0704 Process Control

Quality System Procedure Doc. No.
: SAPL-III /QSP/0704
SAPL-III Revision No. 01
Process Control Date 23.09.2015
Page No 1 to 4
1.0 PURPOSE
The purpose the production process which affect quality and ensure that these
processes are carried out under controlled conditions.
2.0 SCOPE
This procedure is applicable to all manufacturing processes, assembly

operations.
3.0 RESPONSIBILITY
3.1 AGM is responsible for process planning and production planning.
3.2 Production Engineer and / or Production Supervisor is responsible for

manufacturing and execution activities as per this procedure.
3.3 Quality Control Supervisor is responsible for process monitoring activities.
3.4 Line Inspector is responsible for process monitoring activities.
4.0 PROCEDURE
4.1 PROCESS PLANNING
4.1.1 The production processes that affect quality will be identified as simple
process/vital process/special process, based on its impact on final product.
4.1.2 Simple process is defined as a process is defined as a process, which is easy

with regard to setting of tool and whose outputs do not affect the product
performance.
4.1.3 Vital process is defined as a process which is complex and need extra care in
tool setting are whose outputs directly affect the final product quality.
4.1.4 Special process is defined as a process whose result could not be fully verified
by subsequent inspection and processing deficiencies may be apparent only
after the completion of the process.
Reviewed by: Approved by :
Date : Date :
Quality System Procedure Doc. No.: SAPL-III /QSP/0704
Page No 2 to 4
4.1.5 Process flow diagram, Process control charts and/or Process control plans will
be prepared which includes type of process, machineries and equipments
required, process control parameters, product characteristics and specifications,
method of inspection, inspection frequency, sample size, records, responsibility
and reaction plan for out of control situations.
4.1.6 Application of Statistical Techniques for Process Control, as required will be

identified and included in the Process Control Plans by denoting "SPC".
4.1.8 Control Plans are developed at the component level for Pre-Launch and
Production taking Manufacturing Process FMEA outputs.
4.1.9 Control Plans are reviewed and updated, when any change occurs that could
affect product, manufacturing process, measurement, logistics, supply sources
or FMEA.
4.2 PRODUCT PLANNING
4.2.1 Monthly production schedule will be prepared by AGM, based on, the
customer schedule, stock in transit and stock in plant and the same will be
notified to stores, purchase and production department.
4.2.2 Apart From Above All Daily Production Plan Will be Prepared Based on Customers
Requirements for the Day
4.2.3. Material Planning sheet will be prepared by Stores Supervisor as per the
monthly production schedule and stock in stores, for facilitating the necessary
purchase activities.
4.2.4 Daily Production & Delivery Will be Reviewed in the Daily Meeting & Counter
measures Will be Taken as up to Meet Customer Volumes
4.2.5 Materials will be issued to production by Stores Supervisor on indent.
4.3 PROCESS MONITORING AND CONTROL
4.3.1 To carry out process in controlled conditions, process drawings and/or work
standards instructions will be displayed near the workstations. QSP for work
standards addressed for preparation of work standards .Wherever required,
Date : Date :
Page No 3 to 4
"Representative Samples" will be provided as criteria for workmanship.
4.3.2 For process denoted by "SPC" in Process Control Plans, application of

Statistical Techniques for Process Control will be carried out in as mentioned
in the control plans
4.3.3 All production machines, dies and equipments will be properly maintained in
accordance with procedure No.SAPL-III/QSP/0705 & SAPL-III/QSP/0709.
(Maintenance Procedures)
4.3.4 The process parameters and product characteristics will be continuously

monitored in accordance with the relevant process control plans and/or process
Control charts. The results will be recorded in the in process inspection report.
4.3.5 Process studies on all new manufacturing processes to verify process capability
and provide additional input for process control.
The results of process studies are recorded along with specifications, which
include:
a) Objectives for manufacturing process capability

b) Reliability
c) Maintainability
d) Availability
e) Acceptance Criteria
4.4 MANUFACTURING PROCESS VALIDATION
4.4.1 Special processes will be qualified prior to accepting the process for regular
production and such records will be maintained. All special processes will be
carried by qualified PERSONNEL.
4.4.2 Process will be monitored as per the relevant Process Control Plans and/or
Process Control Charts and the operating parameters will be recorded in
"Quality Check Sheet for Special Process".
4.4.3 All the processes are validated once in a year. The records are maintained in
the "Process Validation Report"
4.5 Implementation of 5S Activities
Date : Date :
Page No 4 to 4
4.5.1 The Entire Work Place will be Maintained Clearly Basic 5S Principles 1. Sort
2.Set in order 3.Shine 4. Standardize 5.Sustain will be Followed 5S
Improvement activities will be carried out .Ensure Employee Safety
Preservation of RM & Products maintain a neat and clean Environment and to
Identify ok & NG parts easily
4.5.2 Nursery Training Will be Provided to Employee .5S audit will be Conducted
by Every Month .5S activities will be audited as per the Check Sheet & Result
one Monitored in the Check sheet Itself
4.5.3 Minimum Grading Required is “B” How Ever efforts will be Made to Achieve
“A” Grade and Sustain
5.0 CROSS REFERENCE
5.1 Process Control Plans
5.2 Procedure for Operator work Standards - SAPL –III/QSP/0704 -1
5.3 Procedure for Die Maintenance - SAPL-III/QSP/0705
5.4 Procedure for Machine Maintenance - SAPL-III/QSP/0709
5.5 Work Standard - SAPL-III/WS/41
5.6 Process Flow Chart
5.7 Process FMEA
6.0 RECORDS
6.1 Monthly plan / Daily production
6.2 In process Inspection Report – SAPL-III/F/20
6.3 Material Planning Sheet – SAPL-III/F/17
6.4 Process Validation Reports
Date : Date :

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Quality System Procedure Doc. No.

This procedure is applicable to all manufacturing processes, assembly

3.1 AGM is responsible for process planning and production planning.

3.2 Production Engineer and / or Production Supervisor is responsible for

3.3 Quality Control Supervisor is responsible for process monitoring activities.

3.4 Line Inspector is responsible for process monitoring activities.

4.1 PROCESS PLANNING

4.1.2 Simple process is defined as a process is defined as a process, which is easy

Reviewed by: Approved by :

4.1.6 Application of Statistical Techniques for Process Control, as required will be

4.2 PRODUCT PLANNING

4.2.5 Materials will be issued to production by Stores Supervisor on indent.

4.3 PROCESS MONITORING AND CONTROL

"Representative Samples" will be provided as criteria for workmanship.

4.3.2 For process denoted by "SPC" in Process Control Plans, application of

4.3.4 The process parameters and product characteristics will be continuously

and provide additional input for process control.

a) Objectives for manufacturing process capability

4.4 MANUFACTURING PROCESS VALIDATION

4.5 Implementation of 5S Activities

Reviewed by: Approved by :

5.0 CROSS REFERENCE

5.1 Process Control Plans

5.2 Procedure for Operator work Standards - SAPL –III/QSP/0704 -1

5.3 Procedure for Die Maintenance - SAPL-III/QSP/0705

5.4 Procedure for Machine Maintenance - SAPL-III/QSP/0709

5.5 Work Standard - SAPL-III/WS/41

5.6 Process Flow Chart

5.7 Process FMEA

6.1 Monthly plan / Daily production

6.2 In process Inspection Report – SAPL-III/F/20

6.3 Material Planning Sheet – SAPL-III/F/17

6.4 Process Validation Reports

Reviewed by: Approved by :

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