No 1S09007:2008 Document No: CG-G-7.42 — |Version No: 1.0 Date Effective . 23.03.2011 Document Title: Guidelines for preparing QAP during registration RESEARCH DESIGNS & STANDARDS ORGANIZATION = Manaknagar, Lucknow ~ 226011 Document No: CG-G-7.1-2 Document Title: Guidelines for preparing QAP during registration 1.0 Amendment History: S.No. Amend. Date | Version _| Reasons for Amendment - | 1 | 23032011 / 1.0 —|First Tssue under new documentation system for 1$09001:2008. Approved by EDSC on NP- 2 of file MCIISO/Approval & Issue. SE/E &S/Camiage DIE &S/Carriage | Printed: 23.03.2017 Prepared By Issued By Page 1 of 91$09001:2008 Document No: CG-G-7.1-2 Version No: 1.0 Date Effective 23.03.2011 Document Title: Guidelines for preparing GAP during registration Table of contents Clause No. Description “Page No. | | 4.0 ‘Amendment History _ 01 2.0 Purpose t 03 3.0 ‘Scope of Application 03 40 Procedure/Details a 03 5.0 Referenced Documents 09 6.0 Referenced Documents of External Origin 09 7.0 Associated Records 09. 8.0 Responsibility and Authority 09 (780 ‘Abbreviations — 08 ‘SEVE &S/Cariage DIE 8S/Carriage Printed: 23.03.2011 Prepared By. Issued By. Page 2 of 91S09007:2008 Document No: CG-G-7.1-2 | Version No: 1.0 Date Effective 23.03.2011 Document Title: Guidelines for preparing QAP during registration 2.0 Purpose: These are guidelines for preparing the QAP for product. 3.0 Scope of Application: Applicable for all the Sections of Carriage Directorate, 4.0 Details: The QAP to be submitted by the vendor in triplicate (along with the application form for registration) shall cover the following aspects — 4.1 ORGANISATION CHART Organisational Chart, clearly indicating the Quality Control Set-up, role and responsibilities of key personal 4.2 QUALIFICATION / EXPERIENCE OF QC PERSONNEL Part I: Details of qualification/experience of the quality control personnel specified in. the STRISpecification of RDSO of the items applied for approval/renewal Requirement as per STR/Spec. Details of personnel employed STRISpec a Para No é = sn & | be % 8 gs oo _ g 2 zi ¢ a6 fF $8 8 3s a8 pie foes | I] Part Il: Qualification of other key personnel and the officials deployed in Quality Control Cell: Technical Brief scope of ea Lau Designation Qualification Experience responsibilities SEVE &S/Camage IDIE &SiCarriage Printed: 23.03.2011 Prepared B) Issued By: Page 3 of 91809001:2008 Document No: CG-G-7.1-2 | Version No: 1.0 Date Effective 23.03,2011 Document Title: Guidelines for preparing QAP during registration 4.3 PROCESS FLOW CHARTIDESCRIPTION OF MANUFACTURING PROCESS. Part |: Process Flow Chart indicating process of manufacture for an individual product, with quality control points, Note’ Process flow chart shall indicate all the operation involving manufacturing & testing of product from raw material to finish product, including RDSO/RITES/Consignee inspection/dispatch There should be separate flow chart for each item. Part Il: Brief description of different manufacturing process mentioned in flow chart Details of the manufacturing & testing process specially mentioned in the specificatio SN | Para no of spec. Requirement of manufacturing/testing | Details of the process being process as per spec installed! follows Brief details of the other manufacturing process. SN | Name of the manufacturing process Brief description Part ill: Brief description of ancillaries & additional units (i any): ‘Whether all the facilities are available at a single location (or) multiple location — In case of multiple location give details in following formats SN units | Address "] Whether unit is | Whether unit covered under _| is ISO Mig. processes SEIE &S/Carriage IDiE &S/Carriage Printed: 23.03.2011 Prepared By: Issued By: Page 4 of 91$09001:2008 Document No: CG-G-7.1-2 | Version No: 10) Date Effective 23.03.2011 Document Title: Guidelines for preparing QAP during registration factory heense certified details I 4.4 Details of Sub-assemblies / components manufactured in-house and outsourced. Part |: Details of in-house manufactured (Components/sub-assemblies) SN | Item Name Drawing No [oe Part Il: Details of components/Sub-assemblies purchased from RDSO approved primary / sublet vendors item Name Isita Primary Is ita Sublet SN Drawing No eee an a toga | Name of the source Part Ill : Details of items outsourced from other than RDSO approved items Frequency of review of the performance of sublet source SN | Item Name Drawing No Name of the source 4.5 INCOMING RAW MATERIAL & INPROCESS/FINAL INSPECTION Stage inspection detailing inspection procedure, inspection parameters, method of testing/test procedure including sample sizes for destructive and non- destructive testing etc. Part |: Incoming raw materials/parts/sub-assemblie ‘SE/E &S/Cariage DIE 8S/Carriage Printed: 23.03.2011 Prepared By: Issued By Page 5 of 915090072008 Document No: CG-G7.12 Version No: 7.0 Date Effective 23.03.2011 Document Tile: Guidelines for preparing QAP duriig registration § g Rejection & ° : = 2 Disposal 2 3 ak s zy 3 3 re 5 38 ES z 8 Bo s B38 3 8 3 e & g : 22 gg 3 2 ge oe gs se a2 ag & 23 2 a2 8 Es Bg 5B) a8 | ES 83 8 3 5 Bf é BE os & 6128 ba af | 38 26 gs 5 Part Il: In process inspection {of the product) 2 5 e 3B gs \2 3 5 8 & £ 2 fa. a | E]GE |. Jeb le 5 oss | 3s €3 |g2 sre g3 |2 eee cet co alpetat (ie aeiemiecie caus z|\ 52 | bes | 83 | $2 (823 BF | ge |g. B25 ce ag SS <6 6a |e Part Ill Final internal inspection of the product by the firm ‘Sample Mode of | Acceptance | Rejection Name of Size & its Parameter | inspectio | limits! (disposal! | Traceabilit SN | the tes | Frequency _ s for Ww Criteria. | Reprocesse | Feat process of inspection | equipme |jepecified | d/ inspection ntused Value Scrapped 4.6 CALIBRATION OF TESTING MEASURING EQUIPMENT SE/E &S/Carriage JD/E &S/Carriage Printed: 23.03.2011 Prepared By: Issued By Page 6 of 9~ 1$09007:2008 Document No: CGGT12 Version No: 1.0 Date Effective 23.03.2011 Document Title: Guidelines for preparing QAP during registration Part |: Inhouse Testing facilities available for calibration with the firm en Name of, Master a Range Frequency | Traceability to | of national calibration standard Part Il: Personnel trained for inhouse calibration ‘SN | Name Qualification Experience a ee Part Ill : Calibration plan for the items identified for specified calibration in STR/Specification Ref. para of sn | Measuring | STR/Spec. Equipment 'STR/Spec./Para 10. Frequency Range! Specified in Accuracy | Speci Name of Sutources | 290 4 | outsourced Part IV : Calibration plan for other measuring equipment sn | Measuring Equipment | Range/ Accuracy d Inhouse! Frequency | Outsource Name of calibration agency 4,7 SYSTEM OF MAINTAINING THE DATE OF CUSTOMER COMPLAINTS(WARRANTY. FAILURES Warranty failuresiin-service failures reported from customers SE/E &S/Carriage DIE &SiCarriage Printed: 23.03.2011 Prepared By: Issued By: Page 7 of 91809004: 2008 Document No: CG-G-7.42 ]Version No: 7.0 Date Effective 23.03.2011 Document Tile: Guidelines for preparing QAP during registration = Classification oftature [5S se 5 eee 22 . 2 {8 - 2/2 s “Ee |S |g |s 8 BLE £ z 3 B jo |8 |g5 3 3 | 8 Boros =3 12 |e |s |g = B|s Saaee gs |e oe |e g Cees S23 05o 5 |= © |§2/s Se ea ee eeestee coo) 8 (Seg 3 |E/a | 3 fg255s S8e| 5 o, |s8 |® B/2 3 Eg lese Bse Se|/o5 0 zie || | seEsSe 225) 2 2/2 5 a oa =| 6 o BSS 23 S32} Oo S105 |o | * The firm shall maintain a complaint register in the above format and the summary required to be given during renewal. 4.8 ANY ADDITIONAL INFORMATION FIRM WISH TO SUBMIT The firm can furnish any other information which they wish to submit on items other than furnished in annexure A to F. Note 1.QAP covering all the information as asked above under section ‘A’ to ‘F’ must be given in the form of single document indicating name of the firm and page no. ‘x’ of 'y’ on each page. Each page should be signed by Quality Control in-charge. The approved QAP must be a controlled document and a quality record of ISO Quality Control System of the vendor. A certificate to this effect shall be provided along with the QAP by the vendor. In case of the QAP for sublet items, itis to be provisionally approved by the sponsor and final approval shall be given by the nominated officer for capability assessment One copy of the QAP, after final approval will be given back to the vendor for implementation 2. Standard format for QAP Cover Page ‘QUALITY ASSURANCE PLAN’ should be written in bold preferably in 8 to 10 mm letter size. Name of the firm should be given in bold, with complete address of works and Head office Specification no. of the product (with product name) Edition No. Revision No. (On Top right hand side of the cover sheet) Date of issue (On Top right hand side of the cover sheet) SEIE 8S/Cartiage IDE &5/Carriage Printed: 23.03.2011 Prepared By: Issued By Page 8 of 91$09001:2008 Document No: CG-G-7.1-2 [Version No: 1.0 Date Effective | 23.03.2011 Document Tile: Guidelines for preparing GAP during registration ‘Approved by: ~ Date: - (On bottom side of the page) -- (On bottom side of the page) Designation (On bottom side of the page) QC In charge Total No. of pages. (On bottom side of the page) 2nd Page Index paper/index Table 3rd Page Company/Firm Profile ath Page Company/Firm's Quality Policy. The QAP should also contain Werk Instruction of Manufacturing of product. (Brief details of manufacturing Process in write-up form) Testing of product. ‘Sublet of Vendor selection/ Evaluation their format Written on! 5.0 Referenced Documents: None 6.0 Referenced Documents of External Orig None 7.0 Associated Records: None 8.0 Responsil | —Rainiy Response ES 6g RRR eSRCATTNND Creation, maintenance of | JD/E&S ED/Carr | SE/E&S 1SO Cell All directorates ths document through intronet 9.0 Abbreviations: None. I SEVE &S/Cartiage IDIE &SiCarriage [ Printed: 23.03.2011 4 I Prepared 8 Issued By: Page 9 of 9