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Quality Management Project:
Zamil Steel India Pvt. Ltd.
By: Akhil Singhal 3263
Anushka Srivastava 3269
Rahul Raisinghani 3293
 Zamil Steel manufactures more than
500,000 tons of fabricated steel per
annum of low rise and high rise steel
buildings and structures for diverse
industrial, commercial, agriculture,
aviation, entertainment and military
applications and support of
infrastructure and development projects.
 Zamil Steel’s main factories are based
in India, Saudi Arabia, Egypt, Vietnam
and United Arab Emirates. More than
600 engineers are employed in its
engineering departments in Chennai,
Cochin & Pune, besides its global
engineering networks in Saudi Arabia,
Jordan, United Arab Emirates, Egypt,
and Vietnam
 Inaugurated: February, 2008
 Total area: 87,000 sq. meter
 Covered area: 55,000 sq.
meter
 Production Capacity: 60,000
MT per annum
 Total employees: 500
 Inventory Storage Capacity:
1 month
 Total Quality Inspectors: 30
 RAW MATERIAL
INSPECTION [1st STAGE]
 FIT-UP INSECTION [2nd
STAGE]
 PRE-DISPATCH
INSPECTION [3rd STAGE]
 SITE INSPECTION via Site
Claims [post delivery
inspection]
 The raw materials that hit the
factory floor come from pre-
certified suppliers who follow
the specific stringent
requirements to get certified
from Zamil Steel. The sales
team has to take NOC from
quality head to switch
suppliers if required
 During the manufacturing
process right from cutting of
plates to welding and finally
painting, various types of tests
are conducted in order to
check quality.
• Ultrasonic testing
• Blasting inspection
• Painting inspection
 Before leaving the factory floor, all
the goods are inspected again and if
there was a problem and the goods
do not meet the required standards,
they are sent back into the
production process and reworked
upon.
 Due to the high quality requirements
of Zamil Steel, each product is
earmarked with the employees who
worked on each stage of the
production process. This helps them
hone in onto the cause of problem, if
any.
 All products from Zamil Steel
are judged on quality on the
basis of ‘site claims’ i.e. the
number of faults the customer
raised against the quality of
product he received. CAPA or
Corrective and Preventive
Actions are then undertaken
to make sure this doesn’t
occur again
 Quality is a continuous process at
Zamil Steel – where organization-
wide action is taken to increase
effectiveness and efficiency of the
engineering process.
 Zamil Steel takes a proactive stance
towards quality moving beyond
Quality Control to provide Quality
Assurance, so that clients can be
confident that their requirements will
be met with predictable quality –
consistently.
 The stringent process ensures that
high quality standards are reflected
in the manufactured products,
guaranteeing the customer
satisfaction every time.
 Zamil Steel India has successfully
passed the external certification
audit for Integrated Management
System. This certification unifies the
three key standards – ISO
9001:2015 Quality Management
System; ISO 14001:2015
Environmental Management
System; and OHSAS 18001:2007
Occupational Health & Safety
Management System – into one
coherent system.
 They have been certified by Bvis, a
German multinational who's tests
are considered to be one of the
most rigorous in the country
 IMS Certification refers to a
company-wide quality system
that improves process and
service quality throughout the
business, leading to increased
efficiency through waste
reduction, more efficient
utilization of resources and
streamlining of the current
practices used by the
company.
VARIOUS ASPECTS OF
QUALITY MANAGEMENT
IN ZAMIL STEEL
 QC inspection starts with
checking of raw materials for
compliance with
specifications. The product is
inspected at all stages of
fabrication for quality of
welding and dimensional
tolerances. Surface
preparation and coatings are
inspected. All inspection
records are retained on file for
future reference.
 They are committed to
process adherence through
process improvement plans.
This includes allocating
human resources and funds
for Products Research and
Development, who work to
implement good practices and
maintain high standards in
every project.
 When internal Quality Audits
result in non-conformance,
corrective action is triggered
through corrective and
preventive action plans. The
effectiveness of all such plans
are closely monitored.
Customer complaints are
recorded and detailed
analysis is carried out.
Corrective action is
implemented with a view
towards continual
improvement.
This involves identifying
and recording non-
conformance, performing
detailed analysis and
subsequent resolution of
any non-conformance.
 Roles and responsibilities are
clearly defined, reviews and
audits are conducted regularly
to identify non-conformance
and verify compliance.
 The senior management looks
into the number of site claims
on a monthly basis.
PLAN
DO
CHECK
ACT
They have an apex manual
for every department in order
to carry out their operations
and PDCA cycle. SOPs are
issued to all employees to aid
their work mechanism
Zamil Steel’s Senior
Management reviews and audits
all Quality Assurance activities.
This also includes site claims, a
method in determining how many
faults per delivery were claimed.
 There is a separate list of quality
standards set by Zamil steel itself
which is a bit more comprehensive.
 There is a fixed list of trusted
suppliers from whom the raw
materials are bought.
 Welders are tested by giving them
a mock welding project.
 Regular Quality Checks.
 Quality standards are being
properly communicated to all the
employees.
QUALITY POLICIES
OF ZAMIL STEEL
TQM Zamil Steel 12345

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TQM Zamil Steel 12345

  • 1. Quality Management Project: Zamil Steel India Pvt. Ltd. By: Akhil Singhal 3263 Anushka Srivastava 3269 Rahul Raisinghani 3293
  • 2.
  • 3.
  • 4.  Zamil Steel manufactures more than 500,000 tons of fabricated steel per annum of low rise and high rise steel buildings and structures for diverse industrial, commercial, agriculture, aviation, entertainment and military applications and support of infrastructure and development projects.  Zamil Steel’s main factories are based in India, Saudi Arabia, Egypt, Vietnam and United Arab Emirates. More than 600 engineers are employed in its engineering departments in Chennai, Cochin & Pune, besides its global engineering networks in Saudi Arabia, Jordan, United Arab Emirates, Egypt, and Vietnam
  • 5.  Inaugurated: February, 2008  Total area: 87,000 sq. meter  Covered area: 55,000 sq. meter  Production Capacity: 60,000 MT per annum  Total employees: 500  Inventory Storage Capacity: 1 month  Total Quality Inspectors: 30
  • 6.
  • 7.  RAW MATERIAL INSPECTION [1st STAGE]  FIT-UP INSECTION [2nd STAGE]  PRE-DISPATCH INSPECTION [3rd STAGE]  SITE INSPECTION via Site Claims [post delivery inspection]
  • 8.  The raw materials that hit the factory floor come from pre- certified suppliers who follow the specific stringent requirements to get certified from Zamil Steel. The sales team has to take NOC from quality head to switch suppliers if required
  • 9.  During the manufacturing process right from cutting of plates to welding and finally painting, various types of tests are conducted in order to check quality. • Ultrasonic testing • Blasting inspection • Painting inspection
  • 10.  Before leaving the factory floor, all the goods are inspected again and if there was a problem and the goods do not meet the required standards, they are sent back into the production process and reworked upon.  Due to the high quality requirements of Zamil Steel, each product is earmarked with the employees who worked on each stage of the production process. This helps them hone in onto the cause of problem, if any.
  • 11.  All products from Zamil Steel are judged on quality on the basis of ‘site claims’ i.e. the number of faults the customer raised against the quality of product he received. CAPA or Corrective and Preventive Actions are then undertaken to make sure this doesn’t occur again
  • 12.  Quality is a continuous process at Zamil Steel – where organization- wide action is taken to increase effectiveness and efficiency of the engineering process.  Zamil Steel takes a proactive stance towards quality moving beyond Quality Control to provide Quality Assurance, so that clients can be confident that their requirements will be met with predictable quality – consistently.  The stringent process ensures that high quality standards are reflected in the manufactured products, guaranteeing the customer satisfaction every time.
  • 13.  Zamil Steel India has successfully passed the external certification audit for Integrated Management System. This certification unifies the three key standards – ISO 9001:2015 Quality Management System; ISO 14001:2015 Environmental Management System; and OHSAS 18001:2007 Occupational Health & Safety Management System – into one coherent system.  They have been certified by Bvis, a German multinational who's tests are considered to be one of the most rigorous in the country
  • 14.  IMS Certification refers to a company-wide quality system that improves process and service quality throughout the business, leading to increased efficiency through waste reduction, more efficient utilization of resources and streamlining of the current practices used by the company.
  • 15.
  • 16. VARIOUS ASPECTS OF QUALITY MANAGEMENT IN ZAMIL STEEL
  • 17.  QC inspection starts with checking of raw materials for compliance with specifications. The product is inspected at all stages of fabrication for quality of welding and dimensional tolerances. Surface preparation and coatings are inspected. All inspection records are retained on file for future reference.
  • 18.  They are committed to process adherence through process improvement plans. This includes allocating human resources and funds for Products Research and Development, who work to implement good practices and maintain high standards in every project.
  • 19.
  • 20.  When internal Quality Audits result in non-conformance, corrective action is triggered through corrective and preventive action plans. The effectiveness of all such plans are closely monitored. Customer complaints are recorded and detailed analysis is carried out. Corrective action is implemented with a view towards continual improvement.
  • 21. This involves identifying and recording non- conformance, performing detailed analysis and subsequent resolution of any non-conformance.
  • 22.  Roles and responsibilities are clearly defined, reviews and audits are conducted regularly to identify non-conformance and verify compliance.  The senior management looks into the number of site claims on a monthly basis.
  • 23. PLAN DO CHECK ACT They have an apex manual for every department in order to carry out their operations and PDCA cycle. SOPs are issued to all employees to aid their work mechanism
  • 24. Zamil Steel’s Senior Management reviews and audits all Quality Assurance activities. This also includes site claims, a method in determining how many faults per delivery were claimed.
  • 25.  There is a separate list of quality standards set by Zamil steel itself which is a bit more comprehensive.  There is a fixed list of trusted suppliers from whom the raw materials are bought.  Welders are tested by giving them a mock welding project.  Regular Quality Checks.  Quality standards are being properly communicated to all the employees.