate:-

a? Qalit! e&ties + $e


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? an%ling of en -//-08?

%.# Des(+* 3 Deve'o,e*t e=c'us(o*;

o ($o%&t is eing %esigne% at // A/* (VT T,.

%.$.1 Pu/cas(*+ P/ocess

/a ite's a$e eing p$ase% ! t#e o$ganisation an% In o$%e$ to ens$e &onfo$'it! of t#e p$ase%($o%&tion) t#e a$ios &ont$ols a$e exe$&ise% t#$og# /a 'ate$ial p$ase + ene$al 'ate$ialp$ase p$o&esses ! t#e se$ &on&e$ne%.

T#e spplie$s of 'ate$ials a$e sele&te% asi&all!) *to&ists an% ($o%&tions a$e o$%e$e% as pe$ o$%e$$e&eie% an% a$e 'ate% it# t#e sa'e to 'eet t#e &sto'e$=s $e? Qantit! is also e$ifie% ! &onting an% 'ating (.

All 'ate$ial a$e e$ifie% fo$


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to 'eet t#e &sto'e$s $e


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p$ese$e% as pe$ t#e $e-//-11? #as een estalis#e% + i'ple'ente% in //) to assess t#eleels of &sto'e$ satisfa&tion. A fee%a& fo$' #as een %esigne% to otain &sto'e$ fee%a& an%&al&late &sto'e$ satisfa&tion in%ex. >C*I? T#is info$'ation is se% to assess t#e pe$fo$'an&e of t#eQ"*.

&."." I*te/*a' Au(t

A s!ste' of inte$nal a%its at planne% inte$als of 6 'ont#s #as een estalis#e% an% i'ple'ente% aspe$ t#e %o&'ente% p$o&e%$e. Q(-//-03

T#e inte$nal a%its so &on%&te% a$e se% to %ete$'ine t#e folloing:

a? Confo$'it! of ($o%&tion $eali9ation p$o&esses) t#e $e


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a a%it p$og$a''e is p$epa$e% &onsi%e$ing t#e stats an% i'po$tan&e of Q"* p$o&esses in&l%ingt#e $eslts of p$eios a%its.

T#e A%it C$ite$ia) *&ope) $e


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In &ase t#e non-&onfo$'it! is %ete&te% afte$ ($o%&tion #as een %elie$e% o$ pt to se ! t#e se$) it is&onsi%e$e% as a &sto'e$ &o'plaint an% its $e%$essal is %one to aoi% effe&tsEpotential effe&ts.

&.$ A*a')s(s o8 Data

T#e %ata is gene$ate% on a&&ont of a$ios p$o&e%$es %eelope% fo$ Q"* an% $eleant p$o&esses.* %ata a$e &olle&te% an% anal!se% ! t#e $espe&tie pe$sonnel $esponsile fo$ t#e p$o&ess an% taea&tion to 'eet t#e planne% $eslts. T#e %ata $e


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ANNERE FI

ORGANISATION STRCTRE


APPROVED


DIRECTOR


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(/,FCTI ICA/I/ E"/

AT T/AT"T A**I*TATQFAITB I*(CT/(/AT/*




APPROVED


DIRECTOR


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ANNERE -IIRESPONSI>ILITIES 3 AT4ORITIES

Pe/so**e' Reso*s(('(t(es Auto/(t(es

"AAI,I/CT/

e$all in a$ge of t#e Co'pan! ooing

afte$ 'a$eting) sales) p$o%&tion) $eglato$!$e


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n


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A; Co/e P/ocesses

1. ar5eting6 !n%uiry re0ie E&ecuti0e

4!RE#T-R6R

Section 78

Section 9"7RRG7:*

2. Purcase A3AG!3G4!RE#T-R6Account

Purcase !6#

P7RRG7:;

3. Stores Store 5eeper6Super0isor

Section 9.;

P7RRG7:

4. Production Planning 4G Section 9.8.P7RRG7:8

5.


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16. #ustomer Satisfactioneasurement

R Section 9.;.;

"7RRG7**

*9. #orrecti0e Action6 pre0enti0e

Action

R6process oner Section ?.=.;

P7RRG7:=

P7RRG7:>

*?. anagement Re0ie R6top

management

Section 7=

*+. !nternal Audit R Section ?

P7RRG7:

ANNERE- I


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DIRECTOR


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AMENDMENT RECORD S4EET

#enee$ an! a'en%'ent is in&o$po$ate% in t#is 'anal) it is a&&o'panie% ! an p%ate% $e&o$% s#eetgien elo. All &op! #ol%e$s of t#e 'anal a$e $e

quality manual rr gears

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