Inspection and Testing Procedure
3 Procedure
3.1 General
PPF has established a documented procedure to perform the inspection and testing activities in order to ensure that requirements of products are met at all the times.
All the inspection/test frequencies and sample sizes required for the inspection stages defined in the Docket will be decided by CPM GM/contract depending on the product type and quantity in the relevant work order.
3.2 Acceptance Criterion for Attribute Characteristic
For all attribute characteristics the acceptance criterion is zero defects. The acceptance criteria are defined in Product Specification Sheets and are approved from the customers (external) by the Marketing department.
3.3 Receiving/In-Coming Inspection and Testing
Store checks incoming material against supplied specifications and may request the assistance of HoD (applicable to all types of incoming material). The responsibility for receiving inspection is assigned to Stores, which may request for assistance from the Concern department.
Different records are generated after inspection of the incoming material: if rejected due to non compliance GRA is issued and if accepted GRN is issued in addition to logging in the ledgers.
If contractually agreed, In Charge representative will carry out source inspection according to PPF’s Quality System requirements.
The Store Department performs inspection/testing of incoming materials by either of the following:
• Receiving inspection and testing.
• Receipt and evaluation of statistical data.
• Second party or third party assessments or audits.
• Part evaluation by an accredited lab.
The Central Stores staff/user will check and verify the quantity and condition of the items/materials received, record the inspection results onto GRN. The Quality Control Department/user/Central Stores staff identifies the inspection status on the inspected item using green or red tags for quality inspection pass or fail respectively. For information on reactions to unsatisfactory incoming inspection results see the Control of Nonconforming Product Procedure (QP-4.13).
If the product is ever to be released without verification, it is positively identified using a blue identification tag. Approval for release is sought from HoD in the form of an internal memorandum or verbal a copy of which is sent to Stores and the issuing department. The memo is recorded for a period of 3 years.
3.4 In-Process Inspections
Inspection will be done totally in accordance to the inspection stages and requirements set in the Product Specification. Where required by customer or by specification, specified hold points and inspection or test points are identified. The appointed staff from concerned production department is responsible for carrying out the inspection of in-process material as a routine. Production supervisor inspects the start sample pieces for compliance to the product specifications and Quality Inspector approves and signs the inspection results. If the product sample is found rejected, then readjustment is carried out and the procedure repeated.
3.5 Final Inspection and Testing
Final inspection will be carried out as per relevant Product Specification. In charge HOD’s will scrutinize the test reports against the Product Specification. The sampling frequency for this final inspection can vary depending on the work order. HOD’s will check the samples.
The Product Specification Sheet ensures that all the required inspection and testing activities have been performed on the product and shows whether the product complies with the results or not.
To prevent the products from dispatch until the specified inspection/testing is performed and results meets the requirements and records are maintained, Central Stores are to ensure that the product is affixed with the approval from QA&C department.
In Charge QA&C is responsible for holding products until the required final test is complete where possible.
3.6 Final Test Results
The Quality Control department will apply green/red tag on the product indicating the product status at final test result. Re-inspection and re-testing may be applied on the defective product after rework where applicable or as contractually agreed upon with the customer.
Final inspection and testing will be performed and controlled by personnel of the Quality Control department only. The In Charge after approving the final inspection results shall inform the Central Stores through an internal memorandum as the go-ahead signal to deliver the accepted products. No product will be dispatched until all specified inspection/test activities have been performed and results are available and authorized.
Nonconforming products are held in a specified and legibly identified area by the Central Stores department.
3.7 Training
Inspectors receive training to verify processes and products. Training records are kept in the Administration and Human Resource Administration Department for whole length of service.
3.8 Inspection and Test Records
In Charge QA&C will keep final test reports for 5 years in addition to the year in which it was produced. For inspection and testing the basic requirements are: the Product Specification Sheet, inclusion of inspection points in the Product Specification Sheets and timely intimation to the relevant production personnel of the product requirements.
QA&C department maintains the pertinent inspection records. Some copies may be kept with the relevant section heads.
Against each test the results are given in comparison to the required parameters and consequential result. The report contains in the end the over all summary of the final testing, which will clearly identify the pass/fail situation of the product.
Approval for the Delivery Chalan for dispatch is issued by In Administration Manager.
3.9 Accredited Labs
The external Labs are only used to calibrate the master equipment. Due to lack of accredited labs is Pakistan, it is ensured that Lab is at least certified to ISO 9000 and customer is informed accordingly.