quality manual of vspmadhursunny

8.2.3, 8.2.4 8.4 Control of Nonconforming Product/Service 8.3 Soft copy through Local area network shall be provided to following personnel: Finance Director, Head - Human Resources, Sal

1 GENERAL

The basic objective of this documentation is to provide a brief information regardingcompany commitments towards its quality management system specifying requirements

as per international standards

To achieve this, our

company a) demonstrates its abilities to consistently provide products that meet customer andapplication statutory and regulatory requirements ,and

b) is committed to enhance customer satisfaction through the effective application of thesystem, including processes for continual improvement of the system and the assurance

of conformity to customer and applicable statutory and regulatory requirements

1.2) INTRODUCTION

With a view to give impetus to the industrial growth and to meet the inspiration of the peoplefrom the south India, government of India decided to establish a integrated steel plant in publicsector at Visakhapatnam (Andhra Pradesh)

Seeds were thus sown for the construction of the modern sophisticated steel plant having annualcapacity of 3.4 million tonnes of hot metal In February 1981 the contract was signed with

USSR(now Russia) for preparation of working drawings for Coke Ovens, Blast Furnace and Sinter Plant The blast furnace foundation was laid with first mass concreting in the project in

January 1982 The construction of township also started It has the deepest port and is one of theprincipal outlets for country's exporting Iron ore

Vizag Steel Plant is the only Indian shore-based steel plant, and it has massive land, up to 19,000

acres (7,700 ha), and is poised to become up to 20 MT in a single campus.

Since VSP is accredited with ISO 9001:2000 Quality Management System Standard, all saleable products of Visakhapatnam Steel Plant come under the ISO umbrella

At VSP IS0:14001 has been awarded for Environment Management System in the Plant It is the only integrated steel plant in the country to be certified for ISO 9001:2000, ISO 14001:2004 and OSHAS 18001:1999

Location: The plant is located in Visakhapatnam City, which is on the coast of Bay of Bengal

Visakhapatnam city is an important commercial center of Andhra Pradesh

PRODUCTS:

1) Wire rods (TMT, Plain & Ribbed)

2) Merchant Products

(Angles, Channels, Round & TMT bars)

3) Beam, Billets, Bloooms

4) Reinforce bars

5) Plates (up to 3600 mm wide)

Turnover: The total turn over of this company is reported at last fiscal year (2010-11)

an inspiring work environment to unleash the creative energy of people and to achieve

excellence in enterprise management To be respected corporate citizen, ensure clean and green environment and develop vibrant communities around us In line with the vision in National Steel Policy envisaging 124 MT steel by 2019-20, Vizag Steel is also planning to expand it’s capacity from 3.6 MT to 6.3 MT After considering the buoyancy in domestic steel market for long products, which is the product mix of VSP and the high acceptance of VSP’s brand image

in the market, an expansion plan has been proposed

1.5 Definitions and Abbreviation 2, 3

4.1 Documentation Structure 4.2.1, 4.2.2 4.2 Control of Documents 4.2.3

6.1 Competence, Awareness and Training 6.2

6.2 Infrastructure and Work Environment 6.3, 6.4

7.1 Planning of Service Realization 7.1

7.2 Determination and Review of Requirements Related to Service 7.2.1, 7.2.2

7.3 Shareholder/ Investor Feedback and Complaints 7.2.3

7.4 Design and Development 7.3

7.6 Control of Production and Service Provision 7.5.1

7.7 Validation of Production/Service Process 7.5.2

7.8 Identification and Traceability 7.5.3

7.9 Preservation of Product 7.5.5

7.10 Control of Monitoring and Measuring Devices 7.6

8.1 Customer satisfaction 8.2.1

8.2 Internal Quality Audit 8.2.2

8.3 Monitoring and Measuring of Processes and Product 8.2.3, 8.2.4 8.4 Control of Nonconforming Product/Service 8.3

Soft copy through Local area network shall be provided to following personnel:

Finance Director, Head - Human Resources, Sales Manager, Production Manager, MarketingManager, Purchase Manager

NOTE: Furthermore, the Management Representative (MR) may issue uncontrolled copies to any other person after obtaining prior permission of the Managing Director

The master copy (Hard Copy) shall be held by the MR and shall not have any copy number Thiscopy shall bear original signatures, and shall be printed on sheets bearing the company logo

1.5) DEFINITION

Controller of Document : Management Representative, who will be responsible for controlling and issuing a particular document

Customer : Who take a service or use the product produce

Customer Process : A process that receives inputs in the form

of materials or information from another process iscalled the customer of the supplying process

Direct Process for Service : A process which is directly involved in the

Realization delivery of specific service to Customers is

called a direct process

Document : A document is an entity within the Quality

Management System that needs to be maintained at a known revision status

Internal Quality Auditor : Person within the company, who is having the

Competence to conduct internal quality audit of thedeveloped QMS

Internal Customers : An internal department, which receives

materials/Services from another department

is called internal Customer of the supplying department

Process : A process consists of an activity or a set of

interrelated activities, intended to transform one or more inputs at least one of which represent customer requirements into one or

more outputs that represents solutions from internal or external customer’s point of view

Supplier Process : A process that supplies inputs to another

process in the form of materials or information

is called the supplier of the receiving process.For all other quality related terms, definitions listed in ISO 9000: 2005 are applicable

of desired specific quality steel products

EXCLUSIONS

The Research & Development of organization is based on only verification and validation of products produced at different stages of different process to get the specific required properties rather than design

Hence, the requirements of design and development planning (clauses 7.3.1 of ISO 9001: 2008)

is, consequently, not applicable and have been excluded from the scope of the QualityManagement System

3 PROCESS MANAGEMENT APPROACH

1 The scope of this quality system includes:

 Systematic approach for providing service to the Shareholders/Investors at the same timeensuring compliance with the regulatory requirements framed under different statutesfrom time to time

 Systematic approach for collection and compilation of data obtained through variousroutes like internal quality audit process and process measurement system; Shareholdersatisfaction measures and Shareholder/Investor complaints and consequent planning forimprovements The process of measuring shareholder satisfaction includes obtainingfeedback from the Shareholders/Investors

 To identify and provision of resources in terms of adequately skilled manpower,infrastructure and work environment

 To manage activities including designing the organisational structure; defining theresponsibilities and authorities; communicating the goals and procedures to concernedfunctions and defining as well as reviewing quality policy and objectives

 Supporting activities like control of documents and control of records

The major processes required for effective implementation of this quality management systemhave been identified These processes have been divided into four major categories, viz

 Direct processes for Product Realisation,

 Support processes for identification and provision of resources,

 Measurement processes and

 Management processes

These four categories have been identified keeping in view the four major categoriesidentified by ISO 9001: 2008, namely, management activities, provision of resources,product realisation/service provision and measurement

The major processes in VSP are:

Training and Awareness

Major Process Associated with the Production of final Steel /Stainless Steel Products

are-Metallurgical Coke Making

Direct Process: Iron Making, BOF, Argon Rinsing, AOD/VOD, Degassing

Indirect Process: Making Metallurgical coke, Procurement, Mineral dressing, Maintenance of

Machines

Management Process: Training & Recruitment, Marketing & Sales, Internal Audit, Finance

The process maps of the above processes are available in Annexure-1.

4 QUALITY MANAGEMENT SYSTEM4.1) DOCUMENTATION STRUCTURE

This manual contains documented statements of our quality policy and quality objectives and

references documented procedures required by ISO 9001:2008 and other documents needed to

ensure effective planning, operation and control of our key QMS processes

The level and type of QMS documentation established for our business is continually reviewed

to ensure it remains appropriate for the complexity and interaction of our processes and the competence of our employees QMS documents and data may be in hard copy or electronic media QMS documentation includes this quality manual, process maps and other internal and external documents and data needed to manage, perform or verify work affecting product quality

We also issue and control work instructions, job descriptions, and other internal and external documents and data as appropriate and needed to effectively manage our QMS

The quality manual is that part of our QMS that defines the scope of our QMS and

documents the policy, procedures and processes needed to implement our quality policy and achieve our quality objectives This manual also documents justifications for exclusions

from ISO 9001:2008 requirements and defines the overall sequence of and interaction

between our key QMS processes

Revision / Issue Numbering

To start with every document shall have issue number one and revision number zero

Whenever the contents of a page are modified, the revision number shall be incremented by one When several documents (or sections) of same category have different revision

numbers, issue number of all these documents shall be incremented by one and the revision number of all the entire set shall be set to zero The MR shall have the authority to decide about bringing out a new issue

Format of Document

All pages of the internal document shall bear the issue number and revision number, signatures

of the controlling as well as approving authority and a “CONTROLLED COPY” stamp Thepages shall be numbered as page x of n where n is the total number of pages in the relevantsection and x is the page serial number

Identification of all Documents

The Master list of all documents should be maintained by MR The master list should indicatethe name of the document, controller, approving authority and revision status

Master Copy of Documents

A master copy has to be maintained for every internal document The master copy should bearoriginal signatures of the controller and approving authority of the document Theprevious/obsolete master copies should be destroyed or can be stamped “OBSOLETE” For eachexternal document the copy maintained by the respective controller shall be treated as mastercopy

Review and Approval of Documents

The Quality Manual should be reviewed and approved before being issued Unless specifiedotherwise, reviewer and approving authority of a document should be the same The part

specified as "Approved By" in the documents identifies the approving authority.Whatever be thechange in the document should be incorporated on the master copy and the old copy (orappropriate pages of

the old copy) should be stamped “OBSOLETE” or should be destroyed The modifieddocuments shall also be reviewed and approved before issue

For the external documents the copy received shall be treated as approved copy

Identification of Revision / Status of Amendment

An amendment sheet must be maintained with every internal document, including the mastercopy Whenever a change is made, the reason and nature of change must be recorded in theamendment sheet At the time of issue, the controller should include updated amendment sheet inevery copy circulated ensuring maintenance of the revision history

The date of receipt shall be maintained for external documents to indicate the latest revisionstatus

4.3) CONTROL OF RECORDS

Master List

A master list of all records has to be be prepared and maintained by the ManagementRepresentative This list should identify each record, revision status of record format, theoriginating document, the form of maintenance and the retention period The form ofmaintenance shall specify whether the record will be maintained as loose sheets filed, boundregisters or as computer files

All records must be maintained for the retention period specified and may be dispositional uponthe end of this period at the discretion of the MR The retention period should take care of legalrequirements, if legal process demands

Filing, Storage and Maintenance

Whatever records which are maintained as loose sheets filed, the file should clearly be markedindicating the records stored in the file In case of register,the name and content of the registershould be clearly stated Some records has to be managed as soft copy

Whenever a file which contains more than one type of record, it should be indexed to allow easyretrievability.And further, the name of each record must be prominently marked on the top of therecord to facilitate identification and retrievability

Control and Updating of Records

The blank formats of quality records (wherever the records are filled in a predestined format)shall be maintained by the Management Representative as an Exhibit File

Accessibility

The Quality records should be accessible internally to the internal quality auditors of ISC.Accessibility should be provided for the purpose of reference purpose only However, this rulemust not be

applicable for all records Some records (e.g., service records of different personnel maintained

as part of training records) would have limited accessibility only and should be decided by theManagement Representative as to whom it would be accessible by

Retention and Disposition of Records

Every record has to be maintained as per the retention period mentioned in the Master List ofRecords Once in a year all the records maintained would be checked and identified old recordswould be disposed off, if required The disposition of records has to be done by means ofshredding, pulping or by such other suitable means The job of disposition rests with thepersonnel responsible for management of the records

5 MANAGEMENT RESPONSIBILITY

5.1) MANAGEMENT COMMITMENT AND CUSTOMER FOCUS