RT VISION TECHNOLOGIES PVT.LTD.

Integrated Procedure Manual

QUALITY MANAGEMENT, ENVIRONMENTAL MANAGEMENT AND OCCUPATIONAL

HEALTH & SAFETY MANAGEMENT SYSTEM

(RTVT-IPM-00)

Conforms to:

ISO 9001: 2015, ISO 14001: 2015 & OHSAS 18001: 2007

CONTROLLED COPY NO:

c) [Copyright Year] [RTVT]; all rights reserved. This document may contain proprietary information and may only be released to third
parties with approval of management. Document is uncontrolled unless otherwise marked; uncontrolled documents are notsubject to update
notification

Addresses

Unit- I :- A-110, 111 & 112 , Sector-83 , Noida - 201305,

Uttar Pradesh, India

Unit-II :-Savera Building ,Hospital Road , Kotla Nala ,

Above Thakur Construction Company Solan-172212 ,H.P. (India)
 DOC. NO. RTVT-IPM-00
RT VISION TECHNOLOGIES PVT. LTD. REV.NO. 00

TABLE OF CONTENT ISSUE DATE : 25/01/2018

Sl. ISO Description of Procedure No. of Procedure No.

No. Clause Pages
Ref.
1 7.5 Procedure on Control of Documented Information 5 RTVT-IPM-01

2 9.2 Procedure on Internal Audit 3 RTVT-IPM-02

3 8.7 Procedure on Control of Nonconforming Product. 4 RTVT-IPM-03

4 10.2 Procedure on Corrective action 3 RTVT-IPM-04

5 4.1, 4.2 Procedure for determining context of the organization and 2 RTVT-IPM-05
Interested parties
6 4.3,1 Procedure for conducting Hazard Identification and Risk 2 RTVT-IPM-06
Assessment.
7 4.4,6 Procedure for conducting Environmental Aspect Impact 2 RTVT-IPM-07
Assessment.
8 8.5 Control of production and service provision 2 RTVT-IPM-08

9 8.6 Procedure for dispatch of finish good (Release of product) 2 RTVT-IPM-09

10 6.3 Procedure for Change Management 2 RTVT-IPM-10

11 8.8 Procedure of Management Review 2 RTVT-IPM-11

12 7.1.5.2 Procedure for Calibration 2 RTVT-IPM-12

13 6.1 Procedure of Risk Management 2 RTVT-IPM-13

14 10.1 Procedure of Preventive Maintenance 1 RTVT-IPM-14

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 DOC. NO. RTVT-IPM-01
RT VISION TECHNOLOGIES PVT. LTD. REV.NO. 00
Title :Procedure on Control of
ISSUE DATE : 25/01/2018
Documented Information

1. Purpose:

The purpose of this procedure is to establish and maintain documented system to control all documented
information including documents & records of external origin for ensuring that–

 It is available and suitable for use, where and when it is needed.


 It is adequately protected from loss of integrity or improper use.

For the control of documented information, organization shall ensure for

 Distribution, access, retrieval and use.

 Storage, preservation, retention and disposition.
 Control of change.

2. Scope:
The procedure covers all documented information under the quality, environment and occupational health &
safety management system.

3. Responsibility :
The overall responsibility of document control lies with the DIR. and system cordinator. The individual head
of departments are responsible in their respective areas.

4. General description of the process:

Process de composition

The document control process comprises of one complete process and there is no process
decomposition.

Process overview

The system consists of one complete process for the control of various documented information as
needed for effective operation of activities .

5. Specific description of the process

Activity definition
This defines the process for authorization, issue, maintenance, revision, identification of documents
including documents of external origin.

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 DOC. NO. RTVT-IPM-01
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure on Control of
ISSUE DATE : 25/01/2018
Documented Information

Objective

The objective is to ensure that all quality, environment and safety system related documented
information are maintained in a defined way in order to demonstrate that the company meets the
Quality system, Environment system & OH & S system requirements

Input

Requirement to maintain documents as defined in standard and as required by the organization.

Output

Master list of Documented information

Entry Criteria

Need for preparation of documents and their identification

Exit Criteria

Preparation of document control records

Risk: Lack of awareness.

Mitigation : Providing Training for improving knowledge &awareness.

6. Procedure:

1. All documented information are reviewed and approved for adequacy prior to issue.
2. Integrated System Manual (Quality system, Environmental system and Occupational health & safety
system) is approved by the Director. Control Procedures, Process mappings, Data sheets, Formats as
per ISO standard, Department level Procedures, Process flow, Work instructions, Operation control
procedure, Aspect Impact analysis, HIRA, Formats, Departmental Objectives are approved by the
respective HOD and issued by System cordinator. All the approvals are made on the master copies.
3. With the above approval, “CONTROLLED COPY” seal / stamp is put on each page of the
documented information as an evidence of approval.
4. Distribution of documented information are as per the list identified in Document distribution matrix
(DM-02/7.5.2). Each copy has one unique controlled copy number. (Controlled copy no 1 to
Director, Copy no 2 is for the SC. The Master copy is maintained under control of CEO). SC issues
the rest of copy numbers to other departments e.g. marketing , purchase ,store , QC,R&D , maintenance.

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 DOC. NO. RTVT-IPM-01
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure on Control of
ISSUE DATE : 25/01/2018
Documented Information

5. Any additional distribution to person other than listed ,is done through the same system. If the person
becomes a regular recipient , Document distribution list is updated accordingly, For one time
distribution of document to a person, other than listed, ( i.e. for reference purpose) ; the copy of the
document is identified as “Uncontrolled Copy”.
6. Amendments are authorized in the same manner as detailed above. Latest revision status of each
document is recorded in Master list of documented information i.e., ML-01/7.5.2 . All formats in use
bear the document no and also controlled under document control system.
7. Revision no. of a section / document is changed corresponding to any amendment / updationin the
section / document. Under such situation , the rev. no. is incremented to next higher number i.e. from
‘0’ to ‘1’ , ‘1’ to ‘2’ etc. Issue no. of a section / document is changed corresponding to either
complete revision of the section / document (i.e. if a total change takes place) or after five revisions
of the same section / document have been done. Under such situation , the Issue no. is incremented
8. Individuals seeking / requesting amendment or updationin any quality system document fills up the
Amendment Record Format i.e., AR-03/7.5.2and sends the same to SC, who arranges for the
approval after due judgment . However, if required , SC discusses the amendment request with the
authorities in case of interfacing operations and then only the approval isgiven.
9. On providing the approval, SC incorporates necessary changes in the document. Persons receiving
the amended document replaces the same with the old ones and file the obsolete documented
information in separate file as reference for the future.
10. In case of amendment, the entire section of the old document is replaced with the amended
document i.e., all the pages are replaced ; even though there may not be any change in some pages.
11. All formats are numbered and controlled as per Document control procedure. Records are maintained
in such controlled formats and kept in files / registers/ computers, which have proper identification.
12. Minimum retention period of records are as indicated in the Mater list of Quality records (ref. QR-
01/7.5.3) with controlling authority.
13. All records are to be legible and stored in an environment to prevent damage, deterioration or loss.
14. Relevant supplier’s record is appropriately preserved by the respective controlling authority.
15. Wherever agreed contractually, relevant records are made available for evaluation by customer or
customer’s representative.
16. Records are destroyed after retention period is over.

Associated Documents

AR-03/7.5.2 – Amendment Record

ML-01/7.5.2– Master List of documented information

DM-02/7.5.2–Distribution matrix

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 DOC. NO. RTVT-IPM-01
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure on Control of
ISSUE DATE : 25/01/2018
Documented Information

Document Distribution List

(Hard copy)

Documents Distribution to Controlled copy no.

(for manual)
One set of Integrated system manual Director, CEO&SC

One set of Work Instruction SC& respective HOD

One set of One set of Operation SC& respective HOD CEO –Master Copy
Control Procedure

Director - No 1
One set of Process mapping SC& respective HOD
SC- No 2
One set of Aspect Impact Analysis SC& respective HOD
& HIRA

One set of Environmental :SC& respective HOD

Management programme

One set of Format :SC& respective HOD

Soft copy of Integrated manual and Procedure manual (read only type) are available with all HODs

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 DOC. NO. RTVT-IPM-01
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure on Control of
ISSUE DATE : 25/01/2018
Documented Information

Master List of Quality Records

Retention Controlling
Sl No Title Code No. Remarks
period Authority

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 DOC. NO. RTVT-IPM-02
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00

Title :Procedure on Internal Audit ISSUE DATE : 25/01/2018

1. Purpose:

The purpose of this procedure is to ensure conducting periodic checks on the conformity of the planned
arrangements to the requirements of the International standard (i.e. ISO 9001 : 2015, ISO 14001 : 2015 &
OHSAS 18001 : 2007) as well as the effectiveness of implemented management system for achieving stated
policy and objectives.

2. Scope:

This covers the entire quality system, environmental system and occupational health & safety system as per
standard and includes internal audit process itself.

3. Responsibility :

The direct responsibility of this element lies with the Management. He is assisted by a team of trained
personnel for conducting the internal audits

4. General Description of the process

Process decomposition

The Management process comprises of implementation of the system in the entire process. Internal
audit has to take care of both manufacturing process as well as other requirements of management
system as per standard. The functional decomposition diagram of Auditing management system is
shown below:

Internal audit of Quality

Management ,Environmental
Management &OHSAS

Assurance in manufacturing Other Management System

processes Performance as per standard

Process overview

Every item manufactured is carried out as per the laid out process and testing / checking plan ; this
needs to be audited. The other requirements of the standards are also to be periodically checked.
Both the auditing requirements are to be fulfilled.

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 DOC. NO. RTVT-IPM-02
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Title :Procedure on Internal Audit ISSUE DATE : 25/01/2018

5. Specific Description of the process

 Activity Definition :This activity comprises of preparation of audit plan, conducting audit, follow
up on corrective actions taken.
 Objective: The objective of this process is evaluation of performance and effectiveness of Quality,
Environment , OH & S Management System.
 Input : Audit plan
 Output : Audit finding
 Entry Criteria : Preparation of audit schedule
 Exit criteria : All non-conformity are closed
 Risk: Insufficient knowledge of auditor, Improper audit plant & schedule.
 Mitigation : Training for auditors &make proper audit plan.

6. Procedure:

Initially an Annual Audit Plan is prepared. (ref. AP-04/9.2). Audit schedule/Report (ref. AUR-
02/9.2) is made based on annual plan. The area / functions to be audited are documented in the audit
schedule. However, any additional area may be audited depending on earlier audit status or for any
other reason as decided by CEO/Director.

The audit criteria, scope of audit and methods to be followed are decided and explained to the
auditors. The audit is based on sample audit and the auditee has to take care of all such similar non
conformity in other areas as well. The audits are assigned in such a way that the auditors are
independent of the activities / areas being audited . The scope of audit covers the entire quality &
environment management system as per the ‘scope’ declared in Integrated manual covering all the
clauses of ISO 9001 : 2015 (excepting any exclusion taken) , ISO 14001 : 2015 and OHSAS 18001 :
2007 standards and all applicable statutory / regulatory requirements.

Audit is conducted half yearly. It is ensured that each process is audited at least once in every six
months as per the requirement of all the three standards under integrated management system.
Schedule of audit is made known to the auditee prior to the audit. Any change in audit schedule, if
unavoidable, is done by the SC.

Audit nonconformity are recorded in NCR-01/9.2. NCR-01/9.2is made in duplicate and a copy is
given to the auditee for initiatingcorrectionandcorrectiveactionagainstthenonconformityraised.
Target date for completion of agreed actions based on reasonable estimate is also recorded in the
same format.

Follow up for verifying the implementation and effectiveness of the corrective action is cordinated
by the SC. All relevant records pertaining to the nonconformity including clearing of the same are
recorded in NCR-01/9.2itself.

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 DOC. NO. RTVT-IPM-02
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00

Title :Procedure on Internal Audit ISSUE DATE : 25/01/2018

Internal audit may be initiated due to one or more of the following reasons:

when significant changes take place in the system, e.g., reorganizations, thorough system revisions.
when maintenance of systems and performance of products and / or services are in jeopardy due to
nonconformity.

when the system is evaluated against a quality system standard.

Nonconformity observed during auditing is termed as major or minor,

Major nonconformity - discrepancies leading to system failure / breakdown

- not meeting the requirement of the standard

- non implementation of written system documents

Minor nonconformity- stray incidents of discrepancies not affecting the system in totality or not
violating the requirement of standard
Observation- sometimes the auditor puts his views on certain matter in writing as an observation point,
which may be considered as an improvement suggestion to the auditee or a caution against
future possible nonconformity.

The internal audit is carried out by trained auditors. The auditors may be trained by outside agency or
consultant.

Records of Internal Audit are maintained as part of records. A summary report of nonconformity is made in
NCR-1/9.2

The outcome of audit forms a part of managementreview.

Associated Documents :
AP-04/9.2 Annual audit plan
AUR-02/9.2Audit schedule/report
NCR-01/9.2 Audit nonconformity report

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 DOC. NO. RTVT-IPM-03
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure on Control of
ISSUE DATE : 25/01/2018
Nonconforming Product

1. Purpose:

To ensure that any product not meeting the specified requirement at any stage of operation, is properly
handled to prevent from its unintended use in the subsequent stage and ultimate delivery. It is also ensured
through this procedure that any non fulfillment of environmental and safety issue is also addressed properly.

2. Scope:

All products undergoing inspection and testing at incoming, in process and final stages are coming under the
scope of this element. It also covers all quality, environment and safety related issues in the organization.

3. Responsibility :

The responsibility lies with respective Production and Quality in charge . As required, decision is taken after
discussion with the HOD. For environmental & safety matter, respective HOD and head of environment /
safety department are responsible.

4. General description of the process:

Process decomposition
The process comprises of two functions - control of nonconforming output's including all environment /
safety related nonconformity and the subsequent corrective action (if necessary).

Identification of nonconforming
product / nonconforming
environment / safety requirements

Control of nonconforming product

and nonconforming environment / Corrective action - if necessary
safety norms / targets - actions (dealt in a separate procedure
taken (dealt in the current RTVT- IPM-04)
procedure)

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 DOC. NO. RTVT-IPM-03
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure on Control of
ISSUE DATE : 25/01/2018
Nonconforming Product

Process overview

Identification, segregation, action against nonconforming product / environmental issues.

5. Specific description of the process

Activity definition: This defines the process for taking action after a nonconformity is detected either in
house or after delivery to customer.

Objective : The objective is to ensure that all nonconforming products identified at incoming, in process or
final stage are duly acted upon for proper rectification (including environmental / safety related nonconformity)

Input : Requirement to maintain document for each incident of nonconformity.

Output : Proper action recorded.

Entry Criteria : Need for preparation of document and action required.

Exit Criteria : Proper measures completed ensuring rectification and further inspection for
confirmation.

Risk: Incompetent manpower

Mitigation: Manpower competency increasing through training and development program.

6. Procedure:

 Nonconforming products are detected and controlled at the relevant stages of operations.
Nonconforming products generated at any stage of process is identified and recorded. Non
conformity is assessed against a defined quality plan or customer defined specification. Non
conformity in environmental/ safety issues is assessed against legal requirements as well as
company’s defined targets / objectives and is dulyrecorded.
 Nonconformity of incoming material is reported to the supplier. Such materials are quarantined till a
decision is reached with the supplier about replacing or returning the material. However, in case of
raw materials being found out of specification, certain review takes place and decision is taken jointly
by HOD production regarding its suitability in the production process. Such items are to be procured
in bulk quantity and RTVT has a little control over their availability. In such cases, the control is
exercised in the process to maintain quality of the outgoing product. Acceptance by QC
automatically indicates concurrence by production process in- charge.

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 DOC. NO. RTVT-IPM-03
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure on Control of
ISSUE DATE : 25/01/2018
Nonconforming Product

 Nonconforming products identified during production stage and at final stages (including customer’s
place after delivery) are recorded by the concerned quality control. These products are analyzed to
find out the reasons of nonconformity, which are also noted. The disposition action (rectification,
rework, degradation etc) is decided by Production & Quality In charge along with HOD (if required).
Rectification actions are taken and further checks are made to ascertain the maintenance of quality
characteristics. These are also recorded. The procedure to handle nonconforming product in major
production areas has been documented in department level procedures.
 Similar rectification action is taken for environmental nonconformity by the head of environment in
consultation with departmental HOD.
 The nonconforming product which does not meet the required specification and also cannot be
rectified is identified as rejected. In all types of nonconformity, at all stages of operation , the
authority for disposition is defined in NCP-01/8.7

Associated Documents :

NCP-01/8.7 Authority in case of nonconformity

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 DOC. NO. RTVT-IPM-03
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure on Control of
ISSUE DATE : 25/01/2018
Nonconforming Product

Decision Making Authority in case of Nonconformities (NCP-01/8.7)

Sl. No Items Authority to take Decision Other Considerations

1 Purchase raw material Respective QC & In charge Production Acceptance after review items –
(in consultation with HOD as reqd) Rejected if not suitable to process

2 In process items Production in charge (in consultation with Rework is done when it is
Quality in-charge as reqd) possible to rectify non
conforming items (Acceptance
after further checking of
items)Consult department level
procedures for handling
nonconformity Rejected, if not
rectifiable

3 Finished Products Production in charge & Quality in charge

4 Environmental /Safety
Non conformity
Rework done to meet
possible)(rework / degradation
etc) (Acceptance after further
checking of products) Final
check before dispatch Consult
department level procedures for
handling nonconformity Rejected
in case not rectifiable
SC (in consultation with HOD in charge Rectification done to meet
& HOD environment requirement (legal and company
set targets (Acceptance of closing
after further checking of
environmental / safety issue)

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 DOC. NO. RTVT-IPM-04
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure on Control of
ISSUE DATE : 25/01/2018
Corrective Action

1. Purpose:
The purpose is to eliminate the actual causes of nonconformity, thereby preventing recurrence of similar
nonconformity.
2. Scope:
All product, process, quality, environmental, safety system nonconformity, including customer complaints /
environmental & safety complaints are within the scope of this procedure.
3. Responsibility :
The direct responsibility of this element lies with HODs &SC for in house corrective action. As and when
necessary the involvement of others may be sought. For customer complaint, respective quality in-charge
and marketing in charge are involved. For environment / safety issues, respective HOD & Head of
environment / safety department is responsible.
4. General description of process:

Process decomposition: The Corrective action process comprises of initiating and taking action on actual
problems internal or external (reported by the customer for product related issues or complaints related to
environment / safety related issues).

Corrective Action

External (customer complaint /

Internal (in house problem) environment / safety related
complaint)

Process overview: Review of both internal and external reported nonconformity to take proper
corrective measures with an objective to eliminate similar incident in the future.

5. Specific description of the process

 Activity definition :This defines the process for reporting , taking action and closing the problem.

 Objective :The objective is to ensure that the problems generated due to various reasons in the
company including those reported by customer as well as external / internal reported environmental
& safety issues are taken care of and the causes are eliminated so that they do not occur again.

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 DOC. NO. RTVT-IPM-04
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REV.NO. 00
Title :Procedure on Control of
ISSUE DATE : 25/01/2018
Corrective Action

 Input :Internal Problem & Customer complaint / environment / safety problem reporting.

 Output :Corrective action record.

 Entry criteria: A problem is identified and reported.

 Exit criteria: The problem has been closed.

 Risk: Incompetent manpower

 Mitigation: Manpower competency increasing through training and development program.

6. Procedure:

Corrective actions are initiated for any of the following reasons :

Customer complaints, Legal non compliance's, Major accident/Incident.

Undesirable level of internal non conformity identified during:-

 Internal Audit.
 Analysis of Data.
 Failure analysis.
 Process KPI monitoring.
 Product nonconformity.
 Adverse or unstable trends.
 Management review.
 Maintenance analysis

Undesirable level of non conformity should be considered for CA only when non conformity is on
consistence basis and may cause serious impact on the system if not corrected.

Individuals report the problem with respect to system, process, services etc. faced by them in a format as per
C&P-02/10.2. Respective In-charge &SC analyze the report and interacts with individuals, if required, for
reviewing the course of action needed . This is recorded in same C&P-02/10.2. Depending on the situation,
SC may discuss this with the HOD / Quality In-charge / Production in-charge, if necessary. The results of
the actions taken are recorded.
In case of actions, which are successfully taken and possibility of recurrence of nonconformity is
considered remote , such problem is marked as closed and noted in C&P-02/10.2.

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 DOC. NO. RTVT-IPM-04
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure on Control of
ISSUE DATE : 25/01/2018
Corrective Action

Customer complaints are maintained by the concerned quality in-charge. A responsible person of the
concerned department does necessary analysis for taking corrective action. Follow up / monitoring
record is maintained against each customer complaint and all actions taken are noted. The complaint
is kept alive till it is fully resolved. As required, the Senior managers are also involved. In case of
environment & safety related complaints, SC takes up the issue with concerned HOD for taking
corrective action. The Senior management is also involved, in case certain decision / fund allocation
etcis required. The complaint is kept alive till it is fully resolved.
Records of corrective actions are submitted for management review.
The effectiveness of corrective action taken is assessed after a suitable time gap.
7. Procedure Preventive Action:
Preventive actions are initiated for any of the following reasons:
1. Inadequate process control and non compliance with documented system as available from
production reports and audit reports, which may lead to system failure (quality, environment , safety
related).
2. Potential failures, nonconformities as available from general market feedback and other authentic
sources.6.1.3 Nonconformities which are likely to occur with change in customer’s specification /
requirement.
3. Nonconformities which are likely to occur with change in legal specification /requirement
Individuals report the potential problem with respect to materials, system, product, process,
environment, safety faced by them in a format as per C&P-02/10.2. Respective Incharge & SC
analyze these and interacts with individuals, if required, for reviewing the course of action. This is
recorded in same C&P-02/10.2. Depending on the situation, SC may discuss the same with other
senior managers, necessary. The results of the actions taken are recorded.

In case of actions, which are successfully taken and possibility of occurrence of nonconformity is
considered remote , such problem is marked as closed and noted in C&P-02/10.2

Preventive action is planned on potential problem, which may arise on various accounts. Such
possibility is identified and action is initiated. All such cases are documented. In case certain decision
needs involvement of senior management , say for approval, fund allocation etc., the SC takes
necessary steps.

Records of preventive actions are submitted for management review.

The effectiveness of preventive action taken is assessed after a suitable time gap.

Associated Documents :
C&P-02/10.2Records of corrective and preventive action

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 DOC. NO. RTVT-IPM-05
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure for determining context of the
ISSUE DATE : 25/01/2018
organization and Interested parties

1. Objective:

The purpose of this procedure is to document the methodology to determine context of the organization and
interested parties which may effect its objectives.

2. Process Owner: SC/Director

3. Customer of the Process :All stake Holders.

4. Input : Statutory Requirements, Market demand, customer requirements, Employees,

5. Risk: Incompetent manpower and Lack of awareness

6. Mitigation: Manpower competency and awareness increase through training and development program.

7. Procedure:

1. A group for this will be constituted consisting of

 Director
 SC

2. The group will meet once in a quarter, preferably in Ist month of the quarter (By15th)

3. The group will brain storm on identification & based on risk internal and external context factors.

4. The group will decide on relevant internal context factors

5. For external context factors ,the group will consider one by one the PEST (Political, Economic, Social
andTechnological)factorandwillidentifytherelevantfactors/issuesaffectingtheorganizationconsidering the
risk involved.

6. The group also will identify the relevant interested parties and their needs.

7. Thegroupwillbringoutactionplantomitigatethesecontextfactorsandalsodecideoninterestedparties needs
and expectations. This will be documented.

8. The action plan drown will be implemented and implementation will be reviewed in the next meeting.

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 DOC. NO. RTVT-IPM-05
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REV.NO. 00
Title :Procedure for determining context of ISSUE DATE : 25/01/2018
the organization and Interested parties

8. Output:

Action plan and implementation plan of

1. Internal context mitigation

2. External context factor mitigation
3. Implementation plan for satisfying interested parties needs and expectations

9. Monitoring: Every quarter the progress will be monitored

10. Acceptance Criteria: Sustainable result of the company with minimum of deviation.

11. Forms and records: All forms and records are maintain & controlled as per procedure :control
of documentedInformation-RTVT-IPM-01.

12. Reference: ISO 9001:2015 Clause No. 4.1&4.2

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 DOC. NO. RTVT-IPM-06
RT VISION TECHNOLOGIES PVT. LTD.
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Title : Procedure for conducting Hazard
ISSUE DATE : 25/01/2018
Identification and Risk Assessment

Purpose:

The purpose of this procedure is to document the methodology followed in identification of Hazard and assessing Risks
associated with the said identified hazard.

Scope : It covers:

All activities of the organization

All identified hazards
All persons of the organization.

Responsibility: The responsibility to conduct the risk assessment rests with Safety officer along with the representative
from the concerned work area.

Process Description: All processes are listed and a thorough study is conducted along with a responsible person
from the concerned processes. Identification of Hazard & evaluation of Risk is based on following parameters:

Occurrence&

Consequence

Each of the above parameter is sub-divided into three situations.

Occurrence

Frequent : Usually happen regularly / several times or part of process.

Occasional : Happen sometimes ( minimum in a week interval).

Remote : Unlikely event / happen rarely.

Consequence

Major : Create fatality or any non- recoverable disability (eg. Permanent)

Serious : Damage which is curable with a prolong treatment.

Minor : No long time effect.

The resulting Risk Matrix is assessed based on a combination of parameters and categorized as Insignificant, Low, Medium,
High and Severe.

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 DOC. NO. RTVT-IPM-06
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure for conducting Hazard
ISSUE DATE : 25/01/2018
Identification and Risk Assessment

Risk Matrix
Minor Serious Major

Frequent Medium High Severe

Occasional Low Medium High

Remote Insignificant Low Medium

Significant Risk Risk in category of Severe, High & Medium have been considered as significant, which calls for immediate
attention. The risk is minimized either by better operational discipline through OCP (i.e., Operation Control Procedure) or
where certain series of actions required then OHSAS Management Programme is undertaken which usually requires some time
and investment for implementation.

What we need:

Lists of processes and their associated risk levels.

Input from management as to what level of risk shall be termed as significant.

Results:

One should end up with two documents by completing this step:

A Risk Assessment based on defined parameters

An action plan to control high risk areas (either thru’ OCP or OHSAS Programme) The Risk Handling Plan
documents the following:
the method selected for treating each risk (accept, reduce or discontinue)
which controls are already in place
what additional controls are proposed
the time frame over which the proposed controls are to be implemented

Risk in Procedure: Incompetency and wrong assessment

Mitigation: Manpower competency increase through training and development program.

Associated Documents :

EHS/GRA/F01

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 DOC. NO. RTVT-IPM-07
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure for conducting Environmental
ISSUE DATE : 25/01/2018
Aspect Impact Assessment.

Aspect Impact Assessment is based on the following factors:

Quantity of generation.
Occurrence of frequency.
Impact severity.
Legislation applicability.
Operational control presently available.
Detection possibility.
Rating is applied on a scale of 1 to 5 under each of the above mentioned factors.

The rating is done as per the following guidelines:

A B C D E F

Quantity Occurrence Impact severity Legislation Operational control Detection

5- Excessive 5- Continuous 5-Fatal to human life 5- If legislation 5- Absent or ineffective 5-No provision for
applicable control detection

4- Very High 4-Several times a 4-Human health 1- If legislation not 4- Mechanism in place 3-Late detection
day effects applicable but not reliable

- High 3- Once a day 3-Land contamination 3-Control needs human 1- Immediate

kills flora or global intervention
issue

2- Moderate 2- Once a month 2- Little effect 2-Control needs

improvement

1- Low 1-Once in six 1- No effect 1- Control available

month

For each aspect the following condition are noted: I) Situational i.e. (Normal, Abnormal or Emergency)

The impacts are categorized as:

LC – Land Contamination
AP – Air pollution
NP – Noise Pollution
WP –Water Pollution
RW –Resource waste
SW/LW -Solid Waste /Liquid Waste
HK - HouseKeeping.
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 DOC. NO. RTVT-IPM-07
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure for conducting Environmental
ISSUE DATE : 25/01/2018
Aspect Impact Assessment.

The score under each factor are multiplied to get overall ERPN (Earned Rating Point). As a first step, the aspect for
which ERPN> 200, are considered as significant Aspect and are taken up for exercising control measures. The
areas where legal requirements are to be met, are also considered as significant irrespective of ERPN value.

Such assessment is done once a year. However, if the management feels the need of such Assessment before one
year in certain area, this shall be done.

Once the Aspects having ERPN > 200 have been controlled, the cut off point shall be lowered, as decided by the
management.

Even if ERPN of certain aspect are below the cut off rating points, the management may decide for exercising
control based on certain reasons. (Say, if impact severity is very high).

Risk in Procedure: Incompetency and wrong assessment

Mitigation: Manpower competency increase through training and development program

List of Abbreviations being used during Aspect Impact Study

LC – Land Contamination
AP – Air Pollution
NP – Noise Pollution
WP – Water Pollution
RW – Resource Waste
SW/LW - Solid Waste/ Liquid Waste
HK – House Keeping
ERPN - Earned Rating Points
EAIA - Environmental Aspect Impact Analysis
OCP - Operation Control Procedure
N -Normal
A - Abnormal
E -Emergency
EM – Electrical Maintenance
MM - Mechanical Maintenance
OP -Operation

Associated Documents :

EHS/GRA/F01

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 DOC. NO. RTVT-IPM-08
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Control of production and
ISSUE DATE : 25/01/2018
service provision

Purpose and Objective:

"The highest efficiency in a production is obtained by manufacturing the required quantity, quality of a product at the required
time by the best and cheapest method. Production planning is a tool to co-ordinate all manufacturing activities in a production
system.
Production planning involves the organization of an overall manufacturing operating system to produce a product.
Production planning and control also required to achieve following objectives:

To ensure maximum utilization of all resources.

To maintain optimum inventory levels.
To plan plant capacities for future requirement.
To ensure effective cost reduction & cost control.

Scope: All manufacturing Divisions of RTVT Noida comes under the scope of this procedure.

Responsibility: The direct responsibility of this element lies with the Divisional/Departmental Heads
.He will be assisted by the respective individuals in charge of different functions.

Risk: Wrong estimating of raw material available, non-receipt of raw material, problem due to logistic failure,
Breakdown.

Mitigation: Provide training and regular monitoring of Product Manufacturing activities and follow up for Raw
Material

Procedure for Production Planning:

The key elements of production planning are Market demand, Raw material availability, Cost of raw material
availability.
First take market demand with the consultation from Marketing division. Evaluate the requirement of customers.
Obtain delivery schedule of the forthcoming month from the Customer.
Based on Plan/Schedule, As per weekly /monthly schedule from production department”
On daily basis, Check the availability of raw material through “Daily stock sheet” available
Incase of material is not available for the production then amend the production plan at Daily Schedule/Status.
If the customer wants amendment in the schedule of supply, amend the production schedule and inform the related
department, regarding changed requirement for manufacturing of products
Provide applicable working drawing to operators.
Ensure operators are competent to manage the machine setting.
Ensure process setting parameters are displayed at workplace.
Issue the “Material issue slip” to store department for arranging the material.
Receive the material from store department and keep properly at suitable place.
Check what processes are required for manufacturing of product through process flow chart of product
Intimate the Operators about next stage of process.
Follow the customer requirement.
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 DOC. NO. RTVT-IPM-08
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Control of production and
ISSUE DATE : 25/01/2018
service provision

Procedure for production Control.

In the first week, a review of previous month plan & execution will be taken for each division.

The agenda of review will be:-

MRM of previous month-review.

Performance.
Input &Output.
Quality ofproduction.
Inventory.
Consumption/Cost.
HR issues, Safety & environmental performance.
Housekeeping(5-S).
Improvement project/Plan.
Any other issue.

A MOM will be prepared in the format attached. This will be record of review.

Record:

Production plan.
MOM of review meeting.

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 DOC. NO. RTVT-IPM-09
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure for dispatch of finish good
ISSUE DATE : 25/01/2018
(Release of product)

Objective:-

Dispatch of Finished goods Railway Signals as per RDSO requirements.

Inspection, Gradation & Preservation: In charge QC for sampling /Testing and gradation of product / Stacking of
product.
Dispatch: In charge dispatch for loading of material as per customer requirement.
Non-Conformity Product: QC In charge to decide conformity of non conformity product after repairing.
Recycling: QC in charge for recycling of segregated material.

Customer of the process:-Internal & External customers.

Input & Resources:-Finish product

Dispatch: (i) Customer requirement not properly communicated to dispatch. (ii) Wrong material dispatch by in-
charge (iii) Carelessness of dispatch inspector.

Non-Conformity of Product: (i) Material not repaired/ blended properly (ii) Repaired /blended material not
inspected.

Recycling: (i) Not recycle by in charge QC.

Risk:-Inspection, Segregation, gradation & preservation. Un-skilled Inspector, Negligence of inspector, Customer
requirement or product specification not known to inspector.

Mitigation:-Provide training and development for increasing manpower competency level. FillCustomer
requirements and product specification forms.

Process to release the product:-

Define sampling frequency and testing Physical ,Electrical & Optical parameters as per product requirement.
Take the sample as per frequency decided, check the desire parameter
Note down results and check the conformity of product as per your specification or as per specification received
form customer for special product.

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 DOC. NO. RTVT-IPM-09
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00
Title :Procedure for dispatch of finish good
ISSUE DATE : 25/01/2018
(Release of product)

Kept non-conformity product at defined place decide whether material can be made conformity or not. Finished
good material would be kept as " ready for dispatch "Zone.
Material not repairable shall recycled or dispose.

Procedure to dispatch finish good:-

1.Final inspection is performed when all the process are complete and product becomes to ready to pack.
2.All such product are kept at separate place ( Under inspection ).
3. It must be ensure that all the fixture/equipments/ for inspection are available at OQC department .
4. It is ensure that all the equipments are calibrated as per calibration schedule.
5. 100 % inspection its done of all finished product through testing instruments.
6. If during final inspection material is found conforming to the specification accept the same.
7. If during inspection material is found non conforming put up the in final inspection report and raise the non
conformity report and put the red bin for separate identification.
8.Decide on rejection /rework/segregation of the material and provide material report.
9.Verify four piece after rework /segregation if any single piece if non conforming reject the whole lot.
10.It must be ensure that non conforming or rejected must be kept separate place identify and must not be mix up in
conforming material.
11.We must identify root cause of non conforming product and must take suitable corrective action.

Output:-Delivery chalan, Test certificate, dispatch of finish good as per requirement, customer satisfaction.
Monitoring: Process monitoring at different level.
Measurement :Measurement of Physical , Electrical & Optical parameters. Acceptance criteria :- Customer
requirement and product specifications. Form & Records:-Test certificate & Dispatch challan.
References:-QMS 9001:2015 Clause No. 8.6 (Release of product and services)

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 DOC. NO. RTVT-IPM-10
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00

Title :Procedure for Change Management ISSUE DATE : 25/01/2018

SUMMARY
The purpose of this procedure is to define the methods for managing changes to processes and other aspects of the
management system in a controlled manner.
Where this document discusses changes to processes, this shall be understood to mean the top-level processes
identified in the Integrated System Manual.
SC is a responsible for any amendment in process & system in under approving authority of CEO / Director is
responsible for implementation and management of this procedure.
DEFINITIONS
“Process Output” – the result of any process; these are typically defined in the Integrated System Manual for each
top-level process.
CHANGES TOPROCESSES
Management system processes will undergo changes, typically when:

Improvement opportunities have been identified, typically to improve process effectiveness

Nonconformities within a process are identified and require corrective action
Conditions in the industry or company change, requiring a process to be updated
New processes are added which impact on existing processes, requiring changes
Customer requirements result in a need to change processes
Any other reason determined by management

In such cases, the process must be changed in a controlled manner to ensure proper authorization and
implementation of the changes.
At a minimum, process changes shall include the steps herein:

Therequestforaprocesschangeshallbedocumented,typicallyinaC&P-02/10.2pertheprocedure:
Corrective Preventive Action Proc. The justification for the change shall be recorded.
The change shall be reviewed by appropriate management, including the senior most manager responsible for the
process. Changes must be approved prior to implementation.
The appropriate Integrated System Manual will be updated to reflect the change. This document will undergo review
and approval per the procedure RTVT-IPM-01. The revision indicator of the Integrated System Manual will be
incremented, and the nature of the change recorded.
The follow-up verification step of the CAR process shall seek to ensure the change has had the intended effect,
and/or has improved the process. If not, the change may be rolled back or a new change made to correct any new
issues that arise as a result of the change.

CHANGES TO PROCESSOUTPUTS
The methods for changing process outputs are typically defined in the Integrated System Manual. Where a process
output is a document, the rules for changing documents above shall apply.
Formal changes to process outputs will be used when the change is significant. Minor changes may be made without
formal control, however the decision on what constitutes a significant vs. minor change must be agreed upon by
those involved in the change. If a customer indicates a change is significant, this will trump any internal decision.

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 DOC. NO. RTVT-IPM-10
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00

Title :Procedure for Change Management ISSUE DATE : 25/01/2018

CHANGES TODOCUMENTATION
Management system documents undergo changes when there is a need to revise them.
Changes to documentation are done in accordance with the procedure Control of Documents Proc.
CHANGES TO ORDERS ORCONTRACTS
Changes to active orders or contracts may occur when the customer changes the requirements after the work has
begun, or may be initiated by RTVT when unforeseen circumstances are encountered.
When changes are initiated by the customer, the new requirements will undergo the same review and acceptance per
the procedure RTVT-IPM-15. If the changes cannot be accepted by RTVT a satisfactory solution will be
negotiated with the customer.
When changes are initiated by RTVT the HOD's purchase/ marketing will notify the customer and negotiate are
solution.

Risk : Inaccurate identification of opportunities for change

Mitigation :Training to Improve competency level.

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 DOC. NO. RTVT-IPM-11
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00

Title :Procedure of Management Review ISSUE DATE : 25/01/2018

SUMMARY

This procedure defines the process and methods for conducting both formal and informal management reviews of
the Integrated management system.
The Plant Head is responsible for implementation of this procedure.
Top management is responsible for attending formal management review meetings.

PROCEDURE: CONDUCTING MANAGEMENTREVIEWS

Top Management reviews the suitability, adequacy and effectiveness of the Integrated Management System through
The formal “Management Review Meeting” is held at a minimum of once in a six months.
The minimum attendance for Management Review Meeting with the list of titles those who attend the SC at a
minimum include top management as follows:
CEO HOD Purchase
Director HOD HR
Sales/ Marketing Head HOD Stores
Production Head HOD Environment
Quality Control Head HOD Health & Safety
R&D Head

Other employees shall attend as needed to meet the requirements of the agenda indicated below.

If any attendee is absent, draft minutes will be sent to him/her, for review and so that the person may amend the
minutes with any additional data, notes, opinions or opportunities for improvement they may wish to add.
This review shall include assessing opportunities for improvement and the need for changes to the quality
management system, including the quality policy and quality objectives.
Minutes of the meetings are taken and maintained. The form Management Review Meeting Minutes
may be used as a template for the records, or may be completed and filed as the finished record.
The Management Review Meeting shall include analysis of the following inputs:
review and updating of the COTO Log, including Issues, Risks and Opportunities
review and updating of the Strategic Plan
review and updating of process objectives, metrics and KPIs
review of customer feedback
review of the CAR system and related trends
review of internal and external audit results
review of the performance of external providers;
review of the adequacy of resources;

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 DOC. NO. RTVT-IPM-11
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00

Title :Procedure of Management Review ISSUE DATE : 25/01/2018

review of the effectiveness of actions taken to address risks and opportunities;

review of opportunities for improvement.
recommendations for improvement of the quality management system
follow-up activities from previous Management Reviews
The Management Review Meeting shall generate Corrective and/or Preventive Action Requests(see procedure
Corrective Preventive Action Proc., or take other recorded action, as a result of review topics in an effort to improve
the management system, products, processes and services, and to address resource needs.
This includes any decisions and actions related to the improvement of the effectiveness of the quality management
system and its processes, improvement of product related to customer requirements, and resource needs.
Additional informal management review activities are also conducted, and include:

3. UPDATE THE FOLLOWING AS APPLICABLE

Updating of some objectives data and trending in real time, and making such data available on the ERP Software of
RTVT for constant review. This includes product nonconformity data, CAR data, internal audit data, and customer
complaints.
Weekly meetings are held with the Plant head to discuss issues and problems encountered, and to ensure ongoing
compliance with established quality objectives.
Daily, informal meetings between the management team to ensure ongoing compliance with established quality
objectives, as well as to manage daily processing of orders and manufacturing efficiency.

Risk: Skip in schedule or agenda.

Mitigation: Compulsory review on regular basis(as per schedule).

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 DOC. NO. RTVT-IPM-12
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00

Title :Procedure for Calibration ISSUE DATE : 25/01/2018

SUMMARY
The purpose of this procedure is to define how the company Calibrate Measuring & Monitoring equipment tools
prior to use.
The Div./Dept. Head's is responsible for implementation and management of this procedure.
New Equipment
When new measuring and test equipment is received the Department will determine whether calibration is required.
If the equipment has not been calibrated the Department will either arrange calibration to be conducted internally, at
the Customers (for customer calibrated equipment) or by an approved external Calibration Authority
On initial acceptance the equipment will be entered onto the calibration report by the Concern Department
The following sections of the calibration report are used:-
Equipment Serial No
Manufacturer
Model
Calibration Frequency

Calibrated External & Internally

1. Evidence for external calibration is maintained through calibration certificates, traceable to National/International
standards.
2.ALL M&MR are identified by placing a sticker on each equipment in format MM-03/7.1.5 showing their status of
calibration.
3.In-house calibration done with master calibrated multimeter which is calibrated through external agency . In-
house calibration record is maintained in format IC-04/7.1.5.
4. Calibration report has the detail:
Measurement Units
Actual Measurements found/Equipment used for calibration
Acceptance/Rejection
5.M&MR are handled/used by trained personnel so as to safeguard them against damage.
6.When not in use M&MR is safety stored so as to prevent damage.

Calibration Status
The calibration report will identify Calibration status through the instrument serial number.

Calibration Maintenance
On-going calibration and maintenance of all measuring and test equipment will be automatically identified on calibration
report which will identify calibration requirements.

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 DOC. NO. RTVT-IPM-12
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00

Title :Procedure for Calibration ISSUE DATE : 25/01/2018

Calibration Failures
In the event of a calibration failure the Div./Dept. Head will withdraw the equipment immediately. The nature of the
failure will be analyzed and any product manufactured with this equipment will be reviewed and recalled if deemed
necessary. The failure and the action taken will be documented on spreadsheet
The Department will take the appropriate corrective action and the equipment will be re- calibrated prior to re-
introduction into the system. If the equipment cannot be re-calibrated or it has been damaged and cannot be repaired
the equipment will be removed from the system and destroyed.
If the failure does not affect product quality, the calibration criteria will be amended as appropriate and the
equipment can be released for use.

Manufacturing Use: Inspection measuring and test equipment used in manufacturing will be supported by
inspection instructions or specifications where applicable

Records :Concern Div./Dept. will maintain calibration records for a period of 1 years and will be retained soft
copy& a hard copy .

Risk: Incompetent manpower, error in Master instrument and unsafe environment

Mitigation: Training, master instrument calibrate on time and calibration done at proper place.

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 DOC. NO. RTVT-IPM-13
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00

Title :Procedure of Risk Management ISSUE DATE : 25/01/2018

SUMMARY
The company has established, implemented and maintained this procedure for managing risks and opportunities
throughout the RTVT.
Responsibility and authority for this procedure are spread across various functions, and defined within this
procedure.
Note: this procedure has adopted definitions for key terms developed specifically by RTVT and determined
appropriate for its use within the unique requirements of its management system. It does not adopt current ISO
definitions, which RTVT has determined are not sufficient for its use.
Note: the IMS documentation occasionally uses the term “opportunity for improvement” when discussing internal
audit findings or management review actions; that term does not have the same context as the term “opportunity”
used here.

DEFINITIONS
Risk: Inaccurate evaluation of Risk
Mitigation: Competency level improve through training and development program.
Opportunity: A positive effective of uncertainty.
Uncertainty: A deficiency of information related to understanding or knowledge of an event, its consequence, or
likelihood. (Not to be confused with measurement uncertainty.)
Risk Assessment: a systematic investigation and analysis of potential risks, combined with the assignment of
severities of probabilities and consequences. These are used to rate risks in order to prioritize the mitigation of high
risks.
Risk Mitigation: a plan developed with the intent of addressing all known or possible risks and preventing their
occurrence.
FMEA (Failure Mode Effects Analysis): a specific risk treatment method which ranks risks by probability and
consequence.

PROCEDURE:GENERAL
RTVT considers and manages risks and opportunities differently.
Risks are managed with a focus on decreasing their likelihood, and minimizing their impact if they should occur.
Opportunities are managed to increase their likelihood, and to maximize their benefits if they should occur.
Where risks and opportunities overlap, the best appropriate method for managing them shall be ascertained, given
the situation at hand. Elements of such “blended” uncertainties may require methods which both address the
negative risk and positive opportunity.

PROCEDURE: MANAGEMENT OFRISKS

Risks are identified as part of the “Context of the Organization Exercise” described in
Context of the Org Proc.(RTVT- IPM- 05).
Additional risks may be identified by any employee at anytime.
Each process is defined in detail through a Integrated Procedure Manual. This document includes the identification
and mitigation plans for key risks associated with the defined process. RTVT management reviews these risks and
takes action to minimize them.
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 DOC. NO. RTVT-IPM-13
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00

Title :Procedure of Risk Management ISSUE DATE : 25/01/2018

Risks identified as part of the Context of the Organization exercise defined in the procedure Context of the Org
Proc. (RTVT- IPM- 05)and logged within the COTO Log. This indicates a rough priority, as well as a selected risk
treatment method.

PROCEDURE: MANAGEMENT OFOPPORTUNITIES

RTVT actively seek out opportunities which could enhance its financial viability and market position. For example:

obtaining new contracts

obtaining access to new markets
identification of new industries which may be served by RTVT
development of new offerings that are within the scope of capabilities of RTVT
streamlining existing processes to improve efficiency and reduce costs

Opportunities are identified as part of the “Context of the Organization Exercise” described in Context of the Org
Proc.(RTVT-IPM-05)and as part of the corrective and preventive action program described in Corrective Preventive
Action Proc.RTVT-IPM-04.
Discussing and analyzing opportunities shall be done by top management. If made part of the management review
activities, these shall be recorded in the management review records.

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 DOC. NO. RTVT-IPM-14
RT VISION TECHNOLOGIES PVT. LTD.
REV.NO. 00

Title : Procedure of Preventive Maintenance ISSUE DATE : 25/01/2018

SUMMARY
The purpose of this procedure is to define the methods to maintain critical equipment to ensure such equipment does
not impact product quality or delivery schedules.
Preventive maintenance only applies to “key process equipment”; these are defined as those devices or tooling that
are critical for maintaining continuing process capability (i.e., uninterrupted manufacturing flow), and those
machines and systems that the breakdown of which could adversely impact product quality.
Emphasis shall be put on preventive maintenance (P/M), designed to ensure equipment operates without unexpected
down time or error. Correcting a fault in a machine after it breaks is considered repair, and not maintenance. The
purpose of a robust P/M program is to eliminate the need for unscheduled repairs and downtime.
The Head of Department is responsible for implementation and management of this procedure.
PROCEDURE: PREVENTIVEMAINTENANCE
1. Master list of equipment is being maintained.
2. Check points for all critical machines have been defined.
3.When the new equipment and machinery is received is to be entered in list plant machinery and maintenance
check list is updated.
4. Maintenance check list have been prepared considering the check point must be verified on daily
/monthly/quarterly basis.
5. Schedule for monthly /quarterly maintenance is define in annual preventive maintenance schedule.
6. During maintenance if any part is found break or any part is replaced or repaired than such details are updated in
break down record.
7. It must be ensure that all plant and machinery must be in running condition during production.
8. But if any break down is observable in the plane than the details of immediately forwarded in to maintenance in
charge.
9. Maintenance in charge will immediately go to break down location and will identify the possible impacts on
other plant and machinery, equipments and will take to suitable solution to prevent the impact on other plant and
machinery .
10. If the break down is due to non critical and easily handling and problems than will solve the problem
immediately and will take the machine in running condition .
11. But if identified that more than own or two hours are required to remove the problems than alternative
equipment is available for this purpose.
12. But alternative equipment if not available then will inform to production in charge to analysis the effect of
breakdown on production schedule .
13. Under this condition under maintenance tag must be placed at the machine and must take the suitable action to
keep the machine in running condition .
14.Details of break down is recorded at break down register .
15. After taking immediate action to run the machine maintenance incharge will identify the root cause of the break
down through discussion of operators.
16. Maintenance in charge will identify the possibility of potential problems and will remove such problems.

Risk: Incompetent manpower, faulty spare, irregular schedule

Mitigation: Training &development, use genuine spare, work done on uniform schedule.
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