QUALITY MANAGEMENT SYSTEM

FOR BUTTERFLY-1
Muhammad Naveed Aslam
MS-DME-17-205934
Outline
• What is Quality Management System (QMS) ?
• Why does MRC need QMS in Butterfly-1 Project?
• Recommended Quality Standard for Butterfly-1 Project
• Basic Steps in Implementing a QMS
• Our Strategy for Developing QMS for Butterfly-1
• QMS for Prototype of Butterfly-1
• QMS for Production of Butterfly-1
• Final Quality Tests for Butterfly-1
• After Sales Services
 What is Quality
Management
System (QMS) ?

A Quality
Management
System (QMS) is a
formalized system
that documents;
1. Processes
2. Procedures
3. Responsibilities
for achieving;
Quality Policies
&
Objectives

The objective of QMS is to deliver and satisfy customer needs

Elements
of QMS
1. Customer Focus
2. Vision/Scope
3. Mission
4. Quality Objective
5. Processes / Policies
6. Resources
7. Data based
analytical approach
8. Continual
Improvement
Process
 1. Quality Policy
Elements 2. Processes and their descriptions
of QMS (Contd.)
3. Resources that are to be used
Quality Manual: 4. Product/service that needs to be
delivered
A document that
describes how an 5. Approach for Continual improvement
organization is going
to handle all these 6. Records and documents that needs
elements. to be documented and managed
7. Auditing mechanism for compliance
to QMS
8. Approach for data based analysis
and process correction
Quality Manual
Contains
Are ISO 9001 and QMS the same?
“YES”
• ISO 9001 is a QMS that is
used across the globe by a
huge number of
organizations.
• ISO 9001 is a standard
developed by ISO
(International Organization
for Standardization).
“No”
• ISO is not the only QMS.
Organizations can develop
their own QMS catering to
their business needs.
• It can include principles from
ISO 9001 or adopt the
whole of the ISO 9001
standard, or be a totally
different QMS.
• It is up to the organization
and its management needs.
What are the benefits of using a QMS?
1. QMS brings a defined approach to achieve the objectives of an
organization
2. It sets a standardized requirement for all functions and
departments
3. Implementation of QMS increases the confidence level of the
customers on your product/service
4. QMS ensures that the objectives of the organization are linked
towards the customer needs and thus creates a perfect value
chain
5. Implementation of QMS increases the effective use of resources
6. It sets clear objectives for each job role and each team, and thus
miscommunication and ambiguity in the way of processing is
avoided
7. It enables an organization to understand its pain areas, customer
complaints and concerns, and work towards it
Why does MRC need QMS in Butterfly-1 Project?

1. Fast-Tracks Market Time

2. Improves Bottom Lines
3. Improves Product
4. Ensures Compliance
5. Improves Customer Relation
Recommended Quality Standard for Butterfly-1 Project

• ISO TS 16949
Basic Steps in Implementing a QMS

• The design and build portions serve to develop the structure of a QMS, its processes, and plans
for implementation
Design & • Senior management must oversee this portion to ensure the needs of the organization and the
Build needs of its customers are a driving force behind the systems development.

• Deployment is best served in a granular fashion via breaking each process down into sub
processes, and educating staff on documentation, education, training tools, and metrics
• Company intranets are increasingly being used to assist in the deployment of quality
Deploy management systems

• Control and measurement are two areas of establishing a QMS that are largely accomplished
through routine, systematic audits of the quality management system
Control & • The specifics vary greatly from organization to organization depending on size, potential risk,
Measure and environmental impact

• Review and improvement deal with how the results of an audit are handled
• The goals are to determine the effectiveness and efficiency of each process toward its
Review & objectives, to communicate these findings to the employees, and to develop new best practices
Improve and processes based on the data collected during the audit
Strategy for Developing QMS for Butterfly-1

QMS for Butterfly-1 Project

For After Sale

For Prototype For Production For Overall Tests
Services

In-House Determine After

Develop ATP’s Purchased Parts Out Sourced Parts
Manufactured Parts Sale Service

Develop Process Develop Process Develop Process Develop Process

Flow Charts Flow Chart Flow Chart Flow Chart

Develop Route Develop Inspection Develop Inspection

Sheets Form Form

Develop Job
Progress/Planning
Form

Develop Inspection
Form
QMS for Prototype of Butterfly-1

• It is required to develop a test procedure for the prototype of

Buttefly-1 project
• At Prototype Level, Acceptance Test Procedures (ATPs) for
Performance/Functional tests are performed
• In ATPs we define the following items for a specific part test;

• Criteria • Methodology • Equipment • Results

1 2 3 4
Prototype Test
Plan for • The purpose of this Test Plan and Procedure is
Butterfly-1 to establish the overall approach, testing
sequence, and specific tests to be conducted

1. to demonstrate successful operation of the

Objective prototype of Butterfly-1

• The plan and procedures are designed to

verify stable, safe operational performance

of the prototype
 • In the references of Butterfly-1 Project,
Prototype Test
following are some required details;
Plan for
Butterfly-1
(Contd.)
• Butterfly-1 is a 250CC
car’s prototype
2. 1. Prototype developed in MRC,
References Description NUST

• Engine Power: 250 CC

2. Prototype • Type: 4 Wheel
• Body: Fiber Glass
Specification
Prototype Test
Plan for • Four types of test are suggested to be
Butterfly-1 performed on prototype of Butterfly-1.
(Contd.)
Test Name Objective
3.
Fuel Consumption Test To Check the Fuel Consumption of
Identification Prototype
Power Generation Test To Check the Power Generation of
of Tests Prototype
Turning Radius Test To Check the Turning Radius of Prototype

Stopping Distance Test To Check the Stopping Distance of

Prototype when brakes are applied

Exhaust Gases Quality To Check the Efficiency and Conformance to

Test Environmental Standards of Exhaust Gases
Prototype Test
Plan for It is suggested that;
Butterfly-1
(Contd.)
• All these tests will be performed on “System

4. Level”
Testing • Source of test data should be real
Approach
Prototype Test
Plan for • Schedule for the tests is a mandatory
Butterfly-1 requirement
(Contd.)

5. • Test Schedule will be developed according to

Test the situation when MRC want to perform
Schedule
prototype tests
Prototype Test
Plan for • Fault reporting and data recording for prototype
Butterfly-1 tests is very important step to be carried out
(Contd.)
very carefully.

6.
Fault • In our case for Fault Reporting and Data
Reporting
Recording of all these Four Tests are done in
&
ATP’s designed for each test.
Data
Recording
Prototype Test
Plan for
• Resource Requirements of these tests are;
Butterfly-1
(Contd.)
S. Test Name Required Resources
7. # (Equipment + Manpower)
1 Fuel Consumption Test  Odometer
Resource  Test Team (3 People)
Requirements 2 Power Generation Test  Odometer
 Test Team (3 People)
3 Turning Radius Test  Meter Tape
 Test Team (3 People)
4 Stopping Distance Test  Electronic Sensor
 Test Team (3 People)
5 Exhaust Gases Quality Test  Lab Distillation Tower
 Test Team (3 People)
Prototype Test
Plan for
Butterfly-1
(Contd.)

8.
Test Test procedures are described in
ATP’s designed for these tests
Procedure
ATP for Fuel Consumption & Power Generation Test
ATP for Turning Radius Test
ATP for Stopping Distance Test
ATP for Exhaust Gases Quality Test
QMS for Production of Butterfly-1
Quality Management System for Butterfly-1 Project requires a lot of
documentations, the main requirements of MRC are;

Flow Charts for Manufactured Components

Flow Charts for Purchased/Outsourced Components

Route Sheets for Manufactured Components

Quality Inspection Reports for Manufactured Components

Quality Inspection Report for Purchased/ Outsourced Components

Job Progress & Planning Form for manufactured Components

Documents for the ISO 9001- 2015 Certification

1. Manufactured Parts of Butterfly-1
The components of Butterfly-1 which are being
manufactured at Manufacturing Resource Centre NUST
are;
• Chassis

• Wiring

• Assembly

• Other Components
 Manufactured
Parts of
Butterfly-1

Process Flow Chart

for Manufactured
Components of
Butterfly-1

Note:
1. Flow Chart is Considered
for Machined Components
2. For other Processes
Replace Process with
machining in this Flow
Chart
Manufactured
Parts of
Butterfly-1

Route Sheet
for Manufactured
Components of
Butterfly-1
Standard Route Sheet for Manufactured Components
Job Progress/ Planning Form for Manufactured Components
Quality Inspection Form for Manufactured
Components
2. Purchased Parts of Butterfly-1
 Engine 250cc 5-Gear  Head Light (Core)

 Radiator water cooled  Dashboard (Mehran)

 Meter
 Air filter

 Fuel Tank
 Fuel Pump (Local)
 Seats
 Break Cylinder
 Steering
 Suspension System
 Leaf Spring
 Body
 Gear Box
 Mirror (FX)
 Shocks
 Lock (86 Corolla)  Tire
 Purchased
Parts of
Butterfly-1

Process Flow Chart

for Purchased
Components of
Butterfly-1
Quality Inspection Form for Purchased Components
 Outsourced • Will be added later
Parts of
Butterfly-1

Process Flow Chart

for Outsourced
Components of
Butterfly-1
Quality Inspection Form for Outsourced Components
Documents for ISO 9001-2015 Certification
In future there will be a great need for MRC to get ISO 9001-2015
certification to meet the ever growing competition in the market.

1. Scope of MRC

2. Objectives of MRC

3. Gap Analysis and planning to meet Objectives

4. Organogram of MRC

5. List of Job Description

6. Job Descriptions

7. Working Procedure of MRC

Documents for ISO 9001-2015 Certification (Contd.)
8. Customer Handling Procedure
9. Process Flow Chart
10. Forms
• Job Progress form
• Job Planning Form
• Quality Inspection Form
• Feedback Form
11. List of equipment’s required calibration
12. List of equipment’s not required calibration
13. On job training procedure
14. Preventive and corrective maintenance schedule
15. Quality Policy of MRC
Final Quality Tests for Butterfly-1
The following sections cover the common acceptance test
requirements for vehicle compatibility with the Country Regional
Network (CRN) infrastructure.

• There are two categories of tests;

Static Tests • Static tests/inspections are carried out prior to any movements of
the vehicle on the CRN

• Dynamic tests are required before full operating approval is

Dynamic granted for the vehicle.
• These tests can only be commenced after successful completion

Tests of all the static tests and a CRN TOC Waiver has been issued.
Standard Static Tests for Vehicle
Standard Dynamic Tests for Vehicle
 • This test is designed to ensure that the vehicle is
Static Vehicle compatible with the track twist limits of the CRN, without
Test Proposed exceeding an acceptable level of wheel unloading.
• Vehicles shall be twist tested in the operating configuration
for Butterfly-1 tending to give the highest wheel unloading.
• This will require the test to be undertaken with the vehicle
at minimum tare condition.
• For locomotives this means minimum fuel and sand. For
Static Vehicle passenger vehicles, symmetrically located tanks shall be
Twist Test empty.
Static Vehicle • A static brake test shall be conducted in
accordance with CRN Standard CRN RS 008
Test Proposed
Section 7. Static brake tests include the
for Butterfly-1 following, where applicable, for each type of
vehicle and in some cases, each individual
vehicle.
a) Measurement of brake block force and
Static Brake
calculation of net brake ratio
Test
b) Single car air test
c) Parking/hand brake holding test on a grade
d) Static brake valve operation test
e) Operation of Driver Safety Systems
• Brake performance testing is designed to
ensure that all self-propelled vehicles and
multiple unit trains operate safely within the
current signaling limits.
Data Sheet
Static Vehicle • Lights Test
Test Proposed Check that all required lights are fitted in accordance
with CRN Standard CRN RS 008, Section 8.3,
for Butterfly-1 positioned correctly and operate as required.

Safety • Horns Test

Equipment Horns shall be tested for functionality and noise levels
Functionality checked for compliance with that specified in Table 5
Tests in CRN Standard CRN RS 008.
The horn sound shall be measured with the vehicle
stationary in an unobstructed location with no
significant reflecting infrastructure within 50 meters of
the line of sight between the horn and the sound level
measuring device.
Static Vehicle • Noise Test
Test Proposed All rolling stock shall comply with the noise
requirements as specified in CRN Standard CRN-RS-
for Butterfly-1 008, Section 14 and reporting shall comply with CRN
Standard CRN RS 017.
The results of noise tests must be recorded on the
standard noise test reporting form.
Environmental 1. Noise Test Data Recording Form CRN RF 009
Tests 2. Locomotive Noise Test Recording Spredsheet.xls CRN RF
010

• Vibration Test
All rolling stock shall comply with the vibration
requirements as specified in CRN-RS-008, Section 14.
Type testing will apply to all rolling stock of the same
vehicle type provided there have been no substantial
modifications to any one vehicle, in which case, that
vehicle shall also be tested.
Static Vehicle • Air Quality Emission Test
Test Proposed All powered rolling stock shall comply with the emission
requirements as specified in CRN-RS-008, Section 14.
for Butterfly-1 Emission testing shall include:
1. Visible smoke
2. Nitrogen oxides (NOx)
3. Particulates
Environmental 4. Carbon monoxide
5. Hydrocarbons (VOC)
Tests
6. Exhaust flow
7. Sulphur Dioxide (SO2)

• Waste Management Inspection

Waste handling equipment fitted to vehicles shall be
inspected to ensure all waste material is retained and
not discharged to track.
Waste material includes brown water and grey water on
passenger vehicles as well as fuel, oil, coolant water
and sand leakage/overflow from locomotives and other
engine powered vehicles.
Static Vehicle • Ride Performance Test
Test Proposed A ride performance test is designed to ensure vehicle
compatibility with the track and to establish the
for Butterfly-1 optimum vehicle operating conditions to provide
minimum damage to the track and meet acceptable
train pathing requirements.

Environmental
Tests • Pitch and Bounce Performance Test
A pitch and bounce test is designed to determine the
vehicle critical speeds for pitch and bounce and
ensure that the vehicle suspension is adequately
damped to control vehicle oscillations created when
negotiating cyclic vertical track perturbations at the
critical speed.
Final Quality • Shower Testing is standard prescribes the
procedure for conducting waterproofing test on
Tests for
all automotive vehicles with enclosed
Butterfly-1 compartments for carriage of passenger/
goods, by creating test conditions like those in
rainy seasons to which an automotive vehicle
is likely to be exposed to.
Shower Test
• This shower facility is set up to make an
artificial shower on the test vehicle. It consists
of a concrete floor with adequate facility to
drain-out the water. Over this floor a super
structure of pipe network is built. The super
structure is of adequate height, width and
length to accommodate the test vehicle
underneath it.
Final Quality • Procedure:

Tests for
Butterfly-1 The test vehicle shall be placed stationary inside
shower tester and shall be subjected to the
artificial shower. The engine shall be kept idling,
wipers in action and head lights on. Water entry
Shower Test inside the vehicle shall be observed and shall be
recorded.
• Acceptance Criteria:

There shall be no water entry of any type into

any of the enclosed volume such as
compartment for driver/ crew/passengers, boot
(luggage compartment) and enclosed loading
compartment or load body.
Final Quality • Power-to-weight ratio is a calculation
commonly applied to engines and mobile
Tests for
power sources to enable the comparison of
Butterfly-1 one unit or design to another. Power-to-weight
ratio is a measurement of actual performance
of any engine or power source.
Power to
Weight Ratio • Data is collected as under;
Test
After Sales Services
• In after sales services MRC should provide at least
following services;

After Sales Maintenance

Supply of Spare Parts

 After Sales
Maintenance

Process Flow
Chart

Note:
PLM plays important role
here