CENTURION POWER CABLES PVT. LTD.

DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE

CPC-QPM-12 Title : Procedure on Purchase 01 / 00 15.07.2020

1.0 PURPOSE

To evolve procedure for evaluation and selection of supplier based on their ability to
meet Quality System requirements of CENTURION POWER CABLES PVT. LTD.. to
specify and steps to be taken to initiate purchasing action.

2.0 SCOPE

Applicable to

a) RM Purchase
b) Machinery spares
c) Supplier sub-contract /packing material purchase
d) Transporter/Consumables Purchase
e) Maintenance and calibration services.
f) Other Service providers

3.0 RESPONSIBILITY

Purchase in charge.

4.0 PROCEDURE DETAILS

Method A: On-site evaluation of supplier and other Quality system
In this method supplier evaluation is done jointly by Purchase In charge / Quality

In charge or their representative. During the visit the supplier facilities and Quality
Systems are examined. Results of the assessment are reported on “Supplier Audit
Checklist”.. when the result of the evaluation is satisfactory, the
supplier will be included in the approved Supplier list. This method is followed only for
process activity.

Method B: Past history with similar supplies

In this method Purchase department will verify that the identified supplier has supplied
similar items in the past. After verification, purchase department seek approval by
Quality Incharge. If he approves the item, the supplier is included in the approved
supplier list.
Method C: Experience of other users
In this method suppliers are selected by purchase department based on their reputation

(Ex Branded items) (or) Experience of other users, such suppliers will be included in the

approved Supplier list.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-12 Title : Procedure on Purchase 01 / 00 15.07.2020

Evaluation of the Vendors is done on the basis of Quality of products supplied, Delivery period
maintained and Price offered by them, at least once every year, on the basis of QC,
Purchasing and Storage record. A weight age factor of 45,35 & 20 percent is given to Quality,
Delivery and Price respectively and vendor rating is given to each vendor depending upon his
performance. Supplier with more than 80% are preferred, those between 60-80% are put on
caution and those below 60% are discontinued Grades A/B/C are given respectively on the
basis of their performance. Records are maintained by PURCHASE HEAD in Evaluation of
Vendor Form (F-3/8.4)

No need to do Supplier Evaluation or assessment if supplier is Reputed nationally or

internationally.

APPROVED SUPPLIERS LISTING

The “Approved supplier list” PUR./F-1/8.4 is maintained by Purchase Incharge. Any addition /
deletion to the list of approved supplier is to be authorised by QC Manager /Plant Manager

MONITORING OF SUPPLIERS

Supplier appraisal / Monitoring of Supplier

Supplier rating is done once in three months in the form no.Pur./F-3/8.4 SUPPLIER
EVALUATION FORM to monitor the performance of the supplier for both quality and delivery
time & Cost/Price. Quality rating will be calculated for 50% and Delivery rating for 50%. The
formula for supplier rating is as detailed in the form F/PUR/04.

Supplier processes / activity

The following controls are to be exercised on supplier who carries out subcontract activity. The
selection of supplier shall be by method ‘A’. The technical requirement will be communicated
through Purchase Order Pur./F-2/8.4 (or) in a separate technical requirement in controlled
status. If there is a revision to technical requirement, revised requirement will be sent to
supplier.

CUSTOMERS VERIFICATION AT SUPPLIER END

As and when required, if customers demands for verification of supplier premises than suitable
arrangement to be made to arrange the customers visits at supplier premises. CPCwill initially
define such condition in purchase order that if required than supplier will have to demonstrate
the process to customers.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-12 Title : Procedure on Purchase 01 / 00 15.07.2020

De-listing of supplier

In the event of supplier rating of all items falling below 80% (for both Quality and Quantity
rating), purchase department will communicate to the supplier concerned regarding the rating
and advise them to improve the performance. Where appropriate, purchase department will
decide on inviting the supplier for discussion.

event of supplier rating of an item falling below 80% for consecutively 3 times, supplier will be
de-listed for the particular item in the form no Pur./F-3/8.4

There will be no supplier rating for consumable items and machinery spares. Based on quality
complaints raised by the user department, the purchase department will inform the supplier to
take corrective action. If quality problem persists inspite of the advice, the supplier will be de-
listed.

In respect of single source supplier the de-listing may not be possible. In such case sorting or
reworking of the materials will be carried out to ensure conformance

REAPPROVAL OF SUPPLIERS

The delisted supplier may be considered for re-approval for a particular item under the following
condition only.
The supplier should take corrective action and submit a report.

The adequacy of the corrective action is to be scrutinized and accepted by Quality Manager.

PURCHASING PROCESS / ACTION

Purchasing requirements are communicated to purchasing department through following ways :

Format “MATERIAL REQUIREMENT – AS PER THE WEEKLY / MONTHLY SCHEDULE

FROM THE PRODUCATION DEPT.” is received at purchasing department.

Store Incharge reviews the stock level on daily basis and checks that if material is reached
below inventory level than Indent is raised by store department to purchase depart for
purchasing the material.

Purchase order in the form of Pur./F-2/8.4 is made with approved supplier.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-12 Title : Procedure on Purchase 01 / 00 15.07.2020

Amendment to purchase orders are to be issued to supplier where required. The amendment to
purchase order will be reviewed by Purchase Manager.
Amended purchase order and original purchase order are maintained.

MACHINERY SPARES FOR PREVENTIVE MAINTENANCE

Based on the requirement order for machinery spares will be raised on original manufacturer of
the equipment as and when required.

CONSUMABLE ITEM

Based on the requirement consumable items are procured by the Purchase Incharge. There
will be no supplier rating for consumables.

EMERGENCY PURCHASE

To meet emergencies such as supply failure by the approved supplier, procurement can be
made from the supplier who is not in the approved supplier list. This will be authorized by
Director/GM.

6.0 RECORDS

6.1 Supplier Selection Questionnaire PUR/F-1/8.4

6.3 Approved Supplier List PUR/F-3/8.4
6.4 Purchase order & Amendment to Purchase order PUR/F-4/8.4
6.5 Supplier Rating Form PUR/F-5/8.4

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-13 Title : Procedure on Production Planning 01 / 00 15.07.2020

S.N Activity Responsibility Reference Dept.

1. Obtain delivery schedule of the forthcoming month Production Delivery schedule
from the Customer. Incharge

2 Based on Plan/Schedule, prepare the “Material Production Material

requirement form- As per weekly /monthly schedule Incharge Requirement Form
from production department”
3. On daily basis, Check the availability of raw material Production Daily Stock Sheet
through “Daily stock sheet” Incharge
4. Keeping the production plan and delivery schedule of Production Daily Schedule/
the month in view prepare the Daily schedule status Incharge Status
5. In case of material is not available for the production Production Daily Schedule
then amend the production plan at Daily Incharge /Status
Schedule/Status.
6. If the customer wants amendment in the schedule of Production Daily
supply, amend the production schedule and inform Incharge Schedule/Status
the related department, regarding changed
requirement for manufacturing of products.
7 Provide applicable working drawing OR specification Production Specification
to operators. Incharge
8. Ensure operators are competent to manage the Production
machine setting. Supervisor
9. If operators are not competent for machine setting Production
then send request to MR for arranging on the job Supervisor
training to the operator.
10. Issue the “Material issue slip” to store department for Production Material Issue Slip
arranging the material. Supervisor
11. Receive the material from store department and Production
keep properly at suitable place. Supervisor
12 Check what processes are required for Production
manufacturing of product through process flow chart Supervisor
of product

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-13 Title : Procedure on Production Planning 01 / 00 15.07.2020

16 Intimate the Operators about next stage of process Production

Supervisor
17. Operate the machine as per applicable work Operator
instructions and follow the specification define in
working drawing.
18. Initially produce approximately 4 pieces and got Q.C. Operator /Q.C Inprocess
Department approval. Inspector/ Inspection Sheet
Production
Supervisor
19. If all 4 pieces are acceptable then continue the Operator /
production. Production
Supervisor
20. If any single piece is found unacceptable by the Q.C. Operator/
Department, then verify the process parameters and Production
again produce 4 pieces and got approval of Q.C Supervisor
Department.
21 On the end of day, production supervisor updates Production O.Q.C Packing
the production/packing status in O.Q.C Packing Supervisor Format
Format
22 Based on O.Q.C Packing Format, purchase Incharge Production Daily
update the Daily Schedule/Status supervisor / Schedule/Status
Production
Incharge

Records

Monthly Production Plan

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 CENTURION POWER CABLES PVT. LTD.
DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-14 Title : Procedure for Customer Satisfaction Level 01 / 00 15.07.2020

1. OBJECTIVE

To monitor information on customer perception and their level of satisfaction.

2. SCOPE

This covers all customers of the CPC.

3. RESPONSIBILITIES

Incharge Quality is responsible for satisfactory operation of this procedure.

4. PROCEDURE

4.1 Measurement and monitoring of customer satisfaction is based on review of customer

related information. The collection of such information may be active or passive. The CPC
management has recognized that there are many sources of customer related information
and has established effective and efficient processes to collect analyze and use this
information for improving performance. The E&ASPL. has identified sources of customer
information available in written and verbal forms, from internal and external sources.
4.2 The customer-related information includes:
a) Customer and user surveys;
b) feedback on aspects of product,
c) customer requirements and contract information,
d) market needs for CPC products,
e) service delivery data, and
f) information relating to competition in the market place..
4.3 CPCmanagement uses measurement of customer satisfaction as a vital tool for
improvement. The CPCprocess for requesting, measuring and monitoring feedback of
customer satisfaction provides information on a continual basis. This process considers
conformity to requirements, meeting needs and expectations of customers, as well as price
and delivery of product.
4.4 The CPChas established and uses sources of customer satisfaction information and
cooperates with its customers in order to anticipate future needs. The CPCplans and
establishes processes to listen effectively and efficiently the “voice of the customer”.
Planning of these processes define and implement data collection methods, including
information sources, frequency of collection, and data analysis review

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-14 Title : Procedure for Customer Satisfaction Level 01 / 00 15.07.2020

4.5 Sources of information on customer satisfaction include:

a) customer complaints
b) communication directly with customer,
c) questionnaire and surveys,
d) contracted collection and analysis of data
e) focus groups,
f) reports from consumer groups,
g) reports in various media, and
h) sector and industry studies.

RECORDS

Customer satisfaction data

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-15 Title : Procedure on Work Environment 01 / 00 15.07.2020

MAINTAINING SUITABLE WORKING ENVIRONMENT

1.0 PURPOSE : To maintain safe & clean work environment.

2.0 SCOPE : . All work locations

3.0 RESPONSIBILITY : Plant Head

4.0 PROCEDURE :

Sr.N Activity Responsibility Document/Record

o

1 Provide fire extinguishers, wherever required, Prod.Sup. List of Fire

Extinguishers
after giving consideration to the operations

carried out.

2 Prepare a list of fire extinguishers by identifying Maint. Head

location, last filling date and due date of refilling.

3 Identify the fire extinguishers with sticker, with Maint. Head

due date of refilling.

4 Provide first aid box at work place so as to HR Head Contents of First Aid

provide immediate aid in case of an accident.

5 Review the contents every month and replenish Prod.Sup.

the quantities. Verify sticker on the box.

6 Prepare list of all applicable laws to the Plant Head List of Applicable
Laws
company and maintain the latest copies of the same by

stamping with “MASTER COPY” on first and

last pages. Ensure adherence of the laws.

7 Conduct housekeeping survey once in a month. Plant Head House Keeping

Checklist
Submit the details as backup data for Management

review Meeting.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-16 Title : Procedure on Customer Complaint 01 / 00 15.07.2020

Process Overview

The following key steps must be followed for all customer complaints received by CENTURION
POWER CABLES PVT. LTD.. staff:

Receive & classify

Acknowledge

Investigate

Resolve & Confirm

Respond to Customer

Follow up

QA & Close

The requirements for each of these steps is detailed below

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CENTURION POWER CABLES PVT. LTD.

DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-16 Title : Procedure on Customer Complaint 01 / 00 15.07.2020

1 Receive & classify

 Any complaint, issue or negative customer interaction (whether this is formally logged by the
customer or not), must be logged and classified for action.

 All of these complaints must be formally logged using the Ciclops or paper-based forms (see
below)

 All complaints must be prioritized as follows:

 Priority 1 – urgent, potential high business impact. The CENTURION POWER CABLES
PVT. LTD.. requires a response to the customer within 3 working days.
 This should be used (sparingly) for major issues where the customer may be either a
large national supplier, or any customer who is considering moving their business from
CENTURION POWER CABLES PVT. LTD..
 Also this could be used in a situation where the customer may be in a position to
influence or make public statements that would impact upon CENTURION POWER
CABLES PVT. LTD.. brand or reputation.

 Priority 2, - non-urgent, lower business impact. The CENTURION POWER CABLES

PVT. LTD.. requires a response to the customer within 2 working weeks.
 This should be used for most complaints with individual customers, as this allows a
reasonable time to collect information and produce a balanced response.
 Discretion and flexibility should be exercised in prioritising all complaints
 The staff member logging the complaint should review the complaint and it’s priority with the
Office Manager before proceeding to the next step.
 Office Managers will decide on the appropriate person(s) to carry out subsequent steps,
including the investigation.
 All Priority 1 complaints must be escalated immediately to the Office and/or Operations
Manager.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-16 Title : Procedure on Customer Complaint 01 / 00 15.07.2020

2 Acknowledge

Summary
Ensure that every complaint receives a formal written acknowledgement, containing an
expectation of when they will receive a response, and the person dealing with it.

 All complaints, regardless of priority, should receive a pro forma (see below)
acknowledgement sent out 1st class mail on the day of receipt.

3 Investigate

Summary
Follow up all aspects of the complaint, both internal and external, to ensure that the key facts
are identified and clarified.

 The priority of the complaint will drive the timescale for completion (3 days for urgent or 2
weeks for non-urgent).
 All areas of interaction and communication should be established (who, what, where, when,
why etc) and documented where possible.
4 Resolve & Confirm

Summary
Ensure that the final resolution is clear and fair. Also confirm the proposed action and resolution
with another senior person.

 Ensure that the proposed resolution meets corporate guidelines and does not prejudice
CENTURION POWER CABLES PVT. LTD.. in any unnecessary legal or financial manner.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-16 Title : Procedure on Customer Complaint 01 / 00 15.07.2020

 Document the proposed action and discuss and agree with Office and/or Operations
Manager.

 Discuss and review the solution form both the corporate and customer viewpoint to ensure
fairness and clarity.

 The review should include recognition and documentation of any underlying issues that
have contributed to the complaint and recommendations for actions to prevent further
occurrence.

5 Respond to Customer

Summary
Provide the customer with the resolution within the timescales promised.

 The details of the findings and proposed resolution should be clearly explained (in written or
verbal form as appropriate) to the customer- within the agreed timescales.

 If this cannot be done on time the customer should be contacted by telephone to request
further time.

6 Follow up

Summary
Ensure that complaints are followed up to confirm that customers are satisfied with the response
given.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-16 Title : Procedure on Customer Complaint 01 / 00 15.07.2020

 All Priority 1 complaints and 95% of priority 2 complaints must be followed up within a
reasonable timescale.
 This will be carried out by the Customer Relations team.
 The follow up should identify the following
 Is the customer satisfied with the response?
 Did they feel that their complaint was properly and fairly handled?

 Any negative responses to these questions should be referred to Operations Managers for
action and direct follow up with customers.

QA & Close

Summary
Ensure that the organisation as a whole is aware of complaints and any underlying issues. Plan
actions to remove these and prevent future recurrence.

 All complaints should be reviewed monthly as part of the MRM meetings.

 Any complaints where action can be taken to avoid recurrent must be acted upon and raised
with the appropriate managers/teams across the organization.

Records :
Customer Complaint Register Format

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 CENTURION POWER CABLES PVT. LTD.
DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-17 Title : Procedure on 5S Principles 01 / 00 15.07.2020

1. OBJECTIVE
To ensure clean, hygienic and presentable work environment of office and manufacturing
premises.

2. SCOPE

It shall cover all functional areas and immediate surroundings

3. RESPONSIBILITY

Factory Manager is responsible for general housekeeping of the plant and concerned in-
charges of different units within their functional areas.
4. PROCEDURE

4.1 Principles of house keeping - the `5 S'.- There are five principles of house keeping which
when applied properly change work environment completely. These are based on Japanese
practices of house keeping.

4.1.1. SEIRI (ORGANIZATION)

4.1.1.1 “Organization” is about separating the things which are necessary for the job from those
that are not and keeping the number of necessary items as low as possible and at
convenient locations. Segregating items into groups consisting of items, which are
required, and those, which are, scrap or not required on a daily basis. Look around your
work area and ask yourself," Is it really necessary for all items to be there?
4.1.1.2 This step distinguishes necessary and unnecessary items and eliminates unnecessary
items. This requires sort through what you have, identify what you need and discard
what you do not need.
4.1.1.3 The art of organization is in stratification management. It involves how important some
thing is and the reducing the nonessential inventory. Stratification also ensures that the
essential things are close at hand for maximum efficiency. Thus the key to good
stratification management is the ability to make these decisions about the usage
frequency and ensure that things are in their proper places.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-17 Title : Procedure on 5S Principles 01 / 00 15.07.2020

4.1.2. SEITON (NEATNESS)

4.1.2.1 “Neatness” means putting things away with efficiency, quality and safety in mind.
Demarcating a place for every item and ensuring that every item is kept in its designated
place so that they are easily accessible and can easily be used. Make sure that items
can be clearly identified by labeling them properly.
4.1.2.2 This step enables determination of the type of storage system and a layout that will
guarantee that required amount of necessary items would be easily accessible.
a) Set things in order by creating place for every thing,
b) Put every thing in its place,
c) Keep accessibility as easy as possible,
d) Use the principle of wide range and shallow depth for storage.
4.1.2.3 An example is parking cars in a parking lot efficiently so that any one car can move
when needed. Neatness relates to how things can be got when needed. Similar examples
are warehouse management and layout of tools in workplace. These require three simple
rules:
a) decide where things belong,
b) decide how things should be put away, and
c) obey the put away rules.

4.1.3. SEISO (CLEANING)

4.1.3.1 “Cleaning” means cleaning the work place and all the machinery by ourselves.

4.1.3.2 This eliminates dirt, dust and other foreign matter to make work place immaculately
clean:
a) Clean equipment, furniture, notice boards, records etc,
b) Keep the work place spotlessly clean,
c) Vigorous sweeping, wiping etc

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-17 Title : Procedure on 5S Principles 01 / 00 15.07.2020

4.1.3.3 Broadly there are three steps to proper cleaning:

a) the macro level activity by cleaning every thing and finding ways to deal with
over all causes pertinent to the whole picture.
b) the individual level dealing with specific work places and even specific pieces
of machinery and
c) the micro level where the specific parts and tools are cleaned

4.1.4. SEIKETSU (STANDARDIZATION)

4.1.4.1 “Standardization” means maintaining a state of cleanliness, which includes other

considerations such as, Colour, shapes, clothing and those that give sense of

cleanliness.

4.1.4.2 A clean work place properly selected and with proper arrangement will soon become

dirty if Seiri, Seiton and Seiso are not continuously repeated.

4.1.4.3 Keep your areas neat and clean, including uniforms, through which one will achieve,

serene work environment. This step necessitates the designing and maintaining

standards at the work place.

4.1.4.5 Design clearly understandable house keeping standards, Make every body in the team
aware about the standards and communicate the seriousness of adherence and make
use friendly visual control systems.

4.1.4.6 Make available necessary resources such as dust bins, cleaning solutions, dust covers

etc.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
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4.1.5. SHITSUKE (DISCIPLINE)

4.1.5.1 “Discipline” is a process of repetition and practice. It means instilling the ability of doing

things the way they are supposed to be done repeatedly.

4.1.5.2 Main emphasis is on creating a work place with good habits. Maintenance of standards

of general cleaning set by the work place.

4.1.5.3 Every one should be disciplined to follow strictly the rules and maintain standards while

working. For example, the work timings should be adhered to and the prescribed

operation standards be followed.

4.1.5.4 This step is to ensure that every one sticks to the rule scrupulously

4.2 Training and awareness- Creating general awareness about 5 S and conducting
Organization wide training. Role modeling and regular agenda in communication forum.

4.3. Maintenance of house keeping

4.3.1 There are five levels of development of house keeping achieving the desired objectives:
LEVEL 1- Floor is full of unwanted material-Look around all horizontal surfaces and

examine the work floor and eliminate all garbage and non-essential tools and

storage. Remove unnecessary papers from files, discard old files, stationery

etc. Examine floor corners and remove unwanted things. Make defined

places for the things that are required to be on the floor.

LEVEL 2- Clutter found by the wall- Look at the vertical surfaces and examine walls and

pillars. Eliminate all garbage and non-essential tools leaning against the wall.

Paint all walls and pillars that can be reached by hand.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
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LEVEL 3- Premise is cleaned but things are disorganized-Look inside the shelves and sort

out the papers, material parts and tools. Get rid of locked cabinets remained

unopened for long period. Make separate storage for tools parts, clamps and

documents etc.

LEVEL 4- Premises and things are cleaned and organized-Clean, straighten, tidy and

organize automatically. Develop visual controls,

LEVEL 5- Factory / Office immaculate- Constant and continual cleaning from wall to wall.

Work area immaculate. Origin of rubbish is removed to eliminate dirt, clutter

and garbage at source, inventory at low working level, High quality and

productivity.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-18 Title : Procedure on Training 01 / 00 15.07.2020

1.0 PURPOSE
To determine necessary competence, provide training, evaluate effectiveness of the personnel
performing work, affecting product quality, as per their job requirements.
2.0 SCOPE
This procedure is applicable to all Personnel performing activities affecting the quality of product
and process.
3.0 RESPONSIBILITY
DIRECTOR and the In-charges.

4.0 PROCESS APPROACH

4.1 Process input
S. No. Input Source

1 Quality policy and Objectives SC

2 MRM action plan SC

3 Resume /Approval Form All Dept.

4 Job Profile/Skill Matrix/ Training needs In-charges

5 Individual training record In-charges

6 Customer complaint / claim Customer

4.2 Process
4.2.1 Training Need
4.2.1.1 The need for training identified through
 Training Need Identification Form
 Skill evaluation criteria
 Skill mapping
 Skill Matrix
 Change of system, Technology up-gradation
 Repetitive occurrence of system non conformance
 Customer feedback
 Any other need felt by management

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4.2.1.2 Individual training need recorded in format of identification of training need.

4.2.1.3 TNI format will circulate to Deptt. Head in consultation with the DIRECTOR decides
the nature, the duration, and participants for the training programme.
4.2.1.4 After completion of training programme training records are maintained.
4.2.1.5 The effectiveness of training programme conducted is evaluated by using Training
Feedback form of associates will be just after completion of training.
4.2.1.6 The review of training activities conducted according the plan is taken up during the
Management Review Meeting. Any training programme that could not be
implemented in the scheduled period is planned subsequently. The training
schedule is updated accordingly.& Re-training will be rescheduled if effectiveness of
training of associate will not achieved as per plan.
4.2.2 Induction Training
Induction training is given to orient newly hired employees. Induction training
consists of exposure to Quality Policy, relevant departmental performance
parameters / responsibility & authority and staff introduction.
2 days Induction Training will be given to newly joined employee.
4.2.3 Qualification/Development/Need base training

4.2.3.1 All employees performing specified assigned tasks will be trained for their positions.
4.2.3.2 Training includes any combination of education, training and or experience, which
qualifies the employee for the position.
4.2.3.3 This training arises either as need basis or to further development of employees.

4.2.4 Training Evaluation

Training effectiveness evaluation shall be done concurrently with annual
performance and appraisals after 15 days of training.
After each training session attendance sheet filled up and signed by all trainees.

4.2.5 Identifying Vacancies:

Vacancies are identified by DIRECTOR & In-charges based on the organization

growth, which comprises of increase in product & services.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-18 Title : Procedure on Training 01 / 00 15.07.2020

4.2.5 Advertising and handling applications:

4.2.6.1 An advertisement in national level/local newspaper is released, wherever

requirement exists for staff only.

4.2.6.3 Applicants are selected for the interview if they meet necessary qualifications (refer
Skill matrix for the post for which they have applied.

4.2.6 Interview & Selection:

4.2.7.1 A board for interview comprising of the DIRECTOR and In-charges is formed for
interview and selection.
4.2.7.2 The selected candidates are listed and their appointment letters prepared according
to their respective placements and despatched to them.

4.3 Process output:

S. No. Outputs To

1 Immediate Evaluation & Feedback of In-charges

Training
2 Training Effectiveness & Feedback In-charges

3 Individual Training record In-charges

4 Skill Matrix In-charges

5 PERSONNEL COMPETENCY RECORD In-charges

6 COMPETENCY LEVEL REQUIREMENT In-charges

7 Training Need Identification In-charges

8 Training Log In-charges

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-18 Title : Procedure on Training 01 / 00 15.07.2020

4.4 Process Monitoring:

S. Monitoring Brief Responsibility

No.

1 Customer complaint / In-charge

claim

5.0 RECORDS:
PERSONNEL COMPETENCY RECORD
COMPETENCY LEVEL REQUIREMENT
Training Plan
Training Record

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 CENTURION POWER CABLES PVT. LTD.
DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-19 Title : Procedure on TOOLING MANAGEMENT 01 / 00 15.07.2020

1. PURPOSE
To establish a system for maintenance of Dies, Jigs & fixtures.
2. SCOPE
Applicable to all Dies, Jigs & fixtures used for production.
3. DEFINITION
NIL
4. RESPONSIBILITY
Tool room head is overall responsible for maintenance of tool / dies and molds
(HOD Prod.) is responsible for maintenance of Dies, Jigs & fixtures used for production .
5. PROCEDURE
 Check all new Tools visually dimensionally. Get the same verified from QA. Codify the dies with Part No.
Or Name.
 Make History Card for each dies / Tool production Supervisor.
 Record date of issue to production on History Card.
 Check Tools visually for any damage at the time of use.
 For any damage observed before using, send the Tool to the Tool Room with problem mentioned on the
Tool History Card for rectification.
 For any problem during production send the Tool along with last sample piece and tool History Card
(Problem mentioned) to Tool Room for rectification.
 Check the identified problem. Record rectification done in History Card and issue the Tool and History
Card to Production.
 Maintain machine check sheet and time sheet.
 Keep all Tools/ Die properly.
 Check the dies for the defect, if any, for the requirements as per the relevant operational standards list at
the time of use. Record in the Tool History Card.
 If any defects are observed, send the Tool and Tool History Card to Tool Room for rectification.
 Apply grease/lubricating oil as applicable to avoid rusting during storage.
 Review Tool/Die History Card each time a Tool is scrapped and new Tool is planned for incorporating.
 modifications/changes
 New tools/ Dies shall be planned when tool/ die life is left 25% as tool/Die life defined in tool history
card.
 If tools/ Dies are provided by customer than same shall be informed to customer, if tool/ die is
responsibility of SE than intimated to tool room for the same.
 The in-charge of tool room is plan and manufacture tools as per process flow diagram.
 Note: if customer / SE seems that die / Tools are fit for use after defined life than life of tools die shall be
extended.
 Ensure all the toolings are kept as specified location for easy retrieval.
Perishable Tools
 Assess the list of perishable Tools used in the company and determine frequency of change. Record in the
Tool History Card.
 Plan the manufacturing of new Tools depending upon the time to be taken for making new Tools.
Control of Consumables
 Depending upon the consumption prepare tentative requirement of spares and consumables for the
Tools.
 Decide minimum stock level of all spares and consumables.
 Indent and follow up with Stores for timely availability of all the items

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-20 Title : Procedure on IDENTIFICATION AND 01 / 00 15.07.2020
TRACEABILITY

1. PURPOSE
To establish and maintain system for providing Product Identification and Traceability. at all stages of
operation.
2. SCOPE
Applicable to all products from raw material to finished products.
3. DEFINITION
NIL
4. RESPONSIBILITIES
 Head Stores / Production and Dispatch are overall responsible for implementation of this procedure.
 Product is identified and material is identified by RG no, after issuance of material this identification
number move with tags, Job cards/ daily production report and inspection reports.
 Respective Sectional In-charge are equally responsible for implement this procedure of Identification and
traceability.
 Store in-charge is responsible for issue material as per lot no and heat no as applicable and issues the job
card.
5. PROCEDURES

 After receipt inspection if the material found OK, the “Under Inspection” tag is replaced by “OK” tag
identifying the material.
 Keep the approved material at designated locations and update in Stock Register
 Keep the maintenance spares at identified racks duly numbered and maintain records in Stock Register
 Store in-charge tag the material with the following details:
a) Material Name
b) Party Name
c) Challan No./Date
d) Quantity received
 Store in charge issue the material with job card duly mention heat no, material issued qty, product qty to
be produced.
PRODUCTION DEPARTMENT.
 Receive raw material from Stores with in-process identification tag having details of components name ,
Heat No, Qty etc. For purpose of Traceability.
 Production is responsible to carry this heat no on daily production reports and tag of next operation.
 Quality will also mention this heat no on in-process and final inspection report.
PACKING
 Receive material from Production Deptt. Along with Heat No and Production Slip.
 Affix Material identification ok tag .with following information
 Invoice no.
 Part number
 Date
 Heat No
 Qty
 Enter this detail in final inspection report / PDI and invoice also.
 6. RECORDS
Job Card

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-21 Title : Procedure on REWORK 01 / 00 15.07.2020
1. PURPOSE:

To Establish a Process for rework and handling of rework parts.

2. SCOPE:

Applicable to all Production lines

For reference at all plant site in the Company.

3. DEFINITION / ABBREVIATION:

CFT - Cross Functional Team

PFC - Process Flow Chart

Nonconformance: A deficiency in characteristic, documentation or procedure which renders the

quality of an item unacceptable or indeterminate. Examples of non conformances include: out of
specification condition, test failures, incorrect or inadequate documentation, or deviation from
prescribed processing, inspection or test procedures

Accept: Accept as-is, analysis has determined no nonconformance

Rework – Bringing a non-conforming part back into conformance by simply reprocessing a prior
sequence.

Repair – Bringing a non-conforming part back into conformance using methods outside the original
process.

Reclassify: Reclassify product for another application

Scrap Product: Product cannot be reworked, and must be isolated & scrapped.

4. PROCEDURES:

 Red bin analysis shall be conducted every day with head production, head quality, purchase in-
charge, tool room in-charge and others as required.
 Three type of rejection are discussed in red bin meeting ( supplier rejection , customer rejection
and in-house rejection)
 In the event a suspected nonconforming condition relating to product is detected same shall be
presented in red bin analysis meeting.
 Red bin team members with authority from key functional areas (e.g. quality, engineering,
operations), and temporary members. which have knowledge of the problem and/or the
resolution.
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CPC-QPM-20 Title : Procedure on REWORK 01 / 00 15.07.2020
 Anyone who detects a suspected nonconforming condition shall be responsible for properly
identifying that condition by initiating Nonconformance Case.
 When product is suspected to be nonconforming, it must be conspicuously identified and controlled
to prevent its inadvertent use. The suspect lot shall not be moved/relocated until a disposition is
made.

 In case supplier rejection-- head purchase will call to supplier for meeting and discuss with
supplier for reduce the same in the presence of quality head
 And jointly prepare the MOM and monitor the same for reoccurrence.
 In case of customer rejection-- Quality in-charge will answer that why this rejected material
dispatched to customer and take action by improving detection method than production will
provide solution ( why its produced and it will not produce in future by taking action on occurrence
method ) quality head will fill 8 D format.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-22 Title : Procedure on PACKAGING, PRESERVATION & 01 / 00 15.07.2020
DELIVERY

1.0 PURPOSE

To document the process of packaging preservation and delivery, to

ensure protection and preservation of product quality after final inspection
& testing.

2.0 SCOPE

2.1 Packing and delivery of all products of the company till the ownership
passes on to the customer.

2.2 Preservation of the product at all stages of processing, storage and

delivery.

3.0 RESPONSIBILITY

Store Incharge, Production Manager, Store keeper.

4.0 PROCEDURE

4.1 PACKAGING

4.1.1 All products shall be packed as per customer’s packaging standard, if

available.

4.1.2 In the absence of customer packaging standard, the Multi Disciplinary

Team shall finalise packaging specifications and issue Packaging Work-
Instructions.

4.1.3 The Packaging / Labeling shall be organised and supervised by the

designated supervisor as per the delivery schedule and availability of
material in the Finished Goods Area. Each packaging / bin shall be
identified as per the Packaging Work Instruction / customer’s
requirements.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-22 Title : Procedure on PACKAGING, PRESERVATION & 01 / 00 15.07.2020
DELIVERY

4.2 PRESERVATION

4.2.1 The customer planning information and shipping schedule shall be

received preferably through computerised system. The preservation of the
product at various stages of processing and storage shall be done by the
area supervisor as per the applicable Work Instructions issued by the
Production Manager. Due consideration shall be given to the contractual
requirements and customer’s specification.

4.2.2 The preservation application of the finished product prior to packing and
transferring to the Finished Goods Area shall be done by the Works
Incharge.

4.3 DELIVERY

4.3.1 Dispatch and delivery shall be done by the Dispatch Assistant complying
with all statutory and regulatory requirements. He shall keep a tab on
customer’s requirement for the day and shall accordingly prepare dispatch
documentation.

4.3.2 Where delivery is at customer premises, the mode of delivery shall be

such so as to ensure safe and timely delivery. Company’s own delivery
van / approved transporters shall be engaged for delivery.

4.3.3 The Store Incharge shall review the dispatch documentation for all
statutory/regulatory and contractual compliance before approving. GR No.
shall be transmitted to the customer through e-mail, fax or other means
unless waived by the customer.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-22 Title : Procedure on PACKAGING, PRESERVATION & 01 / 00 15.07.2020
DELIVERY

5.3.4 The security function at the gate shall make requisite entries in the
Material Outward Register and check all authorisations and documents
before allowing the outward movement of material.

5.3.4.1 Incase of any discrepancy, the security function shall withhold the
dispatch and intimate the Dispatch Assistant.
5.3.4.2 100% on time delivery monitoring shall be maintained to meet customer
requirements. Incase of non-achievement of the same, corrective action
shall be taken to improve the delivery performance, including
communicating to the customer.
5.3.5 The premium freight records will be maintained by the purchase personnel.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-23 Title : Procedure on Incoming Inspection 01 / 00 15.07.2020

5.0 PURPOSE

To evolve procedure for incoming material inspection standard, method of inspection

and handling non conforming material to meet the quality system standard of Centurion
Power Cables Pvt. Ltd.

6.0 SCOPE

Applicable to

g) Incoming Quality control

h) Raw material /spare parts from suppliers
i) Store department
j) Purchase department
k) Other related departments .

7.0 RESPONSIBILITY

QA -IQC In charge

8.0 PROCEDURE DETAILS

Sr. Activity Responsibility Reference

No. documents

1 Material is received at factory gate Security Guard Inward

material
register

2 Details of receiving material intimate to store dept Security Guard Gate Receive
by security guard along with invoice and other Note (GRN)
documents from supplier.

3 Intimation regarding receiving material along with Store …..

necessary documents is given to IQC dept.

4 QC inspector review with quality inspection IQC Inspection

standard standard check
sheet
 5 If the material accompanied with the test IQC Supplier test
certificate verify the certificate against certificate
specification.

6 The details of inspection is recorded at incoming IQC Incoming

inspection record. inspection
report in SAP

7 If the material found conforming ,asset the same IQC Incoming

and QC OK sticker is placed inspection
report in SAP

8 If the material is not conforming based on QC In charge Supplier NCR

incoming inspection standard then Supplier Non
conformity report is generated and one copy is
sent to supplier along with incoming inspection
report and such material kept in separate location
(Non confirming product location ) its ensure by
QC and store in charge that non confirming
material must not mix up with confirming material

9 Following decision may be applied for non IQC …..

confirming products

1. Rejection
2. Segregation,
3. Accepted under deviation
10 For all non conforming product details are also Purchase Supplier
sent to purchase in charge for evaluation of incharge evaluation
supplier performance, form

11 If the material is rejected then rejected sticker is IQC & Store in Supplier NCR
placed at the product separately at designated charge
place for rejected material

12 QC In charge try to identify the root cause of the Qc In charge Supplier NCR
problem for rejected for non conforming product
and take the suitable corrective and preventive
action from supplier end .

5.0 RECORDS

1. Incoming inspection record

2. Non-Conforming product format

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-24 Title : Procedure on Inprocess Inspection 01 / 00 15.07.2020

9.0 PURPOSE

To evolve procedure for in process material inspection standard, method of inspection

and handling non conforming material to meet the quality system standard of Centurion
Power Cables Pvt. Ltd.

10.0 SCOPE

Applicable to
l) Line Quality control
m) Production department .
n) Other related departments .

11.0 RESPONSIBILITY

QA -LQC Inspector
PROD- Supervisor

12.0 PROCEDURE DETAILS

Sr Activity Responsibility Reference
no documents

1 Record the result of inspection in the in- LQC inspector Inprocess

process inspection record inspection report

2 Compare the inspection details against LQC inspector Inprocess

process sheets/work drawings at record inspection report
details in the process inspection report

3 If any deviation is observed against the LQC inspector Inprocess

specified parameters then the consider inspection report
the process of the part is not conforming.

4 Immediately inform to production LQC inspector Inprocess

supervisor/production in charge through inspection report
in process non conforming report .

5 It must be ensure no further production LQC …..

would be done until material would not Inspector
be accepted by LQC inspector. /Supervisor
6 Following action may be applied on non LQC Inspector Non conforming
conforming product product
/Supervisor
register/rework
Rejected
register
Rework

Segregation

7 After rework/segregation again verify the LQC Inprocess

five piece if any piece is found non Inspector inspection check
conforming then reject the whole lot. /Supervisor sheet

8 Details of reworked or rejected materials LQC Rejection entry in

must be recorded in rejection analysis Inspector the inprocess
register /sheet . /Supervisor inspection check
sheet .

9 If after rework/segregation, five samples LQC Inprocess

found OK then production will start for Inspector inspection report
rest qty. /Supervisor

10 Production supervisor will identify the Supervisor / Non conformity

root cause of the problem through Non production in product register
conformity product register and will take charge ..
suitable corrective action to prevent the
occurrence of such findings.

6.0 RECORDS

1. In-process format
2. Non conformity product register

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-25 Title : Procedure on Final Inspection 01 / 00 15.07.2020

13.0 PURPOSE
To evolve procedure for final inspection material inspection standard, method of
inspection and handling non conforming material to meet the quality system standard of
Centurion Power Cables Pvt. Ltd.

14.0 SCOPE

Applicable to
o) Final Quality control
p) Production department .
q) Packing and dispatch departments .

15.0 RESPONSIBILITY

QA -FQC Inspector .
PROD- Line supervisors .

16.0 PROCEDURE DETAILS

Sr no Activity Responsibility Reference
documents

1 Final inspection is performed when Line supervisor and Final inspection

all the process are complete and final quality inspector check sheet
product becomes to ready to pack .

2 All such product are kept at Final quality inspector Final inspection
separate place ( Under inspection ) check sheet .

3 It must be ensure that all the Final quality inspector Instrument and
fixture/equipments/ for inspection calibration list
are available at OQC department .

4 It is ensure that all the Final quality inspector Instrument and

equipments/fixtures are calibrated calibration list
as per the procedure for calibration
section report .

5 Finish Good product would be Final quality inspector Final inspection

inspected as per Final inspection check sheet
check sheet
7 On random basis some sample are QC Incharge/shift in Final inspection
selected by Qc In charge and charge check sheet
detailed are recorded in Final
inspection check sheet

8 If during final inspection material is QC Incharge/shift in Final inspection

found conforming to the charge check sheet
specification accept the same.

9 If during inspection material is QC Incharge/shift in Final inspection

found non conforming put up the charge check sheet
in final inspection report and raise
the non conformity report and put
the red tape for separate
identification.

10 It must be ensure that non Qc Incharge and Final inspection

conforming or rejected must be production in charge check sheet
kept separate place identify and
must not be mix up in conforming
material

11 We must identify root cause of non QC & production in Non conformity

conforming product and must take charge product register
suitable corrective action .

5.0 RECORDS
1. Routine test format
2. Non conformity product register

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 CENTURION POWER CABLES PVT. LTD.
DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-26 Title : Procedure on Maintenance 01 / 00 15.07.2020

1. SCOPE

This procedure defines the actions and responsibilities of the maintenance manager in
maintaining the Machinery & equipment in good working condition. This covers activities from
receiving maintenance request up to a turnover of machine & equipment to the concerned unit

2. PURPOSE

To ensure sustenance of machine and equipment capability by periodic preventive maintenance.

3. REFERENCE DOCUMENTS

3.1 CPCPL Quality Manual,

3.2 Procedure for Manufacturing.
3.3 Work instructions for Preventive Maintenance
3.4 Procedure for Equipment Calibration and Maintenance

4. TERMS & DEFINITIONS

4.1 Preventive Maintenance –Preventive maintenance is maintenance that is regularly performed on a
piece of Machinery or equipment to lessen the likelihood of it failing. It is performed while the
equipment is still working so that it does not break down unexpectedly.
4.2 Breakdown Maintenance–Breakdown maintenance is maintenance performed on a piece of
machinery or equipment that has broken down and is unusable. It is based on a breakdown
maintenance trigger. It may be either planned or unplanned.

5. RESPONSIBILITY AND AUTHORITY

The maintenance manager is responsible to plan and carry out periodic preventive maintenance and
ensure continued process capability. Also responsible for oil spillage, vibration, emission, and noise
level.

6. DETAILS OF PROCEDURE
6.1 Based on conditions of use and experience, periodic maintenance work on machines is planned
by maintenance dept. it is identified in relevant preventive maintenance work instruction.
6.2 Maintenance is done based on the maintenance schedule.
6.3 Work instruction for daily maintenance like checking, filling of oil/grease of production machine
is given to PROD for execution.
6.4 Scheduled and other maintenance plans are executed by maintenance dept personnel and
records are maintained in the respective machine file.
6.5 When breakdown occurs necessary repair/rectification work is carried out and records are
maintained. Maintenance manager reviews the record and classifies the machine break down as
either ‘Minor’ or ‘Major’ and maintains records of downtime hours, spares consumed and the
approximate cost of spares/repair. Root cause analysis and corrective/preventive action records shall
be maintained for all the major machine breakdowns, The records shall include details of breakdown
experienced/attended, the effectiveness of action taken and preventive action if any.
6.6 If the root cause of machine break-down is due to normal wear and tear of the repaired/rectified
parts then same shall be considered as ‘Minor’, but in case ‘Minor’ is repeated then it shall be
considered as ‘Major’.
6.7 Machine Details like make, capacity, location and spares parts of the machine shall be
maintained in the respective machine file.

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DOCUMENT NO : QUALITY PROCEDURE MANUAL ISSUE / REV. NO DATE
CPC-QPM-26 Title : Procedure on Maintenance 01 / 00 15.07.2020

6.8 Maintenance Manager plans to procure and stock essential spare parts to ensure maintenance
with minimal downtime. List of critical spares and existing stock is maintained.
6.9 All the spares/accessories with shelf life shall be identified with the label containing details like
Name, the location of use/application and date of receipt etc.
6.10 Breakdown hours reported in the machine breakdown report shall be analyzed for all
production machines on a regular basis.
6.11 Maintenance of production draw dies, rolls & edge rollers are verified to ensure proper working
condition. Records are maintained in respectively.
6.12 Maintenance department should check and maintain the record for Oil spillage, vibration,
emission and noise in work area

7. RETAINED DOCUMENTED INFORMATION

7.1 Preventive Maintenance Plan
7.2 Preventive Maintenance Record
7.3 Breakdown/repairs record

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