Download - DRAFT PRODUCT CERTIFICATION MANUAL FOR …DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS Our Ref.CRO 22 / DLBO(MCM) 20 Jan 2014 Please find enclosed the following draft certification

DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS

Our Ref.CRO 22 / DLBO(MCM) 20 Jan 2014

Please find enclosed the following draft certification manual :

Product Certification Manual on Industrial Safety helmets (IS: 2925:1984)

Kindly examine the draft product certification manual and forward your comments on the draft

manuals.

Last date for comments: 5 Feb 2014.

Comments, if any, may please be made in the format as given below and mailed

to DLBO(MCM), DELHI at the following email id:

mdd1.bis

Sl.

No.

Name of

RO /

BO

Clause/

Sub-

clause

Paragraph /

Figure /

Table

Type of

comment

(General /

Technical /

Editorial)

Comments Proposed

Change

Note: Separate sheets may be attached incase comments are lengthy and cannot be

incorporated in the

S. K. Khanna

Deputy Director General Central Region

Bureau of Indian Standards,

9, B S Z Marg, New Delhi- 110002

Doc. No. ______________________

Date of Issue ___________________

Product Certification Manual

on

Industrial Safety helmets

(IS: 2925:1984)

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9, BAHADUR SHAH ZAFAR MARG,

NEW DELHI – 110002

BUREAU OF INDIAN STANDARDS PRODUCT MANUAL ON INDUSTRIAL SAFETY HELMETS as IS 2925

PREPARED BY‐AMIT CHOUDHARY, Sc. B, DLBO-MCM APPROVED BY

2 | P a g e

I S S U E N O 1

Foreword

Personal Protective equipments has today gained a lot of relevance owing the

increased industrial activity of different types like oil field, offshore, mining, tunneling,

quarrying, ship building, construction projects and similar occupations. Hazards exist in

workplace in many different forms: sharp edges, falling objects, flying sparks, chemicals,

noise and a myriad of other potentially dangerous situations. Employees are exposed to these

unsafe and unhealthy environments which poses serious threats of injury, which are

sometimes fatal leading to untimely death. Head protects our brain which is the most

important organ of our body controlling all our body parts and functions. Head injuries

caused in industrial accidents are usually very serious which may end up in permanent

disability or sometimes it may even lead to death.

Taking cognizance of safety needs of workers in the work place, Indian Standard

specification IS: 2925 was prepared for Industrial Safety Helmets capable of providing

adequate protection from falling objects and other hazards commonly met with in many

industries. This Standard was first published in 1964 and revised in 1974. Second revision of

the standard was adopted in 1984.

This manual has been prepared in order to lay down general guidelines to harmonize

and streamline the different approaches adopted by the Branch Offices (BO) for Certification

against this Indian Standard. This manual envisages drawing a clear outline for the different

stages of Grant of Licence like the details to be included in the Scope of the licence, the

recommended manufacturing process, sample size for Independent Testing, disposal of

remnants of sample, etc.



3 | P a g e

I S S U E N O 1

Table of Contents

Sl. No. Content Page No.

1. Title page 1

2. Foreword 2

3. Table of Contents 3

4. Section I: Product Description 5

1. Description of Product

2. Latest Indian Standard Number with Product

Title and Number of Amendments

3. Check-list for submission of an application

for grant of licence

5. Section II: Raw Materials / Components 5

1. List of important Raw Materials / components,

including those which are required to conform

to the relevant Indian Standards

6. Section III: Manufacturing Process and In-process Quality Controls 5

1. Description of Manufacturing Process(es)

2. Infrastructure for production

7. Section IV: Certification Criteria 7

1. Identification of Critical Requirements of the

Indian Standard

2. Scheme of Testing and Inspection

3. Marking Fee Rates

4. Grouping Guidelines, if any

5. Guidelines for writing Scope of Licence

6. Guidelines for Inclusion of new Varieties

7. Sample size, including guidelines for drawal

of separate samples when samples are required

to be sent to different labs for testing



4 | P a g e

I S S U E N O 1

8. Manner of Sealing of Sample(s)

9. Whether remnants of sample(s) are returnable /

non-returnable, to be scrapped / used, to be

de-shaped before disposal In case of safety

items), any other precaution required for

dealing with remnants

10. Procedure to be followed for destroying /

deshaping / recycling the product that does

not meet the quality parameters during regular

production

8. Section V: Inspection and Testing 11

1. Packing Material requirement (to be available in

factory at all times) for Packing / Dispatch of

Samples

2. List of required Test Equipment / Facilities with

requirement and frequency of Calibration

3. Status of Test Facilities in BIS Labs and OSLs

with Testing Charges, and approximate time

required for testing by BIS labs / OSLs

4. Whether Grant of Licence will be based on:

Factory testing basis or

Independent testing basis or

Mixed (factory testing basis plus independent

testing of some raw materials)

5. Details of Tests to be carried out in the Factory

in case of:

Applicant Samples / Verification Samples

Surveillance / Market Samples

Raw Material Samples to be got tested, if any

List of Annexure

Annexure-I : Check list for submission of an application for Grant of Licence

Annexure-II : Scheme of Testing and Inspection



5 | P a g e

I S S U E N O 1

Section I: Product Description

1. Description of Product

1.1 Industrial safety helmet is a protective covering worn over head in the

manufacturing/engineering workplace and is used for protection of head against

injuries from unforeseen accidents in such workplace. Industrial Safety Helmet is

mainly made of four parts:

1.1.1 Outer protective shell:

It is the outer non-metallic main body of the helmet providing protection to the region

underneath from the external objects during mishappenings.

1.1.2 Cradle:

It is the part which sits over the human skull and together with headband and chin

strap/nape strap, it fixes the protective shell over the human head.

1.1.3 Head band:

It is in the form of a wide band connected with shell surrounds the head for fitting.

1.1.4 Chin strap/nape strap:

It is that part of the helmet which ensures tight fitting of the helmet over the head.

2. Latest Indian Standard No. with Product Title and Number of amendments

2.1 Latest Indian Standard: IS 2925:1984

2.2 No. of Amendments: 4

3. Check-list for submission of an application for grant of licence

Attached as Annexure-I

Section II: Raw Materials / Components

1. List of important Raw Materials / components

1.1 Raw Materials:

1. PVC grains/other non-metallic compounds of suitable quality

2. Straps

3. Threads

4. Fastening devices



6 | P a g e

I S S U E N O 1

1.2 Conformance of raw material to the relevant Standard:

1.2.1 Shell shall conform to Cl. 3.1 of IS 2925:1984

1.2.2 Harness shall conform to Cl. 3.2 of IS 2925:1984

1.2.3 Metal parts (if used) shall conform to CL.3.3.of IS 2925:1984

Section III: Manufacturing Process and In-process Quality Controls

1 Description of Manufacturing Process

A typical manufacturing process of Industrial Safety helmet is given below:



7 | P a g e

I S S U E N O 1

Typical Manufacturing Process

Moulding of Shell and components

Stitching of Chin strap (where applicable)

Fitting of Cradle, Head-Band and Chin-strap

(where applicable) in the Shell

Testing and Marking

Packaging and Despatch



8 | P a g e

I S S U E N O 1

2. Infrastructure for production

For the purpose of manufacturing of Industrial helmets the following machineries are

required:

1. Injection Moulding machinery

2. Sewing machine

3. Scissors

4. Machinery for marking of batch no., etc.

Section IV: Certification Criteria

1. Identification of Critical Requirements of the Indian Standard Scope of Licence

shall include

To be provided by CMD.

2. Scheme of Testing and Inspection

Attached at Annexure-II

3. Marking Fee Rates

Rate of Marking Fee is as given below-

Description Value

Unit 1 HELMET

L S Marking Fee 34000

S S Marking Fee 29000

Slab 1 Rate 0.36

Slab 1 Qty All

Slab 2 Rate 0

Slab 2 Qty 0

Slab 3 Rate 0

Enforcement Date 20120806

Remarks revised



9 | P a g e

I S S U E N O 1

4. Grouping Guidelines, if any

There does not exist any grouping guideline for this product at present.

5. Guidelines for writing Scope of Licence

Scope of Licence shall include

1. Size

2. Constructional details like ‘with or without peak’, ‘ventilation holes’,’ chin

strap/nape strap’, ‘Lamp bracket’, ‘ cable clip’.

6. Guidelines for Inclusion of new Varieties

For Inclusion of new varieties, procedure laid down in OMPC shall be followed in

case of normal procedure for Grant of Licence and for simplified procedure, the

guidelines as given in the CMD circular shall be followed.

7. Sample size, including guidelines for drawl of separate samples

In case of Industrial Safety Hemets, testing of mechanical parameter is taken up by

the lab. For complete independent testing on the sample, a minimum of 8 samples

shall be drawn.

8. Manner of Sealing of Sample(s)

8.1 Packing:

Keeping in mind the damage that can take place in the sample during transportation

to the lab for Independent testing; the samples shall be packed in a durable packing

material to withstand hazards during handling and transportation and shall preferably

be packed in a carton box and wax sealed. As far as possible, it shall be ensured that

all the original markings on the sample indicating origin of the product are

removed/defaced with the objective of concealing the identity of origin of the sample

from the testing laboratory.

8.2 Labeling:

The sample shall also be labeled to indicate-

a) Name of the product;

b) Relevant Indian Standard with its year;

c) Grade/size/type of the product;

d) Quantity of the product;

e) Batch no./Control unit no./Date of production;

f) Declared values, if any; and



10 | P a g e

I S S U E N O 1

g) In case raw material sample is drawn, corresponding specification may also be

indicated.

Labels shall be tagged to the sample.

8.3 Coding:

A code no shall also be given to the sealed sample in the following manner:

Branch office Code/Initials of the technical auditor /Date of drawl of sample/Type of

Sample (i.e. applicant/factory/ market/complaint etc.)/Serial Number of the sample

drawn by the technical auditor on that date.

For coding “type of the sample” in the sample code, the following shall be used:

a) Applicant Sample AS

b) Complaint Sample CP

c) Inclusion Sample IN

d) Market Sample MS

e) Factory Sample FS (Normal Licensee Sample)

f) Counter Sample CS

g) Stop Marking SM

8.4 Sealing:

Sample drawn during inspection shall be properly sealed with official seal and signed

by the technical auditor and the representative of the firm (if he so demands).

9. Remnants of sample

During the course of the test on the sample, all the eight samples are subjected to

conditioning/heat treatment test and therefore, these may not be returned for use as

fresh helmets. The material of PVC helmets is non-biodegradable and poses a serious

environmental hazard, After testing , the remnants may be cut into small pieces.

This material can be disposed off carefully through-

a) Incineration [In accordance with applicable State Laws (if any)]; or

b) Recycled.



11 | P a g e

I S S U E N O 1

Section V: Inspection and Testing

1. Packing Material requirement (to be available in factory at all times)

Firm shall always have in their factory a polythene bag and a large size

carton/corrugated box/any durable packing material sufficient to accommodate eight

safety helmets for packaging of samples of Industrial Safety helmets. In addition, for

sealing of the packed sample, the Licencee/applicant shall have

a) Sufficient quantity of lac

b) Cord for tying of the sample

c) A candle

d) Match box or lighter; and

e) A marker

2. List of required Test Equipment / Facilities with requirement and frequency of

Calibration

To be provided by Central Lab.

3 Status of Test Facilities in BIS Labs and OSLs with Testing Charges,and

approximate time required for testing by BIS labs / OSLs

3.1 List of BIS Lab and OSL having test facility for IS: 2925:1984 with their testing

charges is as under (as on 31.12.2013):

List of BIS Laboratories

Lab Quantity Lab Type Testing Facility Remarks

IS Number :- IS 2925 - 0 : 1984

CL 8 nos. Mech C

IS No. Testing Charges Remarks

IS 2925 : 1984 Rs 1050/-

Testing Facility:: C=Complete Test facility / P=Partial Test Facility/ N=No Test Facility



12 | P a g e

I S S U E N O 1

List of Outside Recognized Laboratories

IS Number :- IS 2925 - INDUSTRIAL SAFETY HELMETS

Sl No.

Name of the Recognized Laboratory Lab Code Testing Charges Remarks

1 CENTRAL MINING RESEARCH INSITITUTE,

Barwa Road

DHANBAD-826001

Jharkhand

Contact : Shri M.N. Tarafdar,Scientist

Incharge

Tel : 0326-202326, 203043

Fax : 0326-202429

5113101 Not recognized by BIS. Facilities of the lab are being utilized by BIS in special case as and when required.

2 Automotive Research Association Of India,(ARAI)

S.No.102, Vetal Hill, Off Paud Road,

Kothrud,

Pune-411038

Maharashtra

Contact : Shri A.V. Mannikar

Tel : 020-3023 1100/1350

Fax : 020-30231104

7106935 Rs. 21,000/-( per type)

3 Central Institure of Plastics Engg.& Tech.(CIPET)

B-27,

Amausi Indusrial Area

Lucknow-226008

Uttar Pradesh

Contact : Dr. Vijay Kumar, Dy.Director

Tel : 0522-2436210,2437646

Fax : 0522-2436227

9102534 Rs.4387.50/- Included w.e.f. 30 Nov 2012

4 Central Institute of Plastics & Engg. Tech.(CIPET)

G. Sector, Govindpura,

Industrial Area

Bhopal-462023

Madhya Pradesh

Contact : Shri P.K. Sahoo Chief

Manager(P)

Tel : 0755-2687454,2688288

Fax : 0755-2689041

8100534 Rs.5,750/- Except Lamp Bracket and cable clip testing



13 | P a g e

I S S U E N O 1

3.2 Approximate time required for testing:

Approximate time required for testing and reporting by the lab is 47 Man-Hours (As

per BIS Testing Charge detailed)

4. Basis of Grant of Licence

Grant of Licence for Industrial Safety helmets as per IS 2925:1984 shall be based on

Independent testing, However, in some cases Grant of Licence may also be

considered on factory testing/mixed basis on approval of competent Authority (please

refer to Cl 2.9.5 of OMPC 2004)

5 Details of Tests to be carried out in the Factory in different cases

5.1 Applicant Samples / Verification Samples:

In case Grant of licence is to considered on Independent Test Report, all possible

tests (tests not requiring conditioning) may be carried out. The tests like

a) Size (Cl. 4)

b) Construction ( only applicable requirements) (Cl. 5)

c) Workmanship and finish (Cl. 6)

d) Mass (Cl. 7)

e) Flammability resistance (Cl.8.3)

f) Heat resistance (Cl 8.6)

may be carried out in the laboratory of the factory. If inspection is carried out

sufficiently long time, the following tests may also be carried out:

a) Shock absorption resistance (Cl. 8.1)

b) Penetration resistance (Cl. 8.2)

However, if licence is to be considered on factory test after approval of competent

authority, all the tests mentioned in the specification shall be carried out in the

laboratory of the factory.

5.2 Surveillance / Market Samples

In case of sample drawn during surveillance visit or market samples, lab shall take up

testing of the Independent sample for all possible tests with the available test facility

in the lab.

During surveillance inspections, all possible testing as per Cl. 5.1 above may be taken

up in the laboratory of the factory within the available time of inspection.



14 | P a g e

I S S U E N O 1

5.3 Raw Material Samples

The material samples of Industrial Safety helmets are tested in the product testing

itself.



15 | P a g e

I S S U E N O 1

ANNEXURE-I

CHECK-LIST FOR SCRUTINY OF APPLICATIONS AT THE COUNTER

(to be checked at the time of receipt of Application)

Sl.

No.

REQUIREMET YES /

NO

1. Whether the application form is as per BIS standard format and filled completely with no

column left as blank?

2. Whether the application is signed and stamped?

3. Whether the application is accompanied with requisite fee (DD or evidence of transfer through

RTGS)?

4. Whether the application is accompanied with check list?

5. Whether the application is accompanied by all documents as per “the list of documents to be attached”? (Please see Annex A, Annex A-1, Annex A-2, Annex A-3 and Annex B)

6. In case the application is under "simplified procedure", is the test report attached with application and is not older than one month from date of submission of application?

Notes:

1. If the application is found to be complete, it shall be recorded and acknowledgement issued to the

applicant across the counter.

2. If the application is found to be incomplete or deficient, the deficiencies shall be clearly communicated to

the applicant in writing and acknowledgement obtained across the counter.

3. The application shall, then, be marked to the Head of the Branch Office, immediately.



16 | P a g e

I S S U E N O 1

CHECK-LIST FOR SCRUTINY OF APPLICATIONS BY CONCERNED OFFICER IN THE BO (to be

checked at the time of receipt of Application)

Sl.

No.

REQUIREMENT YES /

NO

1.

Whether the application is complete in all respects, including the availability of requisite infrastructure for manufacturing and testing as per the Indian Standard? (Please see Check-

list attached as Annex B)

2. Whether the test report(s) attached with the application has / have been submitted within the specified time norms (applicable in case of simplified procedure)?

3. Whether the test report(s) is / are from BIS or BIS recognized laboratory(ies) only?

4. Whether the test report(s) show conformity of the sample(s) tested to the relevant Indian

Standard(s)?

5. Whether all the requirements as per the relevant Indian Standard(s) have been tested?

6. Whether, in case of application under the Foreign Manufacturers’ Certification Scheme, additional requirements, as given in Annex C, have been checked and found in order?

Note -

After scrutiny of the application, the concerned Officer shall communicate the deficiencies, if any, to the

applicant and also indicate the date on which the preliminary / verification inspection is proposed to be carried

out, clearly indicating that all deficiencies shall have to be completed by the applicant within the stipulated

period in order to enable the BIS officer to verify the same during the preliminary / verification inspection.



17 | P a g e

I S S U E N O 1

LIST OF DOCUMENTS TO BE ATTACHED WITH APPLICATION

No. Title of Document Page

1 Check-list (Please see Annex B)

2

In case the application is filed under “simplified Procedure”, the test report(s) in original from BIS

or its recognized laboratories for all the requirements of the product and, where applicable, of raw material(s)/ component(s)

3

Document of Central/State Government (e.g. Registration Certificate, Memorandum of Articles,

etc) authenticating the address and purpose of the establishment of the manufacturing unit for

which the application is made for grant of licence.

4 In case the applicant applies as SSI unit, copy of valid Registration Certificate from the Local /

State authority or from a Chartered Accountant?

5 In case the application is signed by the authorized signatory of the applicant, authorization letter

from CEO in the name of the authorized signatory.

6

Process Flow-chart covering all processes of manufacture (from raw material to finished product

stage), including details of in-process controls at each stage, even for those stages which have

been outsourced?

7 Complete list of manufacturing machinery, clearly indicating the name of the machinery, the details of the process for which it is used, its capacity and quantity in Annex A-1.

8

In case some of the manufacturing processes are outsourced, provide details of such processes

and the controls exercised by you before receipt of such material/components, etc. Also attach

an authenticated copy of the agreement.

9

Complete list of testing facilities, clearly indicating the name of the equipment, the test for which it

is used (mention clause No. of the Indian Standard), range / least count / accuracy of the test equipment, calibration status and quantity in Annex A-2.

Note: Model lists of testing facilities for some of the Indian Standards already covered under

product certification are available on the BIS website and may be referred. However, for other

Indian Standards, you are advised to study the relevant Indian Standard(s) and / or contact the

concerned Branch Office of BIS for guidance.

10 Copies of calibration certificates of testing equipment valid at least till 3 months of acceptance of

application

11 Where applicable, ‘consent letter’ from BIS recognized laboratory (for requirements which have

got to be and / or are proposed to be got tested from outside lab for which the applicant does not

have in-house test facilities).



18 | P a g e

I S S U E N O 1

12 Plant Layout clearly indicating location of manufacturing machinery, lab, office, workshop,

amenities, storage area, etc., available in the factory premises, with the application?

13 Appointment letter of QC personnel indicating names, experience, qualifications, date of

appointment and also attach a copy each of the qualification certificates

14 Copy each of the test reports/suppliers’ test certificates for each of the raw materials /

components.

15 Copy of in-house or independent test report for the product covering all requirements as per the

relevant Indian Standard

16

In case application is under simplified procedure, an undertaking from the applicant on his letter- head (see Annex A-3) that the licence if granted to him shall be put under Stop Marking by BIS

if the verification sample(s) drawn during verification visit of the BIS officer prior to grant of

licence fail to conform to the Indian Standard. In case the licensee does not take corrective

actions, informs BIS and offers two improved lots to BIS for inspection and testing within one

month of the date of Stop Marking, the licence shall be processed for cancellation and no further

chance would be given to the licensee



19 | P a g e

I S S U E N O 1

CMPF 305

ANNEX A-1

(Sl. No. 7 on the List of Documents)

DECLARATION REGARDING MANUFACTURING MACHINERY

1. Applicant name:_____________________________________________

2. Application No.______________________________________________

3. Name/Address______________________________________________

Date Machinery Make Capacity Number Remarks

I hereby declare that the machinery of which details are given overleaf is owned by me and are actually installed in the premises*.

I also declare that in case of grant of licence , I will send prior intimation to BIS whenever any machinery is taken out of the premises of the firm due to any reason

Sig. of Firm’s Representative_______________

Name:_________________________________

Designation __________________________________

Date __________________________________

I have checked and found that machinery of which details are given overleaf was available during my inspection.

Sig. of BIS I.O. ___________________________ Name _____________________________ Designation _____________________________

Date of verification_________________________



20 | P a g e

I S S U E N O 1

CM/PF 306

ANNEX A-2

(Sl. No. 9 on the List of Documents)

DECLARATION REGARDING TEST EQUPMENT

No entry to be crossed

1. Application No._________________________ 2. Licence No.

_______________________

3. Name /Address ________________________

Sl.

No. &

Date

Test Equipment/Chemicals

and Identification Numbers

(Where applicable)

Least Count &

Range (Where

applicable)

Valid

Calibration

(Where

required)

Yes/No

Tests

Used in

with

Clause

Reference

Remarks

(Indicate

number of

Equipment)

I hereby declare that the test equipments of which details are given overleaf are owned by me and are actually installed in the premises

I also declare that in case of grant of licence, I will send intimation to BIS whenever any equipment is taken out of the premises of the firm due to any reason. Sig. of Firm’s Representative_______________

Name:_________________________________

Designation __________________________________

Date __________________________________

I have checked and found that the test equipment of which details are given overleaf was available during my inspection.

Sig. of BIS I.O. ___________________________ Name _____________________________ Designation _____________________________

Date of verification_________________________



21 | P a g e

I S S U E N O 1

ANNEXURE-II



22 | P a g e

I S S U E N O 1



23 | P a g e

I S S U E N O 1