Quality Control

Saj's quality control department has a quality control manager certified by the Institute of Standards and Industrial Research. In line with the product monitoring and measurement procedure and its job descriptions, the department works at three stations: A) incoming materials and parts inspection, B) in-process inspection and C) final product inspection, as described below.

Incoming materials and parts inspection

Incoming materials and parts are inspected as follows:

1. 1The storekeeper notifies quality control that items have arrived at the warehouse by sending the goods receipt note.
2. 2Quality control inspects the incoming goods against the quality plans. Non-conforming parts take priority when results are recorded, and 5 samples of them are entered on the dimensional inspection results sheet.
3. 3If raw materials or incoming goods require analysis, quality control sends samples to accredited external laboratories. The sampling method is set out in each product's quality plan. Incoming inspection may therefore include material analysis, mechanical property tests or dimensional measurements.
4. 4On receiving the analysis report or mechanical test report, the quality control inspector checks the result against the standard and the order requirements. Once approved, the goods receipt note (warehouse receipt) is signed by the quality control inspector and the goods are cleared for storage.

Where there are minor deviations from the analysis report but no non-conformity affecting quality, quality control authorises the use of the material in production.

1. 5Once goods have passed incoming inspection, the storekeeper must attach the raw material traceability and identification form to the consignment.
2. 6In exceptional cases, incoming materials and parts may be released for urgent production before verification. The quality control inspector then marks "Emergency release" on the traceability and identification forms, so that if the material proves not to meet the specified requirements it can be recalled and replaced immediately.

In-process inspection

This procedure is designed to detect non-conformities at every stage of production and so assure production quality. To that end, the following steps are taken:

1. 1When production starts, the first parts are inspected by the quality control inspector against the quality plan prepared for each product, and the results are recorded on the relevant forms. If there is no deviation, production continues. If there is a deviation, the quality control inspector issues a non-conforming product identification and report sheet, and quality control decides on the disposition of the non-conforming product in accordance with the non-conforming product control procedure.

At any stage, if corrective or preventive action is required, it is carried out in accordance with the corrective action procedure or the preventive action procedure. Once the non-conforming product has been dispositioned, corrective or preventive action taken and the causes of the non-conformity removed, quality control issues permission to resume production.

1. 2Inspection is carried out by operators using the definitions on the process sheet (production technology), and by quality control inspectors according to the quality plans at defined intervals, with the results recorded on the relevant forms. If a non-conformity is found at any stage, production is stopped and the steps in item 1 are repeated until its causes are removed.
2. 3Production staff continue production according to the process sheet, and the quality control inspector continues inspection according to each product's inspection plan.
3. 4Non-conforming parts found during production are placed in the red box reserved for non-conforming parts, and the quality control manager must sort them once every two weeks.

Scrap parts must be sent to the scrap store, and reworkable parts must be reworked.

1. 5During production, when parts are transferred to the semi-finished goods warehouse, they are cleared for storage only after quality control approval, given by the quality control stamp and signature on the goods receipt note (warehouse receipt).

Final product inspection

This part of the procedure ensures that all specified inspections and tests have been carried out on product ready for release. To that end, the following steps are taken:

1. 2After quality approval, the product is cleared to enter the warehouse. Once packing is complete in the finished goods warehouse, quality control inspects the packaging of product ready for dispatch. The characteristics to be checked are defined in the quality plans.
2. 3If a non-conformity is identified by the packing operator or by the quality control inspector, action is taken in accordance with the non-conforming product control procedure.
3. 4After packing, the product is ready for dispatch. The packing operator checks 100% of products for appearance and correct arrangement according to the process sheet.
4. 5Packing and its inspection are carried out on 100% of products by the packing operator according to the process sheet. Quality control carries out random checks according to the quality plans.

Product quality report (TEST REPORT)

When initial samples of parts are sent to a customer, a quality report is sent with them (if the customer requests it, especially vehicle manufacturers). The report covers raw material analysis, mechanical and metallurgical properties, a dimensional report and, where required, other special characteristics. The TEST REPORT is prepared by the quality control manager.