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QUALITY MANUAL
Revision No.: 02
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SCOPE
The Quality Management System of KAROONI Knit Composite Ltd. described in this
manual is aimed to achieve the objectives and fulfill the commitments defined in the Quality
Policy of KAROONI Knit Composite Ltd. The manual addresses the requirements of ISO
9001:2008 except for the exclusions shown, with justification, in the table below:
EXCLUSION TABLE
The manual includes reference to the Master Procedures required and established for the
quality management system in KAROONI Knit Composite Ltd. and a description of the
interactions between the Quality Management System processes.
Related Documents:
all procedures in the name of Master Procedure referenced within the pages of this
document.
all work instructions that directly or indirectly have impact on product or process.
all forms used in conjunction within this policy and the procedures and work
instructions described in both of the above.
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TERMINOLOGY
Quality Policy
The KAROONI Knit Composite Ltd. overall intentions including commitment to direct and
control with regard to quality which is formally expressed by the top management.
Master Procedure
Master Procedures of KAROONI Knit Composite Ltd. are prepared and documented in
consistent with the requirements of ISO 9001:2008 standards and Quality Policy. They
describe how the elements of Quality Management System of KAROONI Knit Composite
Ltd. are developed and work and also responsibility to pursue and control activities affecting
quality. They contain functional instructions for the different policy requirements.
General Manager & MR develops the Master Procedures, which are approved by Managing
Director / Deputy Managing Director.
Work Instruction
Instructions contain information that explains how an activity or certain task has to be
performed. KAROONI Knit Composite Ltd. has developed instructions for several
particular activities, which was not mentioned in the Master Procedure but may affect the
quality of product.
Department people develop the instructions, which are reviewed and approved by General
Manager.
The Quality Management System of KAROONI Knit Composite Ltd. is documented and
maintained in 4 (four) tiers. They are:
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Related Documents:
All documents within KAROONI Knit Composite Ltd. quality system prepared in
accordance with the ISO 9001: 2008 standard requirements and company requirements,
which may affect in the quality management system, are controlled. A documented procedure
has been established for effective control of documents.
All quality related documents such as policy, objectives, procedures, forms/checklists are
reviewed for adequacy and approved prior to issue. Changes to document is reviewed and
approved by the same function that is forming the original review unless specifically
designated otherwise.
Before issuing, Management Representative ensures that all documents are legible. All
pertinent quality related documents are available at the point where they apply. Obsolete
documents are promptly removed from all points of use and a copy is retained for archival
purpose by the Management Representative.
Management Representative maintains a Master List of Controlled Documents.
All external documents that affect the quality of products or processes are controlled by
maintaining a list of pertinent issue.
Related Documentation:
MP-04-01: Control of Documents
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Related Documentation:
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Related Documents
Quality Policy
Quality Objectives
Management Review Meeting Minutes.
The highest level of management assures that all customer requirements will be uncovered
through the processes described in 7.2 and 8.2.1 later in this quality manual. Through all of
the policies, objectives and processes described in this quality manual, the highest level of
management assures the required environment to consistently fulfill the customer
requirements. By routinely assessing customer satisfaction, the highest level of management
optimizes the likelihood of moving customer satisfaction closer and closer to customer
delight.
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CLAUSE: 5 MANAGEMENT RESPONSIBILITY (cont.)
5.3 Quality Policy
KAROONI Knit Composite Ltd. has given outstanding consideration to the following
while formulating the Quality Policy:
the purpose of KAROONI Knit Composite Ltd.
the need to include an explicit commitment for compliance to requirements
the need to include an explicit commitment to continual improvement of
effectiveness of the quality management system
the required continual compatibility with quality objectives
The quality policy statement that has been formulated by the highest level of management
can be found within this manual. It is also prominently displayed at many strategic locations
throughout the sites. The quality policy reads as follows:
QUALITY POLICY
KAROONI Knit Composite Ltd.
Karooni Knit Composite Ltd.’s mission is to achieve business excellence through
customer satisfaction by understanding, accepting, meeting and exceeding customer
expectations.
The management of Karooni Knit Composite Ltd.’s commits itself to quality as the
prime consideration in all its business decision.
The Quality Policy is communicated to all level of employees of the organization through
training and discussing in important business events. Employees at all levels of the
organization are expected to fulfill the requirements of this policy in all of their work related
efforts and decisions.
Lastly, the quality policy is reviewed in each management review meeting for suitability. Its
distributions are controlled because of the possibility that it might change.
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Customer Satisfaction
Continual Improvement
When significant changes occur in categories such as the organization, the facilities or
business strategy, KAROONI Knit Composite Ltd. assures integrity and
compatibility of the quality management system
The Organogram illustrates functions, and their interrelations. More specific quality
management system responsibilities and authorities can be found in job descriptions,
flow charts, Quality System Procedures, Work Instructions, Quality Objectives etc.
associated with machines utilized, products manufactured and services provided.
Appropriate distribution of these documents and associated training assures clear
communication of this information.
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Related Documentation:
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When training is required to aid achievement of the required competence, one or more
of the following may occur:
Classroom training (internal or external) will be scheduled and coordinated by
the Manager, Admin & Compliance
On-the-job training will be coordinated by the department supervisor
Apprenticeships will be jointly arranged and coordinated by the concerned
department and the supervisor of the department where the apprenticeship will
take place.
When and where it is necessary, actions other than training will be used to achieve the
needed competence and appropriate measures of effectiveness applied.
One or more of the following will evaluate effectiveness of the training and other
actions taken:
certificates of completion for externally provided training
measuring process outcomes before and after training
performance monitoring and reviews on new hires
arranging briefing sessions for the other staff in the similar jobs by the persons
received external training.
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CLAUSE: 6 RESOURCE MANAGEMENT (cont.)
The respective department is responsible for keeping records of education, training,
skills and experience of employees in the individual personal file. Education records
of employee people shall be maintained for those who have passed at least S.S.C
examination, below S.S.C optional. Experience certificate shall be maintained if it is
provided by the previous employer. Training certificate for any training course
attended by the employee/s mentioned in C.V shall be maintained in employee
personal file.
Related Documentation:
MP-06-01: Hiring of Personnel
MP-06-02: Competence, Awareness and Training
6.3 Infrastructure
Manager, Maintenance (Mechanical & Utility) in consultation with General Manager,
Deputy Managing Director & Managing Director jointly determines the
infrastructure needs for each new product and/or service or significant change to
existing product and/or service. Consideration is given to the following:
Building
- design and dimension
- location
- building materials
workspace
- dimension
- layout
- accessibility and ease of movement
facilities associated with building or workspace
- ventilation
- water
- lighting
- electricity
- telephone systems
- data lines
- machine specific requirements, etc.
equipment-hardware
- furniture
- workbenches
- storage racks
- tools
- gauge
- machines
- test equipment
- vehicles
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CLAUSE: 6 RESOURCE MANAGEMENT
- computers
- other office equipment, etc.
equipment – software
- test
- calibration
- data collection
Support services
- preventive maintenance
- calibration
- engineering
- IT
- transportation
- emergency, etc.
KAROONI Knit Composite Ltd. considers and addresses many different aspects of
the work environment. Most significant among them and the departments assigned to
manage them are listed below:
Facilities-managed by the Production and Maintenance Section
Health and safety-managed by the Admin and compliance
Housekeeping-managed by the Store and Admin.
Work ethics-managed by the Admin.
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Marketing & Merchandising, Quality and Production identify all buyer requirements as they
interface with the buyer and as the product or service development takes place:
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The company has the capability to meet the order requirements.
CLAUSE: 7 PRODUCT REALIZATION
If buyers make any amendment to order that is communicated to the appropriate functions.
If KAROONI Knit Composite Ltd. needs to change any order requirements placed by the
buyer, the change is communicated to buyer and executed only after written approval from
the buyer.
If any requirement communicated to KAROONI Knit Composite Ltd. over telephone,
KAROONI Knit Composite Ltd. documents that requirement and confirms with customer
in writing before being executed.
Records of the results of the review and actions arising from the review are maintained.
Related Documentation:
Customer Order
Order Amendment Records
All others specification provided by customer
KAROONI Knit Composite Ltd. informs customer about its products through visiting to
the local liaison office of buyer/ buying house by the Marketing & Merchandising people and
e-mail/ fax.
All inquiries, contracts or order handling including amendments are managed as stated above
(see 7.2.2).
All complaints and any feedback on dissatisfaction are properly investigated and answered to
customer.
7.4 Purchasing
KAROONI Knit Composite Ltd. selects suppliers based on their capability to meet its
requirements. KAROONI Knit Composite Ltd. purchases from sources that have the
capability to meet the specification.
KAROONI Knit Composite Ltd. evaluates performance of its supplier once every year
using Weighted Point Plan method. Quality has been given the highest rating.
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CLAUSE: 7 PRODUCT REALIZATION
7.4.2 Purchasing information
KAROONI Knit Composite Ltd. always inspects materials upon receipt at its premises.
KAROONI Knit Composite Ltd. allows its customer to visit supplier’s premises and its
own premises. However, this visit by customers is not taken as materials or product
acceptance by the customer. KAROONI Knit Composite Ltd. performs all necessary tasks
to accept or reject of materials or products in spite of such verification and does not take this
visit as a confirmation of product acceptance by the customer. This only takes place when
such provision is included in the contract.
Related Documentation:
KAROONI Knit Composite Ltd. identifies and plans production processes, which directly
affect quality, and ensures that these processes are carried out under controlled conditions.
Documented work processes are available where all necessary information is available
including information relating to product characteristics. This is done through circulating
production schedule or plan.
Equipment having direct affect on quality is suitably maintained to ensure continuous process
capability.
Production operations are planned so that they proceed under controlled conditions and in the
specified manner and sequence.
Suitable process and product characteristics are monitored during production and for this all
required monitoring and measurement devices are made available.
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Related Documentation:
WI/CUT-01: Cutting Activities
WI/DYE-01: Dyeing Activities
WI/KNIT-01: Knitting Activities
WI/SEW-01: Sewing Activities
KAROONI Knit Composite Ltd. has established and maintained procedures for identifying
including inspection & test status of products.
All materials and accessories, production lines and finished products are identified by labels
and as per status declared by Quality Control Department.
Traceability is maintained by buyer name and order/ style number in all records relevant to
order.
All related personnel of KAROONI Knit Composite Ltd. are trained to prevent damage of
products and materials during handling.
When the products are in KAROONI Knit Composite Ltd. custody, they are preserved in
storage areas.
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Related Documentation:
All monitoring and measuring devices, which affect product quality or utilized by Production
and Quality Assurance for product acceptance, are subject to the calibration outlined in this
policy.
All monitoring and measuring devices are identified to show calibration status.
System is maintained to identify, assess, and re-validate any product determined to have been
inspected or processed by out of calibration equipment.
All calibration, measurement and tests are carried out under suitable environmental
conditions and all equipment is maintained and handled to ensure its accuracy and fitness for
use.
Calibration and/or adjustment of all measuring, control, and test equipment are to be
performed by authorized personnel only.
Related Documentation:
WI/CAL-01: Calibration
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8.1 General
KAROONI Knit Composite Ltd. product quality plans are used for planning the necessary
monitoring and measurement processes. The need for statistical techniques is considered as
plans are being made Implementation occurs according to the defined plans, the resulting data
is analyzed and improvements are pursued.
Internal quality audits are planned, executed, and documented to verify whether quality
activities comply with the planned procedures and to determine the effectiveness of the
quality system.
Internal quality audits are scheduled on the basis of the status and importance of the activity
to be audited and results of previous audits.
Auditors are nominated in such a way that they are not directly responsible to perform the
activities being audited.
Management responsible for the area being audited takes action without undue delay to
eliminate detected non-conformities and their causes.
Follow-up audits are performed to verify if the corrective action taken and effective. Results
of audit are reported and reviewed in the management review meetings.
Related Documentation:
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CLAUSE: 8 MEASUREMENT, ANALYSIS AND IMPROVEMENT (cont.)
In-coming products are not processed or used prior to inspection for verification to
requirements.
Planned in-process and final inspections are carried out to ensure conformance to specified
requirements throughout the manufacturing cycle and to identify any non-conformity.
Product release does not proceed until all specified activities have been completed. Records
are maintained to show results of inspection and tests performed.
All records of inspections are reviewed prior to approval for dispatch to ensure all activities
are complete, documented, and results meet with specified requirements.
Related Documentation:
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QC Manager follows established procedures to ensure that a product, which does not conform
to specification, is withheld from use or further processing until disposition is specified and
all concerned departments are advised of the disposition.
KAROONI Knit Composite Ltd. takes appropriate action regarding consequences of non-
conformity detected after delivery or use has started. Where required, KAROONI Knit
Composite Ltd. reports to the customer, if non-conformity is identified after delivery of
products. In such cases actions are taken as per customer advice.
Related Documentation:
In KAROONI Knit Composite Ltd. quality management system related data is recorded as
indicated in Control of Records procedure, analyzed with the objectives below in mind and
used to determine the suitability, effectiveness and opportunities for improvement of the
quality management system. The data analysis objectives for KAROONI Knit Composite
Ltd. are:
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8.5 Improvement
In order to avoid the recurrence of problems, appropriate corrective actions are taken.
KAROONI Knit Composite Ltd. Corrective Action procedure provides a systematic
approach to corrective action problems that includes:
Related Documentation:
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In order to avoid the occurrence of potential problems, appropriate preventive actions are
taken. Preventive Action procedure provides a systematic approach to preventive action
problems that includes:
Related Documentation:
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Merchandising department will provide the buyer order sheet, style description, measurement
sheet, sketch, sample, garments photo and other necessary requirements of the buyer to the
each section of Production department for the start of the bulk production. The
Merchandising department will also communicate regarding the production plan to the
Production department. In case of any deficiencies of the information the Production
Department will notify the Merchandising department. All types of amendment or change
regarding the buyer order will be notified to the Production department by the
Merchandising.
Merchandising department will provide the requirements of the buyer, such as buyer order
sheet, measurements sheet, and garments description to the Quality Control department. The
QC department will communicate to the Merchandising department regarding the all
requirements to the product conformity.
The QC department will check and inspection in every stage of each section of Production
department. The fault and defect will be reported to the Production department for rework
where applicable. The Production department will take the necessary steps for the rework
where necessary and send to the QC again for the rechecking. The QC department will re-
check and re-inspect those processes as the routine check and inspection.
The Production department will place the approved requisition for yarn and accessories to the
Store department. Store department delivers the yarn and accessories as per the production
specification and the requisition on time. The production department will receive the
materials from the store after issuing from the store.
The Marketing & Merchandising Department will provide the buyer requirements
(specification sheet or original sample) to the Sample Section for developing the sample. The
sample section develops the sample and sends it to the Marketing & Merchandising
department for taking the buyer approval. For any change or modification from buyer side the
Marketing & Merchandising Department will provide to the Sample Section and the Sample
Section will do that accordingly.
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Interaction between Quality Control and Sample Section:
The Sample In-charge will request the QC Manager to check/inspect the sample after
developing as per the buyer requirements. The QC Manager will take the initiatives to inspect
and will give the inspection results with comments where necessary.
Whenever a position will be vacant or new position will be created head of the concerned
department shall raise requisition in prescribed format and send to the Admin Department for
taking necessary action. Admin department arrange hiring according to the procedure and
maintain all the documents (interview evaluation sheet, appointment letter, application form,
all necessary papers, leave records) in individual personal file.
Manager Admin & Compliance perform the all training related activities. Accordingly they
first train up their immediate subordinates. After that the subordinates perform the training
activities for their own subordinate. Manager Admin & Compliance follow up overall
effectiveness of training provided.
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Annexure-A
Cross-functional Flowchart:
(Policy)
Production Planning
Monitoring &
Control
Production
Commercial
Store
Shipment to Customer
Customer Satisfaction
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Annexure-B
Organogram:
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