The document summarizes the findings from a third party audit of ISO 9001:2008 standards at a cement plant. It lists three minor non-conformances related to mechanical maintenance and provides details of each. For the first finding about weakness in the corrective action process, the plant responded that they would implement a root cause analysis using a "why why technique" and corrective actions to prevent reoccurrence. For the second and third findings around safety compliance and document retrievability, the plant provided brief details of improvements made.

1. THE K C P LIMITED, CEMENT UNIT I
MACHERLA
1 b. Third party Audit Findings Status – ISO 9001:2008 Std. First Surveillance Audit by LRQA from 21st
– 24th
September 2015
Ref. No. Findings Corrective action Proposed / Taken
Mechanical Maintenance
1509SSK01
Minor NC
Weakness noted in the Corrective action process
Mechanical, E&I stoppage report from jan to Aug 2015 reviewed. Total stoppage
of 18.11 observed in Cement mill. Sampled for Stoppage of 8.42 hrs due to
water spray nozzle pipe cutoff in cement mill dtd 29 Mar 2015 and mill discharge
air slide cloth damage and 2 times inlet chute jammed dtd 17 April 2015
resulted in 7.92 hrs of stoppage. Other stoppages resulted in 14.81 out of overall
stoppage of 36.08 for the period of Jan 2015 to Aug 2015 in cement mill.
No analysis evidenced
As per procedure for Resolving Non conformities during Stoppage of Equipment –
PR/MT/04, Reporting in Non Conformance Report – RC/0081 and CAPA analysis
not evidenced
ISO 9001:2008 clause 8.5.2 states that the organisation shall take action
to eliminate the causes of the nonconformities in order to prevent recurrence.
Corrective actions shall be appropriate to the effects of the nonconformities
encountered.
This has potential impact of not eliminating the root cause of the problem
and the same problem may reoccur.
Root cause analysis process by implementing the why why
technic for ascertaining and analyzing the causes of
operational problems and corrective actions are being taken
to prevent them.
--
RC/0011 A
Page 6 of 125

2. THE K C P LIMITED, CEMENT UNIT I
MACHERLA
1 b. Third party Audit Findings (Observations/Suggestions) Status – ISO 9001:2008 Std. First Surveillance Audit by LRQA
from 21st
– 24th
September 2015 (Contd…..)
Sl. No. Findings Corrective action Proposed / Taken
Mechanical Maintenance
1. Identification and inspection status display of Lifting baskets for
handling materials to be improved
Calibration details and capacity of lifting basket has been displaced
for better clarity.
2. Safety compliance using Fire extinguishers in Hot works at RABH
bag house as per Hot work permit to be strengthened
Hot work permit system is being maintained effectively and also
fire extinguishers being provided in all the required areas.
3. Retrievability of documents and records in ERP to be improved Awareness about the data available in application domains has
been improved.
RC/0011 A
Page 7 of 125