Quality Management System

INTRODUCTION

With the increased demand of INDONESIA garments in the whole world market out side the country, number of garments factories is growing rapidly but Q.A. management system cannot be developed in the same speed due to the lack of Q.A. management system. It is the quality of our product and service along with the efficiency of the work force, which is the foremost objective of The Company aims to produce products and service of the high standard, which meets all the specifications, including environmental concern and safety. Company now expanding its business by establishing a manufacturing the Company commitment to its valued customer always been :

•Maintaining the highest achievable quality possible.

•The most competitive pricing in the world market.

•Shortest lead-time with on time delivery.

•The best environment for ethical standard in accordance with world

    compliance standards. 

This Quality system relates to the full range of company activities to support The Company Mission and Vision.

1. Vision 

The vision is to reinforce our company existence by doing continuous improvement and expanding production item and volume as world class apparel manufacturer

2. Mission 

The mission is to supply product to customer with stable quality, competitive cost and on time delivery required.

POLICY and OBJECTIVE

Objectives of this policies are :

• To understand customer’s perspective of quality.
• To provide better quality of products and service.
• To provide good and safe working environment to the workers, which includes human value, respect, justice, cleanliness, discipline and equality between workers and others.
• To implement quality control system with the aim to achieve zero  defect level through efficient management, research, development  and continuous improvement.

The Company quality police is to achieve sustained, profitable growth by providing services which consistently satisfy the needs and expectations of its customer

This level of quality is achieved through adoption Zero Defect and Zero Variation concept that reflect the competence of the company to existing customer and potential customer

Achievement of this policy involves all staff, who is individually responsible for the quality of their work, resulting in a continually improving working environment for all. This policy is provided and explained to each employee by the Executive Director.

To achieve and maintain the required level of assurance the Executive Director retains responsibility for the quality system with routine operation controlled by the Quality Assurance Manager. The objectives of the quality assurance system are:

A) To maintain an affective Quality assurance system complying with current and potential customer requirement

B) To achieve and maintain a level of quality which enhances the company reputations with customer.

C) To ensure compliance with relevant statutory and safety requirement.

D) To endeavor, at all times, to maximize customer satisfaction with the services provided  of Company. 

COST AND QUALITY

1. QUALITY: Quality is defined as “Totality of characteristics of an entity (product, service etc.) that bears on its ability to satisfy stated and implied needs. 
2. QUALITY CONTROL: Is an effective system for interchanging the quality maintenance and quality improvement efforts of various groups in an organization so as to enable production at the most economical levels which allow full satisfaction for the consumers. 
3. TOTAL QUALITY MANGEMENT SYSTEM (T.Q.M.): Is described as an all- inclusive fully integrated productivity technique. It helps to create new markets, expand existing markets and recapture lost markets by utilizing the optimum capability of man, machine, material, method and produces high and uniform quality of products with reduced costs. Total quality control starts from market i.e. from purchasing material and machine and ends in the market i.e. selling the finished products in the market including after-sale service. It includes market analysis, product development, production planning, statistical quality control, preventive maintenance, wastage control, inventory control, cost reduction and after sales service et. The ultimate goal of T.Q.M. is to increases the quality/cost ration and continuous improvement. It may be done by increasing the quality with same cost, decreasing the cost with same quality and increasing quality and decreasing coast at the same time.

The above graph shown that there is an optimum quality of a product. Above this optimum, the increased the cost, there will be no increase of quality. But below the optimum, lower the quality lesser the cost. The basic quality problem is to set correct balance between the cost and quality i.e. to find out a suitable quality/cost ration for the product which will satisfy the consumer both for cost and quality.

QUALITY SYSTEM

• PURPOSE

To document and maintain a quality system as a means to ensure that

production at factory conforms to specified requirement. 

•  SCOPE

The quality system operated by Company. aims to ensure compliance to specified requirements and is defined and driven by Quality Manual, departmental procedures and work instructions, those are defined in this section.

• QUALITY SYSTEM PROCEDURES

The Quality procedure of  the  factory will be reviewed by the concerned persons of  Management of  that factory. Describing the quality systems of The Company, this manual includes a brief description of the functions and mode of operation of the factory management personnel with respect to quality.

QUALITY PLANNING 

Documented quality planning is stated by this manual, accompanying procedure,  work instructions and quality, all of which comprise the Company. Quality System. Thus, quality planning is, documented and implemented by all Executives and Managers playing a role in the maintenance of product quality and the quality management system.

To achieve the goal of zero defect level following steps has been taken".

1. For massive awareness building regular discussion and meeting are conducted with the concern people. 
2. Regular training session is being conducted on Statistical Quality Control System.
3. Introduce it as a tool to achieve the goal. 
4. Introduce incentives for inspectors and operators for the best performing line. 
5. Introduce operators' quality performance chart to findout source and type of defect for taking preventive and corrective measures. 
6. Reorganize process/10pcs inspectors job allocation, work procedure to make them more accountable for effective control on process inspection with the help I operators quality performance chart. 
7. Weekly defect analysis of process inspection, table inspection and final inspection to find out the irregularities of inspection if any and. to take corrective measures.  
8. Monthly defect analysis and moving average, line and factory wise, to monitor improvement and trend of defect.  
9. For graphical representation of hourly defect percentage in control chart to set upper control limit at 1.0%, central line is 0.65% and lower control limit at 0.0% to brine down defect level towards zero by continuous improvement.

 Quality planning also includes the following,

1. Assignment of responsibility for conducting checks. 
2. Stages at which checks are to be carried out. 
3. Methods to be followed in conducting the checks.
4. Frequency of the checks.
5. Criteria for acceptance/rejections.
6. Related documents to be checked.
7. Documents to maintain as evidence of the checks.
8. Corrective & preventive action to be taken subsequent to the check.

 ORGANIZATION CHART

AUTHORITY and RESPONSIBILITY

• Authority  

1. All staff is allocated with authority to perform their allocated responsibilities. The following provides a summary of the summary of the principal responsibilities of each job role, and these are clarified in greater detail within the operating procedures. 
2. All staff shares the authority and responsibilities of indentifying noncompliance or possible improvements, and recording these instance such that corrective action can be taken, both to rectify the immediate situation and prevent recurrence.
3. The Executive Director continually reviews the company resources to ensure that adequate staff, equipment and materials are available to meet customer requirement.

• Responsibilities 
  The executive Director establishes organizational goals and expectations, the Quality System framework, and corporate policies.  Periodically, the Executive Director participates in a review of the Quality System   it strengths, opportunities for improvement, and need for changes based new business directions. 

      The upper management team is responsible for:

1. Providing leadership and communication to the organization,
2. Defining strategic quality goals and objectives, including statutory and customer requirements,
3. Ensuring continual improvement of products, processes, and the quality system
4. Delegating appropriate responsibilities to meet quality objectives,
5. Defining job descriptions, and organizational responsibilities / authority for all staff.

Functional responsibilities and interrelationships are defined through organizational charts, job descriptions, corporate policies, and key system procedures.  Operational Managers are responsible for ensure all members of their team understand corporate goals and objectives, the scope of the quality system, and the role of their team within that system.

The responsibility and authority for each function or personnel to implement activities in The Company management System are describes on,

• Organization Chart.
• Standard Operating Procedure. 
• Job Description

 Responsibility in General

 (See detail on appendix pages)

MANAGEMENT REVIEW

• General

The purpose of management review is for providing guidelines for reviewing the quality system at appropriate time to ensure suitability and effectiveness of the Quality Management system continuously in the organization.  The Management Review Meeting shall be conducted twice in a year. The minutes of MRM shall be recorded by M.R. The composition of the Management Review Committee may be as follow. This composition of committee is also for guideline purpose. It will vary organization to organization depending upon their organization structure. But it is suggested to include all depart mental heads and other as per requirement.

• Managing Director
• General Manager
• Production Manager
• Production Incharge
• Quality Assistant Manager
• Store incharge
• Management Representative (MR)
• Administrative Officer

MR shall prepare and circulate the agenda verbally or in written form in advance to the

members and organize the meeting. MR shall prepare the minutes and keep the records.

• Review Input

1. The input to management review shall include information on:
2. Results of audit 
3. Customer feedback and Complaints 
4. Process performances and product conformity
5. Continual improvement
6. Status of preventive and corrective action.
7. Follow-up action from previous management system reviews, 
8. Change that could affect the quality management system 
9. Recommendations for improvement 
10. Resource requirement
11. Any other point raised by members
12. Quality Policy & Quality Objectives

•  Review Output

Review output from the management review shall include any decisions/actions related to,

1. Improvement of the effectiveness of the quality management system and its     processes.
2. Improvement of production related to customer requirement
3. Resources needed.

The minutes of the meeting shall be recorded and circulated to all the concerned member of the management review meeting. The minutes of the meeting shall include action plan for corrective measure, responsibility and target date for completion, implementation of corrective measures shall be monitored by the MR.

• Reference 
• Management Review Meeting Minutes

Training plan shall be prepared by administrative department and execution shall be done accordingly. Administrative officer or GM arranges the training either within the department (in- case of internal training) or from the outside agencies and consultants in case of external training. For all newly recruited employee induction training shall be provided by their respective supervisor mentioning the nature of job to be done, the occupational health & safety and overall introduction of department and employee etc.

CONTRACT REVIEW 

The company offers both standard product and specialist services to meet each customer’s needs. Standard product is displayed in the company profile. Specialist service requirements differ from one customer to another (and from one contract to another); therefore each tends to be quoted for the specific contract. Once a proposal is accepted by the customer, or an order is placed, it is recorded and review to establish that the requirements of the order are adequately defined and documented, any differences from the proposal are resolved, and the company is capable of fully satisfying the customer requirement. In addition to the original order / contract specification the customer may also request additional/variation work to be undertaken by the company. In these circumstance the work content is documented and agreed with the customer prior to execution ensure that no ambiguity exists.

PRODUCT DEVELOPMENT CONTROL

All product development activities are strictly controlled to ensure that the product specification complies with customer requirement.

Product development activities are planned and normally executed by specialist and are subject to regular management, review and verification by the Merchandiser Manager, and where relevant, agreement within the customer.

The design input and output items are documented and where ambiguity exists, will be clarified and documented. All items of design documentation and notes are recorded in a file. Design output documentations are produce and reviewed to ensure that it:

1. Meet the design input from customer, 
2. Reference the design input or appropriate criteria,
3. And identifies all the characteristics which are critical to the safe and effective operation of the system ( s )