General Electric Manufacturing Company Limited
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Quality Manual
Quality Manual
Activity
Designation
Reviewed By
Management Representative
Approved By
Managing Director
Issued By
Management Representative
Signature
General Electric Manufacturing Company Limited
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Quality Manual
Revision History
Date
Doc. #
Rev. #
15 -08 -2003
SQM - 01
01
01-02-2010
QM-01 to
QM-08
02
Reason of Change
The complete Manual is changed to
adopt ISO 9001:2000 version.
The Quality Manual is completely
reviewed, amended as per
requirements of ISO 9001:2008
Approved By
Managing
Director
General Electric Manufacturing Company Limited
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Quality Manual
QUALITY POLICY
GENERAL ELECTRIC MANUFACTURING COMPANY LTD is committed to provide full
satisfaction to its customers in terms of quality, reliability and completion time/delivery time for
all types of products and repairs of its range keeping quality improvement drive as a continuous
process. It has been working to gain and establish TRUST of the customer as a manufacturer of
best quality transformer. This commitment will be achieved by:
-
updating the quality management system (QMS) as per ISO 9001: 2008 and maintain it with
commitment for continual improvement of the QMS
-
increasing its production and sales turnover
-
reducing the customer complaints
-
reducing the machine breakdown
This quality policy will be communicated & under-stood within the organization and reviewed
from time to time for its continued suitability.
Managing Director
General Electric Manufacturing Company Limited
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Quality Manual
QUALITY OBJECTIVES
Management of GENERAL ELECTRIC MANUFACTURING COMPANY LIMITED
(GEMCO) has adopted the following Quality Objectives for implementing them during June
2010 to May 2013.
1. It will upgrade its Quality Management System in accordance with ISO 9001:2008 standard
and obtain and maintain third-party certification by
(a) Implementing Quality Management Systems in compliance with the ISO
9001:2008 standard.
(b) Obtaining third-party certification to the ISO 9001:2008 within June 2010.
(c) Maintaining the Quality Management System as measured by subsequent
successful surveillance audit and re-certifications.
2. GEMCO will continually increase its production and sales turnover at least by @5% per
annum to TK. 3,570 Lac, and TK. 3,780 Lac respectively based on the year 2008-09 when
the production turnover was TK. 3,400 Lac, and sales turnover was TK. 3,600 Lac.
3. With a view to achieving a continual growth of its customer’s confidence and satisfaction,
GEMCO will become customer responsive for all of its products. It will reduce the customer
complaints by at least 5% to 0.40% by end of the year 2009-10 from 0.42% based on year
2008-09.
4. It has a target for its main machinery to minimize the break-down maintenance and optimize
the maintenance cost by incorporating planned and scheduled maintenance work with a view
to reducing the m/c down time at least 2% per annum at 15.74 hrs by 771.26 compared to
787 hrs of the year 2009.
These objectives will be reviewed from time to time for its continued suitability and
applicability in the system.
Managing Director
General Electric Manufacturing Company Limited
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Quality Manual
ENDORSEMENT OF THE QMS
GENERAL ELECTRIC MANUFACTURING COMPANY LIMITED (GEMCO) has established Quality Management System since July 1st, 2001. This manual now incorporates the
requirements of ISO 9001 : 2008 thus updating the system to current version of international
standard. This Quality Manual (QM) is an overview of the Quality Management System (QMS)
of GEMCO. Details of inside view of the quality system and commitment, which GEMCO has
been pursuing, are shown in this manual. The quality manual (QM) is the sole property of
GEMCO. Updating of the manual is done as per the Docoment and Data Control procedure of
the Quality Management System. Customer who has been provided with controlled copies of
this manual will be informed whenever an amendment in the Quality Manual is made.
Distribution of the CONTROLLED copies of this manual is limited within the List of Controlled
Copy Holders of the Quality Manual. CONTROLLED/UNCONTROLLED copy of the manual
can be made available to the Customers and any distinguished personality with the written
permission of the Managing Director.
General Electric Manufacturing Company Limited
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Quality Manual
TABLE OF CONTENTS
Doc. No.
Item
No. of page(s)
Page No(s).
QM-01
:
Revision History
1
2
QM-02
:
Quality Policy & Objectives
2
3-4
QM-03
:
Endorsement of the QMS,
Table of Contents, List of Abbreviations
& Distribution
4
5-8
QM-04
:
Quality Management System
9
9-17
QM-05
:
Management Responsibility
12
18-29
QM-06
:
Resource Management
2
30- 31
QM-07
:
Product Realisation
3
32 - 34
QM-08
:
Measurement, Analysis & Improvement
3
35 - 37
Appendix
General Electric Manufacturing Company Limited
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Quality Manual
LIST OF ABBREVIATIONS
ACE
Admin
ADP
AMR
ANSI
BDS
BPDB
BSEC
CAC
COM
CUS
DCE
DCL
DESCO
DGM
DPDC
ECNEC
EE
GEMCO
GM
GP Bldg
I/c
IEC
IQA
ISO
KVA
MD
ME
MKT
MNG
MNT
MR
PABX
PAC
PO
PPC
PROD
PUR
QF
QM
QMS
QP
Ref
RSR
SO
Sr SO
Tech
USSR
WI
WZPDCL
: Additional Chief Engineer
: Administration
: Annual Development Program
: Assisstant Management Representative
: American National Standards Institute
: Bangladesh Standards
: Bangladesh Power Development Board
: Bangladesh Steel & Engineering Corporation
: Corrective Actions
: Commercial
: Customer
: Deputy Chief Engineer
: Document Control
: Dhaka Electric Supply Company Limited
: Deputy General Manager
: Dhaka Power Distribution Company Limited
: Executive Committee of the National Economic Council
: Electrical Engineer
: General Electric Manufacturing Company Limited
: General Manager
: General Production Building
: In Charge
: International Electro-technical Commission
: Internal Quality Audit
: International Organization for Standardization
: Kilo Volt Ampere
: Managing Director
: Mechanical Engineer
: Marketing
: Management
: Maintenance
: Management Representative
: Private Automatic Branch Exchange
: Preventive Actions
: Purchase Order
: Production Planning and Control
: Production
: Purchase
: Quality Forms
: Quality Manual
: Quality Management System
: Quality Procedures
: Referance
: Rejection Status Register
: Store Officer
: Senior Store Officer
: Technical
: Union of Soviet Socialists Republics
: Work Instruction
: West Zone Power Distribution Company Limited
General Electric Manufacturing Company Limited
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DISTRIBUTION LIST OF CONTROLLED COPY OF
QUALITY MANUAL
Copy No.
Copy Holder
1
Managing Director
2
Management Representative
3
General Manager (Prod & Tech)
4
General Manager/DGM (Com)
5
GM/DGM (Admin)
6
ACE/DCE (In Charge, Main Building)
7
ACE/DCE (In Charge, GP Building)
8
DCE/ME (PPC)
9
DGM/Manager (Sales & Mkt)
10
Senior Store Officer/Store Office
11
Pre-Assessor/External Auditor
12
Auditor (Reserved Copy)
General Electric Manufacturing Company Limited
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QUALITY MANAGEMENT SYSTEM:
1. INTRODUCTION:
GENERAL ELECTRIC MANUFACTURING COMPANY LIMITED (GEMCO) is an enterprise of
Bangladesh Steel and Engineering Corporation (BSEC). BSEC is an autonomous body of the
Bangladesh Government under ministry of Industries. General Electric Manufacturing Company
Limited is a member of the Chittagong Chamber of Commerce & Industries. The Government of
Bangladesh owns 100% of its shares. It has its registered office address as follows:
North Patenga,Chittagong-4204, Bangladesh. Telephone no: 88-031-2501160, 2501161,
2501163, 2501164, 2501165 (PABX), Fax No: 88-031-2501162, E-mail :
gemcobd@yahoo.com
a. Project Concept:
The concept of creating a facility for manufacture of electrical distribution equipments was first
conceived in 1964 from a report of the Power Commission of the then East Pakistan. The technical
and economic feasibility study was carried out in 1965 by M/S. A. E. I. Overseas Limited Of
United Kingdom and M/S. Promash Exports of former USSR was appointed in 1966 for the
technical assistance and construction of the project.
b. Project Approval & Implementation:
The implementation works of the project started in 1970 and the project cost was first approved at
TK.219.5 million by the ECNEC in 1971. After liberation of Bangladesh , the agreement with the
USSR was renewed in 1972 and the implementation works were resumed
The project cost was revised at Tk.878.8 million and approved by the ECNEC in 1976. The
implementation works were completed in 1978 at a final cost of Tk.774.0 million.
c. Financing of the Project Cost:
Out of the total cost of TK. 774.0 million, the foreign currency component of TK. 194.4 million
was financed from the Governmental and commercial loan from the U.S.S.R and the local portion
of Tk. 579.6 million was financed from ADP.
d. Trial Production & Commercial start:
The trial production was carried out in 1978. The commercial production started from 1980. The
enterprise was converted to public limited company in 1979.
e. Production Capacity:
In the original project concept the production capacity was 10,000 MT in three working shifts. The
installed production capacity is 6900 MT in three shifts. At present the enterprise is working with
an attainable capacity of 1850MT. Expressed in the terms of the number of 200 KVA transformers
the attainable capacity is 1875 Nos. in single shift.
GEMCO is now providing a major portion of Electrical Distribution Equipments required by
Bangladesh Power Development Board (BPDB), Dhaka Power Distribution Company Limited
(DPDC), Dhaka Electric Supply Company Limited (DESCO), West Zone Power Distribution
Company Limited (WZPDCL).
f. Products:
The factory now produces different type of Electrical Distribution Equipments, mainly three phase
& single phase Transformers (Ranging from 5KVA to 5000KVA).
g. Associations:
GEMCO is a member of the Chittagong Chamber of Commerce & Industries.
The plant is located at the following address:
North Patenga, Chittagong-4204, Bangladesh. Telephone no: 88-031-2501160, 2501161, 2501163,
2501164, 2501165 (PABX) Fax No: 88-031-2501162, E-mail: gemcobd@yahoo.com
General Electric Manufacturing Company Limited
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Quality Manual
2.
3.
4.
5.
6.
GEMCO has four departments: 1. Administration, 2. Accounts, 3. Commercial, & 4. Production &
Technical.
This is the Quality Manual for General Electric Manufacturing Company Limited, which is
responsible for the manufacturing of its products.
This manual describes the Quality System by which the company operates and provides a high-level
guide of the General Electric Manufacturing Company Limited
The Quality System comprises of an authorized set of documentation, including policies, processes,
procedures and records. This documentation guides the employees in manufacturing and delivering
quality products to customers of the General Electric Manufacturing Company Limited, and in
continually improving the products and services.
The Quality System is designed to meet the requirements of the International Standard ISO 9001:2008.
SCOPE:
The General Electric Manufacturing Company Limited quality management system shall apply to
the activities that engage General Electric Manufacturing Company Limited within the Area of its
jurisdiction.
General Electric Manufacturing Company Limited is a Bangladesh registered public limited
company specifically established to produce different types of Electrical Distribution Equipments as
per requirements of customers and the organization itself.
The scope of the quality management system of General Electric Manufacturing Company Limited
has been defined as:
“Manufacturing of different types of Electrical Distribution Equipments and repairing of such products
including Sales & Distribution”
GEMCO has no design and development activity. Products are as per ANSI/IEC & BDS standards.
Hence all functions involving design & development of the product (clause 7.3) is outside the scope of
the QMS and as such excluded in the manual.
HUMAN RESOURCES:
The existing manpower strength of the enterprise is as shown below:
Officer
Staff
Worker
Total
50
88
297
435
General Electric Manufacturing Company Limited develops its Human Resources through training.
PHYSICAL FACILITIES:
The manufacturing plant is located at General Electric Manufacturing Company Limited, North
Patenga, Chittagong-4204.
GEMCO has its own building structures and accommodates manufacturing workplace, office, store,
toilet and washing facilities.
GEMCO has its own Medicare facilities with permanent medical staff.
MACHINERY & EQUIPMENT:
A list of machinery is given in Appendix-C.
Availability of machinery and equipment is ensured through preventive maintenance.
QUALITY MANAGEMENT SYSTEM OF GEMCO:
General Electric Manufacturing Company Limited is responsible to manufacture different types
Electrical Distribution Equipments, mainly Three phase & Single phase Distribution Transformers
(Ranging from 5KVA to 5000KVA). GEMCO is now providing a major portion of Electrical
Distribution Equipments required by Bangladesh Power Development Board (BPDB), Dhaka Power
Distribution Company Limited (DPDC), Dhaka Electric Supply Company (DESCO) & West Zone
Power Distribution Company Limited (WZPDCL).
Accordingly, General Electric Manufacturing Company Limited has planned, mobilised human and
material resources and established the sequence of processes to realize the product. It also established
General Electric Manufacturing Company Limited
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Quality Manual
and maintains a Quality Management System and continually improves its effectiveness in accordance
with the requirements of ISO-9001: 2008 standard. The Quality Manual includes the details of QMS,
references to documented procedures and a description of the interactions between the following
processes:
a. Commercial: dealing with purchase, shipping and procurement.
b. Marketing dealing with sales and transportation.
c. Stores: dealing with storage, handling and safekeeping of materials and products.
d. Production process involves the following,
i.
Preparing the materials required for processes,
ii.
Fabrication, sub-assemblies,
iii. Testing for different stages on different criteria,
iv. Final Assembly
v.
Testing
vi. Packing & Dispatch
e. Human resources Management
f. Maintenance Management.
These are included in the QMS. The Quality Manual of General Electric Manufacturing Company
Limited is a direct collection of QMS documents with references to documented procedures.
7. Objectives:
The Quality Policy indicates the commitment of GEMCO serving the customers. The objectives
stipulate time bound targets of the organization in order to satisfy the needs of the customers.
These are given in QM-02 of this manual.
7.1 Application:
7.1.1 Procedure:
GEMCO quality management system is relevant to the nature of the organization, the service it
delivers, and to customer and regulatory requirements. For this purpose, those requirements of the
Standard that do not apply to GEMCO are excluded from the scope of the GEMCO quality
management system.
The procedure for applying exclusions to the GEMCO quality management system is listed below:
1. A requirement of the Standard may be excluded only when both of the following conditions are
met:
 The requirement must be within Section 7, "Realization of Product", and
 The exclusion may not affect the Company's ability, nor absolves the Company from the
responsibility to provide a service that meets customer and applicable regulatory
requirements.
2. The Management Representative shall be responsible for identifying those requirements of the
Standard (ISO 9001: 2008) that do not apply to GEMCO and the service it provides, and to
propose exclusions of such requirements from the scope of the quality system.
3. Top management has the responsibility and authority for evaluating whether proposed
exclusions are appropriate, and for approving them. Evaluation and approval of exclusions are
conducted within the framework of management reviews of the quality management system
(see Section 5.6)
4. Exclusions taken are documented in this section of the Quality Manual. The excluded
requirements are precisely identified with reference to specific sections and/or statements in the
Standard. There is also a brief justification why the exclusion is taken and why it is appropriate.
8. Normative Reference:
The following normative document applies to this Quality Manual and the GEMCO quality
management system as defined in the Quality Manual.
 ISO 9001:2008, Quality management systems - Requirements
General Electric Manufacturing Company Limited
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9. Terms And Definitions:
For the purpose of this Quality Manual, the terms and definitions given in ISO 9000:2005, Section
3 applies.
10. GEMCO QUALITY MANAGEMENT SYSTEM:
Process Structure of General Electric Manufacturing Company Limited (GEMCO)
GEMCO OPERATIONAL PROCESSES
Regulatory
Requirements
Quality Management
ProcessManagement Process
Resource
Raw Material Processing
Production
Process
Main Processes
Assembly
Finished Product Storing
Delivery
Monitoring & Measuring Process
Nonconformance Management
Process
Product Protection
Marketing
Process
Marketing and Sales
Customer Needs Assessment
Contract Review
Sales
Customer Communications
Process
Purchasing Process
Training Process
Internal Communication Process
Document Control Process
Record Keeping Process
Purchasing
Sub-contracting Services
Internal Audit Process
Management Review Process
Continual Improvement Process
10.1 General Requirements:
The GEMCO quality management system has been established to cover the various processes as
required by the International Standard (ISO 9001: 2008), and of those identified and required by
GEMCO. Where appropriate, the processes, as listed under this section, are described in
documented procedures.
For easy reference, and where applicable, the relevant procedures are mentioned below for each
relevant processes.
Procedures required by "the Standard":
1. Document Control as required and defined in Section 4.2.3.
2. Control of Quality Records as required and defined in Section 4.2.4.
3. The Internal Audit process as required by Section 8.2.2.
4. Control of Nonconforming Products as required and defined in Section 8.3.
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5. Corrective Action as required and defined in Section 8.5.2.
6. Preventive Action as required and defined in Section 8.5.3.
Procedures required by GEMCO:
1. The Management Review process as defined in Section 5.6.
2. The Purchasing Process as defined in Section 7.4.1.
3. The Process Control process as defined in Section 7.3 & 7.5.1.
7. The Monitoring, Measuring, Analysis and Continual Improvement Processes as defined in
Section 8.
The applicable process procedures describe the relationship and interaction between processes and
between the relevant sections/departments to ensure that the required interaction is understood,
implemented and maintained. However a responsibility matrix, given in QM-05, shows the
relationship. Additionally the relationship is also shown in a schematic diagram of workflow given in
page 16 & 17 of 37 of this document QM-04.
Procedures define the relevant resources, human and other, that would be required for executing and
maintaining the applicable processes.
Departmental managers and section heads are responsible to implement and maintain all the
procedures that apply to the relevant processes. They are required to continuously monitor, measure
and analyse the respective processes to ensure that it is and remains effective and that objectives are
being achieved.
Departmental and section heads are required to implement and maintain the necessary and relevant
actions that are required to ensure continual improvement of the processes.
Top management holds periodic review meetings to ensure that appropriate interaction between
processes is maintained and to review the overall effectiveness of the processes (Section 5.6).
GEMCO has planned, mobilised human and material resources and established the sequence of
processes to realize the products. It also established and maintains a Quality Management System and
continually improves its effectiveness in accordance with the requirements of ISO-9001: 2008
standard.
The Quality Manual includes the details of QMS, references to documented procedures and a
description of the interactions between the following processes (details given in page 14 of 37 of this
document QM-04).
GEMCO has a three-tier, Quality System with Quality Policy and Objective being at the tip. Quality
Manual, which is the highest level or Apex Manual, is at the Tier–1. Quality Procedures are at the
Tier-2. Tier-3 contains Work Instructions, Formats, Charts, drawings, and reference
manuals/documents.
The documentation is used to ensure that:
- The service conforms to specified requirements
- Customer satisfaction is achieved as per Quality Policy
- All the works at all the areas are done to achieve Quality Objectives
Quality Policy and Objectives
TIER 1: Quality Manual
TIER 2: Quality Procedures
TIER 3: Work Instructions, Formats,
Charts, Drawings, Reference Manuals
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Quality Manual
A mapping of the quality management system involving the major processes has been given in the
page following next page (page 16 of 37 of this document no. QM-04).
10.2 Documentation And Records:
10.2.1 General:
The GEMCO quality management system consists of several documents that are required by the
Standard, and shall include the following documentation:
a) GEMCO quality policy as required and defined in Section QM 02, and GEMCO's quality
objectives as required by ISO 9001: 2008.
b) A Quality Manual, this document, as required by Section 4.2.2
c) Documented quality procedures (with the procedure number in brackets) that are mandatory
required by the Standard, namely:
(i)
Procedure for Document Control [QP-DCL-2]
(ii) Procedure for the Control of Quality Records [QP-DCL-3]
(iii) Procedure for Internal Quality Audits [QP-IQA-1]
(iv) Procedure for the Control of Non-conforming Products, [QP-QIN-2]
(v) Procedure for Corrective Actions [QP-CAC-1]
(vi) Procedure for Preventive Actions [QP-PAC-1]
In addition following procedures (with the procedure number in brackets) have been established to
make the system more effective and dynamic.
(i)
Procedure for Quality System [QP-DCL-1]
(ii)
Procedure for Management Responsibility [QP-MNG-1]
(iii)
Procedure for Contract Review [QP-CUS-1]
(iv)
(v)
Procedure for Process Control [QP-PROD-1]
Procedure for Preservation of Products & Delivery [QP-PROD-2]
(vi)
Procedure for Product Identification & Traceability [QP-PROD-3]
(vii)
Procedure for Servicing [QP-PROD-4]
(viii) Procedure for Control of Inspection, Measuring and Test Equipment [QP-MNT-2]
(ix) Procedure for Purchasing [QP-PUR-1]
(x)
Procedure for Inspection and Testing [QP-QIN-1]
(xi)
Procedure for Inspection and Test Status [QP-QIN-3]
(xii)
Procedure for Statistical Techniques [QP-QIN-4]
(xiii) Procedure for Customer Complaint Handling [QP-CUS-2]
(xiv) Procedure for Control of Customer Supplied Product [QP-CUS-3)
(xv)
Procedure for Equipment Maintenance [QP-MNT-1)
All these procedures are listed under Master List of Procedures (ref. QF-DCL-02).
d) The processes that are required by the GEMCO quality management system are shown in page
12 of 37 of this document QM-04 and references to the applicable process procedures that are
required to ensure the effective planning, operation and control of the processes are given
above.
e) All the relevant records that are generated through the applicable processes in accordance with
the requirements of the Standard and as required by GEMCO are listed under Master List of
Forms (ref. QF-DCL-03).
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Quality Manual
10.2.2 Quality Manual:
a) The GEMCO Quality Manual defines the scope of the GEMCO quality management system.
The scope includes all of GEMCO's activities, which are described as:

The efficient and effective design of projects as per requirements of market and customers
and also of existing standards/codes

The efficient and satisfactory supervision works of design, projects realization

The maintenance of assets, which includes buildings, electrical and mechanical equipment,
computer network and systems

Training and skills transfer, and

General office administration
b) The relevant documented procedures that apply to the processes of the GEMCO quality
management system are described in Section 10.2.1.
c) At the beginning of this document QM-04, section 10 describes the applicable processes as
identified by the GEMCO quality management system. There is a definitive interaction
between processes that could be regarded as either inputs or outputs, which means that,
outputs from one process are part of the inputs for another process and vice versa.
d) Clause no.7.3 of ISO 9001: 2008 for Design & Development is not applicable for GEMCO
system processes and as such this is not included in the activities of the organization.
The QMS is reviewed from time to time to ensure suitability and continual improvement by the
Management Representative (MR) and Review Committee.
Accordingly, corrective and preventive actions are adopted to improve the system. Customer is
informed whenever any modification in the QMS takes place.
All documents of General Electric Manufacturing Company Limited are controlled in accordance with
the Procedure for Document Control (Ref: QP-DCL-1).
GEMCO established documented procedure (Ref: QP-DCL-2) for the identification, storage,
protection, retrieval, retention time and disposition of quality records.
REFERENCES:
ISO 9001:2008– Quality management systems: Requirements.
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QUALITY MANAGEMENT SYSTEM MAPPING
Continual improvement of
The Quality Management System
C
U
S
T
O
M
E
R
S
R
E
Q
U
I
R
E
M
E
N
T
S
C
U
S
T
O
M
E
R
S
Management
responsibility
Quality Policy, Quality Objectives,
Quality Planning, Customer
Focus, Organogram, Job
Description, MR deployment,
Management Review
Resource
management
Measuring, analysis
& improvement
Manpower Available,
Training, Control of Safe and
Suitable Working Conditions,
List of Equipment, Provision
for Working Space
Internal Audit, Inspection &
Testing, Control of NonConforming Product, Statistical
Techniques, Corrective Action,
Preventive Action,
Product realisation
Input
Process materials,
Components,
Transformer oil,
packing materials etc.
Purchasing, Assembly
Operation, Preservation of
Product, Identification and
Traceability, Inspection & Test
Status, Maintenance
Product
Electrical Distribution
Equipments, three
phase & single
phase Transformers
Value-adding activities
Information Flow
The following schematic example explains the interaction between major processes:
Order
Procurement
Work Plan &
material lists
Material
Procurement
Review of
Requirements/Enquiry
Repair Process in
different floors
Market requirements
Customers Satisfaction
Manufacturing Process
in different floors
Final Inspection
Dispatch-Delivery to
Customers
S
A
T
I
S
F
A
C
T
I
O
N
S
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Quality Manual
PROCESS INTERACTIONS in General Electric Manufacturing Company Limited:
Marketing
Purchase
Store
Manufacturing
Subcontracting
C1
C2
C3
C4
C5
Quality
Inspection
C6
Invoice,
Certification
C7
Delivery
C8
Document
Control
Document
Control
Document
Control
Document
Control
Document
Control
Document
Control
Record
Control
Record
Control
S1
S1
S1
S1
S1
S1
S2
S2
Human
Resources
Human
Resources
Human
Resources
Record
Control
Purchasing
Record
Control
Human
Resources
Human
Resources
S3
S3
S3
S2
S4
S2
S3
S3
Purchasing
Purchasing
Purchasing
Human
Resources
Management
Review
Management
Review
O1
O1
S4
S4
S4
S3
Customer
Satisfaction
Customer
Satisfaction
Customer
Satisfaction
Maintenance
S6
S6
S6
S5
Management
Review
Management
Review
Management
Review
Management
Review
O1
O1
O1
O1
Analysis
Of Data
Analysis
Of Data
Analysis
Of Data
O2
O2
O2
Management
Review
Human
Resources
O1
S3
Customer
Focus
Management
Review
O3
O1
Analysis
Of Data
O2
Customer
Focus
O3
Company processes
Marketing
Purchase
Store
Manufacturing
Subcontracting
C1
C2
C3
C4
C5
Quality
Inspection
C6
Invoice,
Certification
C7
Support processes
Document
Control
Record
Control
Human
Resources
Purchasing
Maintenance
Customer
Satisfaction
S1
S2
S3
S4
S5
S6
Objective processes
Management
Review
Analysis
Of Data
Customer
Focus
O1
O2
O3
Delivery
C8
General Electric Manufacturing Company Limited
Doc #: QM-05
Revision #: 02
Effective Date: February 01, 2010
Page: 18 of 37
Quality Manual
MANAGEMENT RESPONSIBILITY:
1. MANAGEMENT COMMITMENT:
It is the policy of General Electric Manufacturing Company Limited to meticulously implement the
QMS. The QMS will be developed and continually improved. Following measures are taken to
improve the effectiveness of the QMS.
The QM demonstrates the commitment of General Electric Manufacturing Company Limited in
developing and implementing QMS.
A documented procedure for Management Responsibility no. QP-MNG-1 gives details of
management responsibility and activities in the quality system.
2. CUSTOMER FOCUS:
Understanding with Customer:
It is the policy of General Electric Manufacturing Company Limited to meet the requirements of
CUSTOMER. Accordingly, needs and expectations of customer have been identified by GEMCO and
are pursuing the manufacturing of following products only. GEMCO sells its products through Sales
Agent and also directly to the customers.
Electrical Distribution Equipments, mainly three phase & single phase Transformers (Ranging from
5KVA to 5000KVA).
All contracts/orders are reviewed to ensure that requirements are adequately defined and documented,
and to ensure that the company has the capability of meeting the requirements in the contracts.
There are mainly two types of contract in General Electric Manufacturing Company Limited, one is
Purchase Contract and the other is Sales Contract. In case of sales contact, contracts are done
considering purchaser’s acceptable terms & conditions (mainly tender terms & conditions) and
facilities available in General Electric Manufacturing Company Limited.
This process is defined and documented in Procedure QP-CUS-1.
Additionally followings are also taken into consideration for the review of the requirements.
Sl. No
Factor/ Requirement of
Customer
Satisfaction of Customer
1
packing information, if different
from standard practice of GEMCO
Compliant with PO Sheet
2
shipment & delivery information
On Time Full as per PO Sheet
3
Any regulatory requirements
special regulatory requirements
General Electric Manufacturing Company Limited arranged briefing for all its members about the
requirements of customer. Supervisors were provided training so that they thoroughly understand the
expectations of customer.
Review of Purchase Order from Customer:
GEMCO sells its products directly to its customer. Contract Review part starts from point of getting
query/tender etc. from the customer. In case of institutional buyers, customer sends written orders
depending on the quotation, information sent by GEMCO against customer query. Customer orders are
reviewed against the information of the quotations and variations/differences are resolved before
making the delivery.
Review is done by DGM (Sales & Marketing) in consultation with GM (Production & Technical) and
MD approves the same (Ref: QP-CUS-1). Records of review, including if there is a deviation from PO
sheet, are maintained.
Procedure no. QP-CUS-01 may be referred for details of the Contract Review.
General Electric Manufacturing Company Limited
Doc #: QM-05
Revision #: 02
Effective Date: February 01, 2010
Page: 19 of 37
Quality Manual
3. QUALITY POLICY:
The Quality Policy of General Electric Manufacturing Company Limited has been established (Ref:
QM-02, page 3 of 37). Quality Policy embraces all functions of GEMCO. QP reflects the commitment
of GEMCO in meeting the requirements of the customer. The Quality Objectives consistent to QP has
been defined (Ref: QM-02, page 4 of 37). The QMS includes commitment to review the policies and
objectives for continuing suitability and improvement. GEMCO ensures that Quality Policies and
Objectives are understood at all levels through briefing sessions, training and on job performance.
4. PLANNING:
a. Quality Objectives:
Ref: QM-02, page 4 of 37.
b. Quality Planning:
General Electric Manufacturing Company Limited has identified the resources needed to achieve
the Quality Objectives. Accordingly planning has been established. Output of planning is
documented. The integrity of the Quality System will be maintained if there is any change in the
system.
The organization was certified earlier to ISO 9002: 1994. After adopting the new version ISO
9001: 2000 the integrity of the system was not affected.
Interlink of responsibilities between different functions in relation to different activities of Quality
Management System has been shown in the next page.
To explain the requirements of quality and how it is met with the Quality System, quality planning
is made. The planning process takes care of the various activities that are essential to meet the
specified requirements for products manufactured by GEMCO and to ensure customer satisfaction.
The quality-planning format is available in the following pages:
General Electric Manufacturing Company Limited
Doc #: QM-05
Revision #: 02
Effective Date: February 01, 2010
Page: 20 of 37
Quality Manual
Quality Planning Format
Activity
Procedure
Reference
Responsibility
Document and
Data Control
QP-DCL-2
Management Representative
Control of
Quality Records
QP-DCL-3
Do
Management
Review
QP-MNG-1
Do
Training
GM/DGM/Manager (Admin)
Suitable and Safe
GM (Prod & Tech)
Working
Conditions
Contract Review
QP-CUS-1
Purchasing
QP-PUR-1
Process Control
Maintenance
Equipment
of QP-MNT-1
Product
Identification
and Traceability
Inspection &
Test Status
QP-PROD-1
QP-PROD-3
QP-QIN-3
Reference Document
List of Procedures/ Work Master lists of documents,
Instructions/Formats/Tags distribution list, document
/Register/ Specifications
change request
All Quality Records
Internal Audit Summary,
Customer Complaints
Summary, Corrective and
Preventive Action
Summary
Appraisals, Evaluation
Reports
Check Lists, Fire Drill
Records
GM (Com)/DGM (Sales & Mkt) Limits of Authority, Price
Approval, Product
Brochures, Stock Reports
Specifications of Raw
GM/DGM (Com/Mkt)
Material, Limits of
Authority, Purchase
Manual
GM (Prod & Tech), Sectional/ Budget, Production Plan,
Stock Report of Raw
Departmental Heads.
Materials.
Annual Production Plans,
Monthly Production Plan,
Daily production progress
GM (Prod & Tech), Sectional/
Departmental Heads.
GM (Prod & Tech),
Sectional/Departmental Heads ,
EE/EE (Testing), Engineer
(Shop-02A) & Store Officer.
Quality Records
Management Review
Records
Training Records,
evaluation
Fire Drill Records,
Inspection Report on
Accidents
Contract Review and
Amendment Records.
Invoices.
Suppliers Approval
Records, Purchase Orders
Record Register for
production, Batch No
Register.
Annual Maintenance
Annual Maint. Plan,
Plans, Monthly Preventive Break Down Record,
Maintenance Plan
Machine History card
Machine History Card
Raw Materials /Finished
product Identification
Cards/papers.
General Manager (Prod & Tech), Manual and Procedure
DCE/ME (PPC), ACE (Chemist)
(CPL) & Respective Shop/Section
In Charge.
Tag Numbers, Urgent
Permission Tags,
Documents,
Formats & Tags
General Electric Manufacturing Company Limited
Doc #: QM-05
Revision #: 02
Effective Date: February 01, 2010
Page: 21 of 37
Quality Manual
Quality Planning Format (Continued)
Activity
Preservation of
Product
Procedure
Reference
Responsibility
Reference
Document
Quality Records
QP-PROD-2 Sr Store Officer, Respective Material Receipt Memo, Stock Ledger, Bin Cards,
Asstt.Store Officer/Store Material Transfer or Issue Dispatch advises, Material
advices, Store Manual
Receiving Notes.
Keeper.
Control of Inspection, QP-MNT -2
Measuring and Test
Equipment
GM (Prod & Tech), ACE Manual and Procedure
(Chemist) (CPL) & EE
(Testing).
Calibration Records
Internal Quality
Audits
QP–IQA-1
Management
Representative
Nonconformity Reports
Audit Analysis
Inspection and
Testing
QP–QIN-1
GM (Prod & Tech), ACE
(Chemist) (CPL), EE
(Testing), DCE/ME (PPC)
& Respective Shop/Section
Incharge.
Raw Material
Specification, Standards
for Testing and
Inspection.
Receiving Inspection
Report, Final Inspection
Report, In Process
Inspection Reports.
Control of
Nonconforming
Products
QP–QIN-2
Analysis of Product NonStore Officer/ Asst Store Inspection and Testing
Procedure,
Raw
Material
conformity
Officer, Respective
and
Product
Specification
Shop/Section Incharge, GM
(Prod & Tech ) & DCE/ME
(PPC)
Data of Corrective and
Preventive Action
Summary
QP–CAC-1 All Functional Heads of the Monthly Analysis of
Nonconforming Products,
Quality System.
Internal Audit Reports
Summary, Customer
Complaints, Statistical
Analysis Reports.
QP–PAC-1 All Functional Heads of the Monthly Analysis of
Nonconforming Products,
Quality System.
Internal Audit Reports
Summary, Customer
Complaints, Statistical
Analysis Reports.
QP–PROD-4 GM/DGM (Com/Mkt) & Service Contract with
GM (Prod & Tech).
customer, Customer
Complaint Register
Quality Records
Not
applicable
Not applicable
Statistical Techniques QP–QIN-4
Corrective Actions
Preventive Actions
Servicing
MR , EE (Testing), GM
(Prod & Tech)
Monthly Analysis of
Customer Complaints,
Minutes of Corrective
Action Team, Audit
Analysis, Statistical Report
Inferences.
Monthly Analysis of
Customer Complaints,
Minutes of Corrective
Action Team, Audit
Analysis, Statistical Report
Inferences.
Service Records
Control of Customer
supplied Product
Design Control
Not applicable
Not applicable
General Electric Manufacturing Company Limited
Doc #: QM-05
Revision #: 02
Effective Date: February 01, 2010
Page: 22 of 37
Quality Manual
5. RESPONSIBILITY, AUTHORITY AND COMMUNICATION:
Administration of QMS includes Responsibility & Authority, Management Representative, Internal
Communication, Quality Manual, Control of Documents and Control of Quality Records.
a. Responsibility and Authority:
An organizational structure (as on role basis) of the company is shown in the next page. The
company has formerly issued it. Responsibility and Authority of the personnel who are important
for the Quality Management System and who can manage, perform and verify the work affecting
quality are described in the job descriptions (Appendix A: Job Description).
In addition to this, one Responsibility Matrix is shown in following page after Organogram to
make clear the inter-departmental responsibilities.
b. Management Representative:
Mr. Md. Shahjahan, General Manager (Production & Technical) is the Management
Representative of GEMCO. He will do the work of Management Representative in addition to his
present responsibility. MR will be specifically responsible for the following.
1. Reporting to the Managing Director on the performance of the QMS.
2. Needs of improvement in QMS.
3. Promoting awareness about customer requirements throughout the organisation.
4. Where relevant communication with external parties on matters related to QMS.
ACE (Chemist) (CPL), EE, Design and R&D and EE, Testing are assigned to assist MR. They will
do the work of Assistant Management Representatives with the assignments as designated to them
by MR, in addition to their present responsibilities.
c. Internal Communication:
It is a policy of GEMCO to ensure communication between various levels and functions regarding
the process of QMS and their effectiveness through teams, committees and meetings also through
circulars/memo etc.
6. MANAGEMENT RESPONSIBILITY:
The Managing Director of General Electric Manufacturing Company Limited is responsible
for defining and documenting the Quality Policy and communicating the Quality Policy
throughout the General Electric Manufacturing Company Limited In addition, management is
responsible for defining and documenting the responsibilities relating to the Quality System. This
includes assigning a Management Representative to ensure the requirements of the Quality System
are being met and that the organization conforms to these requirements. The Management
Representative reports directly to Managing Director and periodically conducts formal reviews
with Quality Council members to share results of audits and to ensure the ongoing conformance
and effectiveness of the Quality System (Ref: QP-MNG-1).
Management of General Electric Manufacturing Company Limited is also responsible for
ensuring that the appropriate resources are available and qualified to perform and verify
development, manufacturing and servicing activities in accordance with the Quality System.
a)
Organization Structure:
The organization structure of General Electric Manufacturing Company Limited is
defined on the organization chart shown at Page 24 to 28.
d)
Responsibility Matrix:
A Responsibility Matrix is shown in page after Organograms to make clear the interdepartmental responsibilities.
General Electric Manufacturing Company Limited
Doc #: QM-05
Revision #: 02
Effective Date: February 01, 2010
Page: 23 of 37
Quality Manual
7. MANAGEMENT REVIEW:
a. Introduction:
GEMCO evaluates the need for change in QMS including Quality Policy and Objectives. The
review ensures continuing suitability, adequacy and effectiveness of GEMCO established system
for management review. A Management Review Committee has been set up to review the
implementation, maintenance and effectiveness of the Quality Management System with a
commitment of continual improvement of the system. The Committee sits at least once in six
months where MD or any director chairs the meeting and MR acts as Member Secretary.
b. Review Input:
Input of management review includes at least the following
1. Matters arising
2. Follow-Up Actions from Earlier Management Reviews
3. Audit Results
4. Customer Feedback/Complaints
5. Process Performance And Product Conformance
6. Status Of Preventive And Corrective Actions
7. Changes that could affect QMS
8. Recommendations for Improvement
9. Any other business
c. Review Output:
Output from management review includes actions related to
1. Improvement of the effectiveness of QMS and its processes
2. Improvement of product related to customer requirements
3. Resource needs
The agenda of the meeting circular/notice is the input of the review and meeting minutes is the output.
Results of management reviews are recorded in the Minutes of Management Review Committee
Meeting. QMS Procedure (QP-MNG-1) has been established for Management Review process.
General Electric Manufacturing Company Limited
Doc #: QM-05
Revision #: 02
Effective Date: February 01, 2010
Page: 24 of 37
Quality Manual
ORGANOGRAM
Managing Director
CO
Administration
Production & Technical
Accounts
Commercial
(Administration)
GM/DGM (Admin)
Manager/Sr AO
AO
LWO/ALWO
AAO
Office Asst
Sr Store officer/SO
AMO
Security/Asst Security Officer
ASO
Security Habilder
Store Keeper
Security Guard
Office Asst
CO
: Co-ordination Officer
GM : General Manager
Sr AO : Senior Administrative Officer
Asst : Assistant
AAO : Assistant Administrative Officer
ALWO: Assistant Labour Welfare Officer
ASO : Assistant Store Officer
Admin : Administration
DGM : Deputy General Manager
SO
: Store Officer
AO
: Administrative Officer
LWO : Labour Welfare Officer
AMO : Assistant Medical Officer
General Electric Manufacturing Company Limited
Doc #: QM-05
Revision #: 02
Effective Date: February 01, 2010
Page: 25 of 37
Quality Manual
(Production & Technical)
GM (Prod & Tech)
ACE/DCE, In
Charge, Main
Building
ACE/DCE, In
Charge, GP
Building
DCE, In Charge,
Maintenance
ACE/DCE, In
Charge, PPC &
Design
ACE/DCE, In
Charge, CPL, QCC,
Training & Testing
Main Building
ACE/DCE, In
Charge, Main
Building
Engineer, In Charge,
Shop No.: 02A & 27
(carpentry)
Workers
Engineer, In
Charge, Shop
No.: 02B & 09
DCE, In Charge,
Shop No.: 03
Engineer, In Charge,
Shop No.: 06 & 27
(Insulation)
Workers
Workers
AE (Mech) & Asst
Chemist
Workers
GM
Tech
DCE
PPC
AE
Asst
: General Manager
: Technical
: Deputy Chief Engineer
: Production Planning & Control
: Assistant Engineer
: Assistant
Prod
ACE
GP
CPL
Mech
QCC
: Production
: Additional Chief Engineer
: General Production
: Central Plant Laboratory
: Mechanical
: Quality Control Cell
General Electric Manufacturing Company Limited
Doc #: QM-05
Revision #: 02
Effective Date: February 01, 2010
Page: 26 of 37
Quality Manual
General Production Building
ACE/DCE, In
Charge, GP
Building
Engineer, In Charge,
Shop No.: 15
AE (Mech), In
Charge, Shop No.: 16
Senior Foreman
DCE, In Charge,
Shop No.: 17
DCE, In Charge,
Shop No.: 19
Workers
Workers
Workers
Workers
Maintenance
DCE, In Charge,
Maintenance
Engineer, In Charge,
Mechanical Maintenance
DCE, In Charge,
Electrical Maintenance
Workers
ACE : Additional Chief Engineer
GP
: General Production
Mech : Mechanical
Workers
DCE
AE
DCE, In Charge,
Civil
Workers
: Deputy Chief Engineer
: Assistant Engineer
General Electric Manufacturing Company Limited
Doc #: QM-05
Revision #: 02
Effective Date: February 01, 2010
Page: 27 of 37
Quality Manual
Production Planning & Control
ACE/DCE, In
Charge, PPC
Engineer, Design
and R&D
Engineer
Staff/Workers
Central Plant Laboratory, Quality Control Cell & Training and Testing
ACE/DCE, In Charge,
CPL
Sub Asst
(Chemist)/Foreman
Engineer,
Testing
Workers
Staff/Workers
ACE : Additional Chief Engineer
R&D : Research & Development
Asst : Assistant
DCE
CPL
: Deputy Chief Engineer
: Central Plant Laboratory
General Electric Manufacturing Company Limited
Doc #: QM-05
Revision #: 02
Effective Date: February 01, 2010
Page: 28 of 37
Quality Manual
Accounts
CAO/ACAO
DCAO/Asst CAO
DCAO/Asst CAO
AO
AO
AAO
AAO
Accounts Assistant
Accounts Assistant
CAO : Chief Accounts Officer
AO
: Accounts Officer
DCAO : Deputy Chief Accounts Officer
AAO : Assistant Accounts Officer
ACAO : Additional Chief Accounts Officer Asst : Assistant
(Commercial)
GM (Commercial)
DGM/Manager (Pur)
DGM/Manager (Sales & Mkt)
Sr CO/CO (Pur)
Sr MO/MO (Sales)
Asst CO (Pur)
Asst MO (Sales)
Office Asst
Office Asst
GM
: General Manager
DGM : Deputy General Manager
Pur
Sr
MO
: Purchase
: Senior
: Marketing Officer
Mkt
CO
Asst
: Marketing
: Commercial Officer
: Assistant
General Electric Manufacturing Company Limited
Doc #: QM-05
Revision #: 02
Effective Date: February 01, 2010
Page: 29 of 37
Quality Manual
Responsibility Matrix
Clause
Title of requirement
No.
4
Quality Management System
MD
4.2.3 Procedure for Document & Data Control
4.2.4 Procedure for Control of Quality Records
5.0
Procedure for Management Responsibility
5.6
Management Review
6.2.2 Training and Human Resource Development
6.4
Suitable and Safe Working Environment
7.2.2 Procedure for Contract Review
7.3
7.4
Procedure for Design Control
Purchasing Procedure
GM
GM (Com) GM/DGM
(Admin)
(Prod & Tech)
■
■
■
■
■
■
□
■
N
■
■
■
■
■
■
■
■
O
■
□
□
7.5.1 Procedure for Process Control
Procedure for Maintenance
7.5.3 Procedure for Identification and Traceability
7.5.3 Procedure for Inspection and Test Status
7.5.4 Procedure for Control of Customer Property
7.5.5 Procedure for Preservation of Product and
Delivery
7.6 Control of Inspection, Measuring and Test
Equipment
8.2.2 Procedure for Internal Audits
□
□
8.3
8.5.3 Procedure for Preventive Action
□
□
A
P
MR
AMR 1, 2 & 3
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
P
L
□
■
□
I
C
A
■
■
■
■
■
□
■
□
□
■
■
■
■
■
■
■
■
□
■
■
■
■
■
■
■
8.2.3, 4 Procedure for Inspection and Testing
Procedure for Control of Nonconforming
Product
8.5.2 Procedure for Corrective Action
T
■
■
■
■
■
□
Sr SO
■
■
■
B
: Managing Director
■
■
■
■
■
□
□
■
□
■
■
■
□
GM (Prod & Tech): General Manager (Production & Technical)
GM (Com): General Manager (Commercial)
GM (Admin): General Manager (Administration)
Sr SO
: Senior Store Officer
MR: Management Representative
AMR
: Asstt Management Representative
: Direct Responsibility
□: Indirect Responsibility
E
■
Definitions:
MD
L
General Electric Manufacturing Company Limited
Doc #: QM-06
Revision #: 02
Effective Date: February 01, 2010
Page: 30 of 37
Quality Manual
RESOURCE MANAGEMENT:
1 Provision of Resources:
General Electric Manufacturing Company Limited has identified human, physical resources and
environmental conditions to establish and maintain QMS and improve its effectiveness and to
enhance customer satisfaction.
GEMCO identifies the various requirements of resources and provides them for carrying out the
activities efficiently. MD in consultation with other functional heads review the requirements and
when identified provides necessary resources depending on needs. These resources include all types
of management, implementation and Internal Quality Audits. It has trained manpower in all its
departments. GEMCO has trained Internal Quality Auditors to check the Quality Management
System as per ISO 9001: 2008. MR maintains a list of Trained Internal Quality Auditor.
Trained personnel are provided whenever needed and training requirements are taken care depending
on needs. Functional Heads and selected Management Staff have been trained on awareness and
documentation of Quality System to ISO 9001: 2008 to implement and verify their work as desired
by the Quality System.
Adequate plant, machinery and instruments are available to manufacture the products as per required
specifications. Care is taken to assess the needs of the facility and technology from time to time to
cope with the changing needs of the customers and accordingly plans are made to include those.
Functional heads review the requirements and when identified provides necessary resources
depending on needs. These resources include all types of management, implementation and Internal
Quality Audits.
General Electric Manufacturing Company Limited also has the system of imparting on-the job
training to improve the skill level of the people. Employees in GEMCO are skilled enough to carry
out the work and verify quality as per procedure.
2 Human Resources:
GEMCO maintains records of its personnel and GM/DGM (Administration) is responsible for such
record keeping. GEMCO makes yearly assessment of all its employees. To improve the skill for
covering shortcomings, transfer to the new jobs and developing skill of prospective future leaders,
training needs are identified by the superiors. Depending on needs peoples are selected for imparting
training. In case when a program is declared by BSEC and nomination is requested, the organization
selects people on the conditions given by BSEC with due consideration to Need Assessment. Onthe-job trainings are organized as and when necessary for the production and quality control people.
Training on Quality System implementation is organized and conducted whenever there is
amendment, updating or necessity to clear the confusion.
Personnel responsible for testing are posted depending on training records and experience. For all the
jobs, there are set qualification criteria for the employment.
Trained personnel are provided whenever needed and training requirements are taken care depending
on needs. Functional Heads and selected Management Staff have been trained on awareness and
documentation of Quality System to ISO 9001: 2008 to implement and verify their work as desired
by the Quality System.
3 Infrastructure/ Facilities:
General Electric Manufacturing Company Limited has identified and established required facilities to
achieve conformity of the product. Adequate plant, machinery and instruments are available to
manufacture the products as per required specification. Care is taken to assess the needs of the
facility and technology from time to time to cope with the changing need of the customer and
accordingly plans are made to include those.
These are
General Electric Manufacturing Company Limited
Doc #: QM-06
Revision #: 02
Effective Date: February 01, 2010
Page: 31 of 37
Quality Manual
a. Work Space and associated facilities (Appendix-B)
b. Equipment and Machinery (Appendix-C)
4. Work Environment:
a. General Electric Manufacturing Company Limited has established physical factors and
work environment needed to achieve product conformity. These include
I. Physical factors
1. Heat:
At all work areas, excluding areas where necessary to maintain a
temperature of 25±30C is required, eg testing laboratory,
temperature are kept within a range of 25~340C. If necessary
proper air circulation with exhaust fan are maintained
2. Light level:
300~500 lumen
3. Cleanliness: Total cleanliness in work area
4. Air flow:
5. Hygiene:
Well ventilation are provided at the work area, exhaust fans are
provided where cross ventilation is absent
Cleanliness is maintained through out the work area as it is the
prime object for a Good hygiene practice, first-aid boxes are
available at appropriate locations of work areas, safe drinking
water is supplied, good number of clean toilets are made available
at appropriate locations Medical service is available inside the
factory with attending doctor.
II. Human factors:
6. Posture:
7. Safety:
Where applicable, the gap between sitting tool and work table/
standing position are set for checking fatigueness. Working and
sitting arrangements are provided where required.
All working places are marked with red line for safe walking
passage, all moving parts are covered with safety covers, all
protruding edges etc are marked for safety first. All the gates are
kept clean for emergency exits. Regular fire drills are maintained.
Sufficient number of fire extinguishers is available inside the
building in addition to water hydrant. Safe drinking water is
available in all sections. Emergency medical service is available
inside the factory with attending doctor. Additionally first aid
boxes are supplied in all sections.
b. These are monitored and recorded once every month.
General Electric Manufacturing Company Limited
Doc #: QM-08
Revision #: 02
Effective Date: February 01, 2010
Page: 32 of 37
Quality Manual
PRODUCT REALISATION:
1. Planning of Realisation Process:
Realization of Product (manufacturing transformers) in General Electric Manufacturing Company
Limited starts from marketing section (Commercial). After getting the order, Technical section
prepares a plan and makes job orders for concerned sections along with required specification and
drawings.
GEMCO also takes up repair works of transformers from interested clients. After finalizing deal with
the clients by marketing section, concerned sections/shops takes up the job and perform the assigned
tasks as per work order.
At all the stages required checking and testing is ensured including final testing.
GEMCO has established procedure for all the above activities. The works are performed in the
appropriate equipment with due care of the safe and suitable working environment.
During all the process using, maintaining and controlling of parameters are ensured to get expected
quality. Some of the important steps are given approval by the authority. For all the steps of
production, acceptable quality standards/specimens are made available near the workstations and
employees with appropriate knowledge are used to perform the operation.
Equipments are suitably maintained to ensure the process capability.
2. CUSTOMER RELATED PROCESSES:
General Electric Manufacturing Company Limited has identified customer requirement described
in QM-05 item 2. Besides GEMCO reviews identified customer requirements together with
additional requirements determined by GEMCO. Requirements of Customer are documented in their
PO sheet. Reviews are conducted to have a thorough understanding of customer requirement. Review
is carried out following the QM-05 section 2.
DGM/Manager (Sales& Marketing) communicates with the customer in matters related to product
information, enquiries, feedback and complaints.
3. CUSTOMER COMMUNICATION:
General Electric Manufacturing Company Limited has established effective communication
arrangements with its customers, to ensure that relevant information is shared regarding the delivery
of its services.
When communicating with its customers, due consideration is given regarding the following:
a) Information that pertains to the services that are delivered, ie through its agreed periodical
review with the customers.
b) In-process enquiries and proposed amendments, ie through periodic progress meetings and
reports, where applicable.
c) Customer feedback, including complaints, ie through the "Customer Service" line or site
engineers at sites and the progress meetings where applicable.
4. DESIGN AND DEVELOPMENT:
GEMCO has no design and development activity. Products are as per ANSI/IEC & BDS standards.
Hence all functions involving design & development of the product (clause 7.3) is outside the scope
of the QMS.
5. PURCHASING:
General Electric Manufacturing Company Limited has a documented Purchasing Procedure to ensure
that purchased products conform to the specified requirements.
General.
GEMCO being an enterprise of Bangladesh Steel and Engineering Corporation and being a
public sector corporation purchases all raw materials, spares and accessories etc as per approved
General Electric Manufacturing Company Limited
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“Purchase Manual” of the corporation. Selection/approving of the vendor are carried out through
open tender/International tender and by joint decision of the tender committee. The acceptance
criteria for the Vendors are stipulated in the tender schedule on case-to-case basis depending on the
nature and characteristic of the item/materials to be procured. The details for this procedure are
documented in Procedure QP–PUR-1.
Purchase requisition/indents are raised by production planning and control section/consuming
department through store section.
In General Electric Manufacturing Company Limited, there are mainly two types of purchase. One is
Foreign Purchase and the other is Local Purchase.
Purchasing Data:
Considering budgetary sanction Managing Director approves purchase requisition/indent. On
receipt of duly approved purchase requisition/indent, commercial department initiates procurement
action. Considering type of materials, its availability and estimated value etc type of procurement
(Press Tender/Limited Tender/Spot Tender/Cash Purchase etc) is adopted by commercial department.
Purchase Order are reviewed and approved, according to Procedure QP–PUR-1.
Verification of Purchased Product:
The General Electric Manufacturing Company Limited verifies the incoming orders to ensure
that the purchased materials, goods, or services conform to the specified requirements. If the
purchaser chooses to verify the product at the supplier’s premises, the arrangements must be agreed
to and specified on the purchase order. Verification activities performed by General Electric
Manufacturing Company Limited personnel do not absolve the supplier of the responsibility for
delivering acceptable, quality products. Procedure QP-QIN-1 describes the activities required
verifying the order as it is received.
6. PRODUCTION AND SERVICE PROVISION:
PROCESS CONTROL:
DCE/ME (PPC) develops the written manufacturing procedures/process/Quality Plan which is
approved by the General Manager (Prod & Tech). In general, these processes include:
a. Generating job orders according to the production plan.
b. Documenting and controlling work instructions.
c. Controlling and monitoring critical processes during the production process.
d. Approved processes and equipment.
e. Workmanship standards.
f. Training, experience, and certification for all operators in production areas.
Control of the process involves all of the production, operations starting with the production plan and
progressing through all stages of the production process to product delivery. This process is defined
and documented in Procedure QP-PROD-1. Respective Shop Incharges are responsible for
implementation of this procedure, which controls the production process and ensures that processes
are performed in accordance with specific requirements of Quality System. Established procedure for
process control QP-PROD-1 is followed in all processes of GEMCO.
Respective Shop Incharge is also responsible for ensuring that these processes are carried out under
controlled or monitored conditions.
Respective Shop Incharge provides on the job training. The Training Record identifies training
given, trainer, date and duration of training and subject. Respective Departmental Head approves
and signs the training record. The training record for personnel working in GEMCO is maintained
with GM/DGM (Administration) /Respective Dept Heads.
When required for servicing/repair of products by customer GEMCO follows the established
procedure no. QP-PROD-4.
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Revision #: 02
Effective Date: February 01, 2010
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7. VALIDATION OF PROCESS FOR PRODUCTION AND SERVICE PROVISION:
Process Control in General Electric Manufacturing Company Limited starts from commercial
department with the receipt of PO sheet. PO sheet is analysed to plan different processes of the
product realization. At all the stages required checking and testing is ensured including final
checking. These processes are long established by GEMCO for its customers in general.
8. IDENTIFICATION AND TRACEABILITY:
Procedure QP-PROD-3 provides detailed instructions for identifying and labeling parts and products
that are produced or purchased by General Electric Manufacturing Company Limited.
Traceability of part and product configuration is also described in this procedure.
In addition to these, storage locations and in process locations products with marking also declare
inspection and test status. Only the acceptable products are stored in the Raw Materials and Finished
Goods Stores. Unacceptable and Hold items are kept at designated spaces.
In the case when any product or item is used in the production pending some decision under urgent
permission, such item is marked for ready traceability. Serial number of product is maintained for
traceability of finished products.
Procedure no. QP-QIN-3 gives the details of Inspection and Test Status.
9. CUSTOMER PROPERTY:
General Electric Manufacturing Company Limited agrees on using of Product/items supplied by
the Customer for the repair work and also in other works of its manufacturing range. The
items/products are normally mentioned in the agreement/contract made with customer. In the case
where it is not mentioned in the initial contract, the dealing of supply of product by the customer is
made a part of the contract.
GEMCO verifies the product for quality marking to ensure suitability with the work with which it is
used. In addition to this, identification and quantity is verified to ensure correctness with the
document supplied by the customer or as per contract.
Records of the issues in relation to unsuitability, damage and loss of customer-supplied product are
kept and maintained as a Quality Record.
Customer Supplied Product issue is handled as per the Quality Procedure QP-CUS-3.
10. PRESERVATION OF PRODUCT:
Procedure QP-PROD-2 describes the methods used for handling storing, packaging, preserving, and
delivering materials and products.
In general Store Officer is responsible for handling, storing, packaging, preserving, and delivering
all incoming raw materials and intermediate products. The finished products are maintained,
preserved & delivered by Incharge, Shop no.- 03.
Care is taken to deliver the product to the customer premises to ensure that product is not damaged
during transit.
11. CONTROL OF MEASURING, INSPECTION AND TEST EQUIPMENT:
General Electric Manufacturing Company Limited maintains a list of all Inspection, Measuring,
and Test Equipment. The list includes the Instruments identified to be necessary for ensuring product
quality. Instruments are selected for use only when they are found to be suitable for performing the
inspection, measurement or testing at specified locations in terms of accuracy, measurement range
and precision requirement.
GEMCO has documented a procedure to control measuring and monitoring.
Procedure no. QP-MNT-2 may be referred for details on Control of Inspection, Measuring and
Test Equipment.
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MEASUREMENT, ANALYSIS AND IMPROVEMENT:
1. INTRODUCTION:
To demonstrate conformance of the product, ensure conformity of the QMS and continually
improve its effectiveness, General Electric Manufacturing Company Limited utilises
statistical techniques.
2. MONITORING AND MEASUREMENT:
a. Customer Satisfaction:
Customer is the prime importance to General Electric Manufacturing Company Limited. It
analyses the requirement of Customer, which is an integral part of its job-based agreement with
Customer. Quality Parameters, which will satisfy Customer, are outlined in QM-05 item 2, for
achieving maximum customer satisfaction.
GEMCO will monitor whether it has met the requirement of Customer. After every consignment
Customer provides a report stating the extent to which the product and services satisfy them
(form QF-CUS-06). This is taken as an assessment of customer satisfaction.
GEMCO is delivering products to its customers as per agreed terms and conditions. The
effectiveness of these products will be measured on customer satisfaction.
Customer satisfaction is defined as the customer's perception of the degree to which his/her
requirements or needs have been fulfilled.
The following table identifies customers’ needs have been together with the satisfaction
measurement criteria that are applied by GEMCO:
CUSTOMER
Buyer of products
CUSTOMER NEEDS
1. Meeting the existing standards/
codes of the country
2. Meeting the obligation as per
contract with customer
3. Meeting the obligations as per the
Contract
4. Satisfaction of customer after
effective handover of products
SATISFACTION MEASUREMENT
1. Periodic progress report and progress
meetings
2. Monthly progress report and progress
meetings
3 Acceptance of products
4 Survey of customers’ satisfaction
b. Internal Audit:
General Electric Manufacturing Company Limited conducts internal audit to determine
whether the QMS conforms to the requirements of ISO-9001: 2008 effectively implemented and
maintained. Internal Quality Audits of the Quality System are planned, scheduled, conducted and
recorded in accordance with Procedure QP-IQA-1. The audits described in this procedure are
intended to verify the effectiveness of the Quality System, and to ensure that the GEMCO is in
compliance with the ISO 9001:2008
The audit procedure ensures that all applicable aspects of the Quality System are audited in each
area of the GEMCO at least twice a year.
However, more frequent audits may be scheduled, if required. Internal audits are planned,
scheduled, and coordinated by the Management Representative, and are conducted by trained
personnel, independent of the area being audited.
Documented Procedure QP-IQA-1 is followed for internal audits.
c. Monitoring and Measurement of Process:
General Electric Manufacturing Company Limited has established monitoring and
measurement of processes at different stages of product realization (QP–QIN-1), where
applicable, necessary to meet the requirement of Customer. In cases where desired results are not
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obtained corrective (QP–CAC-1) and preventive (QP–PAC-1) actions are taken to ensure
conformity of product.
d.
Monitoring and Measurement of Product:
Receiving Inspection and Testing
General Electric Manufacturing Company Limited expects that the sub-supplier/vendors
supply raw materials as per contractual requirement. Where applicable / possible test result are
supplied along with the raw material. General Manager (Prod & Tech)/Additional Chief
Engineer (Chemist), CPL approves the inspection data. QP–QIN-1 describes the process for
performing receiving, inspection and testing activities. Non-conforming materials are segregated
to prevent their use in production.
In-Process Inspection
General Manager (Prod & Tech)/EE (Testing) performs inprocess inspections, whenever
required/felt necessary. These inspection and tests are performed to verify conformance of the
product to the requirements. It also allows for early detection of non-conformance and likewise,
early application of corrective and preventive actions. Only products that conform to the
requirements are released to the next stage of production.
The amount and frequency of testing are defined for each product and are communicated to the
production personnel. The inspection that needs to be performed is specified in the registers. In
process inspection and testing activities are defined in Procedure QP-QIN-1 and are carried out
by authorized personnel.
Final Inspection and Testing
Final inspection and testing are carried out on completed products to verify compliance with final
product specifications. The final inspection and test process is designed to cover aspects of
product quality as specified in Procedure QP–QIN-1.
Products that pass final inspection are sent to the delivery section, where they are packaged if
required and then sent to the customer.
Inspection and Test Records
General Manager (Prod & Tech)/ Additional Chief Engineer (Chemist), CPL records the
inspection results into Respective Test Registers/Quality Report File (GEM/CPL/18)/Quality
Letters Entry Register (R-02). Procedure QP–QIN-1 describes how these records are captured
and documented. Testing section is responsible for the final test. EE (Testing) maintains records
for final inspection.
3. CONTROL OF NONCONFORMING PRODUCT:
Any incoming material, in-process product, or final product that fails to conform to specified
requirements is identified as a non-conforming product. A product could also be non-conforming
if it fails to meet in process or final testing limits.
Non-conforming products are clearly identified, documented and segregated from conforming
products. The non-conforming product is identified, and held in a segregated area until a
disposition decision is made. Identifying and segregating the non-conforming product prevents
the product from being used or delivered.
Procedure QP–QIN-2 also describes the methods used to identify, control, document, review,
evaluate and disposition a non-conforming product.
4. ANALYSIS OF DATA:
General Electric Manufacturing Company Limited collects applicable data to evaluate the
following.
a. Report of all tests done by Customer to ascertain the extent of customer satisfaction,
b. a conformity report from Customer on completion of an assignment to ascertain the
conformity to product requirement,
c. data reflecting characteristics and trend of processes,
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d. data reflecting characteristics of product including opportunities for preventive
action,
e. data on suppliers,
etc.
General Electric Manufacturing Company Limited analyses these data to determine the
suitability and effectiveness of the QMS and to identify where improvements can be made.
Statistical techniques are applied to decide and implement preventive measures.
Procedures no. QP–QIN-1, QP–QIN-3, QP–QIN-4, QP–IQA-1, QP–MNT-1, QP–CAC-1,
QP–PAC-1 may be referred for Analysis of data.
5. IMPROVEMENT:
5.1 CONTINUAL IMPROVEMENT:
General Electric Manufacturing Company Limited will evaluate quality objectives and
quality management system planning as an effort to align the management approach to continual
improvement as an inherent element in the QMS.
6. CORRECTIVE ACTION:
General Electric Manufacturing Company Limited ensures corrective actions in the following
cases:
– Effective handling of customer complains,
– Report of product non-conformities,
– Analysis of data and process,
– Investigation of causes
– Implementation of solutions
– Verification whether correction is effective and
– Documentation necessary for changes in procedures and quality manual
GEMCO follows documented procedure for taking corrective actions
Procedure no. QP–CAC-1 is referred on the details of the activities in relation to Corrective
Actions.
7. PREVENTIVE ACTION:
Preventive actions are taken to ensure the stoppage of occurrence of any potential problem. The
following activities are taken into consideration through which data are analyzed






Final Inspection
Internal Audit
Machine Breakdown reports
Product/Services specifications
Non-conforming of products
Customer Complaints
The preventive steps are taken to remove potential cause for the faults from which the
nonconformance, customer dissatisfaction developed. GEMCO follows documented procedure
for taking preventive actions.
Procedure no. QP–PAC-1 is referred on the details of the activities in relation to Preventive
Actions.
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