IATF Manual

Document Original Date: 02.08.
2021
Document Issue Level: 00
Document Originator: Management Representative
Document Approval: Managing Director
JOY RUBBER PRODUCTS
IATF 16949:2016
QUALITY MANUAL
PREPARED BY APPROVED BY
Signature Signature
Name: Name:
ADDRESS
No. 223, Highway Nagar, Industrial Park, Valarpuram, Sriperumbudhur Taluk,
Kanchipuram District, Tamil Nadu - 602105
REVISION HISTORY
IATF 16949:2016 Quality System Manual

Revision Level: 00 Revision Date: 02.08.2021 PAGE 1 Document Number: JRP/QSM/01
Document Original Date: 02.08.2021
SL.NO Rev. No. Title Pages
01 00 Initial release 65
2.0 TABLE OF CONTENTS

Doc. No. Title Pages

1.0 Cover Page 01
2.0 Table of contents 03
3.0 Introduction 05
4.0 Context of the organization 06
4.1 Understanding the organization and its context
Understanding the needs and expectations of interested
4.2
parties
4.3 Determining the scope of the quality management system
4.4 Quality management system and its processes
5.0 Leadership 09
5.1 Leadership and commitment
5.2 Quality Policy

5.3 Organizational roles, responsibilities and authorities
6.0 Planning 13
6.1 Actions to address risks and opportunities
6.2 Quality objectives and planning to achieve them
6.3 Planning of changes
7.0 Support 17
7.1 Resources
7.2 Competence
7.3 Awareness
7.4 Communication
7.5 Documented information
8.0 Operation 29
8.1 Operational planning and control
8.2 Requirements for products and services
8.3 Design and development of products and services
Control of externally provided processes, products and
8.4
services

8.5 Production and service provision

8.6 Release of products and services
8.7 Control of nonconforming outputs
9.0 Performance evaluations 54
9.1 Monitoring, measurement, analysis and evaluation
9.2 Internal audit
9.3 Management review
10.0 Improvement 60
10.1 General
10.2 Nonconformity and corrective action
10.3 Continual improvement
11 Abbreviations 63
12 Process Interaction Map
13 Roles, responsibility and authorities-Annexure-A
14 Organization Chart - Annexure-B
3.0 INTRODUCTION

Name M/S. JOY RUBBER PRODUCTS

No. 223, Highway Nagar, Industrial Park,
Address Valarpuram, Sriperumbudhur Taluk, Kanchipuram
District, Tamil Nadu - 602105
Product Design Exclusion
Scope Manufacture of rubber moulded components
Site extension Nil
Remote location Nil
Products Rubber components
4.0 CONTEXT OF THE ORGANIZATION
4.1 Understanding the organization and its context

JOY RUBBER PRODUCTS determine external and internal issues that are relevant
to its purpose and its strategic direction and that affect its ability to achieve the
intended result(s) of its quality management system through process Analysis turtle
diagram. The external and internal issues are identified.
4.2 Understanding the needs and expectations of interested parties
JOY RUBBER PRODUCTS has determined the interested parties who are relevant to
the quality management system and the requirement of the interested parties in
order to prevent the potential effect on the organization's ability to consistently
provide products and services which meet the customer and applicable statutory
and regulatory requirements. Interested party needs & Expectations are identified
and monitored by relevant department HOD’s
Interested
Requirements Monitoring & Review mechanism
parties
1) Specification communication 1) Defined in documented information

2) Payment as agreed of e xternal providers control
External
providers 3) On time supply of
input material (if any) 2) Review in management review
4) Technology support meetings
1) Quality of product
1) Defined in documented information
2) Delivery of product on time
of Marketing & Sales process
Customer
3) Response to complaint
2) Review in Management review
4) Proper Communication meetings
channel
1) Defined in documented information
Statutory & Complying with the statutory of Leader ship
Regulatory and regulatory requirements as
Body defined from time to time. 2) Review in management review
meetings
Updating of changes in
Bankers / Review in management review
the organization
Financiers meetings
whenever it happened

Management support, payments

Employees Accounting control of management
on time
4.3 Determining the scope of the quality management system
The JOY RUBBER PRODUCTS had determined the scope of the quality management system
by considering
1. External and internal issues of organization
2. Requirement of relevant interested parties needs from all departments
3. Product of the JOY RUBBER PRODUCTS
4. Customer specific requirements
4.3.1 Determining the scope of the quality management system-Supplemental
All the activity done by JOY RUBBER PRODUCTS plant (above mentioned factory
location) only, no other supporting involved externally.
4.3.2 Customer - specific requirements
Now we don’t have CSR, if future, customer specific requirement will define in CSR
matrix,
4.4 Quality management system and its processes
4.4.1 JOY RUBBER PRODUCTS has determined the processes needed for the quality
management system and their application throughout the organization in process
map & interactions of processes.
Has determined the inputs required and the outputs expected from each process in
individual process map addressed in documented information of each process
Has determined the sequence and interaction of the processes in process map &
Interactions of processes
JOY RUBBER PRODUCTS determined and applied the criteria and methods
(including monitoring, measurements and related performance indicators) needed

to ensure the effective operation and control of these processes in documented

information of each process
We determined the resources needed for these processes and ensure their
availability in documented information of support process. Assigned the
responsibilities and authorities for each process
JOY RUBBER PRODUCTS has addressed the risks and opportunities for all process.
Internal and External
JOY RUBBER PRODUCTS has been evaluating these processes and implementing
any changes needed to ensure that these processes achieve their intended results
and improve the processes and the quality management system
4.4.1.2. Product safety
The JOY RUBBER PRODUCTS documented the processes for the management of
product-safety related products and manufacturing- processes which shall include,
but not be limited to, the following, where applicable. Refer list of special and
critical characteristics
Identification by the organization of statutory and regulatory product-safety

requirements.
4.4.2 JOY RUBBER PRODUCTS is also maintaining documented information to support

the operation of its processes and retaining documented information to have
confidence that the processes are being carried out as planned
5. LEADERSHIP
5.1 Leadership and commitment
5.1.1 General
JOY RUBBER PRODUCTS has demonstrated leadership and commitment with

respect to the quality management system through
A) Top Management taking accountability for the effectiveness of the quality

management system by periodical review of quality management system

through management review meeting, Quality objectives review and providing

necessary resources.
B) Management has established quality policy and quality objectives for the
quality management system and is compatible with the context and strategic
direction of the organization.
C) Management has determined the organizational processes and integrated with
the quality management system requirement through process map &
Interaction this can be demonstrated.
D) Established procedure for promoting the use of the process approach and risk-
based thinking.
E) Ensuring that the resources needed for the quality management system are
available, this is being periodically reviewed through management review
meeting.
F) Communicating the importance of effective quality management and of
conforming to the quality management system requirements.
G) Ensuring that the quality management system achieves its intended results.
H) Engaging, directing and supporting persons to contribute to the effectiveness
of the quality management system by providing trainings, conducting
awareness programs and
I) Promoting improvement by introducing suggestion scheme.
J) Supporting other relevant management roles to demonstrate their leadership
as it applies to their areas of responsibility.
5.1.1.1. Corporate Responsibility
JOY RUBBER PRODUCTS define and implements corporate responsibility policies,

including at a minimum an anti-bribery policy, an employee code of conduct, and
an ethics escalation policy in our organization
5.1.1.2. Process effectiveness and efficiency
JOY RUBBER PRODUCTS review the product realization and support process for
evaluating and improving the effectiveness and efficiency. And the same is
reviewed in MRM
5.1.1.3. Process owners

Top management identified process owners (Department Representative) who are

responsible for managing the organization’s processes and related outputs. Process
owners shall understand their roles and be competent to perform these roles.
5.1.2. Customer focus
JOY RUBBER PRODUCTS has demonstrated leadership and commitment with

respect to customer focus by ensuring that:
A) Customer and applicable statutory and regulatory requirements are determined,

understood and consistently met.
B) The risks and opportunities that can affect conformity of products and services
and the ability to enhance customer satisfaction are determined and addressed
C) The focus on enhancing customer satisfaction is maintained and procedure for
customer satisfaction is addressed
5.2. Quality Policy
JOY RUBBER PRODUCTS continuously focus on product quality and customer

requirements by setting up quality objectives which are monitored
by Quality Management System.
To achieve above policy every employee must;
1. Adhere all applicable policies and regulations as per the Quality Management
System to fulfill the customer’s requirements.
2. Work towards enhancing the skills and capabilities of our workforce and expand
the capabilities of the factory infrastructure as required for our customer within
the quality standards.
With our Quality Management System, we continually Identify, Measure, Control

and Improve our core Business Practices to deliver outstanding business
performance and superior products with customer satisfaction.
5.2.1. Establishing the quality policy
JOY RUBBER PRODUCTS management has established, implemented and

maintained a quality policy that

A) is appropriate to the purpose and context of the organization and supports its
strategic direction
B) Provides a framework for setting quality objectives
C) Includes a commitment to satisfy applicable requirements
D) Includes a commitment to continual improvement of the quality management
system.
5.2.2. Communicating the quality policy
The quality policy is
A) Available and be maintained as documented information

B) Communicated, understood and applied within the organization through
display, Training and periodical review
C) Available to relevant interested parties, as appropriate
5.3. Organizational roles, responsibilities and authorities
5.3.1 & 5.3.2 JOY RUBBER PRODUCTS has ensured that the responsibilities and
authorities for relevant roles are assigned communicated and understood within the
organization. While assigning roles, responsibility and authority, top management
has considered and ensured that
a) The quality management system conforms to the requirements of this

International Standard
b) The processes are delivering their intended outputs
c) Reporting on the performance of the quality management system and on
opportunities for improvement, in particular to top management
d) The promotion of customer focus throughout the organization
e) The integrity of the quality management system is maintained when changes to
the quality management system are planned and implemented.
Roles, responsibility and authorities assigned Ref annexure-A
Responsibility for quality

Non-conforming Authority Responsibility for Communicatio Authority to
situation for communication n system stop production

corrective
until correction
action
Products non-
Rejection
conforming at Suppliers Quality Inspector HOD-Quality
report
receiving inspection
Products found non- Non-

HOD – HOD-Quality
conforming during Quality Inspector conforming
Production
production stage report
Products found non-
HOD – Product audit
conforming during Auditor HOD-Quality
Production report
internal audit
Products suspected to Non-
HOD – Inspector –
be non-conforming conforming HOD-Quality
Quality Quality
after calibration report
Products suspected to
be non-conforming Non-
HOD – Inspector –
due to out of control conformance HOD-Quality
Production Quality
situation observed in report
control chart
Products suspect to
Engineering
be non-conforming HOD – NPD Engineer/
change review Plant Head
due to engineering Engineering Inspector
record
change.
Products returned by
RTV
customer due to no- Inspector –
HOD-Quality (Return to HOD-Quality
conformance or Quality
Vendor)
failure
The internal communication system together with quality management system

record distribution ensures that this information exchange takes place.
Head - Quality, who is responsible for quality function, is vested with authority to
stop production to correct quality problems.
The production operation across all shifts is staffed with personnel responsible for
or delegated responsibility for ensuring product quality. The Quality inspectors are

vested with authority to stop production to correct the quality problem in their
respective shifts. When the responsibility is delegated to personnel in the shift, the
person carrying out quality responsibility additionally is ensured to be competent
and impartial
6. PLANNING
6.1. Actions to address risks and opportunities
6.1.1. JOY RUBBER PRODUCTS is addressed the issues, requirements the risks and
opportunities
A) Given assurance that the quality management system can achieve its intended
results.
B) Enhance desirable effects.

C) Prevent, or reduce, undesired effects.
D) achieve improvement.
6.1.2. JOY RUBBER PRODUCTS planned
a) Actions to address these risks and opportunities

b) How to
1. Integrate and implement the actions into its quality management system
processes
2. Evaluate the effectiveness of these actions
Interested Risks and

Requirements Effectiveness of actions
parties Opportunities

Communicatio Communication like

Communication, n Gap, Emails, Phone, Payment
External Payment Terms, Payment & & delivery terms mention
providers On Time Supply, Delivery terms in PO, Documented
Technology Support, not in written, information is provided
Output Failure for Technical support
Product Quality, Defined in documented

Business Loss,
Delivery & service of on information of Marketing
Reputation
Customer time, Response to & Sales process & Review
Down for
complaint, Proper in Management review
Organization
Communication channel meetings
Statutory Organization & product Customer is not Defined in documented

& related Statutory & accepted information & Review in
Regulatory regulatory requirements material or loss Management review
Body is kept of business meetings
Organization is
All product & All product &
Bankers / facing the
organization related organization related
financiers problems
documents are kept documents is kept
(funds related)
Work is not On time payments issue
Employees On time Payments properly
operated to employees
Organization
facing
Competitive rates, More Market analysis,
problems in
Marketing amenities, Prime Competent marketing
sales,
Location, team.
Reputation in
market
Organization
facing Finance
problems,
Competitive rates, Good Customer Market analysis,
Purchase Quality material, Timely dissatisfied, Competent Purchase
Delivery, Delay in project team
completion &
Reputation in
market

Power Constant supply of Revenue loss Regular follow up

Generation power
6 .1.2.1 Risk analysis
JOY RUBBER PRODUCTS include its risk analysis, at a minimum, lessons learned
from product recalls, product audits, field returns and repairs, complaints, scrap,
and any rework and shall retain documented information as evidence of the results
of risk analysis.
6.1.2.2. Preventive action
JOY RUBBER PRODUCTS determine and implements the actions for the cause of
major potential nonconformities in order to prevent their occurrence
JOY RUBBER PRODUCTS also establish the process to lessen the impact of negative
effects of risk including the following
a) Determines the potential nonconformities and their causes

b) Evaluating the need for action to prevent occurrence of nonconformities
c) Determining and implementing action needed
d) Documented information of action taken
e) Reviewing the effectiveness of the preventive action taken
f) Utilizing lessons learned to prevent the recurrence in similar process
6.1.2.3. Contingency plans
JOY RUBBER PRODUCTS identified all the function dept. contingency plan, and
effectively controlled.
JOY RUBBER PRODUCTS identify the internal & external risks to all manufacturing
process and infrastructure essential to maintain production output.
Contingency plan is defined based on the risk impact to the customer, contingency
plan includes the provisions to validate that the manufactured product continuous
to meet customer specifications.

6.2. Quality objectives and planning to achieve them
6.2.1 And 6.2.2 JOY RUBBER PRODUCTS establish quality objectives at relevant
functions, levels and processes needed for the quality management system
The quality objectives are consistent with quality policy, measurable,

communicative, and relevant to conformity of products and services to enhance the
customer satisfaction
The quality objectives are monitored timely once in 6 months and reviewed in MRM
6.3. Planning of changes
JOY RUBBER PRODUCTS determine the need for changes to the quality
management system, the changes are carried out in a planned manner
a) The purpose of the changes and their potential consequences
b) The integrity of the quality management system
c) The availability of resources
d) The allocation or reallocation of responsibilities and authorities
JOY RUBBER PRODUCTS has determined the processes needed for the quality
management system and their application throughout the organization in process
map & Interactions of processes.
7. SUPPORT
7.1. Resources
7.1.1. General
JOY RUBBER PRODUCTS determine and provides the resources needed for the
establishment, implementation, maintenance and continual improvement of the
quality management system also considers
a) The capabilities of, and constraints on, existing internal resources

b) What needs to be obtained from external providers
Plant head determine and provide the resources needed to implement and maintain
the quality management system and continually improve its effectiveness and to

enhance customer satisfaction by meeting customer requirement. The resources will

be in the form of
1) Human resources including qualified personnel for verification activities

2) Manufacturing machines, Test Equipment’s & infrastructure
3) Provide raw material & other inputs for realization of product
4) Providing funds
7.1.2. People
JOY RUBBER PRODUCTS determine and provides the persons necessary for the
effective implementation of its quality management system and for the operation
and control of its processes
HR and plant manager along with respective process in charge ensures that
personnel performing work affecting product quality are competent and training to
given on the basis operation and control of its processes
7.1.3. Infrastructure
JOY RUBBER PRODUCTS is determining, provide and maintain the infrastructure
necessary for the operation of its processes and to achieve conformity of products
and services
Infrastructure includes
a) building and associated utilities
b) equipment, including hardware and software

c) transportation resources
d) information and communication technology
7.1.4. Environment for the operation of processes

JOY RUBBER PRODUCTS is determining, provide and maintain the environment
necessary for the operation of its processes and to achieve conformity of products
A suitable environment can be a combination of human and physical factors

a) Social (e.g. non-discriminatory, calm, non-confrontational)

b) Psychological (e.g. stress-reducing, burnout prevention, emotionally protective)
c) Physical (e.g. temperature, heat, humidity, light, airflow, hygiene, noise).
Plant manager in co-ordination with respective in-charge determines and manages
the work environment needed to achieve conformity to product requirement and
reviewed ongoing basis.
7.1.4.1. Environment for the operation of process.

JOY RUBBER PRODUCTS maintain its premises in a start of order. Cleanliness and
repair that is consistent with the product and manufacturing needs.
7.1.5. Monitoring and measuring resources.

7.1.5.1. General.
JOY RUBBER PRODUCTS determine and provides the resources needed to ensure
valid and reliable results when monitoring or measuring is used to verify the
conformity of products and services to requirements. We ensure that the resources
provided
a) Are suitable for the specific type of monitoring and measurement activities being
undertaken
b) Are maintained to ensure their continuing fitness for their purpose
JOY RUBBER PRODUCTS is retaining appropriate documented information as
evidence of fitness for purpose of the monitoring and measurement resources.
7.1.5.1.1. Measurement system analysis

Statistical studies conducted by JOY RUBBER PRODUCTS to analyze the variation
present in the results of each type of inspection, measurement, and test equipment
system identified in the control plan. The analytical methods and acceptance criteria
used shall conform to those in reference manuals on measurement systems analysis.
Other analytical methods and acceptance criteria may be used if approved by the
customer.
Records of customer acceptance of alternative methods shall be retained along with

results from alternative measurement systems analysis.
JOY RUBBER PRODUCTS ensure that MSA studies focus on critical or special
product or process.

7.1.5.2. Measurement traceability

JOY RUBBER PRODUCTS measurement traceability is maintained requirement if
applicable for the instruments, or is considered by the to be an essential part of
providing confidence in the validity of measurement results,
a) Calibrated or verified, or both, at specified intervals, or prior to use, against

measurement standards traceable to international or national measurement
standards; when no such standards exist, the basis used for calibration or
verification shall be retained as documented information
b) Identified in order to determine their status
c) Safeguarded from adjustments, damage or deterioration that would invalidate the
calibration status and subsequent measurement results
JOY RUBBER PRODUCTS is determining the validity of previous measurement
results has been adversely affected when measuring equipment is found to be unfit
for its intended purpose, and shall take appropriate action as necessary.
Control of Monitoring & Measuring Equipment’s

To ensure that the measuring equipment’s operate effectively and give reliable
results, we have taken the following steps:
Equipment’s are maintained properly and are calibrated & adjusted as and when
needed. Necessary safeguards are in place to take care of adjustments that could
lead to invalid results.
Calibrations are carried out as per national standards (by NABL accredited
laboratories only). Where no such standard exists, the basis used for calibration or
verification are recorded. The calibration records include the last date of calibration,
calibrating agency (for external agency), calibration result, and frequency of
calibration as per the process and/or instrument requirement and the next
calibration date. The required accuracy is identified and compared to the
measurement that meets expectations.
Identification of appropriate equipment is accomplished by tagging, labeling,

numbering or by including it in a calibration/maintenance database.

Proper control is maintained to ensure that no faulty equipment is used, the

reliability of the equipment is ensured through routine maintenance and re-
calibration.
Equipment’s are used, handled and stored under conditions that protect accuracy
and prevent unauthorized adjustment. Work environmental controls are all in place
for equipment.
Instrument history cards are maintained for all measuring & Test instruments.
7.1.5.2.1. Calibration/Verification Records

JOY RUBBER PRODUCTS have a documented process for managing
calibration/verification records and ensure that calibration/verification activities
and records like revision, out of spec. etc.
JOY RUBBER PRODUCTS censure’s that calibration/verification activities and

records shall include the following details:
a) Revisions following engineering changes that impact measurement systems;

b) Any out-of-specification readings as received for calibration/verification;
c) An assessment of the risk of the intended use of the product caused by the out of
specification condition
d) when a piece of inspection measurement and test equipment is found to be out of
calibration or defective during its planned verification or calibration or during its
use, documented information on the validity of previous measurement results
obtained with this piece of inspection measurement and test equipment shall be
retained, including the associated standard's last calibration date and the next due
date on the calibration report
e) Notification to the customer if suspect product or material has been shipped
f) Statements of conformity to specification after calibration verification
g) Verification that the software version used for product and process control is as
specified

h) Records of the calibration and maintenance activities for all gauging (including
employee-owned equipment, customer-owned equipment, or on-site supplier-
owned equipment)
i) production-related software verification used for product and process control
(including software installed on employee-owned equipment, customer-owned
equipment, or on-site supplier-owned equipment)
7.1.5.3. Laboratory requirements

7.1.5.3.1. Internal Laboratory
Internal laboratory process is not applicable in JOY RUBBER PRODUCTS,
calibration services is outsourced.
7.1.5.3.2. External Laboratory

Calibration services are out sourced by NABL authorized sources.
7.1.6. Organizational knowledge
JOY RUBBER PRODUCTS is determining the knowledge necessary for the

operation of its processes and to achieve conformity of products and services.
This knowledge shall be maintained and be made available to the extent necessary
When addressing changing needs and trends, the organization shall consider its
current knowledge and determine how to acquire or access any necessary additional
knowledge and required updates
Organizational knowledge is specific to the organization; it is generally gained by

experience. It is information that is used and shared to achieve the organization’s
objectives. Organizational knowledge can be based on:
a) Internal sources (e.g. intellectual property; knowledge gained from experience;

lessons learned from failures and successful projects; capturing and sharing

undocumented knowledge and experience; the results of improvements in

processes, products and services);
b) External sources (e.g. standards; academia; conferences; gathering knowledge
from customers or external providers).
7.2. Competence
JOY RUBBER PRODUCTS has

a) Determines the necessary competence of person(s) doing work under its control
that affects the Performance and effectiveness of the quality management system
b) Ensures that these persons are competent on the basis of appropriate education,
training, or Experience
c) Where applicable, take actions to acquire the necessary competence, and evaluate
the effectiveness of the actions taken
Retain appropriate documented information as evidence of competence for all
employees
7.2.1. Competence
Our organization established training need including of awareness to achieve our
goal as per training plan.
7.2.2. Competence
Our organization shall provide on job training for new operator’s and employees,
we are monitoring and controlling the effectiveness of the training.
JOY RUBBER PRODUCTS provide on-the-job training (which shall include

customer requirements training) for personnel in any new or modified
responsibilities affecting conformity to quality requirements, internal requirements,
regulatory or legislative requirements; this shall include contract or agency
personnel. The level of detail required for on-the-job training shall be commensurate
with the level of education the personnel possess and the complexity of the task(s)
they are required to perform for their daily work.
7.2.3. Internal Auditor Competency

The organization shall have a documented process to verify that internal auditors
are competent, considering any customer- specific requirements. QMS auditors

The organization shall have a documented process to verify that internal auditors
are competent, considering any customer-specific requirements. For additional
guidance on auditor competencies, refer to ISO 19011. The organization shall
maintain a list of qualified internal auditors. Quality management system auditors,
manufacturing process auditors, and product auditors shall all be able to
demonstrate the following minimum competencies:
a) Understanding of the automotive process approach for auditing, including risk-

based thinking
b) Understanding of applicable customer-specific requirements
c) Understanding of applicable ISO 9001 and IATF 16949 requirements related to the
scope of the audit
d) Understanding of applicable core tool requirements related to the scope of the
audit
e) Understanding how to plan, conduct, report, and close out audit findings.
Additionally, manufacturing process auditors shall demonstrate technical
understanding of the relevant manufacturing process to be audited, including
process risk analysis (such as PFMEA) and control plan. Product auditors shall
demonstrate competence in understanding product requirements and use of
relevant measuring and test equipment to verify product conformity. Where
training is provided to achieve competency, documented information shall be
retained to demonstrate the trainer's competency with the above requirements.
Maintenance of and improvement in internal auditor competence shall be
demonstrated through
f) Executing a minimum number of audits per year, as defined by the organization;

and
g) Maintaining knowledge of relevant requirements based on internal changes (e.g.,
process technology, Product technology) and external changes (e.g., ISO 9001, IATF
16949, core tools & customer specific requirements).
7.2.4. Second Party Auditor Competency
JOY RUBBER PRODUCTS shall demonstrate the competence of the auditors

undertaking second party audits to meet customer specific requirements (CSRs) for
auditor qualification and demonstrate the minimum core competencies like process
approach to including, including risk-based thinking, CSR, ISO 9001 and IATF
16949 requirements, PFMEA, control plan, core tools requirement audit report and
closer.

7.3. Awareness
JOY RUBBER PRODUCTS is ensuring that persons doing work under the
organization’s control are aware of
a) The quality policy

b) Relevant quality objectives
c) Their contribution to the effectiveness of the quality management system,
including the benefits of improved performance
d) The implications of not conforming to the quality management system
requirements
7.3.1. Awareness
Our organization shall maintain doc’s awareness of the product and process
7.3.2. Employee motivation and empowerment

Our organization established motivation policy we are working to wards to achieve
the organization goal
7.4. Communication
JOY RUBBER PRODUCTS is determining the internal and external communications
relevant to the quality management system, including off on what it will
communicate, when to communicate, with whom to communicate, how to
communicate and who Communicates
What When with whom How Who

INTERNAL COMMUNICATION
All Employees /
Quality policy Permanent Display / mail Management
Interested parties
As per Training
Importance of
plan / during All Employees Training / Display Management
effective QMS Orientation training
During recruitment
Responsibilities Procedure / Oral /
/ Promotion / Employee Management
and Authority Department change Training

Quality Procedure / Oral /

While defining All employees Management
objectives Mail
Head of the
Customer At the time of department /
complaint / Meeting QA
receipt Respective
Feedback process owner
What When With whom How Who
EXTERNAL COMMUNICATION
Information to Placing purchase Supplier

external order / Quotation (External Purchase order email Purchase
providers collection provider)
Product Email / Website / Marketing

Enquiry stage Customer
information Catalogue / Letter Head
Enquiry, order, Enquiry review / Marketing

Customer Email / Letter
amendments Order review Head
Customer Once in a year / After Forwarding customer Marketing

Customer
feedback service feedback form Head
Action taken
for customer Once action taken Customer Email/ phone Quality head
complaints
Information to
As agreed with Delivery challan /
external Customer Logistics
customer Letter / Email
providers
7.5. Documented information

7.5.1. General
7.5.1.1. QMS Documentation
The organization’s QMS shall be documented and incl. a quality manual, which can
be a series of documents. The quality manual shall incl. as a min., the following

a) Scope of the QMS, incl. details of and justification for exclusions;

b) Documented processes established for the QMS
c) The organization’s processes and their sequence and interactions (inputs and
Outputs) incl. type and extent of control of any outsourced processes;
d) A document (i.e. matrix indicating where within the organization’s MS their
CSRs are addressed
7.5.2. Creating and updating
JOY RUBBER PRODUCTS creating and updating documented information, the JOY
RUBBER PRODUCTS s ensure appropriate
a) Identification and description
b) Format (e.g. language, software version, graphics) and media
c) Review and approval for suitability and adequacy
JOY RUBBER PRODUCTS quality management system is including
Quality management System documentation is established with the following

approach. A three-level documented structure is followed for the operation of
Quality Management System
Level-1: Quality system manual (standard requirement)
Define the approach and responsibility, which includes a documented statement of

quality policy & objectives etc.
Level-2: Procedures
Defines what, where, when, who & why of an activity being done as stated in IATF
16949:2016 standard. The documented procedure activity process flow chart defines
the effective planning, operation and control of processes
Level-3: Documented information (formats).

Defines how exactly an activity is to be done ensuring the effective planning,
operation and control of processes.
Provides the evidence, which has to be established for all the activities, stated above
which in turn Documented Information. A master list of Quality Record is
maintained by respective Departments/ section heads as per the requirement of
IATF 16949:2016.

Control of Quality System Manual
Top management is approving the Quality Manual. Remaining documented

information will approve department head or plant manager or in-charge.
MASTER COPY will be stamped “MASTER COPY" on the back side of all pages in
“GREEN" color
Photo copy will be taken for all MASTER & will be "CONTROLLED COPY"
stamped in “BLUE” color in front side of the page.
Document changes
Obsolete version of revised pages at the time of each amendment for reference
purpose and having “OBSOLETE COPY” stamp in “RED” color in front side of the
page.
System change and amendment to reference ISO, IATF standard or any change in
the organization affecting system described in this manual. Amendments to this
manual are recorded in the amendment list
7.5.3. Control of documented information.

7.5.3.1. Documented information required by the quality management system and by this
International standard shall be controlled to ensure
a) It is available and suitable for use, where and when it is needed
b) It is adequately protected (e.g. from loss of confidentiality, improper use, or loss of
integrity)
7.5.3.2 For the control of documented information, JOY RUBBER PRODUCTS is addressing
the following activities, as applicable.
A) Distribution, access, retrieval and use.

B) Storage and preservation, including preservation of legibility
C) Control of changes
D) Retention and disposition

7.5.3.2.1 Record retention

JOY RUBBER PRODUCTS has defined document and implement a record retention.
And the controls of records satisfied statutory, regulatory, organization and
customer requirements.
7.5.3.2.2. Engineering Specifications

The JOY RUBBER PRODUCTS have a documented process describing the review,
distribution, and
Implementation of all customer engineering standards/specifications and related
revisions based on customer schedules, as required, When an engineering
standard/specification change results in a product design change. The organization
shall retain a record of the date on which each change is implemented in
production. Implementation shall include updated documents.
8. OPERATION
8.1. Operational planning and control
JOY RUBBER PRODUCTS plan, implement and control the processes needed to meet the
requirements for the provision of products and services, and to implement the actions in &
maintained risks and opportunities related to planning maintained in operational planning
control.
a) Determining the requirements for the products and services
b) Establishing criteria for
1. The processes
2. The acceptance of products and services
c) Determining the resources needed to achieve conformity to the product and service
requirements
d) Implementing control of the processes in accordance with the criteria
e) Determining, maintaining and retaining documented information to the extent necessary
1. To have confidence that the processes have been carried out as planned

2. To demonstrate the conformity of products and services to their requirements

JOY RUBBER PRODUCTS is control planned changes and reviews the consequences of
unintended changes, acting to mitigate any adverse effects, as necessary.
8.1.1. Operational planning and control
When planning for product realization, the following topics are included
a) Customer product requirements and technical specifications
b) Logistics requirements
c) Manufacturing feasibility
d) Project planning
e) Acceptance criteria
The resources identified in ISO 9001, Section 8.1 c), refer to the required verification,
validation, monitoring, measurement, inspection, and test activities specific to the product
and the criteria for product acceptance.
8.1.2. Confidentiality
Customer related confidentiality are self-produced by organization one few
authored persons.
8.2. Requirements for products and services

8.2.1. Customer communication
Communication with customers is include
a) Providing information relating to products and services
b) Handling enquiries, contracts or orders, including changes
c) Obtaining customer feedback relating to products and services, including
customer complaints
d) Handling or controlling customer property

e) Establishing specific requirements for contingency actions, when relevant

Customers are communicated regarding the product information though letter, verbal
and/ or through phone, Fax, e-mail. If any amendments in enquiries, purchase orders it
will be communicated through phone, letter & e-mail, the customer complaints are
registered in customer complaint register and the corrective action taken is communicated.
8.2.1.1. Customer communication
JOY RUBBER PRODUCTS ensure the customer communication through mail,
phone or hardcopy
8.2.2. Determining the requirements for products and services
When determining the requirements for the products and services to be offered to
customers, the JOY RUBBER PRODUCTS is ensuring that
a) The requirements for the products and services are defined, including
1) Any applicable statutory and regulatory requirements
2) Those considered necessary by the organization
b) The organization can meet the claims for the products and services it offers
At present the marketing activities are looked after by Plant head and he actively
involved in the determination of customer requirements and for each enquiry he
determines the
1) Requirements related to the product in contract review form with respect to

requirements specified by customer, including the requirements for delivery and
post-delivery activities.
2) Requirements not stated by customer but necessary for specific or intended use
(where known)
3) Statutory and Regulatory requirements related to the product
4) Any additional requirements determined by the organization

JOY RUBBER PRODUCTS ensure the compliance of all the government, safety and
environment regulation for product and services.
8.2.2.1. Determining the requirements for products and services – supplemental

These requirements shall include recycling, environmental impact, and
characteristics identified as a result of the organization's knowledge of the product
and manufacturing processes.
Compliance to ISO 9001, Section 8.2.2 item
a) Shall include but not be limited to the following:
All applicable government, safety, and environmental regulations related to
acquisition, storage, handling, recycling, elimination, or disposal of material.
8.2.3. Review of the requirements for products and services
JOY RUBBER PRODUCTS ensuring that it has the ability to meet the requirements for
products and services to be offered to customers. JOY RUBBER PRODUCTS is conducting
a review before committing to supply products and services to a customer, to include
a) Requirements specified by the customer, including the requirements for delivery
and post-delivery activities
b) Requirements not stated by the customer, but necessary for the specified or
intended use, when known
c) Requirements specified by the organization
d) Statutory and regulatory requirements applicable to the products and services
e) Contract or order requirements differing from those previously expressed
JOY RUBBER PRODUCTS ensure that contract or order requirements differing from
those previously defined are resolved.
The customer’s requirements are confirmed by JOY RUBBER PRODUCTS is before
acceptance, when the customer does not provide a documented statement of their
requirements

8.2.3. Review of the requirements for products and services

8.2.3.1 Review of the requirements for products and services
JOY RUBBER PRODUCTS ensured that ability to meet the requirement for the
products and services. We reviewing before committing to supply products to the
customer to include
A) Requirements specified by the customer, including the requirements for
delivery and post-delivery activity.
B) Requirements not stated by the customer, but necessary for the specified or
intended use, when know
C) Requirements specified by the organization
D) Statutory specified by the customer
E) Contract or order requirement differing from those previously expressed
8.2.3.1.1. Review of the requirements for products and services – supplemental

JOY RUBBER PRODUCTS retain documented evidence of a customer-authorized waiver
for the requirements stated in ISO 9001, Section 8.2.3.1, for a formal review.
8.2.3.1.2. Customer-designated special characteristics
JOY RUBBER PRODUCTS conform to customer requirements for designation, approval
documentation & Control of special characteristics, And SPC control is maintained in shop
floor.
8.2.3.1.3. Organization manufacturing feasibility
JOY RUBBER PRODUCTS utilize a multidisciplinary approach to conduct an analysis to
determine if it is feasible that the organization's manufacturing processes are capable of
consistently producing product that meets all of the engineering and capacity

requirements specified by the customer. JOY RUBBER PRODUCTS conduct this feasibility
analysis for any manufacturing or product technology new to the organization and for any
changed manufacturing process or product design. Additionally, the organization should
validate through production runs, benchmarking studies, or other appropriate methods,
their ability to make product to specifications at the required rate.
8.2.3.2. JOY RUBBER PRODUCTS retain documented information, as applicable

a) On the results of the review
b) On any new requirements for the products and services
8.2.4. Changes to requirements for products and services

JOY RUBBER PRODUCTS is ensuring that relevant documented information is amended,
and that relevant persons are made aware of the changed requirements, when the
requirements for products and services are changed
8.3. Design and development of products and services

JOY RUBBER PRODUCTS is doing manufacturing as per customer CSR, Hence the
product design function is not carried in our plant. Product design provided by customer.
So, we excluding product design.
8.3.1.1 Design and development of products and services – supplemental

JOY RUBBER PRODUCTS shall apply to product and manufacturing process design and
development and shall focus on error prevention rather than detection. The organization
shall document the design and development process.
8.3.2.3 Development of products with embedded software

JOY RUBBER PRODUCTS shall use a process for quality assurance for their products with
internally developed embedded software. A software development assessment

methodology shall be utilized to assess the organization's software development process.

Using prioritization based on risk and potential impact to the customer, the organization
shall retain documented information of a software development capability self-assessment.
The organization shall include software development within the scope of their internal
audit program.
8.3.3.2 Manufacturing process design input
JOY RUBBER PRODUCTS shall identify, document, and review manufacturing process
design input requirements including but not limited to the following:
a) product design output data including special characteristics;
b) targets for productivity, process capability, timing, and cost;
c) manufacturing technology alternatives; d) customer requirements, if any;

e) experience from previous developments; f) new materials;
g) product handling and ergonomic requirements; and

h) design for manufacturing and design for assembly.
The manufacturing process design shall include the use of error-proofing methods to a
degree appropriate to the magnitude of the problem
8.3.3.3 Special characteristics
JOY RUBBER PRODUCTS shall use a multidisciplinary approach to establish, document,

and implement its process (es) to identify special characteristics, including those
determined by the customer and the risk analysis performed by the organization and shall
include the following:
a) documentation of all special characteristics in the drawings (as required), risk analysis
(such as FMEA), control plans, and standard work / operator instructions; special
characteristics are identified with specific markings and are cascaded through each of these
documents;
b) development of control and monitoring strategies for special characteristics of products
and production processes

c) customer-specified approvals, when required;

d) compliance with customer-specified definitions and symbols or the organization’s
equivalent symbols or notations, as defined in a symbol conversion table. The symbol
conversion table shall be submitted to the customer, if required.
8.3.4.1 Monitoring
Measurements at specified stages during the design and development of products and
processes shall be defined, analyzed, and reported with summary results as an input to
management review (see Section 9.3.2.1). When required by the customer, measurements
of the product and process development activity shall be reported to the customer at stages
specified, or agreed to, by the customer.
8.3.5.2 Manufacturing process design output
JOY RUBBER PRODUCTS documented the manufacturing process design output in a
manner that enables verification against the manufacturing process design inputs. The
organization shall verify the outputs against manufacturing process design input
requirements. The manufacturing process design output shall include but is not limited to
the following:
a) specifications and drawings;

b) special characteristics for product and manufacturing process;
c) identification of process input variables that impact characteristics;
d) tooling and equipment for production and control, including capability studies of
equipment and processes;
e) manufacturing process flow charts/layout, including linkage of product, process, and
tooling; f) capacity analysis
g) manufacturing process FMEA;
h) maintenance plans and instructions;
i) control plan (see Annex A);
j) standard work and work instructions;
k) process approval acceptance criteria;
l) data for quality, reliability, maintainability, and measurability;
m) results of error-proofing identification and verification, as appropriate;
n) methods of rapid detection, feedback, and correction of product/manufacturing process
nonconformities.

8.4. Control of externally provided processes, products and services

8.4.1. General
JOY RUBBER PRODUCTS is ensuring that externally provided processes, products and
services conform to requirements, JOY RUBBER PRODUCTS is determining the controls to
be applied to externally provided processes, products and services when
a) Products and services from external providers are intended for incorporation into
the Organization’s own products and services.
b) Products and services are provided directly to the customer(s) by external
providers on behalf of the organization.
c) A process, or part of a process, is provided by an external provider as a result of a
decision by the organization.
JOY RUBBER PRODUCTS determine and applies criteria for the evaluation, selection,
monitoring of performance, and re-evaluation of external providers, based on their ability
to provide processes or products and services in accordance with requirements. The
organization shall retain documented information of these activities and any necessary
actions arising from the evaluations
8.4.1.1 General-Supplemental
JOY RUBBER PRODUCTS include all products and services that affect customer
requirements such as sub-assembly, sequencing, sorting, rework, and calibration services
in the scope of the definition of externally provided products, process.
8.4.1.2. Supplier selection process
Our organization shall have a documented supplier selection process. The selection
process shall include of
a) An assessment of the selected supplier’s risk to product conformity and

uninterrupted supply of the organization’s product to their customers

b) Relevant quality and delivery performance

c) An evaluation of the supplier’s QMS
d) Multidisciplinary decision making; and
e) An assessment of software development capabilities, if applicable.
JOY RUBBER PRODUCTS also ensure supplier selection criteria that considers the
following
 Volume of automotive business (absolute and as a percentage of total business)
 Financial stability;
 Purchased product Material or service complexity;
 Required technology (product or process);
 Adequacy of available resources (e.g., people, infrastructure);
 Design and development capabilities (including project management);
 Manufacturing capability;
 Change management process:
 Business continuity planning (e.g. disaster preparedness, contingency planning)
 Logistics process:
 Customer service.
8.4.1.3. Customer-directed sources
When specified by the customer, the JOY RUBBER PRODUCTS shall purchase Products,
materials, or services from customer-directed sources
All requirements of Section 8.4 (except the requirements in Section 8.4.1.1) are applicable to
the organization’s control of customer- directed sources unless specific agreements are
otherwise defined by the contract between the organization and the customer.
8.4.2. Type and extent of control

JOY RUBBER PRODUCTS ensure that externally provided processes, products and
services do not adversely affect the organization’s ability to consistently deliver
conforming products and services to its customers
JOY RUBBER PRODUCTS shall
a) Ensure that externally provided processes remain within the control of its quality
management system
b) Define both the controls that it intends to apply to an external provider and those
it intends to apply to the resulting output
c) Take into consideration
1) The potential impact of the externally provided processes, products and
services on the organization’s ability to consistently meet customer and
applicable statutory and regulatory requirements
2) The effectiveness of the controls applied by the external provider
d) Determine the verification, or other activities, necessary to ensure that the
externally provided processes, products and services meet requirements
8.4.2.1. Type and extent of control
JOY RUBBER PRODUCTS have a documented procedure to select the types and extent of
controls used to ensure conformity of externally provided products, processes, and
services to internal and external customer requirements.
The process shall include the criteria and actions to escalate or reduce the types and extent
of controls and development activities based on supplier performance and assessment of
product, material, or service risks
8.4.2.2. Statutory and regulatory requirements
JOY RUBBER PRODUCTS define actions and methodologies to ensure that purchased
products, processes, and services conform to the current applicable statutory and

regulatory requirements in the country of receipt, the country of shipment, and of the
customer-identified country of destination, if provided.
If the customer defines special controls for certain products with statutory and regulatory
requirements, the organization shall ensure they are implemented and maintained as
defined, incl. at suppliers.
8.4.2.3. Supplier QMS development
JOY RUBBER PRODUCTS shall ensure their suppliers of automotive products and services
to develop, implement, and improve a QMS certified to ISO 9001, unless otherwise
authorized by the customer, with the ultimate objective of becoming certified to this
Automotive QMS Standard. Unless otherwise specified by the customer, the following
sequence should be applied to this requirement
a) Compliance to ISO 9001 through second-party audits;
b) Certification to ISO 9001 through third party audits;
c) Certification to ISO 9001 with compliance to other customer defined QMS
requirements (e.g. Min. Automotive QMS Requirements for Sub-Tier Suppliers or
equivalent) thru second-party audits.
e) Certification to ISO9001 with compliance to IATF 16949 thru second party audits.
f) Certification to IATF 16949 thru third party audits by valid certification bodies
8.4.2.3.1. Automotive product-related software or automotive products with embedded

software
JOY RUBBER PRODUCTS insist all their suppliers of automotive product- related
software, or automotive products with embedded software, to implement and maintain a
process for software quality assurance for their products.
A software development assessment methodology shall be utilized to assess the supplier’s

software development process. Using prioritization based on risk and potential impact to

the customer, and also JOY RUBBER PRODUCTS insist the supplier to retain documented
information of a software development capability self-assessment.
8.4.2.4. Supplier monitoring

JOY RUBBER PRODUCTS have a documented process and criteria to evaluate supplier
performance in order to ensure conformity of externally provided products, processes, and
services to internal and external customer requirements.
At a minimum, the following supplier performance indicators shall be monitored:

a) Delivered product conformity to requirements;
b) Customer disruptions at the receiving plant, including yard holds and stop ships;
c) Delivery schedule performance;
d) Number of occurrences of premium freight.
If provided by the customer, the organization shall also include the following, as
appropriate, in their supplier performance monitoring
e) Special status customer notifications related to quality or delivery issues
f) Dealer returns, warranty, field actions, and recalls.
8.4.2.4.1. Second-party audits
JOY RUBBER PRODUCTS include a second-party audit process in their supplier
management approach.
Second-party audits used for the following:
a) Supplier risk assessment
b) Supplier monitoring
c) Supplier OMS development
d) Product audits
e) Process audits.
Based on a risk analysis including product safety/regulatory requirements, performance of
the supplier, and OMS certification level, at a minimum, JOY RUBBER PRODUCTS shall
document the criteria for determining the need, type, frequency, and scope of second-party
audits and retain records of the second-party audit reports. If the scope of the second-party

audit is to assess the supplier's quality management system, then the approach shall be
consistent with the automotive process approach.
8.4.2.5. Supplier development

Supplier monitoring process should be considered an input to the supplier development
activities.
Inputs Like
a) Performance issues identified through supplier monitoring (see Section 8.4.2.4)
b) Second-party audit findings (see Section 8.4.2.4.1)
c) Third-party quality management system certification status
d) Risk analysis.
The JOY RUBBER PRODUCTS shall implement actions necessary to resolve open
(unsatisfactory) performance issues and pursue opportunities for continual improvement.
These development activities should consider both short term and long-term goals.
Short term efforts would generally focus on supplier products, and would require defining
suitable methods to assure the quality of purchased product from each supplier.
Long term efforts would generally focus on supplier QMS and manufacturing processes on
the whole, and consider audits, training, and enhancement efforts that implement and
enhance quality assurance agreements between suppliers and the organization, and further
reduce risk.
8.4.3. Information for external providers
JOY RUBBER PRODUCTS ensure the adequacy of requirements prior to their
communication to the external provider
JOY RUBBER PRODUCTS is communicated to external providers its requirements for
a) The processes, products and services to be provided
b) The approval of

• Products and services

• Methods, processes and equipment
• The release of products and services
c) Competence, including any required qualification of persons
d) The external providers’ interactions with the organization
e) Control and monitoring of the external providers’ performance to be applied by
the organization
f) Verification or validation activities that the organization, or its customer, intends
to perform at the external providers’ premises
The Purchase order is describing the product to be purchased including
a) Requirement of Material Test Certificate / Dimensional report / Process Flow
Chart / Process Sheets / Process Capability studies etc.
b) Requirements for qualification of personnel
c) QMS requirements.
8.4.3.1. Information for external providers-Supplemental
Our organization shall pass down all applicable statutory and regulatory
requirements and special product and process characteristics to their suppliers and
require the suppliers to cascade all applicable requirements down the supply chain
to the point of manufacture
8.5. Production and service provision

8.5.1. Control of production and service provision
JOY RUBBER PRODUCTS implement production and service provision under controlled
conditions. Controlled conditions are including, as applicable
a) The availability of documented information that defines
1) The characteristics of the products to be produced, the services to be
provided, or the activities to be performed
2) The results to be achieved

b) The availability and use of suitable monitoring and measuring resources

c) The implementation of monitoring and measurement activities at appropriate
stages to verify that criteria for control of processes or outputs, and acceptance
criteria for products and services, have been met
d) The use of suitable infrastructure and environment for the operation of processes
e) The appointment of competent persons, including any required qualification
f) The validation, and periodic revalidation, of the ability to achieve planned results
of the processes for production and service provision, where the resulting output
cannot be verified by subsequent monitoring or measurement;
g) The implementation of actions to prevent human error
h) The implementation of release, delivery and post-delivery activities
Production in Charge shall plan the production as per and respective section in
charge carry out process under controlled condition as defined in process flow in
respective process procedures-controlled conditions shall include: -
a) Production plans for all processes which describes the characteristics of

the product and process flow chart for sequence of operations
b) Work Instructions made available at all work stations.
c) Use of appropriate equipment for a particular process/operation
d) Use of calibrated monitoring and measuring devices
e) In process inspection/verification
f) Verification of acceptance criteria
8.5.1.1. Control Plan

Control plan for all stages of production, including receipt of material sample, pilot &
regular production shall be used. These Production plans at each stage may be
amendments of production plans of earlier stage.
As described above, Marketing shall be involved in preparation of production plans where
required by customer production Plans will be submitted to customer for approval.

The Control plan shall

 List the controls used for the manufacturing processes
 Include the customer required information, if any
 Include methods for monitoring of control exercised over special characteristics
defined by both the customer and the organization.
 Initiate the specified reaction plan when the process becomes unstable or not
statistically capable production plans shall be reviewed and updated, as
appropriate:
 The product is changed.
 The manufacturing processes are changed.
 The processes become unstable.
 The processes become non-capable.
 Inspection frequency and method changes
 Change in supply sources
 Corrective actions based on process NC & customer concerns
Control plans are developed for all the process involved in the manufacturing by the Cross
functional team. These are identified during the advanced product planning process.
The production plans are live documents and are reviewed and updated when change to
the original product or process occurs.
8.5.1.2. Standardized Work
Respective in charge prepares Work Instructions for all operations / process activities and
for all employees having responsibilities under them. These instructions are made
accessible for use at the work station& are prepared based on trial run result and old
documents of similar product at the time of job induction into production and will be
reviewed for applicable changes in event of production Plan change(s).

Preventive Maintenance
In charge MNT maintains a list of all machines / equipment used in production and
designated key process equipment in the list. A plan for preventive maintenance for this
key equipment shall be developed & implemented to ensure continuing process capability.
This plan shall be based on the available data from manufacturer’s recommendations,
previous break down and preventive history, extent of usage, and rate of wear and tear
etc., based on these details appropriate predictive techniques are used.
In charge MNT ensures that required spare-parts for replacement along with other
resources for maintenance as per preventive maintenance schedule are available in time.
Appropriate records of maintenance shall be maintained by in charge MNT.
A system that describes planned & predictive maintenance method is detailed in
procedure respectively.
8.5.1.3. Verification of job set up

a) All processes are validated before the start of the production through set up
approval and First Five Piece Inspection.
b) The above processes are controlled and continually monitored through
documented work instructions, process qualifications, set up approval and worker
qualification, as
Applicable to ensure that the specified requirements are met
c) Appropriate SPC/Inspection records are maintained by all in charge to
demonstrate the control of these processes and equipment. Records of personnel
qualifications and re-qualifications are maintained by all in charge. Stipulate
workmanship standards to the greatest practicable extent, where appropriate, by
means of written standards, representative samples or display boards.

d) Ensure Handling, Storing and transporting within the production shop are
carried to protect all materials / products. The details of process controls are
described in respective department procedures.
8.5.1.4. Verification after shutdown
JOY RUBBER PRODUCTS define and implements the necessary actions to ensure product
compliance with requirements after a planned or unplanned production shutdown period.
8.5.1.5. Total Productive Maintenance
Our organization develops, implement, and maintain a documented total productive

maintenance system. At a minimum, the system shall include the following
a) Applicable Customer-Specific Requirements

b) Documented maintenance objectives
c) Regular review of maintenance plan and objectives and a documented action
plan to address corrective actions where objectives are not achieved
8.5.1.6. Management of production tooling and manufacturing, test, inspection

tooling and equipment
JOY RUBBER PRODUCTS provide resources for tool and gauge design, fabrication, and
verification activities for production and service materials, as applicable. We establish and
implement a system for production tooling management, whether owned by the
organization or the customer, including:
a) Maintenance and repair facilities and personnel
b) Storage and recovery
c) Set-up
d) tool-change program for perishable tools
e) Tool design modification documentation, including engineering change level of the
product
f) Tool modification and revision to documentation

g) Tool identification, such as serial or asset number; the status, such as production, repair
or disposal; ownership; and location.
8.5.1.7. Production scheduling

Based on the customer schedule JOY RUBBER PRODUCTS plans the production plan to
meet 100% delivery, JOY RUBBER PRODUCTS shall include planning information during
production scheduling like customer orders, supplier on time delivery performance, lead
time, inventory level and preventive maintenance
8.5.2. Identification and traceability

JOY RUBBER PRODUCTS use suitable means to identify outputs when it is necessary to
ensure the conformity of products and services.
JOY RUBBER PRODUCTS identifies the status of outputs with respect to monitoring and
measurement requirements throughout production and service provision.
All material is identified including inspection in appropriate manner (punch mark, labels,
stickers and tagging etc.) from receipts at stores through various stages of production. The
final product is kept on trolleys & transferred to Finished Goods area before delivery to
customer as detailed in work procedures.
8.5.2.1. Identification and traceability-Supplemental

Strengthened the requirements for traceability to support industry lessons learned related
to field issues
8.5.3. Property belonging to customers or external providers
JOY RUBBER PRODUCTS is exercise care with property belonging to customers or

external
Providers while it is under the organization’s control or being used by the organization

JOY RUBBER PRODUCTS is identified, verify, protect and safeguard customers’ or

external providers’ property provided for use or incorporation into the products and
services
When the property of a customer or external provider is lost, damaged or otherwise found
to be unsuitable for use, the organization shall report this to the customer or external
provider and retain documented information on what has occurred
a) Any arrangement of Customer Supplied raw materials, components,
tooling, returnable packaging, measuring instruments etc., are identified
during the contract review by CFT/ Plant manager and communicated to
the people concerned.
b) All such products are uniquely identified after proper verification and
properly stored and maintained. Any such product that is lost damaged or
is otherwise unsuitable for use shall be recorded and reported to the
Customer by customer representative.
c) Tool maintenances customer will take care, few minor works done JOY
RUBBER PRODUCTS
It shall be the responsibility of QA personnel to verify the quality of such product even if it
has been supplied by the Customer.
8.5.4.1. Preservation
JOY RUBBER PRODUCTS preserve’s the outputs during production and service provision,
to the extent necessary to ensure conformity to requirements.
Preservation is including identification, handling, contamination control, packaging,

storage, transmission or transportation, and protection.
At all stages of production, appropriate material / product handling, storage, packing of
products, preservation and delivery of products established viz. Material in storage – are
preserved by packing in bags. In process – material is stored in Bins and poly cover.
Finished goods

8.5.5. Post-delivery activities
JOY RUBBER PRODUCTS is meet requirements for post-delivery activities associated with
the products and services
JOY RUBBER PRODUCTS is considered in determining the extent of post-delivery
activities that are required,
a) statutory and regulatory requirements
b) the potential undesired consequences associated with its products and services
c) the nature, use and intended lifetime of its products and services
d) customer requirements
e) e) Customer feedback
Delivery
The product quality is protected after final inspection & testing and wherever contractually
specified extended from delivery to destination. The deliveries of products are done as per
contract terms / delivery schedules for customer.
8.5.5.1. Feedback of information from services
Our organization ensuring our feedback system respective function dept. like
manufacturing, material, logistics, etc.
8.5.5.2. Service agreement with customer
Services agreement are controlled by internal dept. effectively
8.5.6.1. Control of changes
JOY RUBBER PRODUCTS is review and control changes for production or service
provision, to the extent necessary to ensure continuing conformity with requirements. JOY
RUBBER PRODUCTS is retaining documented information describing the results of the
review of changes, the person(s) authorizing the change, and any necessary actions arising
from the review.

8.5.6.1.1. Temporary Change of Process Controls
Our organization shall identify, document, and maintain a list of process controls, incl.
inspection, measuring, test, and error-proofing devices, that includes the primary process
control and the approved back-up or alternate methods.
Our organization shall document the process that manages the use of the alternate
methods, based on risk analysis (such as FMEA), severity, and the internal approvals to be
obtained prior to production implementation of the alternate control method.
Before shipping product that was inspected or tested using the alternate method, if
required, the organization shall obtain approval from the customer(s)
8.6.1. Release of products and services
JOY RUBBER PRODUCTS is retaining documented information on the release of products

and services. The documented information is including.
a) Evidence of conformity with the acceptance criteria

b) Traceability to the person(s) authorizing the release
To ensure that the products manufactured meet the quality requirements of customer fully,
a systematic approach for inspection and testing at all stage viz. incoming, in process and
final are demonstrated. At each stage the activity is performed according to documented
procedures. Like incoming inspection in process & final inspection.
8.6.2. Layout inspection and function testing

JOY RUBBER PRODUCTS conduct the Layout inspection for fit and functions at defined
interval for all product in defined frequency once in a year as per drawing and control plan
8.6.3. Appearance items

All the products are applicable to visual inspection, inspection standards are ensured for
appearance items.
8.6.4. Verification and acceptance of conformity of externally provided products and

services

JOY RUBBER PRODUCTS ensure the control of externally provided products through
Incoming inspection sample based and through second party audit conducted once in a
year.
8.6.5. Statutory and regulatory conformity
Prior to release of externally provided products into its production flow, the organization
shall confirm and be able to provide evidence that externally provided processes, products,
and services conform to the latest applicable statutory, regulatory, and other requirements
in the countries where they are manufactured and, in the customer, identified countries of
destination, if provided.
8.6.6. Acceptance criteria
JOY RUBBER PRODUCTS define acceptance criteria for all the equipment where
appropriate acceptance criteria based on customer approved
8.7 Control of nonconforming outputs
8.7.1 Procedures are established for identifying non-conforming product at stores and
stages of production / inspection as well as at the final inspection stage. The non-
conforming materials are identified by the production operator/ QA Personnel at these
stages and suitably identified. Responsibility and authority are assigned for segregation,
review and disposition of non-conforming product.
Documented information of segregation, review and suitable disposition of non-
conforming materials are maintained by QA Personnel. Who are authorized to review non-
conforming product? The decisions of review as per applicable for disposition may be
8.7.1.1. Customer authorization for concession

The alignment of terminology and the clarification of concessions applied to rework of
nonconforming product and sub-component reuse.
Appropriate internal verification and validation activities of any rework or reuse of sub-
components should be approved prior to customer submission.
8.7.1.2. Control of nonconforming product – Customer specified process

The organization shall comply with applicable customer specified controls for
nonconforming product
8.7.1.3. Control of suspect product

The organization shall ensure that product with unidentified or suspect status is
Classified and controlled as nonconforming product.
appropriate manufacturing personnel receive training for containment of suspect
and nonconforming product.
8.7.1.4. Control of Reworked Product

JOY RUBBER PRODUCTS utilize risk analysis (such as FMEA) methodology to assess risks
in the rework process prior to a decision to rework the product. If required by the
customer, the organization shall obtain approval from the customer prior to commencing
rework of the product.
Instructions for disassembly or rework, incl. re-inspection and traceability requirements,
shall be accessible to and utilized by the appropriate personnel
The organization shall retain documented information on the disposition of reworked
product incl. quantity, disposition, disposition date, and applicable traceability
information
8.7.1.5. Control of repaired product

JOY RUBBER PRODUCTS utilize risk analysis (such as FMEA) methodology to assess risks
in the repair
Process prior to a decision to repair the product, the organization shall obtain approval
from the customer before commencing repair of the product. The organization shall have a
documented process for repair confirmation in accordance with the control plan or other
relevant documented information. Instructions for disassembly or repair, including re-
inspection and traceability requirements, shall be accessible to and utilized by the
appropriate personnel. The organization shall obtain a documented customer
authorization for concession for the product to be repaired.
8.7.1.6. Customer notification

Our organization is immediately notifying the customer if they ship nonconforming
product, and follow up with detailed documentation.

8.7.1.7. Non-Conforming Product Disposition

Our organization shall have a documented process for disposition of non-conforming
product not subject to rework or repair. For product not meeting requirements, the
organization shall verify that the product to be scrapped is rendered unusable prior to
disposal
8.7.2 JOY RUBBER PRODUCTS have documented information that describes the
nonconformity, describes the actions taken, describes any concession obtained, identifies
the authority deciding the action in respect of the nonconformity
9. PERFORMANCE EVALUATIONS
9.1. Monitoring, measurement, analysis and evaluation
9.1.1. General
9.1.1.1. Monitoring and measurement of manufacturing process
JOY RUBBER PRODUCTS is evaluating the performance and the effectiveness of the
quality management system. JOY RUBBER PRODUCTS is retaining appropriate
documented information as evidence of the results.
Established quality management measurement process and monitor as per planned results
for achievement also establish processes to identify non- Conformity situation and
subsequently corrective & preventive actions to be taken. In charge QA in consultation
with all respective production process heads plan and implement the monitoring,
measurement, analysis and improvement processes needed.
a) What needs to be monitored and measured
b) The methods for monitoring, measurement, analysis and
evaluation needed to ensure valid results
c) When the monitoring and measuring shall be performed
d) When the results from monitoring and measurement is analyzed and evaluated
JOY RUBBER PRODUCTS also perform process studies on all new manufacturing
(including assembly or sequencing) processes to verify process capability and to provide
additional input for process control, including those for special characteristics.

JOY RUBBER PRODUCTS maintain manufacturing process capability or performance

results as specified by the customer's part approval process requirements. The
organization shall verify that the process flow diagram, PFMEA, and control plan are
implemented, including adherence to the following:
a) Measurement techniques;
b) Sampling plans;
c) Acceptance criteria;
d) Records of actual measurement values and/or test results for variable data;
e) Reaction plans and escalation process when acceptance criteria are not met.
Significant process events, such as tool change or machine repair, shall be recorded and
retained as documented information. The organization shall initiate a reaction plan
indicated on the control plan and evaluated for impact on compliance to specifications for
characteristics that are either not· statistically capable or are unstable.
These reaction plans shall include containment of product and 100 percent inspection, as
appropriate. A corrective action plan shall be developed and implemented by the
organization indicating specific actions, timing, and assigned responsibilities to ensure that
the process becomes stable and statistically capable. The plans shall be reviewed with and
approved by the customer, when required. The organization shall maintain records of
effective dates of process changes.
9.1.1.2. Identification of statistical tools

JOY RUBBER PRODUCTS determine the appropriate use of statistical tools. JOY RUBBER
PRODUCTS verifying that appropriate statistical tools like FMEA, SPC, APQP, PPAP and
MSA.
9.1.1.3. Application of statistical concepts

Process variation are monitored for all part weight. Based on data our organization drive
the analysis like 7QC tools
9.1.2 Customer satisfaction

9.1.2.1 JOY RUBBER PRODUCTS is monitor customers’ perceptions of the degree to which
their needs and expectations have been fulfilled. JOY RUBBER PRODUCTS is determining
the methods for obtaining, monitoring and reviewing this information.
Performances indicators shall be based on objective evidence and include but not be
limited to the following:
a) Delivered part quality performance;

b) Customer disruptions;
c) Field returns, recalls, and warranty (where applicable);
d) Delivery schedule performance (including incidents of premium freight);
e) Customer notifications related to quality or delivery issues, including special
status.
9.1.3. Analysis and evaluation

JOY RUBBER PRODUCTS analyze and evaluates appropriate data and information arising
from monitoring and measurement. The results of analysis are used to evaluate
a) Conformity of products and services
b) The degree of customer satisfaction;
c) The performance and effectiveness of the quality management system;
d) If planning has been implemented effectively;
e) The effectiveness of actions taken to address risks and opportunities;
f) The performance of external providers;
g) The need for improvements to the quality management system
9.1.3.1. Prioritization
Actions to improve customer satisfaction need to take precedence as the organization
considers trends and drives towards improvement.
9.2. Internal audit

9.2.1. Internal audit
Procedures are established for a system of planned and documented internal quality audits
to verify that the Quality Management System conforms to the planned arrangements as
per IATF 16949:2016 requirements and effectively implemented and maintained.

Planning and organizing audits at works depending on the importance and the extent of
the activity concerned and the results of the previous audits. The internal quality system
audits as per schedule are to be carried out at least once in 6 months
9.2.2 JOY RUBBER PRODUCTS shall maintain audit plan, schedule, check sheet to audit
and non-conformity. Auditor selected based on the criteria, action is closed within the time
frame.
9.2.2.1. Internal Audit Programme.

JOY RUBBER PRODUCTS shall have a documented internal audit process. The process
shall include the development and implementation of an internal audit program that
covers the entire QMS, include. QMS audits, manufacturing process audits, and product
audits
The audit program shall be prioritized based upon risk, internal and external performance
trends, and criticality of the process.
The frequency of audits shall be reviewed and, where appropriate, adjusted based on
occurrence of process changes, internal and external audit non-conformities, and/or
customer complaints. The effectiveness of the audit program shall be reviewed as a part of
the management review.
9.2.2.2. Quality Management System Audit

Our organization shall audit all QMS processes once in 6 months calendar period,
according to an annual programme, using the process approach to verify compliance with
this Automotive QMS Standard.
Integrated with these audits, the organization shall sample customer- specific QMS
requirements for effective implementation.
9.2.2.3. Manufacturing Process Audit

The organization shall audit all manufacturing processes once in a year. To determine their
effectiveness and efficiency using customer-specific required approaches for process
audits. Where not defined by the customer, the organization shall determine the approach
to be used.
Within each individual audit plan, each manufacturing process shall be audited on all
shifts where it occurs, including the appropriate sampling of the shift handover.

The manufacturing process audit shall include an audit of the effective implementation of
the process risk analysis (such as PFMEA), control plan, and associated documents.
9.2.2.4. Product audit

The JOY RUBBER PRODUCTS shall audit products using customer-specific required
approaches at appropriate
Stages of production and delivery to verify conformity to specified requirements once in a
year, where not defined by the customer. The organization shall define the approach to be
used. The strengthened product audit established to meet the customer requirements,
ensuring at defined interval ref process and product audit plan.
9.3. Management review

9.3.1. General
Top management of JOY RUBBER PRODUCTS is reviewing the organization’s quality
management system, at planned intervals, to ensure its continuing suitability, adequacy,
effectiveness and alignment with the strategic direction of the organization
Management review will be conducted and chaired by top management once in 6 Months
to ensure continuing suitability & effectiveness in satisfying the requirements of IATF
16949:2016 and the stated quality policy and objectives. The Management Review will
include all elements of the entire quality system as detailed in procedure and schedule for
the Management Review
Records of Management Review Meetings shall be maintained

Top management during review shall assess opportunities for improvement and the need
for changes in Quality Management System, including the Quality Policy and Quality
Objectives.
9.3.1.1. Management Review

Management review shall be conducted at 6 months once. The frequency of management
review(s) shall be increased based on risk to compliance with customer requirements
resulting from internal or external changes impacting the QMS and performance-related
issues.

9.3.2. Management review inputs

The management review is planned and carried out taking into consideration
a) The status of actions from previous management reviews
b) Changes in external and internal issues that are relevant to the quality
management system
c) Information on the performance and effectiveness of the quality management
system, including trends in:
1. customer satisfaction and feedback from relevant interested parties;
2. the extent to which quality objectives have been met;
3. process performance and conformity of products and services;
4. nonconformities and corrective actions;
5. monitoring and measurement results;
6. audit results;
7. The performance of external providers
d) The adequacy of resources;
e) The effectiveness of actions taken to address risks and opportunities (see 6.1)
f) Opportunities for improvement.
9.3.2.1. Management review inputs-Supplemental

Input to management review shall include
a) Cost of poor quality (cost of internal and external nonconformance
b) Measures of Process Effectiveness and Efficiency
c) Assessment of manufacturing feasibility made for changes to existing
operations and for new facilities or new product feasibility
d) Review of performance vs. maintenance objectives
e) Warranty Performance (where applicable)
f) Identification of Potential Field Failures identified thru Risk Analysis (FMEA)
9.3.3. Management review outputs

The outputs of the management review shall include decisions and actions related to:
a) Opportunities for improvement;
b) Any need for changes to the quality management system;
c) Resource needs.

The JOY RUBBER PRODUCTS is retaining documented information as evidence of the

results of management reviews.
9.3.3.1. Management Review Outputs

Our top management shall document and implement an action plan when customer
requirements are not met.
10. IMPROVEMENT
10.1. General
JOY RUBBER PRODUCTS is determining and select opportunities for improvement and
implements any necessary actions to meet customer requirements and enhance customer
satisfaction these include
a) Improving products and services to meet requirements as well as to address
future needs and expectations
b) Correcting, preventing or reducing undesired effects;
c) Improving the performance and effectiveness of the quality management system.
Improvement is including correction, corrective action, continual improvement,

breakthrough change, innovation and re-organization
10.2. Nonconformity and corrective action

10.2.1 and 10.2.2
When nonconformity occurs, including any arising from complaints, JOY RUBBER
PRODUCTS is all nonconformities relating to product, process and quality system are
investigated & the results are recorded. While investigating causes of non-conformances &
deciding corrective actions, the team identifies other products / situations where same or
similar nonconformance can occur.
Corrective actions for nonconforming products and processes, detected in the organization
are recorded; analyzed, reviewed and necessary actions are taken. This will be the
responsibility of in charge QA and production (respective production process In-charge)
the corrective action and preventive measures are implemented and their effectiveness is
monitored.

Corrective actions are taken on customer complaints by analyzing the causes of the
complaints and taking suitable action to prevent their reoccurrence. The effectiveness of
the identified corrective action is monitored through customer feedback and also the
customers are kept aware of the corrective actions initiated, with each identified corrective
action.
10.2.3. Problem solving

Our organization shall have defined documentation for solving the problem
Ref procedure for corrective and preventive action
10.2.4. Error proofing

Our organization determined error proofing process, detailed risk is addressed in FMEA.
The process and sequence are defined in error proofing procedure
10.2.5. Warranty management system

Ref warrant management procedure
10.2.6. Customer complaints and field failure test analysis

We received the concern from customer and we will take necessary action for the customer
complaints and field failure. Ref customer complaint handling procedure
10.3. Continual improvement

JOY RUBBER PRODUCTS are continually improved the suitability, adequacy and
effectiveness of the quality management system.
JOY RUBBER PRODUCTS is considering the results of analysis and evaluation, and the
outputs from management review, to determine if there are needs or opportunities that
shall be addressed as part of continual improvement.
10.3.1. Continual improvement

JOY RUBBER PRODUCTS had identifying continual improvement areas and including of
following process.
a) Identification of the methodology used, objectives, measurement, effectiveness
and documented information
b) A manufacturing process improvement action plan with emphasis on the
reduction of the process variation and waste.
c) Risk analysis such as FMEAs
Lists of abbreviations in this quality manual:
MD - Managing Director
PM - Plant Manager
CFT - Cross Functional Team
PPC - Production Planning Control
APQP - Advanced Product Quality Planning
MSA - Measurement System Analysis
QAD - Quality Assurance Department
PFMEA - Process Failure Mode Effect analysis
FMEA - Failure Mode Effect analysis
QSP - Quality System Procedure
DOC - Document
NO - Number
REV - Revision
DEPT - Department
MR - Management Representative
PPM - Parts per Million
PPAP - Production Part Approval Process
SC - Significant Characteristics
SD - Supplier Development

QSP - Quality System Procedure

QC - Quality Control
PSO - Process Sign off
FGTN - Finished Goods Transfer Note
DC - Delivery Challan
FG - Finished Goods
PRD - Production
PO - Purchase Order
WIP - Work in progress
ROHS - Restriction of Hazardous Substances
IQC - In Process Quality Control


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Document Original Date: 02.08.

JOY RUBBER PRODUCTS

IATF 16949:2016 Quality System Manual

SL.NO Rev. No. Title Pages

2.0 TABLE OF CONTENTS

IATF 16949:2016 Quality System Manual

Doc. No. Title Pages

4.4 Quality management system and its processes

5.2 Quality Policy

IATF 16949:2016 Quality System Manual

8.5 Production and service provision

IATF 16949:2016 Quality System Manual

Name M/S. JOY RUBBER PRODUCTS

Product Design Exclusion

Scope Manufacture of rubber moulded components

Site extension Nil

Remote location Nil

Products Rubber components

4.0 CONTEXT OF THE ORGANIZATION

4.1 Understanding the organization and its context

IATF 16949:2016 Quality System Manual

4.2 Understanding the needs and expectations of interested parties

1) Specification communication 1) Defined in documented information

IATF 16949:2016 Quality System Manual

Management support, payments

4.3 Determining the scope of the quality management system

4.3.1 Determining the scope of the quality management system-Supplemental

4.3.2 Customer - specific requirements

4.4 Quality management system and its processes

IATF 16949:2016 Quality System Manual

to ensure the effective operation and control of these processes in documented

4.4.1.2. Product safety

Identification by the organization of statutory and regulatory product-safety

4.4.2 JOY RUBBER PRODUCTS is also maintaining documented information to support

5.1 Leadership and commitment

JOY RUBBER PRODUCTS has demonstrated leadership and commitment with

A) Top Management taking accountability for the effectiveness of the quality

IATF 16949:2016 Quality System Manual

through management review meeting, Quality objectives review and providing

5.1.1.1. Corporate Responsibility

JOY RUBBER PRODUCTS define and implements corporate responsibility policies,

5.1.1.2. Process effectiveness and efficiency

5.1.1.3. Process owners

IATF 16949:2016 Quality System Manual

Top management identified process owners (Department Representative) who are

5.1.2. Customer focus

JOY RUBBER PRODUCTS has demonstrated leadership and commitment with

A) Customer and applicable statutory and regulatory requirements are determined,

5.2. Quality Policy

JOY RUBBER PRODUCTS continuously focus on product quality and customer

To achieve above policy every employee must;

With our Quality Management System, we continually Identify, Measure, Control

5.2.1. Establishing the quality policy

JOY RUBBER PRODUCTS management has established, implemented and

IATF 16949:2016 Quality System Manual

5.2.2. Communicating the quality policy

The quality policy is

A) Available and be maintained as documented information