- Incoming materials-inspection of castings, forging, raw materials, hardware, bars etc.
- Quality Assurance and Inspection of components and sub-assemblies supplied by approved vendors.
- Line inspection of components, sub-assemblies manufactured on the shop floor.
- Final Inspection and Performance Test.
- Inspection of packing and dispatch.
- Tools and instruments calibration and maintenance of test standards.
- Maintaining test records and inspection results.
- The Production Department is totally responsible to achieve the required standards in quality of finished goods. For this purpose, the Quality Assurance Department interacts and assess the fine people. The Quality Assurance Department has full powers to ensure that requisite step of quality are maintained.
Inspection of In-Coming Materials
All raw materials and sub-assemblies viz. castings, forging, bars, plates and hardware etc. are procured as per approved technical specification or specified relevant standards.
Only materials as per Technical Specifications approved by Quality Assurance Department are accepted and stored in raw materials stores.
For the incoming materials the inward in-charge records the data in the in-word register. The Quality Assurance Department is informed through in-slip and the incoming material is stored in the receiving inspection area, until clearance by Quality Assurance Department.
100% inspection or alternatively as per sampling plan laid down in ISO 2500 (Part I) is carried out in accordance with the Quality Assurance Plan for each product.
The Quality Assurance Department arranges to send the test bars and other materials to a reputed chemical and physical laboratory for chemical composition test. Material Test Certificates on various part – Body, Bonnet, Wedge, Disc & Components materials are obtained in advance with the Quality Assurance Plan.
The parts, component sub-assemblies found to be OK are tagged with OK sticker and signature of Quality Assurance Engineer. The rejected parts and materials are market with REJECTED tags and returned to the supplier / sub-contractor. Quality Assurance Engineer verifies the size, pressure rating, material code, manufacturers emblem, arrow mark for flow direction, heat number etc. on the casting before acceptance. The accepted castings of Body & Bonnet are hard punched with the serial number and marked with green paint.
The accepted materials are stored in the proper racks / bins as per identification mark. The materials are issued against a material requisition slip for each specific requirement. All materials are issued along with a Job Card for manufacturing. Job card shall contain all the operations and methods in a sequence. Only approved and dimensionally accepted materials are taken up for further manufacturing process.
In- Process Inspection
The Quality Assurance Engineer carries out inspection and testing at the stages defined in the Quality Assurance Plan for the product. He fills the parts inspection report at stages defined in the Quality Assurance Plan. He shall also indicate the status (OK/REJECT) on the parts by means of a sticker which shall be recorded in the In-process Inspection Register. Product assembly shall be made in accordance with manufacturing plan / drawing. Quality Assurance Department shall carry out the Hydro Static Pressure Test for Body / Bonnet before assembly. Assembly drawing of product, parts specification list and materials requisition slip shall be sent to assembly shop for final assembly of the valves.
The Quality Assurance Engineer Carries out the final inspection and tests on the products as per the Quality Assurance Plan for the valves. He shall fill-up the Final Inspection Report. The final inspection “OK” tag shall be signed by the Quality Assurance Engineer for the accepted valves. The final inspection report shall be authorized by Quality Assurance Head. For rejected valves the Quality Assurance Engineer shall mark the product with “REJECT” tag and shall fill-up the Final Inspection Report. The Quality Assurance Head releases the valves for packing only after the stages specified in the Quality Assurance Plan have been completed satisfactorily and all the inspection and test reports are available and authorized by him.
Control of Measuring, Inspection Tools And Test Equipments
The Quality Assurance Head shall prepare a master list of instruments and gauges along with calibration frequency. The equipment shall be calibrated at the defined frequency by on external agency. The calibration shall be traceable to a standard. After calibration, the calibration history card of the instruments or gauges shall updated by the Quality Assurance Head.
The inspection, measuring and test equipments shall be provided with indicator. This indicator shall be a tag or sticker as appropriate. These tags/ stickers shall identify the equipment and shall indicate the calibration status. When the equipment is found out of calibration, the Quality Assurance Head shall assess and document the validity of providing inspection and test results in the form of a note. All the equipment shall be handled by trained personnel to ensure accuracy and fitness for use. All measuring and test equipment shall be kept under lock and key where practical in dust and grease-free environment.