AS-IS & TO-BE REPORT

QUALITY CONTROL DEPARTMENT

Damodar Valley Corporation

KPMG, KOLKATA
 QUALITY MANAGEMENT
As-Is Business Processes:
Name of the Function Process Name/ Description Platf orm/ Application Used
Boiler water sample Manual
DM make up sample Manual
Main steam sample Manual
CEP discharge sample Manual
D/A outlet sample Manual
Eco inlet sample Manual
Stator/ Primary water system Manual
DMCW sample Manual
ECW (B)/ ECW(T) Manual
Water Lab (Testing Raw water Manual
Module) Clarif ied Water Manual
Filter Water Manual
CW Make up water Manual
CW water sample Manual
ETP I/L sample Manual
ETP O/L sample Manual
PH drain I/L sample Manual
PH drain O/L sample Manual
Hydrogen gas purity Manual
Hydrogen gas dew point Manual
CBD Manual
IBD Manual
HP dosing Manual
Suggestion
LP dosing Manual
DP restriction Manual
Cooling Water Manual
Loading end samples Manual
Coal Lab Mill Fineness Manual
Combustible Manual
DM water production Manual
DM water consumption Manual
Generation consumption Manual
Stator water consumption Manual
Other Data ECW/ DMCW consumption Manual
Drain Tank Manual
Preservation Manual
Lit Up Manual
DM Make up (M3) Manual
Preparation & finalization of QAP in consultation with user
Quality Assurance Plan Manual
section
 Name of the Function Process Name/ Description Platf orm/ Application Used
Implementation of QAP at material inspection process at
Manual
site
Reviewing of QAP of Purchase Orders Manual
Preparation of QAP for preventive & breakdown
Manual
QAP f or Routine maintenance
Maintenance Monitoring of maintenance practice as per QAP Manual
Archiving of maintenance history for plant equipment Manual
Monitoring of QAP for Checking of compliance of QAP for capital/construction
Manual
on- site activity works
Pre-dispatch Inspection Conducting pre dispatch inspection Manual
process Preparation of inspection reports Manual
Pre dispatch inspection process at factory and issuance of
MDCC on acceptance of materials for which consignee is Manual
Controller of stores
Pre-Dispatch Inspection
at Factory Pre dispatch inspection process at factory and issuance of
MDCC on acceptance of materials for which consignee is Manual
not Controller of stores. The turn key projects are included
here
Incorporation of quality chapter in tendering stage Manual
Quality Control &
Approval of MQP & FQP on award of contracts Manual
Inspection
Issuance of Protocol Manual
Journey approval for Pre-dispatch inspection and
Journey approval Manual
acceptance testing etc.
Preparation of QA section of contract Manual
Vetting of QA specification in digital platform Digital
Review of QA section Reviewing of Quality plan for EPC contract Partially Digital
Categorization of Quality plan as CAT-I, CAT-II, CAT-III,
Partially Digital
CAT-IV
Verif ying item category and manufacture mapping Partially digital
Quality plan compliance Preparation of inspection plan Partially digital
Preparation of quality plan Partially digital
Inspector nomination against call raised from vendor Partially digital
Inspection scheduling Partially Digital
Inspection
Preparation& verification of inspection reports Partially digital
Issuance of MDCC Partially Digital

Document digitization Archiving of drawings, quality plans, test reports, MDCC Partially Digital

Electrical Commissioning Job of the Function Manual

Relay Testing and Maintenance Job at site Manual

Relay Testing at CRITL Lab Manual
CTC Activity Investigation of Fault Manual
Transf ormer Oil Testing Manual
Meter Testing Activity Manual
Commissioning of Metering System Manual
Investigation of fault in Metering system Manual
To-Be Business Processes:

Name of the
Process Name/ Description ERP Module
Function
Defects found during a quality inspection are analysed and
captured
Record the root cause analysis of the problems found during
inspection to avoid its re-occurrence
Raising internal quality notification and record the problem
analysis Quality
Quality Notification
A defect record is activated as a quality notification during a Notification
quality inspection
Notification about the outstanding tasks as soon as tasks are
created in the notification and the notification is saved
Notification about the completed tasks as soon as tasks are
created in the notification and the notification is saved

Basic master data for Quality Management:

# Material Master
# Quality info record, sampling scheme/procedure, dynamic
modification rule
# Catalogue Code groups
# Master inspection characteristics, batch master
# Inspection plans, BOM, Routings, quality certificate profiles
Inspection planning using inspection plans of materials, which
brings standardization of quality planning
The system can automatically create inspection lots in the
background (for example, when a goods receipt is posted for a Quality
Quality Planning
material that needs to be inspected) Engineering
If the system creates an inspection lot for a material that has to
be inspected on the basis of a task list, the system must be able
to find and assign the proper task list to the inspection lot
If the system cannot explicitly select and assign a task list, the
inspection lot cannot be released for the inspection. In this
case, the inspection lot it will not appear in the work list for
results recording
Categorization of Quality plan
Stability study / shelf-life study

Source Inspection
Scheduling Inspection
Inspector nomination against call raised from vendor
Inspection for Stock transfer
Pre-Dispatch and Pre-Dispatch and
Recurring inspection of batches
Quality Inspection Quality Inspection
Inspection for delivery to customer
Inspector nomination against call raised from vendor
Inspection for Good Receipt
Pre-Dispatch Inspection
Name of the
Process Name/ Description ERP Module
Function
Reports for Pre-Dispatch inspection (PDI)
Clearance of Pre-Dispatch inspection test reports
Journey approval for Pre-dispatch inspection and acceptance
testing
Pre dispatch inspection process at factory and issuance of
MDCC on acceptance of materials

Quality inspection is performed through inspection lot

processing.
Process quality results to be captured, and usage decision is
taken to accept or reject the inspection lot
Quality certificates of analysis
Quality inspections and statistical process control
Preparation & finalization of QAP in consultation with user
section
Quality Assurance Implementation of QAP at material inspection process at site Quality Assurance
Reviewing of QAP of Purchase Orders
Preparation of QAP for preventive & breakdown maintenance
Monitoring of maintenance practice as per QAP
Archiving of maintenance history for plant equipment
Monitoring of QAP for on- site activity for capital/construction
works
Preparation and vetting of QA section of contract

Quality notifications the root cause analysis is done for the

identified defect
Information system is where one can analyze various reports
like vendor evaluation, a list of quality notification, quality
charts, etc.
Quality Control Process control along the complete supply chain Quality Control
Approval of MQP & FQP on award of contracts
Issuance of Protocol for control and inspection
Verifying item category and manufacture mapping
Quality chapter in tendering stage

Problem management
Quality
Quality Improvement Quality Information System
Improvement
Corrective and preventive actions