Road Map to convert a QUALITY CONTROL division in to QUALITY ASSURANCE in manufacturing industries

1. QUALITY ASSURANCE
QUALITY CONROL QUALITY ASSURANCE
QC FOCUSED ON IDENTIFYING
DEFECTS
GOAL-QC aims to identify (and
correct) defects in the finished
product. Quality control,
therefore, is a reactive process.
Q.A. FOCUSED ON PREVETING
DEFECTS
GOAL-QA aims to prevent
defects with a focus on the
process used to make the
product. It is a proactive quality
process.

2. QUALITY ASSURANCE
IMPLEMENTATION AREAS
STORES(IQA)
BSR (OQA)
LAB/PRODUCTION
/PACKING(IPQA)

3. QUALITY ASSURANCE
1.0 STORES(IQA)
RAW MATPKG MAT
DEFINED INSPECTION PLAN AND
PROCEDURE FOR INSPECTION
ISSUE OF CONTROL NUMBER TO EACH RAW
MATERIAL AND PAG MATERIAL BY Q.A. SAME
WILL BE DISPLAY ON LOT OF RAW MATERIAL
AND PACKING MATERIAL-LINK THIS NUMBER
WITH ERP(SYSTEM TO BE DESIGNED IN
COORDINATION WITH ERP TEAM
2.0 PRODUTION-(I)(IPQA)
FOCUSSED ON CALIBRATION OF WEIGH
BALANCES/SCALES
WILL ENSURE THE SAMPLING PROCEDURE
IS FOLLOWED
WILL ENSURE THE FIFO IS MAINTAINED
DURING TRANSFER OF CONTAINERS TO
PACKING AREA
RECORDS OF EACH ABOVE STEPS FOLLOWED IN
PRODUCTION AREA
WILL CHECK THE PROPER SIEVING OF
MATERIAL

4. QUALITY ASSURANCE
• 2.0 PRODUTION-(I)(IPQA)
HANDELLING OF LINE SAMPLES DURING
PROCESSING OF BATCH
LINE SAMPLES-TESTING AS PER PROCEDURE
,RESULTS WILL BE RECORDED,THESE SAMPLES WILL
BE COLLECTED BY Q.A. INSPECTOR IN
COORDINATION WITH PRODUCTION OFFICER
ANY DEVIAVTION IN RESULT OF TESTING BE
RECORDED AND CONVEYED TO PRODUCTION
IMMIDIATELY AND WILL BE DEALT WITH
CAPA
FINAL BATCH WILL BE SIEVED( PROPER
MONITORING BY Q.A.) ,SAMPLE WILL BE COLLECTED
BY Q.A. INSPECTOR,TESTING AS PER QUALITY PLAN
FINAL BATCH –AFTER TEST RESULT OF BATCH WILL
BE MAINTAINED IN LAB B.P.R (BATCH PRODUCTION
RECORD)BATCH NUMBER WILL BE ISSUED AS PER
QUALITY PLAN
3.0 FILLING AND PACKING-(II)
PACKING PLAN WILL BE ISSUED BY PRODUCTION
AS PER SCHEDULE
BOM OF PACKING WILL BE GENERATED AS PER
PACKING PLAN,EACH PACKING MATERIAL WILL BE
ISSUED AS PER PLAN , THERE WILL BE PROVISION
OF ISSUE OF STANDARD EXCESS QUANTITY AS PER
IDEAL LINE REJECTION IN PARTICULAR PACKING
MATERIAL, EACH PCKING MATERIAL WILL HAVE
CONTROL NUMBER ISSUED BY QUALITY ASSURANCE
TO ENSURE THE FIFO IS MAINTAINED.
FILLING AND PACKING WILL BE STRICTLY AS PER
PLAN,THERE WILL PROPER MONITORING OF
PACKING ,PROVISION OF VARIOUS REPORTS
ENCLOSED WITH THIS BOM –CLEANING OF FILLING
MACHINES ,OVER SIZE TESTED ,LINE
INSPECTION,WASTAGE CALCULATION OF PACKING
MATERIAL AND PRODUCT YIELD ,W.I.P IF
ANY,SFG BALANCE IF ANY AFTER PACKING WILL BE
RECORED IN BPR

5. QUALITY ASSURANCE
POST PACKING ACTIVITIES
EACH MATERIAL PACKED IN PACKING
SECTION -PACKING RELEASED BY Q.A.
INSPECTOR FOR TRANFER THE GOODS IN
BSR
4.0 BSR ACTIVITIES
Q.A.INSPECTOR WILL ENSURE THE QUALITY OF GOODS DISPATCHED
AS PER SALES ORDER(RETESTING OF BULK BEFORE DISPATCH TO
ENSURE QUALITY)
TERMINAL INSPECTION OF GOODS DISPACHED WILL BE CARRIED AS PER
STATISTICAL QUALITY PLAN, AFTER INSPECTION GOODS WILL BE READY
FOR DISPACH, Q.A. WILL ISSUE A CLEARANCE SLIP TO BSR AFTER
INSPECTION

6. QUALITY ASSURANCE
B.P.R-BATCH PRODUCTION RECORD
DOCUMENTATION
RECORD OF PRODUCTION (I),RECORD OF
FILLING AND PACKING(II)COMPLETE
HISTORY OF BATCH INCLUDING DISPATCH
DETAILS,YIELD RECORD,AUDIT REPORT OF
BATCH.
ERP SUPPORT FOR
STORE-ISSUE OF CONTROL NUMBER
OF PACKING MATERIAL RAW
MATERIAL
PRODUCTION PLAN,PACKING
PLAN,ISSUE OF BOM ,ISSUE OF
BOM FOR PACKING
BATCH RELEASED QUANITY AND
ISSUE OF BATCH NUMBER

7. QUALITY ASSURANCE
REQUIREMENT S TO IMPLEMENT QUALITY ASSURANCE
MANPOWER OTHERS
STORE-2
PRODUCTION-5
BSR-1
TWO COMPUTER LINK WITH
ERP/LAB ERP/LAB MASTER
PACKAGE ETC.
PHYSICAL TESTING EQUIPMENTS
FOR PROPER MONITORING IN
PACKING- LEAKAGE TESTER,HOT
AIR OVEN,

8. QUALITY ASSURANCE
BENEFITS OF IMPLEMENTING Q.A.
•WASTAGE CONTROL BY PROPER MONITORING SYSTEM.
•OVER ALL PRODUCT QUALITY WILL BE ENHANCED.
•BETTER YIELD OF PRODUCT AND PACKING MATERIAL.
•CONSISTANTCY IN PRODUCT QUALITY.
•CUSTOMER FAITH WILL ENHANCED.