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STEELRODE (PTY) LTD
QUALITY ASSURANCE POLICY MANUAL
UNCONTROLLED COPY
PLEASE NOTE THAT THIS STEELRODE'S QUALITY ASSURANCE POLICY MANUAL IS SUBJECT TO
THE NORMAL COPYRIGHT CONDITIONS.
MANUAL CONTENTS IN ACCORDANCE TO
INTERNATIONAL ORGANIZATION TO STANDARDIZATION (ISO 9002)
SUBJECT
(-) Manual Control
(-) Revisions
(-) Revisions Sheet
(4.1) Company Quality Policy Statement
(4.1) Organization Chart
(4.1) Responsibility and Authority
(4.1) Management Representative
(4.1) Verification Resources and Personnel
(-) Purchaser's Representative
(4.1) Management Review
(4.2) Quality System - General
(4.2) Quality System - Work Instructions
(4.3) Contract Review
(4.4) Document Control
(4.5) Purchasing
(4.6) Purchaser Supplied Product
(4.7) Product Identification and Traceability
(4.8) Process Control
(4.9) Inspection and Testing
(4.10) Inspection, Measuring and Test Equipment
(4.11) Inspection and Test Status
(4.12) Control of Nonconforming Product
(4.13) Corrective Action
(4.14) Handling, Storage, packing and Delivery
(4.15) Quality Records
(4.16) Internal Quality Audits
(4.17) Training
(4.18) Statistical Technique
CONTROL OF THIS QUALITY ASSURANCE POLICY MANUAL
MANUAL CONTROL
This Manual is issued as a controlled document within the organization, and a
register of all manual holders is kept by the company's Management
Representative.
No part of this Manual is to be removed by any person for any reason, with the
exception of replacing pages issued by the Management Representative.
This Manual is also available for issue to external organizations when
requested, and approved by the General Manger. In these cases the Manual is only
issued as an uncontrolled document (unless otherwise approved) and will not
therefore be kept up to date with any revisions.REVISIONS
Revisions to this Manual are issued as required to reflect the current quality
program status.
Revisions are made by replacing the applicable page (s), and each revised page
is identified by a revision number and issue date.
All revisions are issued in a systematic manner to authorized holders of this
Manual, and all obsolete pages must be destroyed on receipt of the new
information.REVISIONS SHEET
In order to efficiently control revisions ( and issues) to this Manual, a
Revisions Sheet is used for recording contemplated changes which are reviewed
and if necessary incorporated on a periodic basis.
COMPANY QUALITY POLICY STATEMENT
Steelrode was founded in 1994 by Warne Rippon as a trading company, buying
parcels of steel and selling them for profit.
Today, Steelrode is an independent steel merchant and processor that buy its
material mostly direct from Iscor and supply the medium to smaller merchants as
well as end users with coils, slit strip, standard sheets and cut to size
blanks.
The company has embarked on an aggressive growth program investing into a new
dedicated factory of 12 000m©˜, a slitter incorporating the latest technology in
quality, speed and packaging as well as a precision high speed "Synchrocut"
rotary shear cut to length line with automatic stacking facilities.
Management of Steelrode have therefore, decided to formalize their quality
management system, and base it on the requirements of the International
Organization for Standardization . (ISO 9002).
The objective of Steelrode management and staff is to provide products and
services which conform to the Customers requirements or our own in-house
manufacturing standards and procedures.
To ensure conformance and provide objective evidence, all Steelrode's Steelwork
will be done in accordance with this Manual and associated quality management
system documentation. All our employees and I are therefore hereby committed to
a policy of total quality assurance.
RESPONSIBILITY AND AUTHORITY
The lines of responsibility and accountability are shown on the organization
chart. Also refer to the various procedures.
In addition to specific responsibilities and authority, all Steelrode employees
are hereby given the authority to stop production or shipment of any product
when circumstances arise that are detrimental to the quality of the product.
They may also initiate action to prevent the occurrence of product
nonconformity, identify and record any product quality problems, initiate,
recommend or provide solutions through their immediate supervisor, and verify
the implementation of
solutions.MANAGEMENT REPRESENTATIVE
The General Manager is the appointed quality system Management Representative
and has the necessary authority and responsibility for ensuring that the
requirement of the Code of Practice ISO 9002 are implemented and
maintained.VERIFICATION RESOURCES AND PERSONNEL
Management has provided sufficient resources and personnel in keeping with our
product range and services, to ensure the attainment of quality and market
objectives.
Management also keep abreast of development in the market place concerning new
opportunities, processes and technologies in order to allocate the necessary
resources on a planned and timely basis in order to remain competitive.
The above aspects are reviewed on an annual basis by means of the Management
Review task.
PURCHASER'S REPRESENTATIVE
The Company will provide any Purchaser's Representative with reasonable access
to any part of the Company's operations, providing that timely arrangements are
made with the Management Representative.MANAGEMENT REVIEW
In accordance with Steelrode's quality policy, the complete quality management
system is reviewed by Top Management on an annual basis to ensure that the
documented system and its operation are still suitable to satisfy existing and
future Company requirements and objectives.
Management review includes assessment of the results of the Company's Internal
Quality Audits, adequacy of documentation, resources, personnel, etc.
For the full information on Management Reviews then refer to procedure number
1.QUALITY SYSTEM - GENERAL
Our quality Management system is based on the requirements of ISO 9002 and all
sections of this Code of Practice have been addressed.
Also associated with this Manual are quality assurance procedures and these are
related to each operation. They detail how the various processes are controlled,
and the responsibilities and authorities for control.
The quality system includes procedures for the control of the following listed
sections:
QUALITY SYSTEM - WORK INSTRUCTIONS
Work instructions are produced for those operations which are considered fairly
complex, and would without the guidance of the work instructions be subject to
different end results, and thus possible not comply with Customer requirements.
Work instructions comprise any of the following instruction, policy statements,
procedures, in-house written work instruction, specifications, drawings,
photographs, actual examples, etc.
Work instructions are available for reference at the appropriate work place, and
for full details of work instruction development, documentation, approval,
distribution, review and control, refer to procedure number 2. (Also refer to
procedure number 3 - Contract Review).
PROCEDURE SECTION OR NUMBER ACTIVITY
1. Management Review
2. Quality System
3. Contract Review
4. Document Control
5. Purchasing
6. Purchaser Supplied Product
7. Product Identification and Tractability
8. Process Control
9. Inspection and Testing
10. Inspection, Measuring and Test Equipment
11. Inspection and Test Status
12. Control of Nonconforming Product
13. Corrective Action
14. Handling, Storage, Packing and Delivery
15. Quality Records
16. Internal Quality Audits
17. Training
18. Statistical Techniques - sampling Plans.
NOTE: The above procedures are confidential to Steelrode, and are contained in
the
QUALITY ASSURANCE PROCEDURES MANUAL.
CONTRACT REVIEW
Order or contract inquiries are all checked on receipt to ensure that the
requirements of the specification are complete and can be complied with.
Before a new contract is entered into, and extensive review of the requirements
is undertaken to ensure that the identification, planning and acquisition of any
new controls to ensure product quality e.g. Manufacturing equipment and
processes, fixtures, tooling, inspection equipment, manpower and skills, work
instructions, etc.
Any items requiring clarification or revision are resolved with the Customer.
For details see procedure number 3 - Contract Review.DOCUMENT CONTROL
We have established a system for approving and controlling all quality
management system documentation, which ensures that:-
All documentation affecting quality is properly identified, and new or revised
documentation is reviewed and approved by at least the originators immediate
supervisor.
The control and issue of the appropriate documentation pertaining to locations
where the operations are being performed, and the destruction of all superseded
documents.
Master lists are retained and maintained of all quality documents in order to
ascertain revision levels and facilitate reissue after a practical number of
changes have been made.
For Document Control operations see procedure number 4.
PURCHASING
Supplies are only purchased from companies, which appear on the approved
supplier's list.
Control of suppliers is conducted through the receiving inspection function, and
should any nonconforming product be received then it is handled via the Control
of Nonconforming Product and Corrective Action procedures.
Suppliers may be taken off the approved supplier's list for any reasons of
nonconformance to requirements.
Purchase orders contain a full description of the product required, including
all specification and inspection or test data where necessary.
The purchase order is used to control the supplies into the goods receiving
area, to ensure that the product does conform to the ordered requirements prior
to acceptance into the warehouse.
For full details of the control of Purchasing activities refer to procedure
number 5.PURCHASER SUPPLIED PRODUCT
Purchaser supplied product is inspected at receiving inspection in accordance
with the relevant Purchaser delivery documentation, in order to check for
description, quantity, damage, etc.
Should any Purchaser product be short supplied, unsuitable or damaged, then the
Purchaser will be advised accordingly.
Although supplied product is checked against the Purchaser's documentation, it
does not absolve the Purchaser of the responsibility to provide acceptable
product to us in the first instance.
All Purchaser supplied product is identified, handled and stored in accordance
with our standard procedures.
Refer to procedure number 6 - Purchaser Supplied Product.
PRODUCT IDENTIFICATION AND TRACEABILITY
All materials and products from receipt through storage, manufacturing, packing,
dispatch and delivery are suitably identified in accordance with specified
requirements.
When traceability (e.g. . material certification) is required, then the
individual product or batches are suitably identified and the relevant
information is recorded.
Refer to procedure number 8 for details of Product Identification and
Traceability.PROCESS CONTROL
The systems developed and maintained for the control of manufacturing activities
are based on providing suitable production equipment, inspection and testing
equipment, etc., and human resources for ensuring the required product quality,
and when required appropriate Work Instructions are developed, maintained and
adhered to.
Conformance to quality requirements is monitored during the production processes
and the results are recorded, nonconforming product is strictly controlled in
accordance with formal procedures.
Processes identified as requiring special attention are only performed under the
necessary controlled conditions, using certified equipment and personnel when
called for, adequate records are also maintained.
Process Control is conducted in accordance with procedure number 8.
INSPECTION AND TESTING
The purchase order is used to control the supplies through the goods receiving
and inspection operations to ensure that the product does conform to
requirements prior to use.
All items of product specified for final inspection and testing are checked in
accordance with the relevant work instruction and / or specification, and the
results are recorded to provide sufficient visible evidence of compliance with
contractual requirements.
When in-process inspections and / or tests are called for, then the results of
these are checked to ensure compliance with requirements before final acceptance
of the product.
Should any product be rejected for any reason, then it is dealt with in
accordance with the Control of Nonconforming Product and Corrective Action
procedures.
Evidence of final inspection and approval for release, is done in accordance
with procedure number 9 - Inspection and Testing.INSPECTION, MEASURING AND TEST
EQUIPMENT
Appropriate inspection, measuring and test equipment is suitably identified,
controlled, calibrated and maintained to demonstrate the conformance of product
to the specified requirements.
In-house reference standards are themselves calibrated against known standards
which are traceable to National Standards, and all equipment is handled,
preserved and stored in such a manner that the accuracy and fitness for use is
maintained.
Scheduled calibrations are only conducted by authorized persons in accordance
with approved work instructions which includes the required accuracy, and if any
equipment is found to be out if its limits, then the validity of previous
inspections will be assessed and the conclusions recorded.
Records of all calibrations are maintained, refer to procedure number 10 for
full details of Inspection. Measuring and Test Equipment control.
INSPECTION AND TEST STATUS
Inspection and test
status is indicated by either the Supervisors or Senior Controllers signature
for the various operations on the relevant documentation. e.g. Production Order.
Where product has been identified as nonconforming, the relevant identification
can only be removed after dispositioning, by appointed and authorized personnel.
Where no visible identification is evident (that is, not identified as
nonconforming product ) then the product is deemed to be acceptable to proceed
to its next inspection point.
For details of Inspection and Test Status, refer to procedure number 11.CONTROL
OF NONCONFORMING PRODUCT
Nonconforming material or product noted during receipt, manufacture and
inspection is identified, and where possible, segregated to prevent unauthorized
use.
Nonconformance reports are compiled stating the discrepancy and possible or
actual rectification needed to correct the problem, which is then assessed by
the responsible persons and the disposition is recorded.
Reworked product is inspected in accordance with the original inspection Work
Instruction, and should the product not be acceptable then a deviation to use
"as is" or downgrade etc., may be applied for, and the outcome is recorded.
All unsuitable products (scrap) is disposed of as soon as possible.
Refer to procedure number 12 - Control of Nonconforming Product.
CORRECTIVE ACTION
Corrective action procedures have been established for recording and
investigating the cause of any nonconforming product, quality system deficiency
and Customer complaint, and for taking the necessary corrective action to
resolve the problem and prevent recurrence.
Analysis is conducted of all relevant quality records in order to detect and
eliminate potential causes of nonconforming product, quality system
deficiencies, etc., and ensure that corrective actions already taken have in
fact been effective in preventing recurrence.
Corrective Action is conducted in accordance with procedure number 13.HANDLING,
STORAGE, PACKING AND DELIVERY
Trained personnel, utilizing suitable handling equipment, which is periodically
checked for cleanliness and safety, perform product handling.
Product is stored in such a way as to prevent damage and deterioration and where
possible or necessary the principle of "first in" , "first out" is practiced
from receipt through to dispatch.
All products from receipt through to delivery is suitably marked and adequately
packaged to provide clear identification.
Refer to procedure number 14 - Handling, Storage, Packing and Delivery.QUALITY
RECORDS
A procedure has been established for the identification, collection, filing,
storage and disposition of quality records.
Quality records are maintained to demonstrate the achievement of the required
product quality and the effective operation of the quality management system,
and also to record nonconformance's and the corrective actions taken.
All quality records are legible and identifiable to the product concerned, they
are also safely retained for established periods, and available for Customer
evaluation if necessary.
Quality Records are controlled and maintained in accordance with procedure
number 15.
INTERNAL QUALITY AUDITS
The quality management system as detailed in the quality manuals, is audited on
a continuous basis to ensure compliance to all the stated requirements.
Audits are carried out by persons independent of the area being audited, in
order to ensure an objective appraisal of these activities.
Results of the internal audit findings are recorded and should any corrective
action be necessary, then this is fully documented and followed up to ensure
effective implementation.
Records of these audits are maintained and are available to the Customers
representative on request.
For full details of performing the Internal Quality Audits, refer to procedure
number 16.TRAINING
All personnel performing activities, which affect product and service quality,
are adequately trained.
Training ranges from "on the job instruction" to formal class room tuition, and
all education and training records are maintained.
All Company personnel are required to know the quality management system that
affects their area of operation.
The effectiveness of employee training is assessed to ensure that it is adequate
for the job requirements.
Refer to procedure number 17 - Training.
STATISTICAL TECHNIQUES
At this point in time we do not consider it practical or cost effective to
institute any statistical process control techniques.
Receiving and manufacturing inspection is however controlled in accordance with
statistical sampling plans (when required) to provide adequate assurance of
product quality, to a predetermined acceptable quality level.
When required by contract, the Customers sampling plans will be used.
Refer to procedure 18 for details of Statistical Techniques - Sampling Plans.
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