AGROSHAPE [PVT] LTD

TITLE: MANUFACTURING
DOCUMENT NO: PROD-P01 Page 1 of 4

DOCUMENT TYPE EFFECTIVE DATE: PREPARED BY: APPROVED BY: REVISION NUMBER:

PROCEDURE 01/11/2012 PRODUCTION MANAGER TECHNICAL SERVICES 1

MANAGER

1.0 Purpose
This Procedure provides a documented manufacturing process for finished products.

2.0 Scope
The Procedure covers processing of raw materials into finished products.

3.0 Responsibility and authority

The Production Manager is responsible for the implementation, maintenance and
amendment of this procedure.

4.0 Definitions
4.1 Trial Kitting
Checking, from the computer (Tetra 2000), on the availability of raw materials, in
order to establish the possibility of manufacturing a particular product.
4.2 Open stock
Excess product, usually less than the minimum pack size (e.g. less than 5kg,
where this is the minimum pack size), retained for blending into fresh batches or
for customer samples.

5.0 Description of activities

Step
No Activity Responsibility
5.1 Do Trial Kitting in the ERP System (i.e. Tetra 2000) to confirm production Production
possibility as per Confirmed Orders. Check physically the stock available if Manager
the ERP System is down.
5.1 Enter the relevant details on the Production Planning Board which has the Production
format PROD-P01-1. Manager
5.2 a. Generate a Works Order from the computer if the ERP System is up, Production
and request for the Manufacturing Instructions from the Technical Manager
Services Manger. Issue it to the Production Supervisor.
b. Write a Manual Works Order Form when the ERP System is down, or QC/ R & D
when available raw materials are not yet entered into the ERP System Technician
and submit it to the Production Manager/ Supervisor together with the
Manufacturing Instructions.
5.3 Write, or enter, the Batch Number on both the Works Order and in the Production
 AGROSHAPE [PVT] LTD
TITLE: MANUFACTURING
DOCUMENT NO: PROD-P01 Page 2 of 4

DOCUMENT TYPE EFFECTIVE DATE: PREPARED BY: APPROVED BY: REVISION NUMBER:

PROCEDURE 01/11/2012 PRODUCTION MANAGER TECHNICAL SERVICES 1

MANAGER

Production Log Book. Supervisor

5.4 Authorize the use of Open Stock, if any, after verification by the QC/ R & D
Laboratory. Technician
5.5 Ensure that ALL raw materials/ packaging to be used in production are In-process QC
inspected/ verified by the Laboratory before being used. Technician
5.6 Report any defective packaging discovered during packing to the Machine
Production Manager/ Technical Manager who will investigate and proceed Operator.
as per the Control of Non-conforming Product Procedure, QMS-P07.
5.7 Issue the Works Order to the Weigh man and the respective Production
Manufacturing Instructions, who will draw the relevant raw material Supervisor
quantities from Stores, weighing them to conform to Works Order and in
accordance with Manufacturing Instructions.
5.8 Verify the actual raw materials for correctness of identity and quantities In-process QC
against those stated on the Works Order and record on an In-Process QC Technician
Form, PROD-P01-2.
NOTE: The In-Process QC Form will be used for AI and RH Products.
5.9 Record the Batch Number (s) of each raw material used against the Weigher
respective raw material description on the In-Process QC Form, PROD-
P01-2.
5.10 Communicate the Batch Size to the Machine Operator, so the latter can Production
start thorough cleaning of the appropriate Mixer (The mixer to be used is Supervisor
determined by the Batch Size except in Tylon).
5.11 Verify that the Mixer is clean and authorize commencement of production In-process QC
and record on the In-process QC Form, PROD-P01-2. Technician
5.12 Take the weighed raw materials and the respective Works Order to the Weigher
Machine Operator, for verification.
5.13 Load the raw materials into the Mixer, following Manufacturing Instructions. Machine
Operator
5.14 Verify that the Manufacturing Instructions are being followed, paying In-process QC
particular attention to the following, Technician
a. Sequence of loading and mixing raw materials
b. Manufacturing temperature, if any
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TITLE: MANUFACTURING
DOCUMENT NO: PROD-P01 Page 3 of 4

DOCUMENT TYPE EFFECTIVE DATE: PREPARED BY: APPROVED BY: REVISION NUMBER:

PROCEDURE 01/11/2012 PRODUCTION MANAGER TECHNICAL SERVICES 1

MANAGER

c. Mixing time, if stated

d. Any sensitive raw materials that may need special conditions and/or
environment, before they are added.
5.15 Ensure that product is well mixed and submit a sample to the QC Machine
Laboratory, together with the Manufacturing Instructions, for verification at Operator
the appropriate stage as stated on the Manufacturing Instructions.
5.16 Recommend any adjustments (which may require drawing additional raw QC/R & D
materials), if initial product is not meeting QC specifications. Technician
5.17 Weigh the raw material adjustments under the supervision of the In- Weigher
process QC Technician and submit them to the Machine Operator.
5.18 Re-submit a sample to the QC Laboratory, together with the Manufacturing
Instructions, for verification when mixing is completed.
5.19 If the Product passes, write QC results on the Works Order, and QC/ R & D
communicate verbally to the Machine Operator/ Production Supervisor to Technician
start decanting the product.
5.20 Immediately withdraw the Manufacturing Instructions from Production and QC/ R & D
file it back into the formulation file in the sachet that hold the main Technician
formulation of that product.
5.21 Stamp the Works Order to indicate specific QC status after the Final QC/ R & D
Inspection stage as per Final Inspection Procedure TECH-P09. Technician
QC Status can be:
a. QC Passed Stamp- Product conforming to specifications.
b. Hold Sticker- Pending further investigations.
c. QC Failed Stamp- Failed to meet the specifications after doing all that
can be done to adjust the product.
d. Reject Sticker- To identify the QC failed product upon the product
having failed.
5.22 Handle QC failed products as per the Control of Non-Conforming Product Production
Procedure - QMS-P07 Manager

6.0 Records
Record Record Title Location/Holder Retention Period
PROD-P01-1 Production Planning Board Production Plant Maintained current
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TITLE: MANUFACTURING
DOCUMENT NO: PROD-P01 Page 4 of 4

DOCUMENT TYPE EFFECTIVE DATE: PREPARED BY: APPROVED BY: REVISION NUMBER:

PROCEDURE 01/11/2012 PRODUCTION MANAGER TECHNICAL SERVICES 1

MANAGER

PROD-P01-2 In-process QC Form In-process QC Technician 3 years

PROD-P01-3 Manual Works Order Production Supervisor 3 years
Computer Works Order Production Supervisor 3 years
Production Log Book Production Supervisor 3 years
Manufacturing Instructions Production Supervisor Permanent
Daily Production Plan Report Production Manager 3 years

7.0 References
7.1 Product Identification and Traceability Procedure – PROD-P04
7.2 Control of Non-Conforming Products Procedure QMS-P07
7.3 Raw Materials & Finished Product Analysis Procedure – TECH-P07