Quality Management System

ISO9001:2000 – AWARENESS TRAININGISO9001:2000 – AWARENESS TRAINING

Global Sourcing DepartmentGlobal Sourcing Department

Essar Constructions India Ltd.Essar Constructions India Ltd.

Why ISO-9001 for ECIL?

• Formalizing the company’s working practices• Consistency in Quality among all processes• Better Design Control• Competitive edge in the market• Global Recognition and Opportunities • Changes in Customer Perception • Ensuring Customer Satisfaction

Benefits of ISO to the Customer

• Assured Commitment for Quality by an organization (GS/ECIL)

• Customer gets his complaints /Feedback attended• Less non-compliance • Purchasing information;Testing, Acceptance

criteria and Tolerances are known and agreed by both the parties in advance

Adopted from ISO 14001:• Statutory & regulatory requirements• Commitment, awareness• Communication• Continual Improvement

• ISO 9001 9002 9003

• ISO 9004 9004-1 9004-2

•

Which are the standards in use now in QMS?

ISO 9000: Fundamentals and Vocabulary (normative)

ISO 9001: Requirements

ISO 9004: Guidelines for Performance

Improvements

ISO 19011: Guidelines for Auditing Management

Systems

ISO 9001-2000 Family of standards

ability of a set of inherent characteristics of a product, system or process to fulfil requirements of

customers and other interested

parties

Quality

Terminology (ISO 9000)

need or expectation that is stated, customarily implied or obligatory

Requirement

Terminology (ISO 9000)

Requirement forinherent characteristics

of a product, process or system•Inherent Characteristic is part of the producte.g. diameter of bolt•Assigned Characteristic (e.g. price of product) is not an inherent characteristic

•In short we can not be subjective on quality but specific in describing its attributes

Quality Requirement

Terminology (ISO 9000)

something sought, or aimed for, related to quality

Quality Objective

Terminology (ISO 9000)

Mission & Vision Statement ISO 9001:2000

•Vision:

•To be a global Engineering, Procurement and Construction contracting

company.

•Mission:

•To achieve excellence in the field of Engineering, Procurement and

Construction through world class practices and standards in Quality,

Safety, Health & Environment Protection using state of art tools &

techniques of Project Management

Quality Policy - ECIL

• To ensure customer satisfaction by our performance of work

• To reduce rework & ensure quality of work • To ensure reduction of wastage of material • To ensure availability of plant & machinery based on

age of the equipment• To complete the projects within time & budget• To ensure upgradation of employee skill sets by

providing appropriate training• To increase the Turn Over by increased order book

value.

QUALITY OBJECTIVES

What we commit in our Policy?

Commitments in Company Quality Policy

What can be objectives for GS?

Customer Satisfaction by our performance Aim at customer satisfaction-collect proactively (and have mechanism to capture the same)

Ensure good quality

Reduce wastage

Try to do best efforts in work thus reducing rework / revisions of drawings and designs.

Completion of work within budget Aim to complete the project within the budgeted cost

Timely completion To aim to complete the project within targeted time span

Training to employee—Up gradation of employee skill sets

Target ‘x’ man-days of relevant training for all employee

specified way to carry out an activity or a process

Procedure

Terminology (ISO 9000)

information and its support medium

Document

Terminology (ISO 9000)

Extent of Documentation

• Size of the organisation and type of activity

• Complexity and interaction of processes

• Competence of personnel

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Procedures

Quality Policy and Objectives

Quality Manual

Scope of System

Procedures or Reference to them

Description of sequence/interaction of

processes

Types of Documents

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Procedures

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Quality Manualsinformation, both internally and externally, about the

organization's quality management system

Quality Planshow the quality management system is applied to a specific

product, project or contract

Procedureshow to perform activities

Recordsobjective evidence of activities performed or results achieved

Types of Documents

Quality Management Principles

1.Customer-Focused Organisation

2.Leadership

3. Involvement of People

4.Process Approach

5.System Approach by Management

6.Continual Improvement

7.Factual approach to decision making

8.Mutually beneficial supplier relationships

Customer - Focused Organisation

• Understanding customer needs and expectations

• Communicating these needs and expectations throughout the organisation

• Measuring customer satisfaction and acting on results

• Example of application in standard for classes 5.2,7.2,7.2.3,,7.5.4,8.2.1

Leadership

• Establishing a clear vision of the organisation’s future ( by Quality Policy)

• Setting challenging goals and targets • Being proactive & leading by example ( by Quality Objectives

and Quality Policy)• Providing people with required resources

Involvement of People

• Accept ownership and responsibility to solve problems• Actively seek opportunities to make improvements• Actively seek opportunities to enhance their

competencies, knowledge and experience

ProductRealisation

Product

Input Output

Process Approach

• Define Processes needed to achieve desired results• Identify & Measure Inputs & Outputs• Identify interfaces• Evaluate risk, consequence and impact on customers• Establish responsibility, authority and accountability for

managing processes

System Approach

• Define & Develop processes

• Structure the System in most efficient way

• Understand interdependencies of processes in the system

• Continually improve through measurement and evaluation

Continual Improvement

• Its incremental improvement• Improvement of Products, Processes & Systems• Incremental & Breakthrough Concepts• Periodic Assessment against established Criteria

Do

Check

Act

Plan

• Analysing and evaluating the existing situation to identify areas for improvement;• Establish the objectives for improvement;• Searching for possible solutions to achieve the objectives;• Evaluating these solutions and making a selection• Implementing the selected solution;• Measuring, verifying, analysing and evaluating results of the implementation to determine that the objectives have been met;• Formalising changes.

Continual improvement

Factual Approach to Decision-Making

• Measuring & Collecting Data & Information• Ensure accurate, reliable & accessible• Analyse data and information• Understand value of Statistical Techniques• Make Decisions and Take Actions on results of

analysis

Mutually Beneficial Supplier Relationships

• Identify and Select key suppliers• Establish relationships that balance short-term gains

with long-term considerations• Create clear and open communications• Initiate joint development and improvement of

products and processes• Establish joint understanding of customers’ needs• Share information and future plans

4.1 QMS General Requirements

• Establish, document, implement, maintain and continually improve the effectiveness of a quality management system

Establishing the QMS the steps

• Determine processes (and procedures) needed• Sequence and interaction• Criteria and methods for operation and control• Implement the procedures developed• Build mechanism for Measuring , monitoring , and

analyses• Target improvements

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4.2.3 Control of Documents

• Approve, Review, Update

• Identify Current Revision Status and changes

• Ensure availability

• Legible, Identifiable, Retrievable

• Control External Documents

• Control Obsolete Documents

• Records are a special type of document

4.2.4 Control of Quality Records

• To provide evidence of conformity to

requirements and system

• Legible, identifiable, retrievable

• Retention time specified

• Disposition specified

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5.1 Management Commitment

• Demonstrate Commitment to Development Implementation & Continually Improving the effectiveness of System (Including statutory and regulatory requirements )

• Communicating Importance of Meeting Customer Requirements

• Establishing Quality Policy & Objectives

• Conducting Management Reviews

• Providing Necessary Resources

5.2 Customer Focus

• Requirements• Aim of enhancing Customer Satisfaction

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5.3 Quality Policy

• Appropriate to purpose for organisation

• Commitment to Continually Improve the effectiveness of the system

• Framework for setting and reviewing Quality Objectives

5.4 Planning

• 5.4.1 Quality Objectives

• Measurable or objectives may be S.M.A.R.T• Consistent with Policy• The objectives include those needed to meet

requirements for product

5.4 Planning

• 5.4.2 Quality Planning

• Processes of the System to be planned

• Resources needed to be planned

• Quality Objectives for the process are planned

5.5 Responsibility, Authority and Communication

5.5.1 Responsibility & Authorities

• Top Management define and communicate Responsibilities, Authorities & Inter-relations

5.5 Responsibility, Authority and Communication

5.5.2 Management Representative

• Responsible for establishing the QMS .Establishes processes Established

implemented & Maintained

• Promote Awareness of QMS & Customer Requirements

5.5 Responsibility, Authority and Communication

5.5.3 Internal Communications

• Top management shall ensure communication between

various levels and functions regarding effectiveness of system

5.6 Management Review (Inputs)

• Current Performance and Improvement Opportunities

• Audit Results• Customer Feedback• Process/Product Conformance• Preventive/Corrective Actions• Actions from previous reviews• Planned changes• Recommendations for improvement

5.6 Management Review (Outputs)

• Actions related to:

• improvement of the QMS and its processes,

• improvement of product related to customer requirements,

• resource needs

6.1 Resource Management

• Determine & Provide in Timely Manner to– Implement, Maintain & Continually Improve

Processes– Enhance Customer Satisfaction

6.2 Human Resources

6.2.1 General:

• Persons competent to perform work affecting quality

6.2.2 Competence Awareness & Training, • determine competency needs;• provide training or other actions;• evaluate effectiveness of training;• ensure awareness of relevance and importance of activities;• maintain records

6.3 Infrastructure

• Determine, provide & Maintain

– Buildings,Workspace and Utilities

– Equipment, hardware & software

– Supporting Services (transport or communication)

6.4 Work Environment

• Identify & Maintain conditions to achieve conformity of product

• Ensure safe working environment (deemed to include safety)

7.3   DESIGN & DEVELOPMENT 

• Organisation should Design by considering life cycle ,safety, health, testability, usability, user-friendliness, durability ,ergonomics, the environment, product disposal & identified risks.

• The design includes :- Design and drawings and Product specifications including acceptance criteria Process specifications Testing specifications Purchase requirements (read MR /material or equipment

indent)

7.3.1 Design and development planning

•  The Organisation shall prepare design plans for each design and development activity..

• Organisation need to define :-a) Design development stagesb) Determine design review, verification and validation c) responsibilities and authority for D&D

• Design Plan should be updated as per the progress

7.3.2   Design Input

• Need to formally document the design inputs• Design input requirements relating to the product, including:-• Inputs needed for D&D (specs/codes etc)• Functional /performance requirements• Applicable statutory and regulatory requirements, • Previous proven designs where applicable

Design input shall take into consideration the results of any contract review activities.

• Incomplete, ambiguous or conflicting requirements shall be resolved

• Design Input to be reviewed (before use of design engineers/DEC)

7.3.3  Design output

• Design output shall be documented and expressed in terms that can be verified and validated against design input requirements.

• Design Output shall be Meeting Input requirements- design & drawings Appropriate information for purchasing & production Acceptance criteria (including tolerances) Safety instructions /Operating instructions

 

7.3.4 Design review

• At appropriate stages of decision, formal documented reviews of the design results shall be planned and conducted.

• Design review is done for to see the requirements are met and identify any problems and take actions for its mitigation

• Participants at each design review shall include representatives of all functions concerned with the design stage being reviewed

• Records of such reviews shall be maintained

7.3.5  Design verification 

• At appropriate stages of design, design verification shall be performed to ensure that the design stage output meets the design stage input requirements.

• Needs to be documented• Design verification can be done as per following:-• Checking of calculations ( mostly preferred)• Checking design by alternate design method• Checking design by alternate design software

7.3.6   Design validation

• Design validation shall be performed to ensure that product conforms to define user needs and / or requirements.

• This can be done on completed product or prototype• Design validation is on completed work but before handing

over to client e.g of such validation can be Load test of bridges Commissioning tests In case of EEC if commissioning is not in our scope we can

recommend what tests need to be carried out and we should request for its results from client

7.3.7 Design changes

• All design changes and modifications shall be identified, documented, reviewed and approved by authorized personnel before their implementation.

• These design changes will have affect on design plan

7.5 Production and Service Provision

7.5.1 Control of production and service provision

• Availability of information

• Work Instructions, where necessary

• Use & Maintenance of suitable equipment

• Availability & Use of Monitoring & Measuring equipment

• Implement Monitoring Activities• Processes for Release, Delivery & Post Delivery Activities

7.5 Production & Service Provision

• 7.5.2 Validation of Processes-Controls for

Special Process are established

• 7.5.3 Identification & Tracebility

• 7.5.4 Customer Property – Like hardware,

software, land ,equipment given by customer for

production

• 7.5.5 Preservation of Product – Storage of

products and preservation in of the same in state

of conformity

7.6 Control of Monitoring & Measuring Devices

• Determine Measurements (least count etc)

• Identify Devices Required (appropriate equipment for

calibration)

• Use & Control ( to avoid detoriation to the instrument)

• Calibrate or verified, Safeguard, Protect, etc

• includes software

8. Measurement, Analysis & Improvement

• 8.1 Planning

• Define,Plan,Implement

• Measurement & Monitoring Activities

• Conformity of product and system Improve effectiveness of system

• Applicable Methodologies (inc Statistical Techniques)

• 8.2.1 Customer Satisfaction (monitor customer perception to requirement’s

fulfilment)

• 8.2.2 Internal Audits

• Monitoring/Measurement

• 8.2.3 Processes (correction & corrective action)

• 8.2.4 Product

8.2. Monitoring & Measurement

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Proactive not Reactive

8.2.1 Customer Satisfaction8.2.1 Customer Satisfaction

• Monitor Information

• Customer Perception

• Defined Methods

8.2.2 Internal Audit

• Quality System

• Effectively Implemented

• Effectively Maintained

• Conforms to ISO9001

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8.2.3 Monitoring & Measurement of Processes

• Suitable Methods

• Realisation Processes

• Demonstrate Ability

• Achieve planned results

• Correction and Corrective action

8.2.4 Monitoring & Measurement of Product

• Measure and monitor characteristics of the product to verify that requirements are met

• Appropriate Stages

• Evidence of conformity (records)

• No release/delivery until all OK (approved by relevant authority)

• Related to Product

• Identified and Controlled

• Prevent Unintended Use or Delivery

• Corrected and re-verified

• Applies to post delivery problems which will require appropriate action

8.3 Control of Nonconforming Product

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8.4 Analysis of Data

• Customer Satisfaction

• Conformance to Product Requirements

Characteristics and Trends of Processes, & Products

• Suppliers

8.5.1 Planning for Continual Improvement

8.5 Improvement

• Plan and Manage the processes necessary for continual improvement

• (quality policy, quality objectives, audit results, data, corrective/preventive action)

Continual Improvement

• Defining, measuring and analysing existing situation;

• Establishing objectives for improvement;

• Searching for possible solutions;

• Evaluating solutions;

• Implementing selected solution;

• Measuring, verifying, and analysing results of implementation;

• Formalising changes.

• Review Nonconformities (incl Complaints)

• Determine Cause

• Evaluate Need for Action

• Determine & Implement Action including prevention of recurrence

• Record Results

• Review Corrective action

8.5.2 Corrective Action

8.5 Improvement

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• Action

• Implement Action

• Record Results

• Review Preventive action Identification

• Determine Cause

• Determine

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8.5.3 Preventive Action

8.5 Improvement

It’s Team Work !! Lets do it!!

Thank You!