SOP OF D&DSTANDARD OPERATING PROCEDURE FOR DESIGN & DEVELOPMENT DEPARTMENT1.0 SUBJECT:SOP No.SOP OF DESIGN AND DEVELOPMENT DEPARTMENT (D&D)2.0 PURPOSE:Issued Date:* To Plan and Develop New Components / Assemblies for Commercial Production

* To Conduct Vendor development and to liaise with Cost & Supply committee

* To Design & Manufacture Jigs / Fixtures / Gauges for smooth flow of Production Lines to develop new products

* To Provide Design Services to MEL3.0 SCOPE:This procedure covers all functions related to D&D Department3.0 CONTROL OBJECTIVES:Reference No:3.1To evaluate viability of the New Projects / Products3.2To work out / generate costing and feasibility reports based on product data provided by the customer3.3To provide necessary design services for new and existing products3.4Development of Engineering documentation like OP Sheets, Quality Plans, Tooling & Gauges drawing and provision of these documents to the related department3.5Control of technical data in Hard & Soft formats3.6Verification of manufacturing processes, tool proofing, First Piece Approval and consequently handing over the product to production Department for Pilot lot and Commercial production3.7To Manufacture Jigs / Fixtures, Gauges, Machine accessories and auxiliary equipment3.8To develop Forging, Casting, Machining and Hardware Vendors3.9To conduct Price Negotiation with vendors and to liaise with C&S Committee for PO finalization3.10.To Conduct Vendor Evaluation3.11Evaluation of market prices (Local / International) of Raw Materials / Forgings to get optimum price benefitsTaskElectronic / Manual(E / M)Responsible PersonnelRemarks4PRODUCT DEVELOPMENT4.1Receipt of Drawing(s) / Sample(s) / Data Sheet(s) through Commercial Department for new development queriesE / MHOD4.2Study & Evaluation of received Drawing(s) / Sample(s) / Data Sheet(s)MIncharge Prod. Development4.3Preparation of Feasibility & Costing pro-formaE / MIncharge Prod. Development4.4To seek project approval from CEO for final decision to start development process.E / MHOD4.5Preparation & approval of Operation Sheets, Drawings of Components, Jigs, Fixtures, Gauges, Quality Plans etc.E / MIncharge Design Section4.6Final approval of Operation Sheets, Drawings of Components, Jigs, Fixtures, Gauges, Quality Plans etc.MHOD4.7Initiate CAPEX proposal of the required Machine(s) for the approval of CEO / Higher AuthoritiesMHOD4.8Identify and provide specs of required Tooling (both local and imported) to Commercial department for its procurementMIncharge Prod. Development4.9Technical scrutiny of Quotations and liaise with Commercial department for placement of OrdersE / MIncharge Prod. Development4.10.Proofing of Operation SheetsMIncharge Design Section4.11Receipt of recommendations for revision in Drawings (if required)E / MIncharge Design Section4.12Approval / disapproval of recommended revisionMHOD4.13Recording of REVISION (if approved)E / MIncharge Design Section4.14Submission of FPA to QAMHOD4.15Handing over new product for Commercial Production to Production Department and provide full backup support in Trial ProductionMHOD4.16Provision of Operation Sheets to all concerned departmentsMIncharge Design Section5SERVICES5.1Receipt of Request (through Request Form Annexure 1) for Design / Manufacturing Services regarding Tooling, Gauges, jigs and Fixture etc.E / MHODAnnexure 15.2Preparation of detailed drawing(s)EIncharge Design Section5.3Approval of detailed drawing(s)MIncharge Design Section / HOD5.4Handing over of drawing to requesting department/ personnel.MHOD / Incharge Design Section5.5Manufacturing of Machine Elements, Gauges, Fixtures or Utility Equipments etc. as per approved drawingMIncharge Tool Room6DATA ARCHIVING / DOCUMENTATION6.1Uploading of Soft format of drawings / design work to MEL ServerEIncharge Design Section6.2Recording of Amendments in drawings by indicating REVISION INDEX (Soft Format)EIncharge Design Section6.3Verification of above both activitiesEHOD6.4Maintaining of Controlled (New / Old) Documents (in-hard format) in Master FilesMIncharge Design Section6.5Verification of Filing data (in Hard Format) in Master FilesMHOD6.6Documents marked with CONTROLLED COPY stamp would be issued to the concerned departmentMHOD / Incharge Design Section7VENDOR DEVELOPMENT7.1VENDOR EVALUATION - NEW ORDER7.1.1As per Flow Chart (Annex 2)Annex -27.1.2Proposed Vendor will submit introductory letter along with Company ProfileMAnnex -37.1.3HOD to review and decide whether to evaluate Vendor or not and advise concerned executives for evaluationMHOD7.1.4Visit will be conducted on the basis of information provided by vendor and subsequently Vendor Evaluation report will be Prepared (Annex 4)MIncharge Vendor DevelopmentAnnex - 47.1.5Vendor Evaluation report with recommendations will be put up to CEO for ApprovalMHOD7.1.6After Approval of Vendor, Ordering Process will be startedMIncharge Vendor Development7.1.7Re- Evaluation to be carried out in case a vendor informs D&D that new facility or improvement in the setup has been madeMHOD7.2COST & SUPPLY - NEW ORDER7.2.1As per Flow Chart (annex - 5)Annex -57.2.2Quotation along with Price Breakup will be provided by Vendor7.2.3MEL cost estimation will be prepared for particular Parts / ServicesMIncharge Vendor Development7.2.4C&S case will be prepared on C&S proforma (Annex -6) after receipt of all relevant information(s)MIncharge Vendor DevelopmentAnnex - 67.2.5C&S case will be reviewed and if found OK, will be forwarded to C&S committee for reviewMHOD7.2.6C&S Committee will review C&S cases and if found OK will be sent to Incharge Vendor Development for arrangement of C&S MeetingMC&S Committee7.2.7C&S Committee will negotiate Price with vendor and give recommendationsMC&S Committee7.2.8C&S case will be sent to CEO for ApprovalMHOD7.2.9C&S case duly approved by CEO will be sent to Commercial Dept for preparation of Purchase Order / Work OrderMIncharge Vendor Development7.2.10.Commercial Dept will provide original Purchase / Work Order to D&D for review and issuance to vendorERP / MCommercial Department7.2.11D&D will issue one copy of PO / WO each to MMD and vendor (Annex -7)MIncharge Vendor Development(Annex -7)7.3COST & SUPPLY - PRICE REVISION7.3.1The price revision cases will be entertained due to change in the following:1- Raw material Prices2- Utility Prices3- Factors like Tooling, Labor, Foreign Currency Rates etc7.3.2Incharge Vendor Development will obtain revised quotations with evidences (price breakup) to ensure the price increase demands made by vendorMIncharge Vendor Development7.3.3Rest of the Procedure will remain the same as mentioned under COST & SUPPLY - New Order [clause 7.2]MIncharge Vendor Development7.4PARTS DEVELOPMENT - VENDOR BASED7.4.1As per Flow Chart (FPA) (Annex -8)Annex - 87.4.2Vendor will submit Samples along with Inspection report within approved development time, along with the inspection gaugesM7.4.3Samples will be forwarded to QA for evaluationMIncharge Vendor Development7.4.4In case of acceptance of samples, vendor will be informed along-with FPA report for the submission of Pilot LotMIncharge Vendor Development7.4.5In case of rejection of samples, vendor will be informed along-with QA report for re-submission of samplesMIncharge Vendor Development7.4.6Vendor will submit Pilot Lot along with Inspection report within approved Time frameM7.4.7Pilot Lot will be sent to QA for evaluationMIncharge Vendor Development7.4.8In case of acceptance of Pilot Lot, vendor will be informed along-with Inspection report. In addition to above MMD will also be informed for issuance of monthly schedule for regularization of supplies.MIncharge Vendor Development7.4.9In case of rejection of Pilot Lot, vendor will be informed along-with inspection report for re-submission of Pilot LotMIncharge Vendor Development*D&D DEPARTMENT ORGANOGRAM (Annex 9)Annex -9*D&D DEPARTMENT ACTIVITIES FLOW CHART (Annex 10)Annex -10Prepared By:* Incharge Tool Room(Allah Raham Rathor)* Incharge Vendor Development (Muhammad Abid Aleem)* Incharge Product Development (Shahid Iqbal)* Incharge Design Section (Arslan Haider)SOP is subjected to change from time to time whenever found necessary. The revision detail shall be maintained in index Form AnnexureReviewed By:HOD (Raafey Zaman Durrani)Date:31-01-2010Approved By:CEO

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