Quality manual of vsp madhur & sunny

VISAKHAPATNAM STEEL PLANT (VSP)(RASHTRIYA ISPAT NIGAM LIMITED)

QUALITY MANUAL

Submitted bySunny Gupta (QR1101)

Madhur Rawat (QR1105)Indian Statistical Institute, Kolkata

Approved by Issued by:

Managing DirectorManager Quality AssuranceManagement Representative

VISAKHAPATNAM STEEL PLANT

(RASHTRIYA ISPAT NIGAM LIMITED),VISAKHAPATNAM

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Issue/Rev. No :01/00

1. GENERAL

The basic objective of this documentation is to provide a brief information regarding company 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 and application statutory and regulatory requirements ,and

b) is committed to enhance customer satisfaction through the effective application of the system, including processes for continual improvement of the system and the assurance of conformity to customer and applicable statutory and regulatory requirements.





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1.1) COMPANY”S NAME

VISAKHAPATNAM STEEL PLANT(RASHTRIYA ISPAT NIGAM LIMITED),VISAKHAPATNAM

ADDRESS

VISAKHAPATNAM STEEL PLANT (VSP) Dr. V. Phaneendrudu Dy. General Manager Email : [email protected] Website: www.vizagsteel.com Tel: +91 - 891 - 2515854 (Off) +91 - 891 - 2518017 (Fax)





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mailto:[email protected]

1.2) INTRODUCTION

With a view to give impetus to the industrial growth and to meet the inspiration of the people from the south India, government of India decided to establish a integrated steel plant in public sector at Visakhapatnam (Andhra Pradesh).Seeds were thus sown for the construction of the modern sophisticated steel plant having annual capacity 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 the principal 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)





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http://en.wikipedia.org/w/index.php?title=OSHAS_18001:1999&action=edit&redlink=1

http://en.wikipedia.org/wiki/ISO_14001

http://en.wikipedia.org/wiki/ISO_9001:2000

http://en.wikipedia.org/wiki/Blast_Furnace

Turnover: The total turn over of this company is reported at last fiscal year (2010-11) around Rs 11,500 Crores .

Manpower: The total manpower of VSP is about 17000 strong trained personnel.

Future Plan:

VSP is committed to harness its growth potential at its best and sustain profitable growth and to

deliver high quality and cost competitive products and be the first choice of customers. To create

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.





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1.3) TABLE OF CONTENTS

Section No. Description ISO 9001 Clause

1 GENERAL ---1.1 Company’s Name and Address ---1.2 Introduction ---1.3 Table of Contents ---1.4 Manual Distribution 4.2.31.5 Definitions and Abbreviation 2, 32 SCOPE & EXCLUSIONS 1.23 PROCESS MANAGEMENT APPROACH 4.14 QUALITY MANAGEMENT SYSTEM 44.1 Documentation Structure 4.2.1, 4.2.24.2 Control of Documents 4.2.34.3 Control of Records 4.2.45 MANAGEMENT RESPONSIBILITY 55.2 Quality Policy 5.35.3 Quality Planning 5.45.4 Responsibility and Authority 5.5.15.5 Management Representative 5.5.25.6 Internal Communication 5.5.35.7 Management Review 5.66 RESOURCE MANAGEMENT 66.1 Competence, Awareness and Training 6.26.2 Infrastructure and Work Environment 6.3, 6.47 PRODUCT/SERVICE REALISATION 77.1 Planning of Service Realization 7.17.2 Determination and Review of Requirements Related to Service 7.2.1, 7.2.27.3 Shareholder/ Investor Feedback and Complaints 7.2.37.4 Design and Development 7.37.5 Purchasing 7.47.6 Control of Production and Service Provision 7.5.17.7 Validation of Production/Service Process 7.5.27.8 Identification and Traceability 7.5.37.9 Preservation of Product 7.5.57.10 Control of Monitoring and Measuring Devices 7.68 MEASUREMENT, ANALYSIS AND IMPROVEMENT 88.1 Customer satisfaction 8.2.18.2 Internal Quality Audit 8.2.28.3 Monitoring and Measuring of Processes and Product. 8.2.3, 8.2.48.4 Control of Nonconforming Product/Service 8.38.5 Analysis of Data 8.48.6 Continual Improvement 8.5.18.7 Corrective Action 8.5.28.8 Preventive Action 8.5.3

Annexure-1 PDF AND Process Map ---





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1.4)MANUAL DISTRUBUTION

Sl. No. Copy Copy Holder

1. Hard copy Chairman cum Managing Director

2. Hard copy Auditor

3. Master copy Management Representative (MR)

4. Departmental copy HOD of individual departments

Soft copy through Local area network shall be provided to following personnel:Finance Director, Head - Human Resources, Sales Manager, Production Manager, Marketing Manager, 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. This copy shall bear original signatures, and shall be printed on sheets bearing the company logo.





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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 from company.

Customer Process : A process that receives inputs in the formof materials or information from another process is called 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 QualityManagement System that needs to be maintained at a known revision status.

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





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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.

Abbreviation

SL No.

Abbreviation Explanation

1. QMSQuality Manual system

2. QPQuality Process

3. POProcess Map

4. MRManagement Representative

5. ISOInternational organization of standard

6. VSPVisakhapatnam Steel Plant

7. OCOrganization Chart

8. CRMCustomer Relationship Management

9. R&DResearch and Development

10.TS Technical specification

11. PFD Process flow diagram





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2. SCOPEApart from steel production,VSP is also engaged in production of other byproducts such as Tar, Pitch, Chemicals like Benzoyl (and its product), Ammonium Sulphate, Methanol, Ethanol etc. The scope of this quality management system restricted to production and distribution 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 designHence, 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 Quality Management System.

3. PROCESS MANAGEMENT APPROACH1. The scope of this quality system includes:

Systematic approach for providing service to the Shareholders/Investors at the same time ensuring compliance with the regulatory requirements framed under different statutes from time to time.

Systematic approach for collection and compilation of data obtained through various routes like internal quality audit process and process measurement system; Shareholder satisfaction measures and Shareholder/Investor complaints and consequent planning for improvements. The process of measuring shareholder satisfaction includes obtaining feedback 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 the responsibilities and authorities; communicating the goals and procedures to concerned functions and defining as well as reviewing quality policy and objectives.

Supporting activities like control of documents and control of records.





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The major processes required for effective implementation of this quality management system have 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 categories identified by ISO 9001: 2008, namely, management activities, provision of resources, product realisation/service provision and measurement.

The major processes in VSP are:

PurchaseStorageProductionInspectionMaintenanceMarketingSalesTraining and Awareness

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

Metallurgical Coke MakingSinteringIron MakingSteel MakingContinuous CastingRolling





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

4.1) 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 NumberingTo 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.





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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. The pages shall be numbered as page x of n where n is the total number of pages in the relevant section and x is the page serial number.

4.2) CONTROL OF DOCUMENTSThis procedure aims at ensuring that all documents and data, including the ones of external origin are identified and controlled. Control shall include

Ensuring that all documents and data are reviewed and approved properly, and pertinent copies of appropriate documents should be made available at all points of usage.

The formulation of a system for withdrawal or identification of obsolete documents to prevent unintentional usages.

Identification of all Documents

The Master list of all documents should be maintained by MR. The master list should indicate the 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 bear original signatures of the controller and approving authority of the document. The previous/obsolete master copies should be destroyed or can be stamped “OBSOLETE”. For each external document the copy maintained by the respective controller shall be treated as master copy.

Review and Approval of Documents

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





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specified as "Approved By" in the documents identifies the approving authority.Whatever be the change in the document should be incorporated on the master copy and the old copy (or appropriate pages of the old copy) should be stamped “OBSOLETE” or should be destroyed. The modified documents 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 master copy. Whenever a change is made, the reason and nature of change must be recorded in the amendment sheet. At the time of issue, the controller should include updated amendment sheet in every copy circulated ensuring maintenance of the revision history.The date of receipt shall be maintained for external documents to indicate the latest revision status.

4.3) CONTROL OF RECORDS

Master ListA master list of all records has to be be prepared and maintained by the Management Representative. This list should identify each record, revision status of record format, the originating document, the form of maintenance and the retention period. The form of maintenance shall specify whether the record will be maintained as loose sheets filed, bound registers or as computer files.All records must be maintained for the retention period specified and may be dispositional upon the end of this period at the discretion of the MR. The retention period should take care of legal requirements, if legal process demands.





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Filing, Storage and MaintenanceWhatever records which are maintained as loose sheets filed, the file should clearly be marked indicating the records stored in the file. In case of register,the name and content of the register should 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 easy retrievability.And further, the name of each record must be prominently marked on the top of the record 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 rule must 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 the Management Representative as to whom it would be accessible by.

Retention and Disposition of RecordsEvery record has to be maintained as per the retention period mentioned in the Master List of Records. Once in a year all the records maintained would be checked and identified old records would be disposed off, if required. The disposition of records has to be done by means of shredding, pulping or by such other suitable means. The job of disposition rests with the personnel responsible for management of the records.

5. MANAGEMENT RESPONSIBILITY

5.1) MANAGEMENT COMMITMENT AND CUSTOMER FOCUS

Management commitmentThe VSP’s top management has nourished a quality policy, quality objectives and a quality management system by which our company performs its operations to make sure the customer





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satisfaction. The quality policy and efficiency of the quality management system is evaluated at least annually during Management Review Meetings, where quality measurements are analyzed against their established objectives and suggestions for improvement of the system are considered. Quality planning is also conducted during Management Review Meetings to ensure the continuous availability of the resources necessary to meet the expectations of our customers.

Customer focusThe company’s training focuses on the fact that each employee understands the necessity of fulfilling requirements of both internal and external customers. The needs and expectations of customers are processed in such a manner to satisfy customer requirements, in an effort to gain and retain their confidence. To that end, customer requirements are identified,reviewed, and translated into work orders under controlled conditions to make it sure that the necessities are fully understood and met.

5.2) QUALITY POLICY

The quality policies of VSP are:

VSP is committed to be amongst the most admired & trusted Steel Producing Companies in India.

VSP shall deliver reliable and quality products and services to all customers at competitive costs, with international standards of customer care – thereby creating superior value for all stakeholders.

VSP is committed to comply with requirements and continually improve the effectiveness of the Quality Management System as per ISO 9001:2008.

The quality policies of VSP are:

.VSP is committed to be amongst the most admired & trusted Steel Producing Company in

India.

VSP shall deliver reliable and quality products and services to all customers at competitive costs, with international standards of customer care – thereby creating superior value for all stakeholders.





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VSP is committed to comply with requirements and continually improve the effectiveness of the Quality Management System as per ISO 9001:2008.

5.3) QUALITY PLANNING

Quality objectives

The management of VSP establishes annual key initiatives, which include quality objectives. which are derived from the Quality Policy. Quality objectives have been established to continually improve the quality management system as a whole as well as each management process, extending to processes involved with meeting product requirements. Quality objectives are measurable, so that they can be analyzed during Management Review to determine the degree to which they are met.

Quality management system planning

As a routine maintenance of our quality system, several proposed modifications to processes and procedures are reviewed during Management Review Meetings to make it sure that the requirements of the quality system have been addressed prior to the implementation of any modifications. This review ensures that no new process is implemented without first considering the actions that must be taken to ensure that the company remains in compliance with the system





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Quality atcore

Customer satisfaction

Continuous improvement

Reliability Safety Performance/Suitability

√Freedom from

defect

as it is documented. Items evaluated and planned actions are documented in the Management Review Meetings.

Organization structure (VSP)

5.4) RESPONSIBILITY AND AUTHORITY

The responsibilities and authorities of the key personnels of the Quality System are described below:

Authorities:

1. All staff are having authority to perform their allocated responsibilities. The following provides a summary of the principal responsibilities of each job role, and these are clarified in greater detail within the Operating Procedures.

2. All staff shares the authority and responsibility of identifying non-compliances or possible improvements, and recording these instances such that corrective action can be taken, both to rectify the immediate situation and to prevent recurrence.

Chairman cumManaging Director

Finance DirectorHuman Resource

HeadSales Manager

Executive Director

Production Manager Purchase Manager Marketing Manager

Inspection Unit HeadMaintenance

SupervisorStorage

Supervisor





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3. The Managing Director continually reviews the company's resources to ensure that adequate staff, equipment and materials are available to satisfy customer requirements.

Responsibilities:

1. Chairman cum Managing Director

Approval of the Quality Management System Management Review Supplier & Customer dealing Contract Management & Control Training

2. Executive Director

Approval of various processes. Management & Co-ordination of different departments. Project Management Issuing Quality Management System Planning & organization Management Representative

3. Purchase Manager

Maintaining the master-list of suppliers Supplier Selection Order placing Purchasing

4. Sales Manager

Contract Review Quotations Sales Order Processing Estimating Control of Contract Documentation





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5. Human Resource Head

Resource Management Competence, Training and Awareness Talent Acquisition Recruitment Retention Retirement

6. Production Manager

Definition of Installation, Inspection, Test & Maintenance Requirements

Planning & Performance of Installation, Technical Assistance Repairs, Testing and Maintenance Activities Control of Equipment and Materials Allocated

7. Finance Director

Control of Finance, Accounts and Warehouse Operations Training Approving Sales and Purchasing

8. Marketing Manager

Creating, maintaining and satisfying the customers Increasing the profit Analysis of customer demand Analysis of product features Advertising the product and company

9. Storage Supervisor

Control of Stock Replenishment Recommendation





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Protection and Preservation of Stock Packaging and Dispatch

10. Inspection Unit Head

Control of measuring equipments Control of conformed and non-conformed products Communicate with Sales and Manufacturing Departments

11. Maintenance Supervisor

Control of maintenance materials.

Communicate with Production and Inspection unit

Control of machines

5.5) MANAGEMENT REPRESENTATIVE

The Managing Director has been appointed Management Representative. His responsibilities as Management Representative include:

1. To recognize the processes required for the efficient implementation of a QMS in line with ISO 9001: 2008.

2. To ensure that these processes are established, implemented and maintained in a manner such that a QMS in line with ISO 9001: 2008 is effectively operative and the laid down policies and objectives of the organisation are met.

3. Convening the Management Review Meetings.

4. To encourage the importance of customer requirements throughout the organisation.

5. To plan and conduct internal quality audits to verify the adequacy of and compliance to the system and interacting with the individuals, on NCRs found during audits, for review and system improvement.





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6.

To ensure clarification of all issues related to the adopted quality management system.

7. Liaising with audit and other external agencies on matters related to quality management system.

The Management Representative is responsible for the identification and recording of problems related to the quality system, initiating actions to prevent occurrence of such non-conformance and providing solutions for corrections of the existing ones. The management review system has been designed to support the MR for carrying out the aforementioned activities effectively.

5.6) INTERNAL COMMUNICATION

VSP ensures smooth flow communication between its various levels and functions regarding the processes of the quality engineering & management system through:a. Top Management Meetingb. Zonal Level Meetingc. Circle Level Meetingd. Internal notes/circulars.e. Telephonic communication.f. Fax and Carrier messages.g. Personal communication.h.Internet communication

5.7) MANAGEMENT REVIEW

The objective of this procedure is to introduce a structured method of reviewing the quality system so as to ensure that

The system has been implemented and is effective in satisfying the stated quality policy and objectives.

The system continues to be suitable towards meeting the requirements of ISO 9001: 2008.

Corrective and preventive actions are being taken for continual improvement of the system.





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Management Review Committee-

A committee called the Management Review Committee (MRC) has been formed. The members of MRC are as follows:

Managing Director Finance Director Head - Human Resources Sales Director Production Manager Marketing Manager





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Quality manual of vsp madhur & sunny

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