Srwf Quality Manual

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Saudi ROCKwool

ISO 9001 :2008

SAUDI ROCKWOOL FACTORY Co. QUALITY MANUAL Clause: 4.2.2 I Document No.: QMM

SCOPE " Manufacturing, Marketing, Sales & After Sales services of Rockwool Thermal & Acoustical insulation materials for residential & industrial purpose". The scope extends to all Company personnel in terms of their individual and corporate responsibilities for Quality. This QMS Manual describes and dictates the quality system used by SAUDI ROCKWOOL and is modeled after the ISO 9001 :2008 standard. Due to the nature of production, testing and service provided in this quality system, exception to [section 7.3 pertains to 'Design and Development', 7.5.2 pertains to 'Validation of processes for production and service provision' and section 7.5.4 which pertains to 'Customer Property'J is being taken.

PURPOSE & ADMINISTRATION OF THE QUALITY MANUAL.

The Purpose of this Quality Manual is to formally establish the foundation upon which the Quality Management System operated by our Company is documented and implemented.

Based Upon the requirements of ISO 9001 :2008, this Quality Manual defines the Organizational structure of ROCKWOOL, together with Policies and Objectives for Quality that under proper operational management:

SAUDI

.:. Aim to enhance customer satisfaction . •:. Assure consistent conformance to product and service standards . •:. Assure compliance to recognized Health, Safety and other associated regulatory and mandatory requirements . •:. Effect a strategy of ongoing Continuous Improvement.

Copies of the Quality Manual provided to Customers, unless specifically requested otherwise, shall be "Uncontrolled" and will not be subjected to update.

The Quality Management Representative (M.R) is responsible for the administration of the Quality Manual and all associated procedures and forms that constitute the Quality Management System operated, in accordance with policy and procedures for Document Control.

Measurable Quality Objectives to measure the performance of functions and key parameters are documented as an integral part of Process Control applied.

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ISO 9001 :2008 Clause: 4.2.2

ROCKWOOL FACTORY Co. QUALITY MANUAL I Document No.: QMM

COMPANY

PROFILE

SAUDI ROCKWOOL was established in year 1412-Hijri corresponding to (1992-G) as specialized in the production of the Rockwool (Thermal, Acoustical and Fire Resistant Insulation). SAUDI ROCKWOOL' s manufacturing unit is situated in 2"d Industrial Area, P.O.Box: 145, Riyadh: 11383, Kingdom of Saudi Arabia. SAUDI ROCKWOOL has installed up to date machinery and test equipment from the leading manufacturers in Thermal & Acoustical Industry. The very quick success of SAUDI ROCKWOOL has experienced mainly due to its commitment to excellence, quality and best customer service. SAUDI ROCKWOOL' s policy of offering the highest possible standards guarantee, that all material chosen for their high quality, durability, and competent in the world market. SAUDI ROCKWOOL offers high-grade products under Commercial Registration No. 10100972741001 and using wealth of knowledge from highly qualified engineers and well skilled workers and professionals. SAUDI ROCKWOOL not only take pride in the Quality of their Products but in the ability to respond quickly to customer requirements. SAUDI ROCKWOOL is small enough to be flexible and large enough to meet the demands of the market. We have illustrious and prompt position in Kingdom Ministries as reliable Manufacturer since 14 years of active experience, such as in Saudi ARAMCO, SABIC, KNPC, Petrochemical Ind. Co.-Kuwait etc. also in all over Saudi Arabia Kingdom and in Local Market. The availability of locally based experienced application engineering and design are outfitted by very Experience Engineers which can handle more comfortably as well as part of our job.

The "Mission" of our company in continued business expansion, is striving always to improve upon the Quality of what we do. To this effect "SAUDI ROCKWOOL" have embarked upon an Ongoing Business Improvement Program based upon the standard ISO 9001:2008, the corner stone of which are effective strategic Planning, Team Enterprise, Continuous Improvement and Commitment to our customers and our Company. By this means we are seeking the security and prosperity of all associated with SAUDI ROCKWOOL, our customers, suppliers and staff alike.

CORPORATE

QUALITY

OBJECTIVES

OF SAUDI ROCKWOOL

SAUDI ROCKWOOL stands committed to assuring that products and services provided to our customers consistently meet or exceed their needs, expectations and own perception of Quality. •

Provide a work environment that values integrity and encourage teamwork, innovation and personal professional growth at all levels of the organization. • Enhance our competitiveness and esteem in our market by maintaining and endeavoring to continuously improve upon the Quality of products and services provided to our customers. At different department and functional level e measurable quality objectives have been defined and documented. It shall b eviewe p riodically as a part of continual improvement.

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ROCKwool

ISO 9001 :2008


MANAGEMENT COMMITMENT Our Management

Team is committed

to:

•

Maintain a high Profile in leading the Quality Awareness Strategy to assure compliance with requirements and continually improve the effectiveness of the Quality Management System operated.

•

An ongoing strategy of Continuous Improvement striving always to better previous performance in terms of operational practice and Quality in it's broadest sense.

•

Establishing measurable Objectives at appropriate levels and functions of the organization, whereby performance in the achievement of defined goals may be monitored and continually updated as targets are met, in line with the Ongoing Improvement Strategy.

•

Encouraging participation and support for the implementation of this Policy through Training, Empowerment and Delegation, operating a formal Quality Management System meeting the requirements of ISO 9001 :2008.

•

Building long term relation ship with our customers and suppliers based upon mutual trust and respect, actively liaison with them to enable us to Plan in advance the technology and processes that will assure that products are produced consistently correct to specification, within the agreed time scale, at an optimum cost.

•

As a General Manager I accept my fundamental responsibility for the Quality of Products and Services provided to our customers. I will discharge my responsibility through my management team who will, by direction and example, ensure that this policy is understood, accepted, implemented and maintained throughout our organization.

We, the management and staff of SAUDI ROCKWOOL are committed and has an objective to timely provide our customers the products and services which are of high grade quality, cost effective, consistent and conforms with special customer's as well as statutory and regulatory requirement. This will be achieved through continuous development, application of latest and advanced technology. Intensive rigid training, for the manpower force to improve the quality of our products and services that exceeds our customer's expectations and to be competitive in the world market. SAUDI ROCKWOOL top management is fully committed to provide the adequate resources for the achievement of quality objectives. The management and staff of SAUDI ROCKWOOL are committed to use proper monitoring & measuring tools for the continual improvement of the company Quality Management System. The Quality Policy shall be achieved by the management and all employees in implementing IS09001:2008 quaiity management system which covers all the company operations and applies to all company personnel.

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ISO 9001 :2008

QUALITY 1.


MANAGEMENT

SYSTEMS

IS09001 :2000 - REQUIREMENTS

SCOPE The scope of SAUDI ROCKWOOL' s Quality Management System under the framework of ISO 9001 :2008 (E) standard is defined as: " Manufacturing, Marketing, Sales & After Sales services of Rockwool Thermal & Acoustical insulation materials for residential & industrial purpose fl.

This Quality Manual clearly specifies the scope related to SAUDI ROCKWOOL's Manufacturing Thermal & Acoustical insulation materials in the Kingdom of Saudi Arabia. This is the first level document, which outlines the Quality Management System of the company and shows how, the requirements of ISO 9001 :2008(E) standard are met through effective implementation of the system. The ultimate goal is to enhance the customer satisfaction through the effective control and implementation of the system through timely measures for continuous improvement. The system assures the conformity to customer requirements and to the applicable regulatory and legal codes. 1.1.

Application: In this Quality Manual Design & Development - 7.3 and the Customer Property - 7.5.4 and Validation of Processes for production and service provision - 7.5.2 have been excluded in consideration to the nature of business.

2.

NORMATIVE REFERENCE This Quality Manual complies with the requirements of the International Quality Standard: ISO 9001 :2008(E) Quality Management System· Fundamentals and Vocabulary.

QAP SOP QMM WI PFC FM Supplier QA SA Organization

QMS :Quality Management System : Quality Assurance Procedures. : System Operating Procedures. MR : Management Representative. : Quality Management Manual. PU : Purchase. : Work Instructions. CL : Calibration IT : Identification/Trace-ability : Process Flow Chart MT : Maintenance. : Quality Records (Forms). : Subcontractor or Vendor. QC :Quality Control Laboratory : Quality Assurance. PR : Production : Sales : Refers to the unit to which QMS applies (SAUDI ROCKWOOL).

Quality: Quality Audits:

Quality Assurance: Quality Control: Quality Policy:

The totality of features and characteristics of a product or service that bears on its ability to satisfy stated or implied needs. Activities and related results comply with planned arrangements and whether these arrangements are implemented effectively and are suitable to achieve objectives. The operational Techniques and activities that are used to fulfill requirements for Quality. A document setti out the specific quality practices, resources and sequence of actlvi I s relev to a particular product, service or project. The overall quaIi . tentio nd direction of an organization as regards qUility, is form II expres by top management.

A

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4.1

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ISO 9001 :2008


General: SAUDI ROCKWOOL is to establish, document, implement and maintain a quality management system and Continually Improve its effectiveness. This will be achieved by: • • • • •

4.2.

Identifying the processes needed and their application in the organization. Determining the sequence and interaction of these processes. Documenting responsibilities and control applied to ensure effective operation and control. Ensuring the availability of resources and information necessary to support the operation and monitoring of these processes. Monitoring, Measuring and Analyzing the outputs of all business processes, re-qualifying the processes where necessary to achieve the planned results or to continually improve and add value to the processes.

DOCUMENTATION REQUIREMENTS:

4.2.1

•

General: The Quality Management System documentation will include: Published statements of the Quality Policy and as an integral part of Process Planning, Measurable Quality Objectives.

•

A Quality Manual, Quality Assurance Procedures, System Operating Procedures and Work Instructions as required by the Standard ISO 9001 :2008 to assure the effective, Operation and Control of Processes.

•

Quality Records to demonstrate the achievement of planned strategies, product and service quality and to demonstrate the effectiveness of the Quality Management System in Operation.

4.2.2

The Quality management System of SAUDI ROCKWOOL operated on six level documentation.

1. Quality Manual: Containing the Company Quality Policy, the Organization Structure and policies describing the controls to be applied and referencing Quality Assurance Procedures, System Operating Procedures. They describe the departmental interaction involved in the processing of the

Quality Management System.

fine responsibilities and controls applied.

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ISO 9001 :2008 Clause: 4.2.2


3. System Operating Procedures: Written for the smooth Operation of the process or the Plant. Assigning the responsibilities and authorities to perform the specific job. Departmental & Functional objectives together with their measurable quantifiers, established to provide targets in terms of achievement and ongoing improvement. 4. Work Instructions: Comprising of company standards, specifications, Technical Directives, codes of Practice or legislation and safety requirements associated to the Industry. 5. Forms: That constitutes the Quality Records generated by the system. 6. Appendix: Contains standard acceptable measures used in the procedure.

Quality Plans, specific to individual contracts may be generated to augment the established Quality System. 7. Documents of External Origin

4.2.3

Control of Documents. All documents forming part of the SAUDI ROCKWOOL' s Quality Management System are subject to documented procedures to ensure that: • • • • • • •

Each document is provided with a unique identification and is registered. Documents are approved by the designated authority prior to issue to a defined and controlled distribution. All changes to document are reviewed and approved by the concerned Dept Head and General Manager for the original approval and issue, prior to re-issue. Only current issues of documents are available at designated locations. Obsolete documents are removed from all points of use. Obsolete documents required for historical purpose are suitably identified prior to segregated filing. Master copies of documents are retained by Management Representative.

The system applied will be extended to control Externally Sourced documents and any Electronically Produced Data. Reference Documents: Control of Data & Documents Document & Data Master List QSD Issue Register Document Change Note Electronic Data Register

QAP01 FM.DD.01 FM.DD.02 FM.DD.03 FM.DD.04

Quality Quality Quality Quality Quality

Assurance Procedure Record Record Record Record

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4.2.4

ISO 9001 :2008 Clause: 4.2.2


Control of Quality Records. A formal procedure QAP 02 will direct the Generation Reporting Indexing Filing

Collection Security

And maintenance of all records generated by the Quality Management System. The Record in hard copy or electronically processed will demonstrate the effectiveness of the Quality System operated and that all contracted product standards have been achieved. The records will be maintained for defined periods established by our company, or as consistent with contract requirements or prevailing legislation. Records will be subject to systematic review and analysis as an integral part of the company's Internal Audit Plan and Management Review Process to identify any apparent trends. It also proves the effectiveness of their application and identifies opportunities for improvement. The disposal of records at the end of their retention period will be carried out under controlled conditions designed to protect the status of any confidential or exclusive information. By this means SAUDI ROCKWOOL will ensure that at all times, records remain legible, identifiable and retrievable.

Reference Documents: Control of Records Quality Record Log

5.

QAP02 FM.QR.01

Quality Assurance Procedure. Quality Record.

MANAGEMENT RESPONSIBILITY

5.1

Management Commitment The Management of SAUDI ROCKWOOL will be pro-active demonstrating commitment and direction to the implementation of the Quality Management System and it's continuing improvement. • Regularly communicating to the organization the importance of meeting customer and regulatory requirements via: Quality policy, Routing Instructions and meeting etc. • Establishing the Quality Policy. • Assign the Quality Objectives. • Management Reviews: such as the Management Review Meeting. • Ensuring the availability of Resources.

5.2

Customer Focus iOp Management ensures that cu

eentraet reviews and meesurem

Mana

r ments are Identified and achieved throl"Jgh t

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5.2

ISO 9001 :2008


Quality Policy.

Quality Policy has been defined on page No.4 of this manual. Quality policy, approved by the General Manager and have published it in strategic locations throughout the organization as an integral element of the company's Quality Awareness Program and will be reviewed as an integral part of Company's Management Review meetings to assure its integrity and suitability in the light of customer response and current business strategy. 5.4

Planning. 5.4.1

Quality Objectives SAUDI ROCKWOOl Quantifiable

Quality Objectives, including those required to realize product standards will be established at all relevant functions and levels of the organization. The corporate Quality Objectives are to: Objectives

Responsibility

Reduce oxygen consumption to Cupola furnace >- Cupola line production yield >- Coke consumption/ton of finished product >- Cupola line product weight variation Percentage of breakdown time per running Hr monthly: >- New line to be max. 2% >- Old panel line to be max. 1.25% Updating Independent Third Party Test Report

Production Manager, Shift Supervisor, Furnace Operators, Control Room Operator, Rock Charger, Superintendent.

Department Production

Maintenance

Quality

5.4.2

>-

Time Span.

Monitoring Tools

Present Status

Maintenance Manager Mech. Maintenance Eng. Elec. Maintenance Eng. Quality& Technical Support Manager. Quality Enoineer

Quality ManagementSystem Planning. •

5.5

Top Management ensures that the resources needed to achieve the quality objectives are identified and planned. • Planning is conducted to ensure changes to the quality management system are conducted in a controlled manner and the integrity of the quality management system is maintained. Responsibility, Authority and Communication. 5.5.1

Responsibility and Authority. Organizational responsibilities and authorities are defined graphically in the organization Structure illustrated in Appendix A-01 of this manual and documented Quality Assurance Procedures and System Operating Procedures. The responsibilities and authorities are well defined for all the quality affecting personnel.

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5.5.2

ISO 9001 :2008


Management Representative Top management has appointed a member of management, who irrespective of other responsibilities shall have responsibility and authority that includes: • Ensuring processes needed for the quality system are established, implemented and maintained. • Reporting the performance of the quality system and improvement needs to top management. • Ensuring the promotion of awareness of customer requirements throughout the organ ization.

5.5.3

Internal Communication. Management will ensure that appropriate channels of communications are established to clearly define responsibilities and authorities, ensure the understanding of customer or statutory 1 regulatory requirements and to report upon and demonstrate the effectiveness of the Quality Management System in Operation.

5.6

Management Review. 5.6.1

General. At determined intervals SAUDI ROCKWOOL Management will conduct formal Management Review Meetings, chaired by the General Manager and organized by MR to establish the ongoing effectiveness of the Quality System in terms of Customer Satisfaction, the achievement of objectives and as a focus for Continuous Improvement. The quorum for attendees to the review meeting is designated in the Meeting Minutes FM.MR.01. At a minimum the meeting shall be conducted on a half yearly basis.

5.6.2

Review Input (Minimum). At a minimum the following points have been discussed in the review meeting: • Results of Internal and External Audits. • Customer Feedback. • Process performance and Product conformance. • Status of Preventive and Corrective Actions. • Supplier Performance and Evaluation. • Follow-up actions from the previous management review meeting. • Planned changes that could effect the quality management system. • Recommendations for the improvement.

5.6.3

Review Output (Minimum). • •

Recommendations for improvement of the QMS and its Processes. Recommendations for improvement of product related to customer requirements.

•

ResQl,Jrcesneeded for the organization

achieve the objectives,

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Management Review meeting report Management Review Organization Structure Objectives as a Continuous Improvement Quality Policy

6.

FMMR.01 Quality Record QAP .06 Quality Assurance Procedure. Appendix A-01 FMQM01 Page#:03 of this Quality System Manual.

RESOURCEMANAGEMENT

6.1

Provision of Resources. The SAUDI ROCKWOOL as an Organization at all times will be adequately resourced in terms of equipment, raw materials, work areas, and trained personnel to enable all functions to operate effectively in terms of: • Managing, performing and verifying the effectiveness of all business activities. • Implementing and maintaining the Quality Management System and continually Improving its effectiveness. • Enhancing Customer Satisfaction.

6.2

Human Resources. 6.2.1

General Personnel performing work effecting product quality will be competent on the basis of appropriate education, training, skills and experience. The levels of Competency required will be documented and provide input to the Company's Training Program.

6.2.2

Competence, Awareness and Training. The skills and qualifications of all personnel within the organization are essential to achieving business and quality objectives. Accordingly all personnel will be employed suitably qualified to carry out their allotted tasks. Special attention shall be given to the initial training of new employees, and to ensure their awareness of the relevance of their activities and contribution to the achievement of objectives. Knowledge and skills possessed shall be augmented by further training as the needs of individuals are identified, or as specific training requirements become evident as a result of new technology, or in support to the company's business plans.

intilini

I

Tr~lnl 9

t i iffiQtiv niii of triining will b riviiw d nd rovlded will be monitored to ~rovlde Inl'ut to

.ee will be assessed and appraised according to

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ISO 9001 :2008

their personal performance will be provided accordingly

every year. If any employee to fulfill our quality needs.

found incompatible,

training

Reference Documents: Training, Competency & Administration New Employee Training Request Employee Training Request . Employee Training Record Personnel Following up & Evaluation Register

6.3

Infrastructure &

6.4

SOP 04 FM. TR.01 FM. TR..02 FM. TR.03 FM.TR.04

System Operating Procedure Quality Record Quality Record Quality Record Quality Record

Work Environment

As an integral part of planning for the Product Realization, the infrastructure and work environment to achieve conformance to product requirements will be planned, implemented and maintained. Machines and supporting equipment were maintained as per schedule and closely watch the breakdown time as well as cost of the maintenance. The machine maintenance have been controlled by proper planning and scheduling as per the System Operating Procedure SOP 05.

Reference Documents: Equipment Maintenance Machine Maint Request Preventive Maint work order Equipment detail report Out side Maintenance/Fabrication Request New Installed machine/equipment Emergency Stop Request Spare parts Re-order level 7.

SOP 05 FM.MT01 FM.MT02 FM.MT03 FM.MT04 FM.MT05 FM.MT06 FM.MT07

System Operating Procedure Quality Record Quality Record Quality Record Quality Record Quality Record Quality Record Quality Record

PRODUCT REALIZATION 7.1

Planning of Product Realization. The effectiveness System operated

of Process Controls applied is fundamental to the proficiency by SAUDI ROCKWOOL to Product Realization.

Accordingly controls applied to materials control, production planning, and the service 1 delivery process will be planned and documented. Production • • • •

• • •

of the Quality

manufacturing

process

Process will ensure that:

Material availability is scheduled and controlled. Responsibilities and accountabilities are clearly defined. People employed are adequately skilled to perform their allotted tasks. Machinery and supporting equipment used in the process is regularly serviced and is capable of operation to the required quality standards. Maintenance of equipment will be done as per SOP 05. Inspection and test criteria are established and defined together with acceptance criteria to control the Quality of the products. Records are established a maint n d in a controlled manner. Legislation, standards an c des p actice, where appropriate, are complying accordingly. Issue. No.

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Reference Documents: Received Material Inspection Report Stock Ledger Daily Production Plan Production Order Internal Transfer of Stored products! Reprocessing Order Daily List of Production Process Control Flow Chart Work Instructions 7.2

FMST01 FMST03 FM PR.01 FM PR.03 - 04

Quality Record Quality Record Quality Record Quality Record

FM PR.05 FM PR.06 - 08 PFG.01- 03 WI.PR.01- 13

Quality Record Quality Record Process Charts

Customer Related Processes. 7.2.1

Determination of Requirements Related to the Product. SAUDI ROCKWOOL will determine and document the customer's requirement as an integral part of customer's contract for Sales. It shall be regularly monitored through visits and meetings. Customer's complaints shall be forwarded to SAUDI ROCKWOOL through Tel, emails, Fax or visits. • Customer's requirements including delivery and post delivery activities where applicable. • Product specifications, Standards and user Instructions as applicable. • Reference to any regulatory requirements. • Statutory or legal requirements not stated by the customer but necessary for specified or intended and safe use, where known. • Any additional requirement will be determined by the Organization.

7.2.2

Review of Requirements Related to the Product. The SAUDI ROCKWOOL shall review the requirements related to the Products before the commitment to supply. All customer sales orders, inquiries or invitations to tenders shall be subject to a formal system of Customer Contract Review as per the

PFC.SA.01. Personnel assigned responsibility for the review will include all concerned department heads who will contribute to establishing and implementing the condition of contract through Internal Feedback process.

• • •

• • •

As a minimum the review will ensure that: The product requirements are well defined and understood. Customer requirements are clearly documented and compatible to the scope of business operated by SAUDI ROCKWOOL. SAUDI ROCKWOOL has a necessary resource in terms of materials, equipment, people and skills to meet all conditions of contract within the defined time scales at optimum costs. Any customer needs differing from that as originally proposed shall be identified and resolved. Any variation to contracted conditions are formally reviewed and agreed by both the customer and SAUDI ROCKWOOL p( to effecting any change to the contract. Records of the review and e actio s rising are maintained.

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By this means SAUDI ROCKWOOL will ensure that all Technical, Commercial, Legal and Quality conditions of the contract are fully understood and acceptable to both the customer and SAUDI ROCKWOOL prior to completing the contract, and that our company has the ability of meeting all contract conditions, Right First Time.

7.2.3

Reference Documents: Quotation Contract Review Quotation / Contract Review Form (Amendment) Sales Order Sales Production Request Quartely Sales Forcast Customer Contract Review Process Fast Moving Standard Product List Price List Customer Communication.

FMSA01 FMSA01-a FMSA02 FMSA03 FMSA04 PFG.SACU 1.1 Appendix SA01 Appendix SA 02

SAUDI ROCKWOOL will be pro-active communicating with customers. Organization has been equipped with best Intercom Telephone system to access all department easily by the customers. SAUDI ROCKWOOL used to communicate with the customers in particular in relation to: • • •

7.3

The provision of product information. Handling "Customer orders and inquiries". Dealing proficiently in the event of customer complaints and customer's feedback or any queries from customers ..

Design and Development. SAUDI ROCKWOOL undertakes no Design and Developing work at their own. It is not in the scope of SAUDI ROCKWOOL' s Quality Management System.

7.4

Purchasing 7.4.1

Purchasing Process All the Purchase Orders and contracts for the supply of Raw Material, Product related Parts / Equipment or Services will be placed with listed companies of proven capability of being able to meet all quality and commercial conditions of contract. Such suppliers will constitute the Companies Approved Supplier List. New or prospective Suppliers will be subject to a formal system of approval to assure their capability of consistently meeting the standards of supply and service required by SAUDI ROCKWOOL. The performance of all listed suppliers in meeting the required standard will be monitored on a continuing basis and where the need is identified. Evaluation will be carried out to consolidate the Supplier's Status as an Approved Supplier. Any negative remarks fro evaluate it in the Manag

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7.4.2


Reference Documents: Purchasing & Supplier Evaluation Purchase Order New- Supplier Assessment Re-Evaluation of Supplier Approved Supplier List (ASL) Purchase Request Quotation Request Quote Analysis Report Sample Approval Form Purchase & Purchase Product Inspection New Supplier Evaluation & Re-Evaluation of Existing Suppliers Purchase Process Purchasing Information.

SOP 08 FMPU01 FMPU02 FMPU03 FMPU04 FMPU05 FMPU06 FMPU07 FMPU08 PFCPU02

System Operating Procedure Quality Record Quality Record Quality Record Quality Record Quality Record Quality Record Quality Record Quality Record Flow Chart

PFC.PU03 PFCPU01

Flow Chart Flow Chart

All purchase orders or contracts placed with the suppliers will contain a clear description of the requirements and will cross-reference any specifications, certificate or other standards to be applied. Any changes to the procurement document require the same degree of control as the original issue.

7.4.3

Verification of Purchased Product. Purchased products will be inspected upon receipt into the company to the degree necessary to assure conformance to specified purchase requirements. Concerned Inspectors shall sign on the Receipt Voucher of that material. Where specified in the contract, the customer's representative or a representative from SAUDI ROCKWOOL, will be given the right to verify at a supplier's premises that the goods / service conforms to specified requirements. By this means SAUDI ROCKWOOL will ensure that the required procurement and supply are constantly maintained.

standards

of

Reference Documents: Purchasing & Supplier Evaluation SOP 08 System Purchase Order FMPU01 Received Material Inspection Report FMST.01 New Supplier Evaluation & Re-Evaluation of Existing Suppliers PFCPU 03

7.5

Operating Procedure Quality Record. Quality Record. Flow Chart

Production and Service Provision 7.5.1

Control of Production & Service Provision. The Controls applied to production and service provision will be planned and documented as an integral part of plannin product realization. This will be achieved

•

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ISO 9001 :2008

• • • • •

Clause: 4.2.2

The The The The The


availability of Work Instructions and System Operating Procedures. use of suitable equipment. availability and use of monitoring and measuring devices. implementation of monitoring and measuring and implementation of release, delivery and post delivery activities.

Reference Documents: Process Control Chart Daily Production Plan Received Material Inspection Report Quality Control Process Control

7.5.2

PFC.PR.01-03 FM.PR.01 FM.ST.01 SOP.02 SOP.01

Validation of Process for Production & Service Provision. SAUDI ROCKWOOL undertakes no Validation of Process for Production & Service Provision. It is not in the scope of SAUDI ROCKWOOL' s Quality Management System.

7.5.3

Identification and Traceability.

Each Material like Raw Material 1 Spare Parts 1 Finished or Semi Finished Products and allocated areas shall be identified, upon receipt and through out the process to determine the material status. Monitoring and Measuring results shall be recorded. In order to prevent the misuse or misapplication and to maintain identification of purchased material, In-Process material and completed products, SAUDI ROCKWOOL utilizes (Identification and Trace ability) in System Operating Procedure (SOP.09). Identification during delivery is accomplished through the use of identifiers on product packaging and 1 or the product itself. These identification Stickers are unique to each product.

Reference Documents:

Identification and Traceability SOP.09 S. Operating Procedure. Material Identification Card FM.IT.01 Identification Label Storage Rack FM.IT.02 Identification Label Product Label FM.IT.03 Identification Label Prodn. Label Pipe FM.IT.04 Identification Label Received Material Inspection Report FM.ST.01 Quality Records Identification Slip / stickers during In-Process and Finished Products as well as Raw Material Identification Slips / Stickers as required. 7.5.4

Customer Property. SAUDI ROCKWOOL

G

unde

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SAUDI

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ISO 9001 :2008

7.5.5

Clause: 4.2.2


Preservation of Products. Documented Storage, Handling, Delivery & Preservation procedure SOP.O? and a strategy of Safety and Handling practice assures that SAUDI ROCKWOOL employ due diligence to good engineering practice in terms of: • • •

Safety material handling for both the "Material" and the "Handler". The operation of equipment and machinery. Any hazards associated to the handling of substances Hazardous

to Health.

All Raw Material and Finished goods storage area will be effectively managed to the degree necessary in terms of security, identification and the preservation of material and products in the storage area. All stock movements into or out of storage area will be subject to the principles of stock rotation in First In First Out (FIFO) basis. Reference Documents: Control of Non- Conforming Material/ Product Purchasing & Supplier Evaluation Stores Sales Order Received Material Inspection Report 7.6

QAP03 SOP 08 SOP.07 FMSA.02 FMSr01

Q. Assurance Procedure. S. Operating Procedure S. Operating Procedure Quality Record Quality Record.

Control of Monitoring & Measuring Devices.

All Monitoring planned and specified.

and Measuring Devices invovled assured suitable and appropriate

in the assurance to the criticality

of product quality will be of measurement or test

Equipment will be registered, uniquely identified and subject to calibration and certification against reference standards traceable to International or National Standards or Standards recognized within the Industry. The Calibration status of each item of equipment will be maintained and calibration records established would be closely monitored to ensure that re-calibration or service takes place prior to any probable change in accuracy that may be significant to the assurance of product quality.

Reference Documents: Calibration Equipment Calibration Sticker Instrument Calibration Report Calibration Master List

8.

SOP.06 FMCL.01 FMCL.02 FM CL.03

System Operating Procedure Quality Record. Quality Record Quality Record.

MEASUREMENT, ANALYSIS AND IMPROVEMENT.

8.1

General

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ISO 9001 :2008


The SAUDI ROCKWOOL will plan and implement the monitoring, measurement, analysis and improvement processes needed to: • • •

8.2

Demonstrate conformity of Products. Ensure conformity of the Quality Management System. Continually improve the effectiveness of Quality Management System.

Monitoring 8.2.1

& Measurement.

Customer

Satisfaction.

SAUDI ROCKWOOL will be pro-active in determining to degree to which the products and services provided to customers continue to meet or exceed their expectations of Quality.

This will be achieved through planned visit to key accounts and statistically designed questionnaire survey will be provided to identify the strength and weaknesses of SAUDI ROCKWOOL and direct the improvement process. Continuous Improvement will be done by using latest technology and highly skilled man power. Reference Documents: Non Conforming Material Report/Potential Problem FMNC.01 Corrective & Preventive Action QAP 05 Customer Satisfaction Survey FMCC.01 Corrective & Preventive Action Register. FM CPo01 Customer Complaint & Satisfaction Survey SOP. 10 8.2.2

Quality Record Quality Assurance Procedure Quality Record. Quality Record System Operating Procedure

Internal Audit

The Internal Audits in SAUDI ROCKWOOL' s audit system are tackled in Quality Assurance Procedure QAP.04. Audits are scheduled and these schedules remain dynamic responding to the health of the Quality Management System. The Quality Management System operated by SAUDI ROCKWOOL will be subject to a documented and systematic program of Internal Quality Audits. Audit Plan is designed to ensure that, over twelve-month duration, each business function is subject to audit. The audit shall be scheduled to gain maximum benefit, taking due account of the strategic importance of department and functions in contributing to Quality and the results of previous audits. Areas considered "critical" would be audited more frequently each year than others. The audits will be carried out by suitably qualified auditors from within the company, ideally independent of having direct responsibility in the function or department being audited. Where Non-Compliance or opportunity to improve systems are identified, appropriate corrective actions or control ed chang ill be implemented.

.:

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ISO 9001 :2008 Clause: 4.2.2


The results of Internal Audits will be recorded, maintained and subject to further review as an integral part of Management Review Meeting, thus assuring the effectiveness of the Audit program in achieving desired goals. Reference Documents: Internal Audit Audit Schedule Internal Audit Checklist Nonconformance Report/Corrective Action Request (NCRICAR) Internal Audit Report CAR Status Log

8.2.3

QAP04 FM/A01 FM IA 02.

Quality Assurance Procedure. Quality Record. Quality Record

FM IA 03 FM IA 04 FM IA 05

Quality Record Quality Record. Quality Record.

Monitoring & Measurement of Processes. The SAUDI ROCKWOOL use suitable methods for monitoring where applicable, the measurement of quality management system processes. These methods demonstrating the ability of processes to achieve planned results. When planned results are not achieved, Correction and Corrective Actions shall be taken as appropriate, to ensure the Conformity of the Product. Reference Documents: Process Control Flow Chart Quality Control Procedure Raw Material Tolerances Finished Product Tolerances

8.2.4

PFC.PR. 01-03 SOP. 02 Appendix - QC.01 Appendix - QG.02

Monitoring and Measurement of Product.

The Product characteristics requirement have been met.

to be determined

and measured

to verify that

This has been carried out at appropriate stages of the realization process. Products release and delivery not to proceed until planned arrangements have been satisfactorily completed unless otherwise approved by a relevant authority and, where applicable by customer. Reference Documents: Phenolic Formaldehyde Resin Test Report Inspection Report for Packing & facing Materials Rock and coke Inspection Report Final Inspection Report Daily Quantity control of production Final Inspection Report For Pipe cti n Finished Product Laboratory Te Re ort

FMQG.01 FMQG.02 FMQG.03 FMQC.04 FMQC.05 FMQC.06 FMQC.07

Quality Record Quality Record Quality Record Quality Record Quality Record Quality Record Quality Record

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r~ S:~.PJl.f(J1SIS~CfJ 1,,1' • .-,11 Y'~I ~I Saudi Rockwool

ISO 9001 :2008


Preventing inadvertent use or installation of product is accomplished through the use of QAP.05 Quality assurance Procedure for Control of Non Conforming Products. All non conforming material or products identified at any stage of processing will be subject to formal procedures that will provide for their Prominent identification and Segregation where applicable into Quarantine areas. • • •

Recording, reporting and review of these Non Conformances. Assignment of actions required for the disposition of the "Non Conforming Products". Assignment of actions required upon In-process or already Dispatched to the customers.

As an integral part of the review of any reported non-conforming products, effort to established the cause of the non conformance and actions required to prevent from Recurrence of similar non conformance, will be paramount. The proposed supply of any product not "totally" in conformance to contracted specifications, will be formally reported to the customer to get the necessary approval. In the event that assigned actions involve "re-process / repair" the DGM Technical, Q.C Manager along with M.R will decide and assure the effectiveness of such actions. All records associated to the control of Non Conforming Products will be subjected to review and analysis at Management Review Meetings in order to identify any significant trends or failure modes warranting corrective and preventive action.

Reference Documents: Control of Non Conforming Material/Product Corrective & Preventive Action Corrective & Preventive Action Register Customer Complaint Report Non Conformance Material/Product Report (Finished Products or Purchased Material)

8.4

QAP03 QAP05 FM.CP.01 FM.CC.02 FM.NC.01

Quality Assurance Procedure Quality Assurance Procedure Quality Record. Quality Record. Quality Record

Analysis of Data The Data generated by monitoring and measurement activities and other process performance indicators, will be determined, collected and analyzed to demonstrate the suitability and effectiveness of the quality management system and to evaluate where continual improvement can be made. The data to be analyzed to provide information on: • Customer Satisfaction. • Conformance to product requirements. • Characteristics and trends of processes nd products including opportunities for preventive action and Process ectiven s. • Suppliers Performance.

8.5

Improvement A

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ROCKwool

ISO 9001 :2008

8.5.1


Continual Improvement. Through the use of company Quality Policy, Quality Objectives, Audit Results, Analysis of Data, Corrective and Preventive Actions and Management Review Meetings (FM.MR.01), SAUDI ROCKWOOl will establish the strategy for the Continuous Improvement effectively. Reference Documents: Management Review Meeting Report Corrective & Preventive Action Register CAR Status Log

8.5.2

FMMR.01 FMCP.01 FM IA. 05

Corrective Action. SAUDI ROCKWOOl will operate a formally documented system of Corrective Action. The system will be applied to all identified Non-Conformance, whether associated to the quality system, process or the product or service supplied.

Procedure shall detail methods and responsibilities in order to direct: • • • •

Investigation into the cause of Non-conforming product or materials and the Corrective Action required preventing recurrence. The initiating of actions to deal with problems to a level corresponding to the Risk encountered. The application of controls to ensure that the appropriate corrective actions are taken and that they are effective. The implementation of control of change resulting from Corrective Action.

All Corrective Actions will be officially assigned, be time limited, implemented and upon completion will be reviewed for effectiveness.

8.5.3

PreventiveAction.

SAUDI ROCKWOOl will operate a formally documented Procedure QAP 05 of Preventive Action, which define the responsibilities and direct the controls applied to the analysis of all processes, work operations, concessions, quality records, and customer complaints, to detect and eli inate or reduce the probability of the occurrence of potential causes f Non c formance. Where potential causes of 0 confer i es are identified, special techniques will be applied in an effort to e I mate educe the probability of non conformance occurred. Such Techniqu could (PPFMEA) Potential Process Failure Modes & A r ed b : Issue. No. Date of Issue Pa e 2/1

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ISO 9001 :2008


Effects Analysis. The records generated forming an integral part of ongoing Improvement Process.

Reference Documents: Corrective & Preventive Action Internal Audit

QAP05 QAP 04

Quality Assurance Procedure. Quality Assurance Procedure.

Issue. No.

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21 of 21

SAUDI ROCKWOOL FACTORY CO. ORGANIZATION STRUCTURE CEO GIG

GENERAL MANAGER

PURCUREMENT MANAGER

HUMAN RESOURCE

SALES MANAGER

MARKETING MANAGER

OPERATION MANAGER

ec Support Manager t---------,

Issue: 2/1

Issued by:

_~

~

Approved by:

APPENDIX:A-Ol

Srwf Quality Manual

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