Section : PS:QM:11
PSPL/PEW GHAZIABAD Issue No. : 01
QUALITY MANUAL Page No. : 14 of 51
INPUT - OUTPUT MODEL (MARKETING DEPARTMENT)
SUPPORT FUNCTIONS PROCESS QUANTIFIER
1. Finance / Accounts EFFECTIVENESS
2. H.R. 1. Increment in Sales
3. Purchase 2. Introduction of New product
4. Production
5. Q.A. EFFICIENCY
6. Stores 1. Revenue Enhancement
7. Maintenance
INPUT OUTPUT
1. Customer Enquiry Deptt. : - Marketing 1. More Volume
2. Customer drawings / Specifications / (Process Owner - 2. Competitive price
Standards HOD Marketing) 3. New Customer
3. Samples 4. Customer Satisfaction
4. Customer Master Rings
5. Specific requirements
SUPPORT PROCESS / PROCEDURES /
TRAINING SKILL AND COMPETENCY
METHODS AND TOOLS
1. Contract Review (PS:SOP:MKT:01) 1. Product and process knowledge
2. Regular Order (PS:SOP:MKT:02) 2. Communication skill
3. Customer Satisfaction (PS:SOP:MKT:03) 3. Price Negotiation
4. Customer Complaints (PS:SOP:MKT:04)
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Section : PS:QM:11
PSPL/PEW GHAZIABAD Issue No. : 01
QUALITY MANUAL Page No. : 15 of 51
INPUT - OUTPUT MODEL (PRODUCT DEVELOPMENT)
SUPPORT FUNCTIONS PROCESS QUANTIFIER
1. Marketing EFFECTIVENESS
2. Finance / Accounts 1. First time PPAP OK
3. Production 2. FMEA Review
4. Q.A.
5. Stores EFFICIENCY
6. Purchase 1. Cost
7. H.R. 2. Time effective
INPUT OUTPUT
1. Customer requirements / Expectations Deptt. : - Product 1. Process flow Diagram (PFD)
2. Legal and statutory requirements Development 2. PFMEA
3. Order confirmation (Process Owner - HOD 3. Control Plan
4. Packaging requirements Development) 4. Master Charts
5. Price and volume 5. PPAP
6. Development time 6. Control Plans
7. Experience from previous 7. Process Parameter Charts
Development 8. Work Instructions
9. Packing Std.
10. Load control charts
SUPPORT PROCESS / PROCEDURES /
TRAINING SKILL AND COMPETENCY
METHODS AND TOOLS
1. APQP (PS:SOP:DEV:01) 1. APQP, FMEA, PPAP awareness
2. FMEA (PS:SOP:DEV:02) 2. Product and Process knowledge
3. PPAP (PS:SOP:DEV:03) 3. Customer specific requirements
4. Problem Solving Process 4. Safety awareness
(PS:SOP:DEV:04) 5. Machine knowledge
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Section : PS:QM:11
PSPL/PEW GHAZIABAD Issue No. : 01
QUALITY MANUAL Page No. : 16 of 51
INPUT - OUTPUT MODEL ( PURCHASE DEPARTMENT)
SUPPORT FUNCTIONS PROCESS QUANTIFIER
1. Marketing EFFECTIVENESS
2. Q.A. 1. Schedule vs. Receipts
3. Production 2. Supplier ratings
4. H.R. 3. Supplier Audit as per plan
5. Finance / Accounts EFFICIENCY
6. Stores 1. Cost reduction for R.M.,
7. Maintenance Consumables from agreed cost
INPUT OUTPUT
1. Stock Schedule Deptt. : - Purchase 1. Material Planning
2. R.M. Specifications 2. P.O. / Delievery schedule
3. Indents
(Process Owner - 3. OK. Material in Store
4. Customer specified Supplier HOD Purchase) 4. Supplier rating
5. Competitive cost
6. Development of alternative sources
SUPPORT PROCESS / PROCEDURES / TRAINING SKILL AND COMPETENCY
METHODS AND TOOLS
1. Negotiation
1. New Supplier Selection and 2. Part / Component knowledge
approval (PS:SOP:PUR:01) 3. MSDS (Material Safety Data Sheet)
2. Regular Purchase (PS:SOP:PUR:02) 4. Communication skill
3. Supplier Rating (PS:SOP:PUR:03) 5. Costing
4. Supplier Upgradation (PS:SOP:PUR:04) 6. Material Planning
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Section : PS:QM:11
PSPL/PEW GHAZIABAD Issue No. : 01
QUALITY MANUAL Page No. : 17 of 51
INPUT - OUTPUT MODEL (PRODUCTION)
SUPPORT FUNCTIONS PROCESS QUANTIFIER
1. Finance / Accounts EFFECTIVENESS
2. Stores 1. Plan vs. Production
3. Q.A. 2. O.E.E.(Overall Equipment Effectiveness)
4. Marketing
5. Purchase EFFICIENCY
6. Maintenance 1. Cost effective in each operation
7. H.R. 2. No Customer line stoppage
INPUT OUTPUT
1. Customer Schedule 1. Production Plan
Deptt. : - Production
2. Manpower Availability 2. OK, Finished product
3. Instruments
(Process Owner - 3. Utilization of resources
4. Raw Materials HOD Production) 4. Minimum losses and rejection
5. Machines and Tools 5. Personnel Safety
6. Utilities 6. House keeping
SUPPORT PROCESS / PROCEDURES / TRAINING SKILL AND COMPETENCY
METHODS AND TOOLS
1. Loading plan knowledge
2. Machine knowledge
1. Production Planning (PS:SOP:PD:01) 3. Product and process knowledge
2. Process Control (PS:SOP:PD:02) 4. Inspection skill
5. Decision making skill
6. Safety awareness
7. Operating skill
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Section : PS:QM:11
PSPL/PEW GHAZIABAD Issue No. : 01
QUALITY MANUAL Page No. : 18 of 51
INPUT - OUTPUT MODEL (QA DEPARTMENT)
SUPPORT FUNCTIONS PROCESS QUANTIFIER
1. Production EFFECTIVENESS
2. Finance / Accounts 1. Calibration as per plan
3. Marketing 2. MSA as per plan
4. Stores 3. Reduction in Customer Complaints
5. Purchase 4. Reduction in Rework
6. H.R. EFFICIENCY
7. Maintenance 1. Cost of Poor Quality with respect to Sales
INPUT OUTPUT
1. Master Charts 1. Judgement of product quality at receipt in
Deptt. : - QA
2. Process Charts process and final inspection.
3. Instruments (Process Owner - 2. Calibration as per plan
4. Drawings HOD QA) 3. Dock Audit
5. Calibration Plan 4. Layout Inspection
5. Measurement System analysis
6. Internal rejection analysis
7. Customer Complaints handling
SUPPORT PROCESS / PROCEDURES /
TRAINING SKILL AND COMPETENCY
METHODS AND TOOLS
1. Calibration (PS:SOP:QA:01) 1. Inspection / Measurement skill
2. Product Identification and 2. SPC & MSA knowledge
Traceability (PS:SOP:QA:02) 3. Handling storage and prevention of IMTE
3. Control of Non-Conforming Product 4. Decision making skill
(PS:SOP:QA:03) 5. Drawing Study
4. Lay Out Inspection (PS:SOP:QA:04)
5. MSA (PS:SOP:QA:05)
6. SPC (PS:SOP:QA:06)
MSA - Mesurement System and Analysis IMTE - Inspection Measurement and Test Equipment
SPC - Statistical Process Control
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Section : PS:QM:11
PSPL/PEW GHAZIABAD
Issue No. : 01
QUALITY MANUAL
Page No. : 19 of 51
INPUT - OUTPUT MODEL (MAINTENANCE)
SUPPORT FUNCTIONS PROCESS QUANTIFIER
1. Production EFFECTIVENESS
2. Q.A. 1. Preventive Maintenance as per plan
3. Purchase 2. Break down reduction
4. Marketing EFFICIENCY
5. Stores 1. Spare and Consumable cost
6. Finance / Accounts reduction
7. H.R. 2. Unit cost of power
INPUT OUTPUT
1. Machines Catalogues / Drawings Deptt. : -Maintenance 1. Maximum availability of machines
2. Tools / Equipments (Process Owner - HOD 2. No accident
3. Spare Parts Maintenance) 3. Safety
4. Preventive Maintenance
SUPPORT PROCESS / PROCEDURES TRAINING SKILL AND COMPETENCY
/ METHODS AND TOOLS
1. Preventive and Predictive knowledge
1. Maintenance Procedure No. 2. Handling of machines / Equipments
(PS:SOP:MT:01) 3. Safety awareness
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Section : PS:QM:11
PSPL/PEW GHAZIABAD
Issue No. : 01
QUALITY MANUAL
Page No. : 20 of 51
INPUT - OUTPUT MODEL (STORES)
SUPPORT FUNCTIONS PROCESS QUANTIFIER
1. Marketing EFFECTIVENESS
2. Q.A. 1. FIFO
3. Production 2. Usage of Shelf life item before expiry
4. H.R.
5. Finance / Accounts EFFICIENCY
6. Purchase 1. Shelf life of Materials
7. Maintenance 2. Inventory turn over ratio
INPUT OUTPUT
1. Raw Materials / Consumables Deptt. : - Stores 1. OK Material in Store
2. Purchase Order (Process Owner - 2. Preservation of Material
3. Delievery / Despatch Schedules 3. Inventory turn over ratio.
HOD Stores)
SUPPORT PROCESS / PROCEDURES TRAINING SKILL AND COMPETENCY
/ METHODS AND TOOLS
1. Product knowledge
1. Incoming Stores (PS:SOP:STR:01) 2. Preservation / Handling / Storage /
2. Delivery / Despatches Packaging / Despatch knowledge
(PS:SOP:STR:02) 3. Inventory Management / Control
3. Inventory Management
(PS:SOP:STR:03)
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Section : PS:QM:11
PSPL/PEW GHAZIABAD Issue No. : 01
QUALITY MANUAL Page No. : 21 of 51
INPUT - OUTPUT MODEL (HR DEPARTMENT)
SUPPORT FUNCTIONS PROCESS QUANTIFIER
1. Finance / Accounts EFFECTIVENESS
2. Marketing 1. Training as per plan
3. Production 2. Absenteeism
4. Stores 3. Employee Satisfaction
5. Maintenance 4. Employee turn over ratio
6. Q.A. 5. Training Effectiveness
7. Purchase EFFICIENCY
1. Training Cost expenditure with
respect to Budget
INPUT OUTPUT
1. Manpower Deptt. : - HR 1. Skilled and Motivated Manpower
2. Training need Identification 2. Annual training plan
3. Appraisals
(Process Owner - 3. Employee Satisfaction
4. Faculty Selection HOD HR) 4. Personnel Safety
5. Skill Matrix
6. Job Description
SUPPORT PROCESS / PROCEDURES / TRAINING SKILL AND COMPETENCY
METHODS AND TOOLS
1. Faculty Selection
2. Legal and Statutory requirements
1. Training Procedures No. 3. Safety Awareness
(PS:SOP:HR:01) 4. Recruitment Skill
5. [Link]
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Section : PS:QM:11
PSPL/PEW GHAZIABAD Issue No. : 01
QUALITY MANUAL Date : 22 of 51
INPUT - OUTPUT MODEL (MR DEPARTMENT)
SUPPORT FUNCTIONS PROCESS QUANTIFIER
1. Marketing EFFECTIVENESS AND EFFICIENCY
2. Purchase
3. Q.A. 1. Quality objectives measurable
4. Production
5. Maintenance
6. Stores
7. Finance / Accounts
8. H.R.
INPUT OUTPUT
1. M.R. Agenda Deptt. : - MR 1. A firm Quality Management system
2. Mission and Vision (Process Owner - 2. Quality Policy
HOD MR) 3. Quality Objectives
4. Minutes of Management review
SUPPORT PROCESS / PROCEDURES /
TRAINING SKILL AND COMPETENCY
METHODS AND TOOLS
1. Document and Data Control (PS:SOP:MR:01) 1. Management skill
2. Control of Quality records (PS:SOP:MR:02) 2. Communication skill
3. Business Plan (PS:SOP:MR:03) 3. Quality Management System
4. Internal Quality Audit (PS:SOP:MR:04) Awareness / Knowledge
5. Corrective Action (PS:SOP:MR:05)
6. Preventive Action (PS:SOP:MR:06)
7. Continual Improvement (PS:SOP:MR:07)
8. Management Review (PS:SOP:MR:08)
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Section : PS:QM:10
PSPL/PEW GHAZIABAD Issue No. : 01
QUALITY MANUAL Page No. : 12 of 51
Sub Process Main Process (INPUT) Main Process (OUTPUT)
MAIN
[Link]. SUB PROCESS PROCEDURE FLOW DIAGRAM
PROCESS
00 Strategic A0-Business Planning Document and Data Control (PS:SOP:MR:01) External
Planning B0-Company Wide Policy Quality records (PS:SOP:MR:02) Customer A0 B0 00
05
and deployment Business Plan (PS:SOP:MR:03)
01 Marketing A1-Contract review ECN Document and Data Control (PS:SOP:MR:01) External
B0
B0-Company Wide Policy Quality records (PS:SOP:MR:02) Customer
and deployment Contract review (PS:SOP:MKT:01) A1 01
02 Product A2-Product realization planning Supplier Evaluation and approval (PS:SOP:PUR:01)
Development B2-Process Design & Dev. Training and Development (PS:SOP:HR:01)
C2-Facility Installation & Management Measuring Instruments-Calibration (PS:SOP:QA:01)
D2-Process validation PPAP Non Conforming product control and review (PS:SOP:QA:03)
01 A2 B2 C2 D2 E2 02
E2-Customer approval Corrective and Preventive action (PS:SOP:MR:05/06)
A3-Supplier evaluation and approval Continual Improvement (PS:SOP:MR:07)
B3-Supplier PPAP (Only for Document and Data Control (PS:SOP:MR:01)
Automotive parts) Quality records (PS:SOP:MR:02) A3
APQP (PS:SOP:DEV:01)
B3
FMEA (PS:SOP:DEV:02)
PPAP (PS:SOP:DEV:03)
Supplier PPAP (PS:SOP:DEV:03)
03 Purchase A3-Supplier evaluation and approval Document and Data Control (PS:SOP:MR:01)
B3-Supplier PPAP (Only for Quality records (PS:SOP:MR:02)
Automotive parts) Non Conforming product control and review (PS:SOP:QA:03)
C3-Generation and release PO & Corrective and Preventive action (PS:SOP:MR:05/06)
A3 B3 C3 D3 E3 F3 03
RM/BOP Schedule Receiving Inspection (PS:SOP:STR:01) 01
D3-Receiving inspection, handling, Continual Improvement (PS:SOP:MR:07)
storage & preservation of incoming Supplier Evaluation and approval (PS:SOP:PUR:01)
material. Purchase Control (PS:SOP:PUR:02)
A4
E3-Supplier performance monitoring Sup. Perf. Monitoring (PS:SOP:PUR:03)
corrective action, upgradation. Supplier Upgradation (PS:SOP:PUR:04)
F3-Incoming stores Supplier corrective action (PS:SOP:PUR:03/04)
A4-Production Planning and Control Incoming Stores (PS:SOP:STR:01)
04 Manufacturing Document and Data Control (PS:SOP:MR:01)
(Production, REFER ANNEXURE - A Quality records (PS:SOP:MR:02) REFER ANNEXURE - A
QA, FOR DETAILED ANALYSIS Non Conforming product control and review (PS:SOP:QA:03) FOR DETAILED ANALYSIS
Maintenance Corrective and Preventive action (PS:SOP:MR:05/06)
Store, HR) Continual Improvement (PS:SOP:MR:07)
Incoming Stores (PS:SOP:STR:01)
Production Planning (PS:SOP:PD:01)
Process Control (PS:SOP:PD:02)
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Section : PS:QM:10
PSPL/PEW GHAZIABAD Issue No. : 01
QUALITY MANUAL Page No. : 13 of 51
Sub Process Main Process (INPUT) Main Process (OUTPUT)
MAIN
[Link]. SUB PROCESS PROCEDURE FLOW DIAGRAM
PROCESS
05 Customer A5-Customer feedback (Complaint Document and Data Control (PS:SOP:MR:01)
Feedback & Handling and Positive aspect) Training and Development (PS:SOP:HR:01)
Top B5-Customer Satisfaction Handling of Customer Complaints (PS:SOP:MKT:04)
Management C5-Internal Quality Audit Non Confirming product control and review (PS:SOP:QA:03)
Involvement D5-Continual Improvement Corrective and Preventive action (PS:SOP:MR:05/06) 04
E5-Management Review Problem Solving Process (PS:SOP:DEV:04) A5 B5 C5 D5 E5 05
Customer Satisfaction (PS:SOP:MKT:03)
0
Internal Quality Audits (PS:SOP:MR:04)
Management review meetings (PS:SOP:MR:08)
Continual Improvement (PS:SOP:MR:07)
Quality records (PS:SOP:MR:02)
NOTE : ANNEXURE - A ( MANUFACTURING )
A4 Production Planning and Control M4 Chemical Deburring (If required - Outsource)
B4 Rec. Matl. From Stores N4 Paint Marking
C4 Coiling (Inhouse / Outsource) O4 Rust preventive application
D4 Receipt Inspection P4 Teflon Sleeve Assy (If required)
E4 Centreless Grinding (If required) Q4 Notching (If required)
F4 Washing R4 Tension Checking
G4 Inprocess Inspection S4 Shape Checking
H4 Length Grinding T4 Final Insp. / Audit
I4 Ring Forming U4 Handling Storage
J4 Stress Relieving V4 Preservation, Packaging and Despatch
K4 Vibro Finishing (If required) W4 Dock Audit
L4 Plating Outsource (If required)
G4 G4 G4 D4 D4 G4 G4
A4
02 B4 C4 D4 E4 F4 H4 I4 J4 K4 L4 M4 N4 O4 P4 N4 R4
03
External
04 W4 V4 T4 S4
Customer
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