Process Control Procedure
1 Purpose
• To carry out production under controlled conditions.
• To ensure availability of information for production processes to relevant personnel at all times.
• To maximize opportunity for a quality product where resulting output of a process cannot be verified by subsequent monitoring.
2 Supporting Documents
Quality Manual of PPF, Section 6.3, 6.4, 7.5.1, 7.5.2
ISO 9001:2008 Manual, Section 6.3, 6.4, 7.5.1, 7.5.2
Process Flow Diagrams
Daily Production Report (PRD-4-001)
3 Procedure
3.1 Infrastructure
The current infrastructure fulfills the requirements of PPF in terms of building, work place, process equipment etc. In future if need arises then it will be discussed in management review meetings. Side by side, Management Representative will keep planning development projects for PPF to achieve enhanced conformity to product requirements.
3.2 Work Environment
Management Representative is responsible to make a list of all that requires any special work environment like temperature, humidity etc. Each departmental head is responsible to maintain the work environment. They are also responsible to take the corrective action if required environment is not achieved. Currently no special requirements are the need of a production unit.
3.3 Control of Production and Service Provision
PPF has identified and planned the production processes to ensure the quality of product. All the processes are carried out according to documented Work Instructions. It is also ensured that proper equipment and machinery is available for all the processes performed.
Different records have been established to provide a clearer perspective of the production of some of the mass produced products at PPF. These include:
• Process Flow Diagrams for Flanges, and Tooling produced for PPF
• Daily Production & Docket Sheets of all the variety of operations at different sections of PPF
Preventive maintenance of all the machines and equipment is carried out according to preventive maintenance schedule. This is to ensure availability of precise equipment for production of conforming products.
3.4 Production Initiation and Monitoring
3.4.1 Batches Breakup and Control
Products to be sent under production will first be analyzed by PM for the breakup required to distribute the products into batches that would move on the production shop floor at maximum efficiency with easy control.
3.4.2 Initiation of Production
PM shall brief Process for the product (or every type of product if more than one) in the docket. The Film will identify the Job details, batch size to be employed, batch number, and docket contain all detail with unique number. A copy of the Scan film defining the process sequence will be sent for every batch to the initiating production section. That production section will in turn attach a Product Identification docket to the batch in accordance to the details, and write the DOCKET number on the Process for traceability. The batch will be controlled as a whole when under production and will never be broken up when forwarded to the next production process. Upon delivery of the product, the Process will be accordingly completed and returned to the Production department for record keeping.
3.4.3 Daily Progress Record
Daily Progress Reports (PRD-4-001) have been designed to keep a record of day to day production activities taking place at different production departments. One working shifts are employed at Machine at printing Shop whereas only one working shift is employed at the rest of the production departments. Two copies of a DPR are prepared for a by production section. One is kept by the section while the other is submitted to the PPC department at the beginning of the next working day.