.
Copy Holder : ______
QUALITY MANUAL
As per
ISO 9001: 2008
GUN AND SHELL FACTORY
(INDIAN ORDNANCEFACTORIES)
COSSIPORE, KOLKATA 700 002
Editing By : S. K.GHOSH, HOS/ISO
Preface
It gives me immense pleasure to bring out the IS Standard IS 9001 : 2008 version of Gun & Shell Factory, Cossipore.
This edition has been necessitated due to the transfer of inspection responsibility for input material, vendor development, capacity verification & vendor registration from DGQA organization to DGOF.
I am very grateful to the General Manager and other senior officers for the trust imposed on ISO-Cell and me. I also take this opportunity to record my sincere thanks to the General Manager and other senior officers for their valuable help and guidance.
I also appreciate the efforts of my predecessors who have obtained the coveted standard and strove hard to maintain the same.
I am confident that this document will help to serve in the management of QMS in the organization.
Ranjan Roy
Jt. General Manager
Management Representative
Gun & Shell Factory
Cossipore
Kolkata – 700 002
Cossipore
20thJune’ 2010
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1.0RECORD OF REVISIONS
Sl.No / REV. No & Date / DETAILS OF REVISION / SECTION No / PAGE No / SIGNATUREOF MR
01 / 01/15-11-2010 / Para 5.4.1
Quality Objectives
have been modified / 5.4 / 8 9
APPROVED BY
GENERAL MANAGER / ISSUED BY
MANAGEMENT REPRESENTATIVE / DATE
20-06-2010
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2.0 CONTENTS
SEC. No / DESCRIPTION / PAGE No / CLAUSE OFISO 9001:2008
1.0 / Record of revision / 1
2.0 / Contents / 2
3.1 / QMS Vocabulary & Abbreviations / 3
3.2 / About GSF / 3
3.3 / Scope of Certification / 4
3.4 / Documentation / 4
4.0 / Quality Management Responsibility / 5 / 4.0
4.1 / Introduction / 5 / 4.1
4.2 / Documentation / 6 / 4.2
5.0 / Management Responsibility / 7 / 5.0
5.1 / Management Commitment / 7 / 5.1
5.2 / Customer Focus / 8 / 5.2
5.3 / Quality Policy / 8 / 5.3
5.4 / Planning / 8 / 5.4
5.5 / Responsibility, Authority & Communication / 10 / 5.5
5.6 / Management Review / 12 / 5.6
6.0 / Resource Management / 14 / 6.0
6.1 / Provision of Resources / 14 / 6.1
6.2 / Human Resources / 14 / 6.2
6.3 / Infrastructure / 16 / 6.3
6.4 / Work Environment / 16 / 6.4
7.0 / Product Realization / 16 / 7.0
7.1 / Planning of Product / Services Realization / 16 / 7.1
7.2 / Customer Related Processes / 17 / 7.2
7.3 / Design and Development / 20 / 7.3
7.4 / Purchasing / 20 / 7.4
7.5 / Production and Service Provision / 20 / 7.5
7.6 / Control of Monitoring and Measuring Device / 23 / 7.6
8.0 / Measurement, Analysis and Improvement / 24 / 8.0
8.1 / Introduction / 24 / 8.1
8.2 / Monitoring and Measurement / 25 / 8.2
8.3 / Control of Non-conforming Product / 27 / 8.3
8.4 / Analysis of data / 28 / 8.4
8.5 / Improvement / 29 / 8.5
Annexures ( Contents ) / 30
APPROVED BY
GENERAL MANAGER / ISSUED BY
MANAGEMENT REPRESENTATIVE / DATE
20-06-2010
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3.1 QUALITY MANAGEMENT SYSTEM VOCABULARY & ABBREVIATIONS
a)The terminology related to ISO 9001 : 2008 used in this documented Quality Management System are as per the definitions defined in ISO 9000 : 2000. The list of terms used in Quality Management System documentations and their interpretations as per ISO 9001:2008 may be referred to in Annexure 1 of this document.
b)The list of abbreviated terms widely understood/used in this organization and finding a place in Quality Management System documentation may be referred to in Annexure 2 of this document.
3.2 ABOUT GUN AND SHELL FACTORY
i)Gun and Shell Factory, Cossipore is one of the manufacturing units of Ordnance Factory Board under the Ministry of Defence, Govt. of India. The corporate Headquarters of Ordnance Factories is located at Kolkata. The Ordnance Factory Board consists of a Chairman and Members representing various disciplines.
ii) Gun & Shell Factory was founded in 1801 A.D. and is located on the bank of HooghlyRiver about 8 Kms. from Howrah station in northern part of the city of Kolkata
iii) The Gun & Shell Factory manufactures Gun, Shell and Fuze of different calibers. In addition some items for the use of civilians are also being manufactured. The facilities for manufacturing these items include conventional machines, special purpose machines and Automatic Machines. Manufacturing activity is supported by the under-mentioned
supporting sections :
- Quality Control - Planning - Central Design Office - Stores
- Maintenance - Personnel - Material Management - Tool Room
- Carpentry - Training - Electro Deposition Section
iv)Each section, whether production or supporting is headed by Addl.General Manager(also know as Controlling Officer or Cost Centre Head). The Addl. General Managers are assisted by Group Officers of the rank of Dy. General Manager / Joint General Manager who is turn are assisted by Divisional Officer of the rank of either Works Manager or Asstt. Works Manager. All the sections are headed by a “Head of Section” of the rank of Junior Works Manager/Foreman/StoreHolder.
APPROVED BYGENERAL MANAGER / ISSUED BY
MANAGEMENT REPRESENTATIVE / DATE
20-06-2010
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v)The security of the factory is managed by a Sr. Security Officer, who reported to the General Manager and is assisted by Security Officer.
vi)The Financial division of Gun & Shell Factory is managed by Controller of Accounts (Fys), who is assisted by his team of experts.
vii)The Medical Coverage of all employees of the factory is provided by the OrdnanceFactoryHospital which is headed by a Principal Medical Officer who is assisted by other Medical Officer.
viii)The representatives of the Defence Services are located in the factory premises.
3.3SCOPE OF CERTIFICATION
The scope of this ISO 9001 : 2008 Quality Management System certification includes all the sections manufacturing Guns, Shell and Fuzes at GSF, Cossipore, Kolkata-700 002.
3.4EXCLUSIONS
Gun & Shell Factory gets the product designs and specifications from customer/AHSP, DRDO or from Collaborators. Any modification to the product design need the approval of AHSP before it can be implemented during production. Product development/modification by way of reverse engineering or otherwise. CDO functioning at GSF is primarily engaged for designing work holding Fixtures, Tools & Gauges etc. As such the Clause 7.3 pertaining to design and development is not applicable to GSF.
3.5 OUTSOURCING OF PROCESSES
Finished goods are dispatched to consignee through hired private transports, contract for which is concluded by Purchase dept. based on annual requirement worked out by Stores as per the production plan. Delivery performance of transporter is assessed by Stores based on timely availability of transport at GSF and delivery of consignment in good condition at consignee’s end.
Trade assistance for Heat Treatment/Surface Treatment of a few selected components is obtained for which facilities don’t exist in house. Control is exercised by QC(Main) through inspection of process at Contractor’s end and appropriate tests at GSF on receipt.
APPROVED BYGENERAL MANAGER / ISSUED BY
MANAGEMENT REPRESENTATIVE / DATE
20-06-2010
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4.0QUALITY MANAGEMENT SYSTEM
4.1INTRODUCTION
GSF establishes, documents, implements, and maintains a Quality Management System as per ISO 9001: 2008 for achieving continually improved effectiveness. The documented QMS have been developed based on processes flow chart. The process map of key processes at GSF and their inter-relationship is enclosed as Annexure – 3 to this manual.
GSF has
a)Determine the processes needed for the Quality Management System and their application through out the organization. (see 1.2)
b)Established the sequence and interaction of these processes as detailed in different work instructions and procedures.
c)Determined the criteria and methods needed to ensure that both the operation and control of these processes are effective as detailed in different work instructions, procedures, drawings, specifications and etc.
d)Ensured the availability of resources and the information necessary to support the operation and monitoring of these processes. Resource requirement of identified at section level and is discussed if necessary, in MRM meeting to ensure its availability.
e)Established a system of monitoring, measuring and analysis these processes, as detailed in different work instructions and procedures, and monitor, measure where applicable and analyse these processes and.
f)Established a system to implement actions necessary to achieve planned results and continual improvement to the processes/services.
g)Details of outsourcing of processes is referred to in clause 3.5 above.
Gun & Shell Factory ensures control over out sourced process which affect product conformity to requirements . The type and extent of control applied to these is defind in procedure of QSP-II/QC(MAIN)/08. Input material inspection and capacity verification of firms is done as per standard operating procedure issued by MOD vide order No 16(2)/2004/D(QA) dated 31-03-2005. Process referred above includes process for Management activities, Provision of Resources, Product Realization & Measurement Analysis and improvement.
APPROVED BYGENERAL MANAGER / ISSUED BY
MANAGEMENT REPRESENTATIVE / DATE
20-06-2010
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4.2 DOCUMENTION
4.2.1 The Quality Management System documents and records required by this
International standard and include the followings :
4.2.1.1 The Quality Policy statement and quality objectives of GSF.
4.2.1.2 The Quality Manual ( Doc. No. QM/2008 ).
4.2.1.3 Quality System Procedures Part-I and Part-II (QSP-I & QSP-II).
4.2.1.4Quality plan including Design Drgs., specification, process schedule, inspection
schedule, gauge schedule, proof schedule
4.2.1.5 Work instructions, Flowcharts, Reference manuals, competence map ( on computer) etc. needed to ensure effective planning, operation and control of
processes and
4.2.1.6 Records : Documents including Records determined by the organization to be necessary for effective Planning, Operation and Control of Processes and Quality Records as required.
4.2.2 QUALITY MANUAL
This quality Manual (Doc. No. QMS/2008) addresses all the relevant clauses and sub-clauses of the standard ISO 9001:2008. The justification for the exclusion of a part of clause number 7.3 is also included below. The reference to different QSPs, WIs and other relevant documents are made. It also describes the nature of the interactions between the processes of the Quality Management system. This Quality Manual is a signpost documents.
4.2.3CONTROL OF DOCUMENTS
4.2.3.1Scope : All documents, which have an impact on quality of products/services are controlled to ensure that the latest version of valid documents duly approved by the designated authority are available at the point of use. The QSP on document control (Doc No. QSP/DC/01) is established for the same.
4.2.3.2RESPONSIBILITY : The responsibility of controlling documents lies with MR and functional Head as per QSP on document control.
4.2.3.3The control is established to,
a)Approve documents for adequacy prior to issue.
b)Review of update as necessary and re-approve.
c)Ensure that changes and the current revision status of documents are identified.
d)Ensure that relevant version of applicable documents are available at the point of use.
e)Ensure that documents remain legible and readily identifiable.
f)To ensure that documents of external origin determined by the organization to be necessary for the planning and operation of the Quality Management System are identified and their distribution controlled, and.
g)Prevent the unintended use of obsolete documents, and apply suitable identification to them in case they are retained for any purpose.
APPROVED BYGENERAL MANAGER / ISSUED BY
MANAGEMENT REPRESENTATIVE / DATE
20-06-2010
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4.2.3.4Reference document :
Quality System Procedure on document control (Doc. No. QSP/DC/01) List of QSPs in Annexure – 4
4.2.4CONTROL OF RECORDS :
4..2.4.1Scope : This section of the manual out-lines the system implemented and
procedure applicable to all types of quality records at GSF to provide evidence of conformity to the requirements and of the effectiveness of the operation of the QMS and its improvement.
4.2.4.2A QSP is established and maintained to ensure the quality records remain
legible, readily identifiable, retrievable, properly stored, protected, retained f
for specific period of time and timely disposition. A list of quality records is
available with the details at all the sections.
4.2.4.3The quality records of QMS at GSF includes the following :
a)MOM of Management Review Meeting
b)Records of customers’ need identification
c)Objective monitoring record
d)Calibration data of measuring instruments
e)Records pertaining to customer complains
f)Evaluation/rating of suppliers
g)Non-conformance reports
h)Process deviations
i)Record of corrective and preventive action
j)Training record/Review record
k)IQA reports
l)Inspection reports
m)Record of legislative/statutory requirements
n)Incident/accident record
o)Log book/Registers
p)Customer feedback
q)Record in internal/customer communication
r)Record of analysis of process deviation, product deviation, supplier performance, customer satisfaction data
4.2.4.4Reference documents :
a)QSP on control of quality records (Doc. No. QSP/CR/02)
b)List of quality records in sections
5.0.MANAGEMENT RESPONSIBILITY
5.1.MANAGEMENT COMMITMENT
The management of GSF provides the evidence of its commitment to the development and implementation of the QMS and for its continually improved effectiveness through :
a)Making people aware of the importance of meeting customers requirements,
b)Identifying, Communicating and complying with statutory and regulatory requirements,
c)Establishing the quality policy,
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MANAGEMENT REPRESENTATIVE / DATE
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d)Establishing the quality objectives and communicating to the functions and levels,
e)Conducting management review meeting at an interval of at least once in three months and,
f)Providing resources wherever required as identified by different functional heads and also in management review meetings.
5.2CUSTOMER FOCUS
Customer’s requirement (in respect of three armed services) are received either through OF Board or from sister ordnance factories indicating details of the product, drawing no., delivery requirement, inspection agency etc. Monitoring at all functions is done by the HOS and in turn by the Divisional Officer (D.O.) / Group Officer (G.O.) for complying with the requirements of customer and to enhance the customer satisfaction level. Internal customer orientation is established through awareness at working level through formal/in-formal internal communication. Customer survey is also carried out once in six months to get the feedback of the satisfaction level. Different performance indicators are established to achieve enhanced customer satisfaction level and improvement in operation. This is further elaborated in section no. 7.2.1 & 8.2.1.
5.3QUALITY POLICY
Quality Policy of GSF have been developed as per the requirements of ISO 9001:2008 standards and by the approval of the General Manager(GM), the Chief Executive.
5.3.1Quality Policy
Gun & Shell Factory manufactures a variety of Guns, shell and Fuze of different calibers beside some civil trade items. As a part of quality management system the top management of the factory have declared the following quality policy :
QUALITY POLICY
WE, THE EMPLOYEES OF GUN SHELL FACTORY MANUFACTURING GUNS,SHELLS & FUZE ARE COMMITED TO PROVIDE PRODUCTS & SERVICESMEETING CUSTOMERS’ REQUIREMENTS AS PER LAID DOWN SPECIFICATION ENSURING SAFETY AND RELIABILITY AT OPTIMUM PRICE.
WE FURTHER COMMIT TO CONTINUALLY IMPROVE OUR QUALITY MANAGEMENT SYSTEM TO ENHANCE CUSTOMER SATISFACTION.
5.4.PLANNING
5.4.1.Quality Objectives
To meet customer’s requirement Gun & Shell Factory has set the following quality objectives in its endeavor to enhance customers’ satisfaction.
i) MONITORING OF QUALITY TO ENSURE ADHERENCE TO THE
LAID DOWN STANDARDS.
ii) SUPPLY OF PRODUCTS & SERVICES WITHIN DELIVERY
SCHEDULED IN CONSULTATION WITH CUSTOMER.
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MANAGEMENT REPRESENTATIVE / DATE
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iii) CONTINUAL PROCESS IMPROVEMENTS THEREBY IMPROVING QUALITY
STANDARDS.
iv) SUPPLY PRODUCTS & SERVICES AT MUTUALLY AGREED PRICE
v) CUSTOMER COMPLAINTS WILL BE SETTLED WITHIN 4(FOUR) MONTHS
vi) TO REDUCE RFR BY 2.5% OF PREVIOUS YEAR PERCENTAGE
vii) TO MAINTAIN PROCESS CAPABILITY i.e. CPK > 1 FOR CRITICAL
IDENTIFIED PROCESSES.
These quality objectives are drawn from and are consistent with the quali policy. Specific measurable targets against each/some of these objectives are setseparately every year and monitored. These factory wide objectives are further supported by section level objectives. The continuing suitability of these objectives are assessed once in a year or earlier whenever specifically required and monitored. Relevant data is collected and analyzed periodically and mid-course correction wherever required are taken. Progress on achievement of these quality objectives is monitored/reviewed in MRM.
5.4.2Quality Management system Planning
Planning is carried out by the concerned G.O. in order to meet the requirements of quality management system. The same is approved by G.M./C.O./G.O. wherever required. The focus of planning is given on the following points,
a)Skill and knowledge needed by GSF – HOS of each functional area work out the skill & knowledge needed to meet the customers’ requirement. Identification of training need and the area in which training is needed is carried out once a year and is communicated to Training section. Training section in turn prepares training calendar for all category of employees and after approval at appropriate level these are taken for implementation.
b)For process improvements, the plans are prepared by the respective G.O. of production section in consultation with the C.O. these are monitored at the level of controlling Officer in the cost centre level review meetings.
c)Planning for resources needed :
1) Manpower resource planning is done based on the estimates of different products by the Technical Service (R.E.)department. Manpower resource planning for the whole GSF is done annually by the planning depts. vetted by GM for onward transmission to OFB. The progress of the same is reviewed by the GM on receipt of the response from the competent authority of OFB and interacted with for resolving the same. Periodical reviews are made at appropriate action taken.
APPROVED BYGENERAL MANAGER / ISSUED BY
MANAGEMENT REPRESENTATIVE / DATE
15 – 11 - 2010
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2) Resource planning for capital (machinery and equipment) and revenue expenditure is prepared by different functional heads, planning department and controlling officers, vetted by GM for onward transmission to OFB for its approval. The progress of the same is reviewed by GM on receipt of the response from the competent authority and interacted with for resolving the same. The progress is periodically reviewed and corrective actions as needed are taken.
3) Resource plan for infrastructure development is prepared by different functional heads, planning department and controlling officers. These are vetted by GM for onward transmission to OFB which in turn gets approved by OFB for its implementation by the Factory. The infrastructure development plans costing unto Rs. 5 Lakh (through contract action) does not need the approval of OFB. The progress of various infrastructure development plans is reviewed by GM periodically and corrective actions wherever needed are decided and acted upon by the concerned agency. The implementation of the approved plan is also monitored by concerned divisional heads.
d) Different performance indicators for the quality objectives have been
established for different functions which are document and reviewed periodically. Planning for compliance with those PI’s and for its improvement wherever possible is made by HOS and communicated to the functional people. The same is monitored by G.O. and appraised in MRM.
e) Planning for improvement in methods, tooling, work holding devices etc and
incorporation of new system is carried out by HOS on need basis and implemented with the approval of D.O./G.O.
f) Planning for incorporation of different documentation including records are