Ims Manual New
Ims Manual New
Ims Manual New
Integrated
Management System
(IMS) Manual
ISO 9001-2015 CLAUSE NO. 8.3 & 8.5.1(F) NOT APPLICABLE
EFFECTIVE DATE: 02/07/2018 , REF NO: JPE-IMS-01
Scope of Certification:
Manufacture & Supply of All Kinds of Rubber &
Plastic Moulding Parts and Foam Based Items
1.1 CONTENTS
PAGE NO. OF
SEC. NO. DESCRIPTION
NO. SHEET
0.0 COVER PAGE 01 1
1.1 CONTENTS 02 1
1.2 ABBREVIATIONS 03 1
1.3 DISTRIBUTION LIST OF CONTROLLED COPY HOLDERS 04 1
1.4 REVISION RECORD 05 1
1.5 SCOPE OF MANUAL 06 1
1.6 BRIEF HISTORY OF M/S J.P ENTERPRISES 07 1
2.0 QUALITY POLICY & QUALITY OBJECTIVES 08 1
3.0 EHS & S POLICY & EMS OBJECTIVES 09 2
4.0 CONTEXT OF THE ORGANIZATION 11 2
5.0 LEADERSHIP 13 4
6.0 PLANNING 17 2
7.0 SUPPORT 19 5
8.0 OPERATIONS 24 6
9.0 PERFORMANCE EVALUATION 30 4
10.0 IMPROVEMENT 34 3
11.0 INTERACTION OF PROCESSES FOR QMS 37 1
12.0 INTERACTION OF PROCESSES FOR EMS 38 1
13.0 PROCEDURE FOR DETERMINING SIGNIFICANT ASPECTS 39 1
14.0 PROCEDURE FOR HAZARD IDENTIFICATION AND RISK ASSESSMENT 40 2
15.0 PROCEDURE FOR OPERATIONAL CONTROL 42 1
16.0 PROCEDURE FOR OBJECTIVE AND TARGETS 43 2
17.0 PROCEDURE FOR MONITORING AND MEASUREMENT 45 1
18.0 PROCEDURE FOR COMMUNICATION WITH INTERNAL & EXTERNAL AGENCIES 46 2
19.0 LIST OF FORMATS 48 3
J.P ENTERPRISES
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1.2 ABBREVIATIONS
For the sake of convenience in typing, the following abbreviations are used in Integrated Quality and
Environmental Management System documents:
Abbreviation Expanded
PTR PARTNER
AIPL J.P ENTERPRISES
ES Environmental System
MR Management ,Environment Representative
IMS Integrated Quality ,Environmental& Occupational
Health and safety standard management system
manual
PRODUCT Rubber & Plastic Moulding Parts and Foam Based Items
MKT Marketing
DES Dispatch
PROC Procurement
Cons Manufacture
QA Quality assurance
INT Internal
AUD Audit
TRG Training
INST Installation
MAINT Maintenance
MMD Monitoring and Measuring Devices
MRM Management Review Meeting
OC Operation Control
IDEN Identification
SEA Significant Environmental Aspects
L&OR Legal and Other Requirements
PREP Preparedness
Mgr Q.A Manager Quality Assurance
MR Management Representative
NC Non Conformance
NCR Non Conformance Report
No Number
Nos Numbers
QC Quality Control
Qty Quality
QP Quality Policy
QS Quality System
Sec Section
WI Work Instructions
OH&S Occupational Health & Safety Standard
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1.3.1 This manual is a controlled document. Controlled copies are identified by a blue colored stamp
“CONTROLLED COPY” with a distinctive number and original copy as “Master Copy”.
1.3.2 All copies not having the above referred stamp are considered to be uncontrolled copies. No
uncontrolled copy is permitted to be used in the company, however uncontrolled copy of the manual
may be given to customers.
1.3.3. It is the responsibility of the controlled copy holder to ensure that all amendments are incorporated
promptly and the manual is kept up to date.
1 PARTNER
2 Head (QA/AC)
3 Certifying body
1.3.5. Written permission of the Management Representative shall be obtained before giving the
photocopies of the IMS to prospective customers and others. Such copies are to be treated as
uncontrolled copies.
1.3.6. Removal of controlled copy from the premises of J.P ENTERPRISES is strictly prohibited until
authorized by the PARTNER
J.P ENTERPRISES
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SR. Rev.
Sec. No. Sheet No. Date Brief Description of Revision
No. No.
ISO 9001 – 2015 & 14001-2015 Standard
1 1 ALL 02 02/11/2018
Combined an Integrated Manual System (IMS)
J.P ENTERPRISES
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1.5.1. The Integrated Quality, Environmental & occupational health & safety Management
System Manual is the apex document laying down intent of the company with regard
to quality and environmental management system requirements laid down in ISO
9001-2015, ISO 14001:2015
1.5.2. The Integrated Quality, Environmental & occupational health & safety Management
System Manual is a solemn assurance to customers that their requirements shall be
met to ensure their utmost satisfaction.
1.5.3 The Integrated Quality, Environmental & occupational health & safety Management
System Manual makes reference to various procedures for translating intentions to
actions and results.
PRODUCT RANGE
“Manufacture & Supply of All Kinds of Rubber & Plastic Moulding Parts
and Foam Based Items”
J.P ENTERPRISES
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2.0
QUALITY POLICY
J.P ENTERPRISES IS COMMITTED TO:
Have a full understanding of customer needs
Produce high quality rubber, plastic part and
wiring harness
To follow the Zero Defect Policy
Delivery of part at appropriate time
Providing customer values at a higher level
Continuous improvement in company structure
and technology
Continuous improvement in the working ability of
employees
Improving the basic features of employees
Continuous improvement in quality management
system
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DATE: 02/11/2018
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ENVIRONMENTAL POLICY
The organization has identified environmental management as one of its highest corporate
priorities. The organization has established policies, programs and practices to reduce risk to
the environment and the organization and conduct business activities in an environmentally
sound manner.
The organization is committed to environmental management and will:
Integrate its environmental policies and procedures fully into all business activities as a
critical element,
Comply with all environmental legislation, standards and contract requirements that are
applicable to the company’s operation,
Develop, implement and maintain emergency preparedness plan
conservation of resources like water energy and minimizing environmental impacts
DATE: 02/11/2018
All the objectives and targets will be achieved by the organization as per the
targets given in the measurement analysis chart (JPE/F/44).
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(4) Stores, Legal, Technological, Competitive, Cultural, Social and economic environments etc.
The same shall be converted into the risk and opportunities (JPE/F/41) and CAPA will be generated.
4.2 The organization has determined the following interested parties that are relevant to the quality
management system and the requirements of these interested parties that are relevant to the
Quality/Environmental management system. Eg.
(1) Customer
(2) External providers
(3) Consultant
(4) Certification body
(5) Employees
(6) Neighbors etc.
The requirements of the interested parties(JPE/F/40) shall be recorded in the conversation document such as
PO mails etc. also all verbal communications shall be recorded in the personal notes. The requirement/
expectations of the interested parties
4.3 The organization shall determine the scope of Quality/Environmental management system keeping
the following aspects in the mind:
(a) The external and internal issues
(b) The requirement of relevant interested parties
(c) The product and services of the organization. (ref. Cover page of the IMS manual)
(d) The compliance obligations.
The scope of the Quality/Environmental management system shall be maintained in the process manual. All
the process and sub processes are being carried out by the organization itself. The following clause of ISO
9001:2015 are excluded from the applicability ie. 8.3 ie. Design and development. The details of the
justifications for exclusion are given in the respective clauses of this manual.
1- An IMS has been established, documented, implemented and maintained, which is continuously
improved in its effectiveness in accordance with the requirements of ISO 9001:2015, ISO
14001:2015 and
2- The processes needed for the IMS and their application throughout the organization have been
identified.
3- The sequence and interaction of these processes have been determined.
4- Determined criteria and method needed to ensure that both the operation and control of these
processes are effective.
5- Ensured the availability of resources and information necessary to support the operation and
monitoring of these processes.
6- Monitored, measured and analyzed these processes.
7- Implemented action necessary to achieve planned results and continual improvement of these
processes.
8- 8.3 of the standard ISO 9001:2015 are excluded from the working of the organization.
9- These processes are managed in accordance with requirements of ISO 14001:2015.
10- Environmental Monitoring (Effluent testing, DG set stack monitoring, Ambient air monitoring and
calibration of devices) are outsourced.
A. (1) The Raw materials and parts (2) Packing material and (3) chemicals are purchased and
inspected as per the laid down procedures of J.P ENTERPRISES
B. The process parameters and in- process product parameters are defined and monitored by J.P
ENTERPRISES
C. Final inspected and decisions are taken by J.P ENTERPRISES The records are maintained.
5.0 LEADERSHIP
5.1.1 Commitment
The management has ensured that customer requirements are determined and are met with the aim of
enhancing customer satisfaction.
Quality/Environmental Policy of the Organization is appropriate to the purpose of the organization and
includes a commitment to comply with the requirements and continual improvement of the effectiveness of
the Quality/Environmental Management System. It provides framework for establishing and reviewing the
Quality/Environmental Objectives of the Organization. The Quality/Environmental Policy has been widely
communicated in the organization to facilitate its understanding by all concerned. It is reviewed periodically
in the Management Reviews to ensure its continuing suitability. It includes the commitment to the protection
of environment, including prevention of pollution and other specific commitments relevant to the context of
the organization. It includes a commitment to fulfill its compliance obligations.
1- Quality is the responsibility of every employee of J.P ENTERPRISES The PARTNER of the
Company is ultimately responsible for overall quality of the Products.
2- Organization chart of the company is given as follows, indicating the reporting and communication
structure.
3- Responsibilities and authority of all employees are defined and communicated to all concerned
within the organization.
4- Reporting on the performance of the EMS, including environmental performance.
5- Responsibilities of key personnel is given as follows: Responsibility and Authority Record Reference
number (JPE/F/77)
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Plant Head:
Responsible for overall Manufacture, allotment of work, monitoring the progress, Ensuring quality and
guiding store. Take corrective and preventive actions. Plant Head is authorized for disposition of non-
conforming material. Plans manufacture of the project as per the pert chart/target. Keeps QA department
informed of any problem facing during manufacture. Is authorized to appoint engineers and supervisory
staff after taking approval from PARTNER. Is authorized to issue show cause notices to all employees for
omissions, mistakes and disciplinary breaches. Ensure the legal requirement for fully implemented.
Implements all measures and environmental programs in co-ordination with MR. Ensures implementation
of the operational control measured on manufacture site . Implements all measures and OH&S
Management programs and measures as per the plan and requirements.
Purchase Manager
Responsible for all purchase functions. Ensures selection of suppliers as per laid down criteria. Ensures
their evaluation is done as per laid down frequency. Warns the suppliers in case their rating falls below
the laid down acceptable level. Is authorized to review purchase orders and issue the same. Is authorized
to interact with suppliers on behalf of organization and issue them warning letter in case they fail to meet
our quality, delivery all response requirements. Ensures that suppliers are educated about the
environmental aspects for the organization and how they can contribute in preventing pollution.
Marketing Manager
Is responsible for all marketing functions. Educates customers about the environmental aspects affecting
our Product. Attends to customer and external parties complaints and feedback. Reviews all enquiries and
orders and ensures that any aspect of the enquiry or order violating the statutory and regulatory
requirements is brought to notice of the customers and clarified before acceptance of the orders. Ensures
amendments to orders is communicated to all concerned.
I/C Store :
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Responsible for up keep of store. Receives stores and issues material. Keeps the stock ledger up to date.
Ensures storing of material in a manner that facilitates easy irretrievability. Displays safety precautions in
the stores.
Quality Engineer
Works under the manufacture head. Ensures safety of personal by providing them personal protective
equipment as necessary. Ensure implementation of works instructions by workers. Is authorized to allot
work to operators as per his own plan. Ensures that all workers follow the quality, environment and
OH&S policy while in the premises. Ensures that workers and supervisors implement the operational
control measures during their respective operations. Ensures safety of personal by providing them
personal protective equipment as necessary
6.0 PLANNING
6.1 Actions to address Risk and Opportunities
6.1.1 General
When planning the Quality/Environmental management system the organization shall consider the issues
and requirements and determine the risk and opportunities that need to be addressed to:
1- Giving assurance that the Quality/Environmental management system can achieve its intended use.
2- Enhance desirable effects.
3- Prevent or reduce, undesirable effects.
4- Achieve improvement
a) To identify the environmental aspects of its activities, Product and services within the defined scope of
the EMS that it can control and those it can influence taking into account planned or new developments,
or new or modified activities, Product and services.
b) To determine those aspects those have significant impact(s) on the environment (i.e. significant
environmental aspects).
c) Any other aspect of the environment, health and safety may cause loss to property, Product, process
human health and working environment may be considered for the analysis and improvement.
The organization ensures that this information is documented and kept up to date.
a) Identify and have access to the applicable legal requirements and other requirements to which it
subscribes related to its environmental aspects.
b) Determine as to how these requirements apply to environmental aspects.
The organization ensures that all these applicable legal requirements and other requirements to which the
organization subscribes are taken into account in establishing, implementing and maintaining its
environmental management system. Details of any new applicable legal and other requirements are checked
prior to every MRM to update the register of applicable legal and other requirements and take necessary
action to enforce their compliance.
6.1.4 The organization shall plan to take action to address its significant environmental aspects, compliance
obligations and risk and opportunities identified.
The organization shall establish quality objectives at relevant functions, level and process needed for the
Quality/Environmental management systems. It should have the following features:
The Quality/Environmental objectives shall be maintained in the form of measurement analysis chart.
The measurement analysis chart shall be structured as followed:
1- Statement of objectives
2- Need of resources
3- Responsibility
4- Tentative date of completion
5- Method for evaluation of results
When there is need to change the quality management system, the following shall be considered:
7.0 SUPPORT
7.1 Resources
7.1.1 Infrastructure, Human Resources & Work Environment required to maintain the Quality/
Environmental Management System and continually improve its effectiveness and to enhance customer
satisfaction have been identified and provided for by Top Management of the J.P ENTERPRISES and are
being utilized at points of their use.
The required resources which include human resources and specialized skills, organizational infrastructure,
technology and financial resources are determined and provided;
1- To implement and maintain the QMS and EMS and continually improve their effectiveness.
2- To enhance customer satisfaction by meeting customer requirements.
7.1.2 People
Before recruitment, it is ensured that the employee possesses necessary education, training, skills and
experience required to execute the work assigned to the person. Requirement of competence and training of
the employees performing work affecting Product quality are identified. Training is provided to the
employees, wherever the gap is identified. Effectiveness of the training is continuously evaluated. HR
department maintains appropriate records relating to education, training, skill and experience of all the
employees. All the employees are aware of the relevance and importance of their activities and their
expected, contribution to the achievement of quality objectives. Employees performing well are recognized
and rewarded.
7.1.3 Infrastructure
The infrastructure needed to achieve conformity to Product requirements are determined, provided and
maintained. Record of preventive maintenance of machines is maintained as per format JPE/F/12 The record
of break down maintenance is maintained in the format no. JPE/F/13.The list of machines (JPE/F/11) for
which the preventive maintenance record to be maintained shall be prepared. The DG log book shall be
maintained in the register.
The MR shall identify and recommend to top management the necessary infrastructure required for the
Product realization.
The infrastructure includes;
1- Buildings, workspace and associated utilities
2- Process equipment
3- Supporting services such as communication devices, Talley and transport facilities.
4- Necessary personal protective equipment as identified for Product and process.(JPE/F/57)
6- The effort of the employees are recognized and awarded. The organization is fully committed to
support the employees in the odd situations related to employee and their dependents.
7- For further details the operational control manual may be referred.
7.1.5.1 General
1- The organization shall determine and provide the resources needed to ensure valid and reliable
results when monitoring and measuring is used to verify the conformity of Product and services to
requirements.
2- The organization shall ensure that the resources provided:
a- Are suitable for the specific type of monitoring and measurement activities being undertaken
b- Or maintained to ensure their continual fitment for their purpose
3- The organization shall retain appropriate documented information as evidence of fitness for purpose
of the monitoring and measurement resources.
The organization determines monitoring and measurement to be under taken for processes' performance and
Product characteristics and the monitoring devices needed to provide evidence of conformity of Product to
determined requirements.
A list of monitoring and measuring devices is maintained at each location and their calibration records are
maintained in the calibration register.
Where necessary to ensure valid results, measuring equipment are:
1- Calibrated or verified at specified intervals or prior to use against measurement standards traceable to
international measurement standards; where no such standards exist, the basis used for calibration or
verification shall be recorded.
2- Adjusted or re-adjusted as necessary.
3- Identified to enable the calibration status to be determined.
4- Safeguarded from adjustments that would invalidate the measurement results.
5- Protected from damage and deterioration during handling, maintenance and storage.
6- Based on the Product profile and customer requirement the Technical cell ( QUALITY CONTROL ,
DEVELOPMENT AND MANUFACTURE) shall identify all equipment, both for manufacturing and
testing and put up its proposal to management for consideration.
7- It shall also decide the periodicity for calibration of all such Test and Measuring equipment, besides
other relevant measuring gadgets such as thermometers, vacuum/pressure gauges etc.
8- The method of operation of all Test and Measuring equipment and their calibration periodicities shall
be documented in the form of –MMD calibration plan(JPE/F/76) and shall be preserved at Quality
control department.
9- Similarly the calibration schedules and records for Manufacturing equipment and gauges shall be
monitored by user department.
10- In addition, the validity of the previous measuring results are assessed and recorded when the
equipment is found not to conform to requirements.
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11- Records of the results of calibration and are maintained by the maintenance department.
12- The calibration activity is performed externally from approved sources who are NABL accredited.
13- The software used in the measuring devices are validated by the manufacturer/supplier on yearly
basis.( presently this sub clause of the standard is not applicable)
7.1.6 The organization shall determine the knowledge necessary for the operation of its processes and to
achieve conformity of the Product and services. The organization knowledge will be gained by experience
and this will be used and shared to achieve the organization’s objectives.
When addressing changing needs and trends, the organization will consider its current knowledge and
determine the additional knowledge through internal and external resources.
7.2 Competence
1- The necessary competence and training needs for personnel performing work affecting Product
quality and environmental aspects are determined by respective Section Heads of the Department
and forwarded to HR at least once in a year.
2- HR collects the training requirement, gets approval of the training to be conducted. He prepares the
training calendar and intimates the department concerned about the same. He also ensures that the
necessary faculty and other facilities are also provided for the training to be conducted in calendar
year.
3- Quality system section plans training on QMS, EMSand other Product and process related trainings.
4- Department Heads/HR are responsible for imparting training to work force to satisfy their needs.
5- The effectiveness of the training is evaluated by the department heads/HR.
6- Heads of Depts. ensure that their personnel are aware of the relevance and importance of their
activities and how they contribute to the achievement to the quality and environmental objectives.
7- Maintain appropriate records of education, training, skills and experience. Training record is
maintained by HR department of J.P ENTERPRISES
8- The competence requirements are defined (JPE/F/73).
9- The following records related to the training shall be maintained: Training, Record (JPE/F/06),
TRAINING PLAN (JPE/F/31)
7.3 Awareness
The organization shall ensure that the person doing work under the organization’s control is aware
of:
1- The Quality/Environmental Policy
2- Relevant Quality objectives and significant Environmental aspects related to actual or potential
environment impacts associated with their work.
3- Their contribution to the effectiveness of the Quality/Environmental management systems including
the benefits of enhanced performance.
4- Implication of not conforming with the Quality/Environmental management systems requirements
including compliance obligations.
7.4 Communication
With regard to its Quality/Environmental Management Systems, the organization shall follow the following
procedure.
1- What it will be communicating (subject of communication)
2- When to communicate (situation for communication)
3- With whom to communicate (the department/ person to be communicated)
4- How to communicate (Mode of communication)
5- Who communicates (Responsibility for communication)
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7.5.1 General
The IMS documentation includes
1- Documented statements of policy & objectives of QMS,EMS .
2- This Integrated Quality Environmental Management System Manual.
3- Required documented procedures for both QMS , EMS .
4- Documents needed to ensure the effective planning, operation and control of processes and
quality records.
5- Operational control procedure manual
1- Identification and Description (eg. Title, Date of Issue/Effectiveness, Prepared by, Reference no. etc.)
2- Format (eg. Language, Software version, Graphics) and Media (eg. Paper, Electronic etc.)
3- Review and Approval for suitability and adequacy
2.) MR ensures that all controlled documents are legible and easily identifiable. A master list of
documents (JPE/F/01) indicating the current status is maintained by MR. The master list for external
origin documents shall be maintained by In-charge QS.
3.) The documents of external origin like ISO 9001:2015, ISO14001:2015, and applicable rules and laws
are identified and their distribution controlled by the MR.
4.) MR ensures that pertinent issues of appropriate documents are available at all locations performing the
respective activities.
5.) All controlled documents are marked as “controlled document “in blue and master is indicated by
stamping it as master document in red at the back of the document. IMS manual paragraph has
numbers same as cl of ISO 9001:2015 and applicable cl for the same paragraph for EMS is given in
bracket after EMS. IMS manual has both revision number and issue number where as all other
controlled documents have only issue number. Suggestions for amendment to documents may be made
by any person, but the review and approval is done by the same authority, who originally did this. He
has access to the pertinent background information upon which to base review and approval. The brief
description of change is recorded in the revision record (Sec.1.5) the nature of change is identified by
typing changes in italics. On amendment to pages of manual revision number is changed to next
number i.e. from 00 to 01 and from 01 to 02 and so on and for all other controlled documents issue
number is revised to next issue number i.e. from 01 to 02 and from 02 to 03 and so on.
6.) The complete document shall be reviewed at least once in three years or when there is any change in
the existing standard.
7.) On approval of amendment, issuing authority issues the amendment.
8.) MR ensures that the obsolete documents are withdrawn from all places and replaced with revised
document.
9.) If any obsolete document is to be retained for legal or knowledge purposes, the same is suitably
identified with red colored stamp “OBSOLETE”. All other obsolete documents are destroyed.
10.) All holders of controlled copies ensure that their copy is kept up to date.
11.) All controlled documents are re-approved after three years. For revision in formats, WI/Quality Plans
a new issue is taken out.
12.) Distribution list is maintained with MR.
14) QMS, EMS records are made legible.
15) These are filed and numbered in a manner facilitating easy irretrievability.
16) These records are stored with proper care to avoid deterioration and damage.
17) The records are disposed off by tearing after the retention period.
18) List of all applicable records are maintained in the record format ref. No. JPE/F/02
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8.0 OPERATIONS
The organization has identified and planned those operations that are associated with the significant
environmental aspects and quality issues consistent with its environmental/quality policy, objectives and
targets, in order to ensure that they are carried out under specified conditions, by:
Marketing shall identify and establish various channels of communication with its important and major
customers on regular basis to get feedback on regular basis on various aspects of business, including the
following:
Similarly Marketing shall also keep the customer apprised of any of the changes in the Product profile, which
may include:
3- Addressing of any customer complaints, including corrective and preventive actions undertaken and
implemented.
4- Any relevant information of the Product, such as MSDS, application manual, literature etc. wherever
customer demands.
The organization has established, implemented and maintained a procedure to identify potential emergency
situations and potential accidents that can have impact(s) on the environment and how it will respond to
them. The organization responds to actual emergency situations and accidents and prevents or mitigates
associated adverse environmental aspects. The organization periodically reviews, and where necessary,
revises its emergency preparedness and response procedures, in particular, after the occurrence of accidents,
incidents, near misses situations emergency situations etc.
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2- The methodology can be of by conducting market survey, direct interaction processes, by electronic
communication systems such as e-mail , through correspondences etc.
3- Upon receipt of above inputs, it shall review them with the concerned process owners, such as
Manufacture, Purchase, Quality Assurance, marketing etc and generate a requirement list on monthly
basis.
4- It shall also seek guidance on the legal and statutory aspects, wherever found necessary from
respective competent authorities.
1- Marketing through its survey, market intelligence strategies shall identify its annualized requirement of
each Product at the beginning of every calendar year as its Budgeted Volumes for the consideration of
management.
2- After the approval of management, the Manufacture and quality control shall review the
manufacturing feasibility and revert to marketing with its consent.
3- Simultaneously the quality control and Manufacture shall put forward any additional resource /
infrastructure required to fulfill the marketing requirements to the management for its consideration.
4- Any conflicting issue between Marketing and Manufacturing shall be resolved, in case any constraint
in resource availability is identified.
5- Any additional requirements by Marketing, beyond the already projected quantity and quality shall be
reviewed by Manufacture department and shall be intimated to Marketing.
6- Marketing shall make any commitment to the customer for additional volumes, based on the above
feedback only.
7- If the requirement from the customer is for a new Product, or any change in the specification not
identified earlier, Marketing shall initiate the process of viability study, involving other members such
as Quality Assurance, and Purchase etc. before making any commitment.
The organization shall ensure that relevant documented information is amended and that the relevant persons
are made aware of the changed requirements.
8.4.1 General
1- Purchase department shall acquire all relevant data on the Product to be purchased, such as
Specifications, quantity and any other specific requirement of the Product from the Manufacture/
marketing department of the organization.
2- Based on the above information, it shall identify the potential suppliers for that Product from its
approved suppliers(JPE/F/07).
3- A copy of the Purchase Order JPE/F/08 containing relevant details such as Product details [having
linkage to its pre-communicated specifications, ], price, delivery schedule etc. along with other
terms and conditions of the dealing shall be sent to the vendor under acknowledgement of receipt
and acceptance by the vendor.
4- Upon receipt of the ordered Product, it shall verify through store and security gate.
5- The status of the Product such as received quantity, quality, date of receipt and date of inspection etc.
through proper documentation.
6- In case of any discrepancy in terms of quantity, quality etc. Purchase department shall intimate such
findings to the supplier by suitable communication means.
7- If the Product is found inferior in quality and not acceptable to the user department, such Product
shall be quarantined and the joint decision will be taken for the acceptance/ rejection of the material.
8- Purchase Department shall also ensure that if any specific document such as Analysis Report, Safety
Data Sheet etc. of the Product, needs to accompany the supplies from the supplier, they shall be made
available.
9- It also falls under the purview of Purchase Department to ensure that all its dealings with various
vendors and transaction of business is carried out, without any violation of Govt. rules, prevailing
laws and statutory requirements.
10- Purchase Department will evolve a documented procedure for: 1. Supplier Rating 2. Criteria to
qualify as an approved vendor and shall review such procedures periodically.
11- It shall also generate and implement a documented process for periodic visits at Supplier’s premises
for validation of their quality management systems and to assess their capabilities.
1- All purchased items are tested and verified as per the laid down test methods indicated in the Quality
Plan (JPE/QP/01 .
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2- The result of such testing (acceptance or rejection) shall be communicated by the Head QC to
Purchase department in writing with details of non-conformance in case of rejection within a
reasonable time.
3- Upon receipt of such communication, the Purchase department shall intimate the supplier
accordingly and make necessary arrangement for transporting back such materials to the supplier.
4- If any Product needs pre-inspection before taking delivery it shall be mentioned in the purchase
order.
5- The purchase department shall also plan and undertake periodic inspection of Suppliers premises
with a view of evaluating his capability of supply and prevailing quality management systems, with
the support of quality system and Manufacture department , wherever the need is felt.
The organization has identified and planned those operations that are associated with the significant
environmental aspects consistent with its environmental policy, objectives and targets, in order to
ensure that they are carried out under specified conditions, by:
a) Establishing, implementing and maintaining a documented procedure as given at section 17.0 to
control situations where their absence could lead to deviation from the environmental policy,
objectives and targets.
b) Stipulating the operating criteria in the procedure/ work instructions/ OCP manual.
c) Establishing, implementing and maintaining procedures related to the identified significant
environmental aspects of goods and services used by the organization and communicating
applicable procedures and requirements to suppliers, including contractors.
d) The organization has identified those operations and activities that are associated with identified
risks where control measures need to be applied. The organization plans these activities,
including maintenance, in order to ensure that these are carried out under specified conditions by:
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a) Establishing and maintaining documented procedures to cover situations where their absence
could lead to deviations from the OH&S policy and objectives.
c) Establishing and maintaining procedures for the, process, installations, machinery, operating
procedures and work organization, including their adoption to human capabilities, in order to
eliminate or reduce OH&S risks at their source. Procedure for Operational control is available ref.
no. JPE/PR/03.
(a) Identification
All Material and stages shall be identified as per their status or usage. Rejected material shall
be identified as Non-Conforming Product.
(b) Traceability
The product shall be identified by giving the details of the product e.g. product name, Lot no. &
manufacturing date.
For Example:
8.5.4 Preservation
1. On receipt of any material from the supplier, it shall be the responsibility of the manufacturer to
ensure that the material has proper identity and there is no physical damage to the container/bags ,
leakage , breakage etc. which might happen during transit.
2. If any physical damage or deformity is observed the material shall be segregated and kept separately
for further decision.
3. Each Product shall be stored separately at allocated storage place. in order to avoid any natural
impact
4. All Product shall be stored at their respective bays indicating their status at any point of time such as
Receipt , Under Test , Approved , Rejected etc.
5. Similarly all semi processed materials and finished goods shall also be identified with appropriate
labels and stored separately at their respective bays.
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c) Continually improves the effectiveness of the IMS through management review meetings.
As one of the measurement of the performance of quality management system, information relating
to customer perception is monitored as to whether customer requirements are fulfilled. The method
for obtaining and using this information is through Format -(Customer Feedback).
The team involved in various operations of J.P ENTERPRISES decides the suitability and
appropriateness of data for analysis. Such data is collected during monitoring and measurement of
processes and from other relevant sources. The purpose of data analysis is to demonstrate the suitability
and effectiveness of Quality Management System. Analysis of Data provides information related to:
It is imperative that each department shall analyze the data obtained from various out-lets and related to
its functions and strive to achieve improvements in its quality management systems to pave the way for
enhanced customer delight. In this direction each functional head shall undertake following tasks to
achieve its objectives under this aspect :
Marketing: The Marketing department shall compile all data received through customer visits,
interaction with user departments, both internal and external, correspondences and feed backs from
customers, e-mail and telephonic communications, customer complaints etc. and evaluate customer
satisfaction over the Product and service parameters and suggest means to improve the whole process to
achieve better customer satisfaction. Such achievements shall be shared with other process owners in the
Six monthly Management Review Meetings.
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Manufacturing: The PRODUCTION HEAD, from sources such as Process record, analysis reports,
through continual interaction with operating persons shall review the manufacturing efficiency in totality
and try to incorporate improvements wherever possible so that such steps shall result ultimately on
Product improvement. Such improvements and achievements shall be reviewed in the management
review meetings.
Quality Assurance: It shall be under the purview of Quality Assurance to impart improvements in the
final Product by way of monitoring the data of analysis , bench marking studies , trend analysis of
critical parameters etc , including development of better and more efficient Analytical techniques. He
shall make a presentation of such improvements during the quarterly MR. Meeting.
Purchase: Purchase shall constantly try to procure better quality materials through the process of better
vendor development systems, by educating the vendors and by periodic visits at vendor’s locations etc.
The efficiency in the purchase cost , better quality and timely delivery etc. are few of other areas where
improvements can be brought about and the purchase executive shall make continuous and all out efforts
to achieve such improvements and shall share the same in the MR meetings.
HR & Training: The training contents to the employees shall be made more result oriented taking into
account of the need , methodology of conducting the training to make it more effective , follow-up action
to measure the improvements in the employees skill ,attitude etc. Such improvements shall be
documented and forms the basis for further training. The HR& Training department shall make a
presentation on the above subject in every management review meetings.
As part of changing scenario with respect to customer requirements and expectations on the already
existing Product as well as regarding new Product requirements, all such customer requirements shall be
recorded by the Marketing manager from time to time and these data and information shall be passed on
to the quality, Manufacture and maintenance , which in turn shall review the feasibility of supply with
relevant departments such as Manufacture, Quality Assurance, Purchase, engineering , before making
commitment.
There shall be situations wherein availability of resources and other infrastructure could become a
constraint in the endeavor of implementing such processes for improvement. In such cases the
Manufacture dept. together with other process owners shall evaluate the merits and scopes of such
attempts and put up its proposal to the top management for its consideration.
2. Management Representative deputes trained internal auditors for carrying out internal audits.
3. He ensures that the deputed auditors are independent of the activity being audited.
4. Management representative schedules the audit after considering the convenience of auditees
and auditors. Departments found deficient in compliance of requirements are audited more
frequently if desired by the Management.
5. Auditors carryout internal audit and prepare an audit report highlighting the Nonconformity
in internal Audit nonconformity report .
6. Auditors and auditee together decide about the follow up corrective action along with a time
frame.
7. Auditee inform the auditors about the completion of the timely corrective action.
8. During/after the internal audit, follow up activities are verified and the implementation of the
corrective action taken are recorded wherever required.
11. Results of audits and their corrective and preventive actions are discussed in MRM.
9.3.1 General
Management Review Meeting to review the QMS and EMS is held at least once in 6 months to ensure their
continued suitability, adequacy and effectiveness.
The M.R shall Coordinate and record minutes of the MRM. The purpose of conducting the MRM to review
the status of implemented Quality, Environmental and OH&S Management System, identification of
resource requirement & to meet the requirement of QMS , EMS standard.
The meeting shall be conducted in the Site and will be chaired by the PRODUCTION HEAD. The members
of meeting are MR, concerned dept. heads and any other person as felt necessary.
The Input to Management Review includes some or all of the following points:
The output from the Management Review includes decisions and action related to
10.0 Improvement
10.1 General
The organization shall determine and select opportunities for improvement and implement necessary actions
to meet customer requirements and enhance customer satisfaction.
Corrective actions become necessary whenever any or all of the most probable causes of following nature
are observed:
5- Market share drops for any particular or for a large number of Product.
8- Accidents and un-pleasant situations in the work place increases. And so on and so forth.
When the management identifies any of above causes, it becomes its prime responsibility to investigate the
sources of such shortfalls and take appropriate corrective steps as early as possible, depending upon the
nature of deformity. Some of the common tools adopted to redress such issues include:
Non-Conformity with respect to specifications: When a Product fails to meet the desired specification,
with respect to any parameter, the root cause shall be identified after investigation such as:
Non-Conformity arising out of Process: If non-conformity is repeated in a similar pattern on the final
Product, most probably it could be because of any deficiency in the process and immediate review of the
process shall be undertaken jointly by the Process and QA.
Non-Conformity reported by customers through their complaints: All complaints received from
customers are to be systematically documented and reviewed by the marketing and are to be investigated in-
depth. Corrective actions should be implemented after identifying the cause of the non-compliances and
documented for future references.
Non-Conformity owing to lack of skill and training: There could be instances, where the Product
manufacture / testing operations are carried out by persons having in-adequate experience, even for a
temporary occasion. It shall be the responsibility of the GM- Finance to ensure that right kind of persons
with required skill and experience are deployed on each job and their skills are harnessed on continual basis
through counseling and training.
Non-Conformity on account of poor quality of in-puts: If the cause of Product deformity or deterioration
is attributed to the inferior quality of the in-puts such as Raw Materials, it shall be brought to the notice of
the Purchase Executive by QC Head or PRODUCTION HEAD for appropriate corrective actions. It is
expected that the QC- Head shall generate trend analysis data on the quality of all in-coming Raw Materials
periodically and share it with Purchase Executive.
Each Process owner viz. Manufacture, Quality Assurance, Materials, HR& Training and Marketing shall
demonstrate continual improvements in their respective areas with regard to quality management systems,
ultimately leading to Product improvement. The expected areas for continual improvements can be from a
variety of quality attributes such as:
1- Product Specifications: A Product may have different applications for different customers and
unless most of the requirements of customers are known, the Product shall have obviously a limited
span of acceptability. Hence it is imperative that from the in-puts available from customer
applications, the Product shall undergo changes towards betterment.
2- Manufacturing Process: As and when the Product specification undergoes changes, simultaneously
the method of manufacture also needs reviewing and necessary changes shall be incorporated to
achieve such end results.
3- Analytical Techniques: It should be a continual endeavor on the part of Quality Assurance to adopt
more and more sophisticated analytical methods through instrumentation techniques to evaluate the
Product characteristics more accurately.
5- Better Customer rating: of the Product is also an indicator towards continual improvement. All out
efforts shall be made by all process owners in terms of quality , quantity , service , prompt responses
to customer queries and complaints etc. to achieve enhanced customer satisfaction and delight.
6- Less Number of Rejections: Considerable attention shall be devoted , particularly in the areas of
manufacture and purchase to ensure that quality rejections of both processed items and raw materials
are contained to bare minimum and monitoring and achieving of such improvements shall be
evidenced on quarterly basis .
7- Lower Accidents and better Safety measures adopted at the operational areas and supportive areas
shall also speak out level of improvements achieved. It should be of paramount importance to all ,
beyond all levels of hierarchy in the Organization to make sure that - all operations are validated and
safe enough – the Site and Equipment are designed taking all safety aspects into account – People
working are trained on safety and have safety awareness – Employees are provided with appropriate
Safety aids such as gloves , goggles , aprons , safety shoes etc as and when required and are educated
and encouraged to make use of them - Existence of a strong system of reporting any accident or near
miss accident to higher levels and implementation of preventive steps. Etc. All such incidents
related to Safety shall be recorded as and when it occurs immediately and corrective / preventive
actions shall be implemented without delay. Records of such incidents and preventive actions taken
shall be reviewed in the management review meetings.
8- The organization shall continually improve the suitability, adequacy and effectiveness of the EMS to
enhance environmental performance.
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PROCESS MANAGE MARKETMANUFACT QUALITY HR & MAINTENAN PROCUREME STORES DISPATCH &
MENT ING URE ASSURANCE TRAINING CE NT LOGISTICS
MANAGEMENT √ √
√ √ √ √ √ √ √
MARKETING
√ X √ X √ X √ √ √
PROCUREMENT
X √ √ √ X √ X √ X
MANUFACTURE
√ √ X √ √ √ √
√ √
QUALITY
ASSURANCE
√ √ √ X √ √ √ √ √
CALIBRATION
√ X √ √ X √ √ X X
IQA
√ √ √ √ √ √ √ √ √
TRAINING
√ √ √ √ √ √ √ √ √
MAINTENANCE
√ √ √ √ √ X √ √ X
IDENTIFICATION OF
SIG. ASPECTS
√ √ √ √ √ √ √ √ √
EVALUATION
OFCOMPLIANCE OF
LEGAL
REQUIREMENTS √ √ √ √ √ √ √ √ √
EVALUATION OF
EMERGENCY
PREPAREDNESS
√ √ √ √ √ √ √ √ √
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ASPECT/IMPACT
MRM
INTERNAL AUDITS
NC & CA/PA
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13.1 Scope
The procedure covers all activities of the organization that have significant impact on the
environment.
13.2 Responsibility
The responsibility for the above lies with the environmental management committee consisting
of MR, Quality Incharge and the PM.
13.3 Procedure
To determine the significant environmental aspects the following needs to be considered for the
activities performed by the organization if these when these have environmental aspect:
a a)Emissions to air.
b)Releases to water.
c)Waste management.
b d)Contamination of land.
c e) Operating conditions (historical, Normal, Abnormal & emergency) resulting in direct/indirect
d (a) to ( d) above
e f) Use of raw material and natural energy resources.
f g) Local environmental and community issues
g h) Noise pollution.
h 13.4 The activities are under the following headings and the organization has awarded the
weightage for each of the above as given against each:
14.0 Purpose
To lay down the procedure for identification of hazards and assessment of risk of the organization.
14.1 Scope
The procedure covers all activities, materials, workplace, equipment and people of the organization
14.2 Responsibility
The responsibility for the above lies with the OH&S committee consisting of MR, HR, Manufacture
Head QC and Purchase manager.
14.3 Procedure
i 8.4.1To carry out identification of hazards and assessment of risk we need to consider the following
j stages:
a) Consider all activities, materials, workplace, equipment and people including own employees, suppliers,
contractors and visitors in the organization.
b) Identify the hazards that are or may be involved.
c) Identify those who may be exposed to the hazards.
d) Analyze the risk of loss or injury from the hazards to obtain risk score.
e) Evaluate if the risk is adequately controlled.
f) Consider measures that may eliminate or reduce the risk further in line with basic principles of hazard
control.
g) Implement the risk control measures.
h) Monitor and measure.
i) Review and feedback.
14.4 :Aspects Considered for Identification of Hazards: The various activities of the organization that may
result in hazards resulting in risks are listed at Format for Risk Assessment JPE/F/70.The raw materials and
machines that are in use in the organization that may cause hazard and result in risk are considered along with
activities. The organization does not carry out any abnormal activities. However the emergencies activities
like fire and compressor burst also need to be considered for identification of hazards. The organization has
employees including women and children below 18 years. Visitors are requested to read the instructions at
the security when they enter the premises.
14.5 Identify the hazards that are or may be involved with above: The details of the hazards that may be
involved with the above are indicated in the Format for Risk Assessment JPE/F/70.The likelihood of these
hazards occurring (probability of occurrence) have been given award as under:
a) Very Likely ( H) : 3 Marks(When it occurs frequently or Chances approx. more than 50%)
b) Medium Probable (M) : 2 Marks(When it occurs occasionally or Chances between 10% to 50%)
c) Low Possible (L) :1 Mark(When it has never occurred before or chances less than
approximately 10%)
14.6 Identify those who may be exposed to the hazards: The personnel at risk with respect to above are
indicated in Format for Risk Assessment JPE/F/70.
24.7 Analyze the severity of risk of loss or injury from the hazards to obtain Risk Score: The level of
risk is a Product of probability/likelihood of the event and consequence/severity. The organization has defined
severity as under. The multiplication of the two gives us the Risk Level/Score.
a) When it can lead to fatality or permanent disability (H) : 3 Marks
b) When it can lead to temporary disability or doctor visit is required : 2 Marks
c) - When it can lead to First aid Injury : 1 marks
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Calculation of Risk Level: The risk level is calculated by multiplying Severity (S) x Probability (P) of
occurrence.
The Risk levels (SXP=RL) are categorized as follows:
1 = Trivial,
2 - 3 = Tolerable
4 = Moderate,
5 = Substantial
6-9 = Intolerable
14.8 Evaluate if the risk is adequately controlled: For each of the activities hazard consider the existing
controls that are available to minimize the risk level. The details of the existing control for each of the
activities is indicated in Format for Risk Assessment. Determine the revised Risk.
14.9 Consider measures that may eliminate or reduce the risk further in line with basic principles of
hazard control: These measures should include all measures taken in respect of 4M & 1E( Man, Machine,
Material, Method and Environment))
14.10 Implement the risk control measures: Implement the additional/ongoing measures after planning the
Improvement Management Programs and determine a Final Score and lay down objectives to be achieved.
14.11Monitor and measure: Monitor the performance of those against the laid down objectives as per laid
down time frame.
14.12 Review and feedback: Review the performance of these in MRM and lay down fresh objectives. Also
review any additional activities which are required to be covered under risk assessment or which might have
changed the identified hazard and risk level.
k
14.13 Records
The various records to be maintained are:
a) Risk Assessment Record: (JPE/F/70)
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15.0 Purpose
To lay down the procedure for operation control of those operations/activities those are
associated with environmental aspects consistent with environmental policy, objectives and
targets.
15.1 Scope
This procedure covers all aspects of operation of Manufacture and covers the activities
of all person involved in the same.
15.2 Procedure
Site Manager receives the rolling sales plan for the month from the logistics department in the
form of dispatch plan for the month. The Manufacture manager checks the availability of
material for the work assigned and calculated the RM & PM required for the same. Based on the
Manufacture quantity assigned for Manufacture during the month, the balance material orders to
the approved suppliers with target dates for delivery. All the operators perform their activities
and get their work inspected as per sampling plan by the quality control department. In addition
the supervisor ensures that all operators check their respective work visually and carries out a
random check of the quality of their work. The Manufacture manager along with the
Manufacture supervisor ensures that all workers follow the defined norms of quality,
environment ,health and safety.
The processes are evaluated from time to time through process validation procedures. The
Internal audits for the EMS & QMS are performed as per the defined procedures. For fire safety
and other types of emergency situations, various types of mock drills are conducted to make the
people aware of escape rules and methods.
The I/C Manufacture also ensures that operators on the shop floor segregate paper, plastic and
hazardous waste and the same is disposed off effectively in properly marked bins for the same.
He also ensures that spillage of oil does not go to the soil by ensuring proper cemented flooring
below the machine area and wiping off the spilled oil with cotton waste and storing the same till
its disposal as hazardous waste. I/c HR ensures that canteen waste is collected separately and
disposed off daily to Municipal Committee Garbage bin in the area.
Site head ensures that all the machines are given supply through MCBs and have proper
earthing . In addition he ensures that power factor for the Office is always above 0.98 by use of
electronic panel. He also instructs the supervisors to stress on all operators to switch off lights,
fans and machines when not in use. He also ensures that wiring of the Office is tested for proper
insulation at least once in two years after installation.
15.3Records
Records used are same as used for Manufacture and QC.
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1. Purpose : To establish a procedure for setting environmental objectives, targets and developing the environmental
management program to achieve the set environmental objectives and targets.
4. System
4. System
5. Environmental Records:
5.1 Measurement Analysis Chart JPE/F/44.
5.2 Improvement Management Program .
5.3 Legal register JPE/F/42.
5.4 Aspect/ Impact analysis JPE/F/59.
5.5 Minutes of Management review meeting JPE/F/03.
6. References:
NIL
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4. System
5. Environmental Records:
5.1 Calibration Records : JPE/F/14.
5.2 Environmental Monitoring plan : JPE/F/67.
6. References:
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1. Purpose :To establish a procedure for communication with Internal and External agencies is
effectively done through designated channel to ensure the following:
1) Development function at various levels aware of the Environmental Management System
including the significant Environmental aspects and impacts in their working areas.
2) The communication from interested parties are received, documented and responded to relevant
points.
2. Scope: Applicable to all processes, Product and services under Environmental Management System.
3. Responsibility: MR and respective HODs as defined in responsibility column.
4. System
ANNEXUER-A
S. Retn Issue
Name of Document Ref. No
No Period No.
1 Master List of Documents JPE/F/01 6 years 1
2 List of Quality Record JPE/F/02 6 years 1
3 Management Review Meeting JPE/F/03 6 years 1
4 Index of Training Record JPE/F/04 6 years 1
5 Skill Matrix Record JPE/F/05 6 years 1
6 Training Record JPE/F/06 Till Emp. Exists