ISSUE NO: 1 ISSUE DATE: 24/05/2011 REV NO: 0
QUALITY MANAGEMENT SYSTEM MODERN PREFAB
QUALITY ASSURANCE PLAN : INCOMING MATERIAL
MANESAR
S.No
Process Part
Doc. No.:
Equipment / instrument / tool used
Sampling size / testing frequency
Specification Customer / Manufacturer Internal test certificate
W - width,
Measuring tape
One in every five coils
1040 / 1220mm
T - thickness
Micrometer
One in every five coils
Visual inspection
One in every five coils
Colour
Visual
One in every five coils
Customer spec
(C) Hardness test
Hardness tester
One in every five coils
Check parameter
MPS - QAP - 01
REV DATE: Page No: 01 of 03
Tolerance limit / acceptable acceptable deviation
Control point
Periodicity of calibration / servicing
Internal
± 2mm
Calibration
Customer spec
NA
± 2%
NA
Internal
Calibration Method
External / internal
Once in a year
Comparison with standard scale
Internal
Calibration
Once in a year
Measuring Standard thickness
External
Zero tolerance
NA
NA
NA
NA
NA
Zero tolerance
Inspection against standard sample
NA
NA
NA
65 HRB maximum
Internal
65 HRB
NA
Once in a year
Standard sample
External
6.5mm
Internal
- 0.5mm to + 2mm
Calibration
Once in a year
Comparison with standard length
External
Calibration
Once in a year
Comparison with standard weights
External
Record
Responsib ility
(A) Dimensions
(B) Attributes scratch, dent, damage, paint peel off
1
Pre-Painted Galvanised Iron (PPGI) Coil
Cupping machine / One in every five (D) Cupping Test visual inspection coils for fracture of paint
QC Incharge
Visual –
2
Polyol/ Isocyanate
(E) Scratch Hardness test
Hand operated scratch tester
One in every five Apply load 1.8 to coils 2.5 kg
Internal
(F) Paint Adhesion Test
Cross hatch test
One in every five coils
Internal
Visual - peel off of paint.
NA
NA
NA
External
(A) Batch no.
Visual
Every Lot
Matched with given Test Certificate
Internal
Zero
NA
NA
NA
Internal
27Kg/m3
Internal
Satisfactory adhesion – visual
penetration of scratch into substrate
QC Incharge
(B) PU Property Free Rise Density
Weighing M/C
Every Batch
REVIEWED AND APPROVED BY: DIRECTOR (OPERATIONS) SIGNATURE: DATE 24 05 11
3
± 2 Kg/m
Calibration
Once in a year
ISSUED BY: MANAGEMENT REPRESENTATIVE, QMS SIGNATURE: DATE 24 05 11
Comparison with standard weights
External
ISSUE NO: 1 ISSUE DATE: 24/05/2011 REV NO: 0
QUALITY MANAGEMENT SYSTEM MODERN PREFAB
QUALITY ASSURANCE PLAN : INCOMING MATERIAL
MANESAR
S.No
Process Part
Doc. No.:
Specification Customer / Manufacturer Internal test certificate
Equipment / instrument / tool used
Sampling size / testing frequency
L- Length
Measuring tape
Five in every Lot
NA
W - width
Vernier Callipers
Five in every Lot
T - thickness
Micrometer
MPS - QAP - 01
REV DATE: Page No: 02 of 03
Tolerance limit / acceptable deviation
Control point
Periodicity of calibration / servicing
Internal
± 10%
Calibration
Customer spec
NA
± 10%
Five in every Lot
Customer spec
Na
Visual
Five in every Lot
NA
L- Length
Measuring tape
Five in every Lot
W - Width
Measuring tape
Five in every Lot
Check parameter
Calibration Method
External / internal
Once in a year
Comparison with standard scale
Internal
Calibration
Once in a year
NA
External
± 10%
Calibration
Once in a year
NA
External
Internal
Satisfactory
NA
NA
NA
NA
NA
Internal
± 10%
Calibration
Once in a year
Comparison with standard scale
Internal
NA
Internal
± 10%
Calibration
Once in a year
Comparison with standard scale
Internal External
Record
Responsib ility
(A)Dimensions
3
MS Pipe
QC Incharge
(B) Attributes Rust/ Oil free
(A) Dimensions
4
CR sheet Micrometer
Five in every Lot
Customer spec
Internal
± 8%
Calibration
Once in a year
Measuring Standard thickness
Visual inspection
Five in every Lot
NA
Internal
Zero tolerance
NA
NA
NA
NA
L- Length
Measuring tape
Five in every Lot
6300mm
Internal
± 10%
Calibration
Once in a year
Comparison with standard scale
Internal
W - Width
Measuring tape
Five in every Lot
1500mm
Internal
± 10%
Calibration
Once in a year
Comparison with standard scale
Internal External
NA
T - Thickness
QC Incharge
(B) Attributes Dent, damage, Rust, Oil free
(A) Dimensions
5
HR sheet T - Thickness
Micrometer
Five in every Lot
Customer spec
Internal
± 8%
Calibration
Once in a year
Measuring Standard thickness
Visual inspection
Five in every Lot
NA
Internal
Zero tolerance
NA
NA
NA
(B) Attributes Dent, damage, Rust, Oil free
REVIEWED AND APPROVED BY: DIRECTOR (OPERATIONS) SIGNATURE: DATE 24 05 11
ISSUED BY: MANAGEMENT REPRESENTATIVE, QMS SIGNATURE: DATE 24 05 11
QC Incharge
ISSUE NO: 1 ISSUE DATE: 24/05/2011 REV NO: 0
QUALITY MANAGEMENT SYSTEM MODERN PREFAB
QUALITY ASSURANCE PLAN : INCOMING MATERIAL
MANESAR
S.No
Process Part
Doc. No.:
Specification
Equipment / instrument / tool used
Sampling size / testing frequency
L - Length
Measuring tape
Five in every Lot
W - Width,
Measuring tape
Five in every Lot
T - Thickness
Micrometer
Five in every Lot
Visual inspection
Five in every Lot
Measuring tape/Vernier callipers
Five in every Lot
Visual inspection
Five in every Lot
NA
Check parameter
MPS - QAP - 01
REV DATE: Page No: 03 of 03
Internal
Tolerance limit / acceptable deviation
Control point
Periodicity of calibration / servicing
Internal
± 5mm
Calibration
Internal
± 2mm
Customer spec
Internal
NA
Customer / Manufacturer test certificate
2440mm
Calibration Method
External / internal
Once in a year
Comparison with standard scale
Internal
Calibration
Once in a year
Comparison with standard scale
Internal
± 2%
Calibration
Once in a year
Measuring Standard thickness
External
Internal
Zero tolerance
NA
NA
NA
NA
Internal
± 2%
Internal
Zero tolerance
Record
Responsib ility
(A) Dimensions
6
Aluminium Plate
QC Incharge
(B) Attributes Dent, damage, Rust, Oil free
(A) Dimensions 7
Aluminium Extrusion
Size
QC Incharge
(B) Attributes Dent, damage, Anodising,Coating
NA
NA
NA
NA
8
Door Lock
Properties
Five in every Lot
Customer spec
Zero tolerance
QC Incharge
9
Hinge
Properties
Five in every Lot
Customer spec
± 2%
QC Incharge
(A) Dimensions Size
10
Hard ware
Measuring tape/Vernier callipers/Micrometer
Internal
Five in every Lot
± 2% QC Incharge
(B) Attributes Rust, Rust, coating,T coating,Thread hread Visual Visual inspectio inspection n
Five in every Lot
REVIEWED AND APPROVED BY: DIRECTOR (OPERATIONS) SIGNATURE:
NA
Internal
Zero tolerance
NA
NA
ISSUED BY: MANAGEMENT REPRESENTATIVE, QMS SIGNATURE:
NA
NA
QUALITY MANAGEMENT SYSTEM
ISSUE NO: 1 ISSUE DATE: REV NO: 1
QUALITY ASSURANCE PLAN : INPROCESS FABRICATION REV DATE: 10/02/2012 Doc. No.:
S.No
Description
Characteristic
Type of Check
Extent of Check
Page No: 01 of 02
Reference Document
Specification Codes & Standards for Acceptance Criteria
Challan, Mill TC / Lab TC
IS 2062, IS: 1730, IS 1852
Inspection By Client / TPI
Format of Record
Remarks
1.0 Raw material a) 1.1
1.2
Plates
Hot Rolled Sections
Physical
b) Chemical c)
Mechanical
a)
Physical
b) Chemical c)
Mechanical
Measurement, Visual
10% of each lot
Mill TC & Fabricator Lab Report / Independent Lab TC Verification
100% 100%
Measurement, Visual
10% of each lot
Mill TC & Fabricator Lab Report / Independent Lab TC Verification
100%
Visual / Measurement
10% of each lot
Challan, Mill TC / Lab TC
100%
IS 2062 IS 1852
I
W
IR
R
R
Mill TC
R
R
Mill TC
I
W
IR
R
R
Mill TC
R
R
Mill TC
I
RW
IR
R
R
Manufacturer TC
R
R
Manufacturer TC
R
RW
Manufacturer TC
2.0 BOUGHT OUT ITEMS a) 2.1
2.2
Bolts Nuts & Washers
Physical
b) Mechanical c)
Chemical
a)
P hy hys ic ica l
100% Visual, Manufacturer TC Verification
100%
Paint
a) Welding Consumables
IS: 1367, IS: 3757, IS:4000, IS: 1599
Challan, Manufacturer IS: 101, ASTM D 2697 TC b) Chemical
2.3
100% Manufacturer TC
Challan, Manufacturer TC
Dimension
Manufacturer TC
100%
R
R
Manufacturer TC
Measurement
Per Batch
I
RW
IR
R
R
Manufacturer TC
R
R
Manufacturer TC
IR
b) Chemical
100% Manufacturer TC
c) Mecha echani nica call
Challan, Manufacturer TC
AWS D1.1 (2010) / ASME Sec II Part C
100%
3.0 FABRICATION PROCESS 3.1 3.1
Cutt Cuttin ing g & Shea Sheari ring ng
3.2
Fit Up
3.3
Welding Qualification
Dimension
Visual & Measurement
10%
Drawing
IS: 800
I
RW
Approved Drawings
IS: 800
I
RW
IR
I
R
WPS
I
R
P QR
I
R
WPQR
Visual & dimension
Measurement
10%
a) Procdu Procdure re Specif Specifica icatio tion n
Verification
100%
b) Procdu Procdure re Specif Specifica icatio tion n
Verification
100%
c) Welder Welder Qualif Qualifica icatio tion n
Verification
100%
Reference Documents & Test Reports
AWS D1.1 (2010)
Tensile, Bend & Chemical test for each Heat Number per 50 MT.
--do--
QUALITY MANAGEMENT SYSTEM
ISSUE NO: 1 ISSUE DATE: REV NO: 1
QUALITY ASSURANCE PLAN : INPROCESS FABRICATION REV DATE: 10/02/2012 Doc. No.:
Description
S.No
Characteristic
100%
DP & RT
10%
Dimension
Measurement
10%
a) Dime Dimens nsiion
Measurement
100%
Welding Inspection b) NDT
3.5
3.6
4
Drilling through approved Jigs / Templates
Final Inspection
Specification Codes & Standards for Acceptance Criteria
Approved Procedures
AWS D1.1 & ASME Sec V
b) Physi Physical cal Dama Damage ge
Visual
100%
c) Part Part Ident Identif ific icat atio ion n
Verification
100%
Approved Drawings
IS: 800
Approved Drawings
IS: 800, IS: 7215, IS 9595 & Approved Drawings
Inspection By Client / TPI I
Format of Record
Remarks
IR
RT if applicable on 10% of length of each Butt Joints & DP on atleast 10% of Length of all other joints
RW
I
RW
I
RW
IR
RW I
RW
IR
RW
GALVANIZING a)
4.1
Surface Defects
Visual
Galvanizing b) Mass Mass of Coat Coatin ing g
5
Reference Document
Extent of Check
Free from Cracks, Porosity, Inclusion, etc defects.
a) Visual 3.4
Type of Check
Page No: 02 of 02
Random
Technical Specification
IS: 2629; IS: 6745; IS: 2633
I
RW
IR
Measurement
SURFACE CLEANING & PAINTING
5.1
Sand Blasting
5.2
Painting
Surface Preparation
Measurement
Random
Approved Procedures
IS: 1477 (1971) Part I or SA 2.5
I
RW
IR
DFT & Adhesion Test
Measurement
Random
Approved Procedure
IS: 1477 (1971) Part II
I
W
IR
Legend :I - Inspection
RW - Random Witness
IS - Indian Standard
UT - Ultrasonic Test
R - Review
TC - Test Certificate
TPI - Third Party Inspector
DP - Dye Penetrant Test
W - Witness
MT - Metric Tonne
DFT - Dry Film Thickness
TPI - Third P arty Inspector
IR - Inspection Report
ASTM - American Society for Testing and Materials
AWS - American Welding Society
Prepared By :-
ASME: American Sosciety of Mechanical Engineering
Reviewed & Approved By :Client / Third Party Inspector
.
