K G DENIM LIMITED

(Mechanical Engineering)

IMS DEPARTMENT MANUAL

DEPARTMENT : Mechanical Enigneering

PREPARED BY : T.Nagaraj / R.Sethuram

REVIEWED & APPROVED By : N.Jaganathan

KG DENIM LTD – Mech.Engg IMS DEPARTMENT MANUAL

TABLE OF CONTENTS

SECTION DESCRIPTION

A Table of contents

B Revision record sheet

C Master index

D Distribution list

E Department procedures

O.O List of work instructions/ job descriptions/ other documents

1.O List of quality formats/ check lists/ exhibits/ flow charts

2.O Record master index

3.O Documents master index-level -III

4.O List of standards

5.O List of abbreviations

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 KG DENIM LTD– Processing Division IMS DEPARTMENT MANUAL

REVISION RECORD SHEET

DATE SECTION CHANGE DETAILS REVISION APPROVED BY

FROM TO

SECTION :B PAGE 1 OF 3
 KG DENIM LTD IMS DEPARTMENT MANUAL

MASTER INDEX

SECTION No. OF PAGES ISSUE REVISION

A 1 B 1

B 3 B 3

C 1 C 4

D 1 B 1

E 1 B 2

O.O 1 C 3

1.O 2 B 4

2.O 3 C 1

3.O 1 C 2

4.O 1 B 1

5.O 1 B 1

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 KG DENIM LTD IMS DEPARTMENT MANUAL

DISTRIBUTION LIST

Distribution - MR

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KG DENIM LTD IMS DEPARTMENT MANUAL

LIST OF WORK INSTRUCTIONS / ROLES,RESPONSIBILITY,AUTHORITY and ACCOUNTABLITY/ OTHER DOCUMENTS

I. LIST OF WORK INSTRUCTIONS

S.NO TITLE NAME DOCUMENT NO TOTAL PAGES
1 WORK INSTRUCTION FOR FITTERS WI/001/ENGG 1 OF 1
2 WORK INSTRUCTION FOR GEAR BOX OIL CHANGING WI/003/ENGG 1 OF 1
3 WORK INSTRUCTION FOR ROLLER CHANGING WI/004/ENGG 1 OF 1
4 WORK INSTRUCTION FOR BEARING CHANGING WI/006/ENGG 1 OF 2
5 WORK INSTRUCTION FOR RUBBER BELT GRINDING WI/007/ENGG 1 OF 6
6 WORK INSTRUCTION FOR EMEREY CHANGES WI/008/ENGG 1 OF 1
7 WORK INSTRUCTION FOR RUBBER BLANKET CHANGING WI/009/ENGG 1 OF 2

II.LIST OF ROLES, RESPONSIBILITY,AUTHORITY AND ACCOUNTABILITY

1 RRA&AGM-ENGENEERING IMS/DOC/001/ENGG 1 OF2
2 RRA&A for ASSISATANT MANAGER IMS/DOC/002/ENGG 1 OF 2
3 RRA&A for FITTRS IMS/DOC/004/ENGG 1 OF 2

III. OTHER DOCUMENTS

1 DEPARTMENT OBJECTIVES IMS/DOC/005/ENGG 1 OF 1
2 LIST OF MEASURING &TEST EQIUPMENTS DOC/002/ENGG 1 OF 1
3 LIST OF INDICATORS DOC/003/ENGG 1 OF 9
4 DEPARTMENT ORGANISATION CHART DOC/004/ENGG 1 OF 1
5 LIST OF MACHINARIES DOC/011/ENGG 1 OF 1
6 RUBBER ROLLERS IDENTIFICATION DOC/013/ENGG 1 OF 3
7 COMPETENCY & SKILL MATRIX DOC/009/ENGG 1 OF 1
8 TRAINING MANUAL DOC/006/ENGG
9 PREVENTIVE MAINTENANCE SCHDULE DOC/014/ENGG 1 OF 7
10 PREVENTIVE MAINTENANCE SCHDULE IN LAB MACHINE DOC/015/ENGG 1 OF 4
11 LIST OF MACHINARIES AIR REQUIREMENT DOC/016/ENGG 1 OF 1
13 LIST OF INTERNAL ISSUES DOC/017/ENGG 1 OF 1
14 LIST OF EXTERNAL ISSUES DOC/018/ENGG 1 OF 1
15 LIST OF INTERESTED PARTIES DOC/019/ENGG 1 OF 1
16 LIST QUALITEY RISK ASSESMENT DOC/020/ENGG 1 OF 1

II.EMS DOCUMENTS ORGINATING FROM THE DEPARTMENT

1 DO'S & DON'T FOR FITTERS ESP 0402/DC/001/ENGG 1 OF 1
2 SAFETY PROCEDURES ESP 0402/DC/002/ENGG 1 OF 1
3 PROCEDURE FOR DISPOSAL OF USED OILS AND BIO PRODUC
ESP 0406A/DC/001/ENGG 1 OF 1
4 LIST OF PERSONNEL PROTECTIVE EQUIPMENTS ESP 0407/DC/002/ENGG 1 OF 1

III. EMS DOCUMENTS ORGINATING FROM THE OTHER DEPARTMENT

1 List of environmental aspect*** ESP 0301/DOC/001 1 OF 1
2 List of significant environmental aspects*** ESP 0301/DOC/002 1 OF 1
3 List of legal and regulatory requirements*** ESP 0302/DOC/001/PER 1 OF 1

V.LIST OF DOCUMENTS RECEIVED FROM OTHER DEPARTMENT

1 LIST OF LAB MACHINARIES DOC/005/ APP -LAB 1 OF 2
2 YEARLY AUDIT SCHEDULE DOC/001/ QMR
3 MEASURING & TEST EQUIPMENTS CALIBRATION REPORT( INT DOC/011/ PP 1 OF 8

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KG DENIM LTD – Processing division IMS DEPARTMENT MANU

RECORD MASTER INDEX

III. OH&S RECORDS ORIGINATING FROM THE DEPARTMENT
1 HIRA (Hazard identification and risk assessment record)*** OHS/001/ENGG
2 Incident & Accident & Unsafe condition & Unsafe activities OHS/002/ENGG
IV. RECORD RECEIVED FROM OTHER DEPARTMENT
1 Audit Summary QF/001/QMR
2 Non Conformance audit Report QF/002/QMR
3 Minutes of Management Review Meeting * QF/004/QMR
4 Audit plan * QF/005/QMR
5 Corr & Pre-Action Meeting Minutes * QF/006/QMR
6 production meeting minutes * QF/007/QMR
7 EHS Review meeting minutes QF/008/QMR
8 House keeping audit report QF/009/QMR
9 Safety audit report ESP / 0407 / CL / SAFETY

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IMS DEPARTMENT MANUAL

*** MR
3 MONTHS NIL

6 months -
6 months Rel. Depts
All Depts/
1 Year
sr.Managers
6 months Rel. Depts
2 months -
All Depts/
6 months
sr.Managers
6 months MR
House keeping
6 months
Leader
Health and
6 months
safety members

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KG DENIM LTD – Processing division IMS DEPARTMENT MANUAL

DOCUMENT MASTER INDEX

CURRENT
S.No TITLE NAME DOCUMENT No
ISS./REV.
I LIST OF WORK INSTRUCTION
1 WORK INSTRUCTION FOR FITTERS WI/001/ENGG A/0
2 WORK INSTRUCTION FOR GEAR BOX OIL CHANGING WI/003/ENGG A/0
3 WORK INSTRUCTION FOR ROLLER CHANGES WI/004/ENGG A/0
4 WORK INSTRUCTION FOR BEARING CHANGES WI/006/ENGG A/0
5 WORK INSTRUCTION FOR RUBBER BELT GRINDING WI/007/ENGG A/0
6 WORK INSTRUCTION FOR EMEREY CHANGES WI/008/ENGG A/0
7 WORK INSTRUCTION FOR RUBBER BLANKET CHANGE WI/009/ENGG A/0
II.LIST OF ROLES RESPONSIBILITY,AUTHORITY AND ACCOUNTABILITY
1 RRA&AGM-ENGENEERING IMS/DOC/001/ENGG A/0
2 RRA&A for ASSISATANT MANAGER IMS/DOC/002/ENGG A/0
3 RRA&A for FITTRS IMS/DOC/004/ENGG A/0
III OTHER DOCUMENTS
1 DEPARTMENT OBJECTIVES IMS /DOC/005/ENGG A/4
2 LIST OF MEASURING &TEST EQIUPMENTS DOC/002/ENGG A/1
3 LIST OF INDICATORS DOC/003/ENGG A/2
4 DEPARTMENT ORGANISATION CHART DOC/004/ENGG A/3
5 LIST OF MACHINARIES DOC/011/ENGG A/3
6 RUBBER ROLLERS IDENTIFICATION DOC/013/ENGG A/0
7 COMPETENCY & SKILL MATRIX DOC/009/ENGG B/0
8 TRAINING MANUAL DOC/006/ENGG A/0
10 PREVENTIVE MAINTENANCE SCHDULE DOC/014/ENGG C/0
11 PREVENTIVE MAINTENANCE SCHDULE IN LAB MACHINE DOC/015/ENGG C/0
12 LIST OF MACHINARIES AIR REQUIREMENT DOC/016/ENGG C/0
13 LIST OF INTERNAL ISSUES DOC/017/ENGG A/0
14 LIST OF EXTERNAL ISSUES DOC/018/ENGG A/0
15 LIST OF INTERESTED PARTIES DOC/019/ENGG A/0
16 LIST QUALITEY RISK ASSESMENT DOC/020/ENGG A/0

II. EMS DOCUMENTS ORIGINATING FROM THE DEPARTMENT

1 DO'S & DON'T FOR FITTERS ESP 0402/DC/001/ENGG A/0
2 SAFETY PROCEDURES ESP 0402/DC/002/ENGG A/0
3 PROCEDURE FOR DISPOSAL OF USED OILS AND BIO PRODUCTS ESP 0406A/DC/001/ENGG A/1
4 LIST OF PERSONAL PROTECTIVE EQUIPMENTS ESP 0407/DC/002/ENGG A/1

III. EMS DOCUMENTS ORIGINATING FROM THE OTHER DEPARTMENT

1 List of environmental aspect ESP 0301/DOC/001 ***
2 List of significant environmental aspects *** ESP 0301/DOC/002 ***
3 List of legal and regulatory requirements *** ESP 0302/DOC/001/PER ***

V.DOCUMENTS RECEIVED FROM OTHER DEPARMENTS

1 LIST OF LAB MACHINARIES DOC/005/ APP -LAB A/0
2 YEARLY AUDIT SCHEDULE DOC/001/ QMR A/0
3 MEASURING & TEST EQUIPMENTS CALIBRATION REPORT( INTERNAL) DOC/011/ PP A/0

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ARTMENT MANUAL

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KG DENIM LTD – Mech.Engg IMS DEPARTMENT MANUAL

LIST OF FORMATS / EXHIBITS

CURRENT
SL.NO TITLE NAME FORMAT NUMBER
ISSUE/REV
I QUALITY FORMATS
121 PREVENTIVE MAINTENANCE PROGRAMME FOR PEACHING QF/051/MECH
122 PREVENTIVE MAINTENANCE PROGRAMME FOR CALEDARING QF/052/MECH
123 PREVENTIVE MAINTENANCE PROGRAMME FOR SOFT FLOW / DRYER QF/053/MECH
124 PREVENTIVE MAINTENANCE PROGRAMME FOR JIGGER QF/054/MECH
125 PREVENTIVE MAINTENANCE PROGRAMME FOR INSPECTION / PACKING QF/055/MECH
126 PREVENTIVE MAINTENANCE PROGRAMME FOR CAUSTIC RECOVRY PLANT QF/056/MECH
127 PREVENTIVE MAINTENANCE PROGRAMME FOR LAB MACHINES QF/057/MECH
128 PREVENTIVE MAINTENANCE PROGRAMME FOR MATERIAL HANDLING EQUIPMENTS QF/058/MECH
129 PREVENTIVE MAINTENANCE PROGRAMME FOR TERRY INSPECTION QF/059/MECH
130 PREVENTIVE MAINTENANCE PROGRAMME FOR POLYMERIZER (CURRING) QF/060/MECH
131 PREVENTIVE MAINTENANCE PROGRAMME FOR STENTER ( HARISH ) QF/061/MECH
132 PREVENTIVE MAINTENANCE PROGRAMME FOR LOPPAGER QF/062/MECH
133 FITTER'S LOG BOOK QF/063/MECH
134 CHANGE OF SPARES RECORD QF/064/MECH
135 BREAK DOWN RECORD QF/065/MECH
136 USED OIL & OIL WASTE QF/066/MECH
137 TRAINING MANUAL CHECK LIST QF/067/MECH

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KG DENIM LTD IMS DEPARTMENT MANUAL

LIST OF STANDARDS
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 KG DENIM LTD IMS DEPARTMENT MANUAL

DEPARTMENT PROCEDURES

QMS

OPM – 11

EMS
SYSTEM PROCEDURE & MANUALS AVAILABLE IN P – DRIVE

OHSAS
SYSTEM PROCEDURE & MANUALS AVAILABLE IN P – DRIVE

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 KG DENIM LTD MSDEPARTMENT MANUAL

LIST OF ABBREVIATIONS

RRA&A – Roles, Responsibility. Authority and Accountability

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 COMP

KG DENIM LTD – PROCESS DIVISION DOC/009/ENGG

COMPETENCY NEEDS

DEPARTMENT : SATHYABAMA MILLS – ENGINEERING

CADRE : FITTER

EYE SIGHT : 6/6 NORMAL

HEALTH DETAILS : NORMAL HUMAN HEALTH

QUALIFICATION : MIN.ENGG ITI / DIPLOMA

PREVIOUS EXPERIANCE : ABOVE THREE YEARS EXPERIENCE IN ENGINEERING DEPARTMENT

GENDER : MALE

AGE LIMIT : MIN.22

HEIGHT : MIN.155 CMS

WEIGHT : MIN.60 KG

SKILL ITEMS ( MUST BE GAINED BY THE EMPLOYEE BEFORE PUT

SL.NO INTO THE JOB )

1 INTRODUCTION OF OUR COMPANY & RULES AND REGULATION

2 ISO 9001 : 2008, EMS 14001 & OHSAS 18001

3 ELECTRICAL WIRING & MAINTENANCE

4 COMMUNICATION SKILL

SL.NO KNOWLEDGE ITEMS

1 MACHINE KNOWLEDGE

2 BASIC KNOWEDGE IN MECHANICAL RELATED WORKS

3 MACHINE MAINTENANCE

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 KG DENIM LIMITED ENGINEERING DEPARTMENT

INTEGRATED MANAGEMENT SYSTEM

DEPARTMENT OBJECTIVE STATUS

SBM ENGINEERING

ISO 9001:2015 TARGET

SL.NO OBJECTIVE CURRENT LEVEL 2017-18

TO REDUCE THE
BREAKDOWNS WHILE
1 RUNNING THE MACHINES
( BOTH ELECTRICAL AND
MECHANICAL )

( A ) PRETREATMENT 2 – 5 PER MONTH LESS THAN 2

( B ) DYEING 0 – 3 PER MONTH LESS THAN 2

( C ) FINISHING 0 – 4 PER MONTH LESS THAN 2

EMS 14001:2015 TARGET

SL.NO OBJECTIVE CURRENT LEVEL 2017-18

TO REDUCE THE LEAKAGES IN

THE MACHINARIES AND ITS
SURROUNDINGS. LEAKAGES
INCLUDES
CHEMICALS,WATER,AIR,STEA
1 M,THERMIC FLUID AND OILS AVG OF 8 - 10 OCCURENCES PER MONTH LESS THAN 5

OHSAS 18001:2007 TARGET

SL.NO OBJECTIVE CURRENT LEVEL 2017-18

1 ACCIDENT LEVEL 0 – 2 PER YEAR LESS THAN 0

REDUCING THE NO . OF
2 UNSAFE ACTIVITIES 0 – 2PER MONTH LESS THAN 1

REDUCING THE NO / .OF

3 UNSAFE CONDITIONS 3 – 5 PER MONTH LESS THAN 3

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