JAI

REV.NO 00

REVISION RECORD SHEET

TITLE : PROCEDURE FOR CALIBRATION OF GAUGES &
INSTRUMENTS. DESC. OF AMENDMENT PROCEDURE RE-STATED.AS PER QS 9000:1995 REQUIREMENTS DATE OF AMENDMENT 16.03.1997

PR.NO : QP-11-01 PAGE NO : 1 OF 6 ISSUE NO : 01 REV NO : 00 DATE : 16.03.1997 REASON FOR AMENDMENT QS 9000 ; 1995 UPDATION

DISTRIBUTED TO :
SL.NO DESIGNATION NAME & SIGNATURE OF THE RECEIVER 01 VICE PRESIDENT MR. S.P.S.KOHLI 02 G.M. (COMM) MR. S.K.SINGH 03 AGM (STB & PROJECTS) MR.SHASHI TANDON 04 AGM (QA) MR. B.K.KHANDELWAL 05 DY. MGR.-QA STB MR. SANDEEP SHARMA 06 DY. MGR. LS PROD. MR. R.L.RANA 07 DY. MGR. STB. PROD. MR. R.P.BHALERAO 08 DY. MGR. PUR. MR. RATAN KHEMCHANDANI 09 DY. MGR. MAINT. MR. MANAB DATTA 10 ASST. MGR. QA LS MR. ASHOK AGARWAL 11 ENGR. CALIBRATION MR. MANOJ AGARWAL 12 MANAGEMENT REPRESENTATIVE MR. PIYUSH KUMAR PREPARED BY: APPROVED & REVIEWED AND RELEASE CONTROLLED BY:

JAI

QUALITY ASSURANCE PROCEDURE

TITLE : Procedure for Calibration of Gauges &
Instruments.

PR.NO : PAGE NO : ISSUE NO : REV NO : DATE :

QP-11-01 2 OF 6 01 00 16.03.1997

PURPOSE : To describe the system followed in identifying the needs, ensuring accuracies of measurements by controlling, calibrating and maintaining all gauges instruments and equipments used for measurements used in manufacturing process. Scope : The procedure is applicable for calibration of all gauges instruments and test equipments used in manufacturing process in inspection at all stages like incoming, inprocess and final inspectionThis is also applicable for periodic verification of accuracies on Inspection fixtures ,apparatus and equipments used in chemical & physical test laboratory.

Responsibility : Asst. Gen. Manager (QA & Engg)-LS Procedure : 01. Engr. Calib. shall maintain masterlist of gauges, instruments, test equipments used in inspection, Inspection fixtures (used in production at all stages like incoming inprocess and final inspection). This list shall indicate details like description, size type and code no., calibration frequency & calibration agency. The reference for calibration standards, acceptance criteria & record reference for each instrument / gauge shall be mentioned in the respective Work Instructions. 02. This list shall be updated at the time of induction of new products into production for related gauges / instruments , Inspection fixtures, introduced in the system which are procured by Engg & Development Department during APQP. 03. Engr. Calib. shall be responsible for codification of gauges, inspection devices / aids & Inspection fixtures. The gauges / instruments codification system is described in WI-11-26. 04. Engr. calibration shall define calibration parameters, calibration method and frequency for each instrument & gauge in respective work instructions. 05. New gauge instrument received shall be accepted against calibration certificate from the manufacturer. If the certificate not provided or not having traceability to national standards, Engr. Calib. shall arrange for calibration of the same before its acceptance, recording and putting into use. 06. He shall also include in the masterlist all the gauges/measuring instruments sent to the sub-contractors, if any, by JAI for our products and prepare schedule for verification of their calibration status. 07. He shall also be responsible for preparing ,following calibration schedule, maintaining calibration status & records & for verification of the validity of the same.

JAI

QUALITY ASSURANCE PROCEDURE

TITLE : Procedure for Calibration of Gauges &

Instruments. 08. For gauges, meters and indicators fitted or used on machine tools, production equipments, Dy.Mgr.Maintenance shall be responsible for maintaining masterlist with calibration / verification status of each along with calibration schedule. He shall also maintain a list of approved sources for calibration with NPL traceability of masters &

PR.NO : QP-11-01 PAGE NO : 3 OF 6 ISSUE NO : 01 REV NO : 00 DATE : 16.03.1997

carry out calibration as per schedule. 09. G.M. (Comm) shall get verified all weighing scales (all types) used in the organisation for periodic inspection by weight & measurement deptt. Repairs , if any, shall be done by the competent agency and inspected again. Inhouse verification by putting weights on the balance is also done from time to time in order to ensure proper weighment. Before due dates of Inspection, Dy. Mgr. (Pur) shall remind the Inspection agency. In case of delays user department head shall take follow up with the purchase deptt. for calling Inspection agencys Representative. Purchase deptt. shall maintain records of Inspection and ensure that all weighing scales are accurate at any time. 10. Engr. Calib. shall identify reliable calibration agencies outside, if calibration facilities in-house are not available. He shall maintain a list of such approved calibration agencies having necessary facilities, for calibration of intended devices, which have traceability to national / international standards. 11. The devices for which in-house calibration facilities having traceability to national standards are available, work instruction for the calibration on the device shall be approved by AGM(QA) and shall be used for calibration of the respective devices. Appropriate environmental control shall be applicable for calibration. 12. All the gauges, measuring instruments & Inspection fixtures shall be subjected to calibration within two days of due dates. 13. Engr. Calib or as deputed by AGM (QA) shall carry out verification of gauges / instruments used at sub-contractors end as per verification schedule mentioned in 06 and submit his report in calibration status report to AGM(Q. A.) 14. Results of calibration and inspection shall be recorded in History Card/ Inspection Report / Validation Report 15. The actual reading and gauge conditions, if not satisfactory, shall be referred at the stage of receiving for calibration / verification. This means in case of devices needing repairs / adjustments shall have actual readings both before and after repairs or adjustments. 16. The records shall be made available to customers representative when needed contractually, in respect of measuring devices used for their product manufacturing. 17. For every engineering change implemented, Q. A. incharge shall review these records of calibration to ensure suitability of the devices, accuracy level, additional facilities

JAI

QUALITY ASSURANCE PROCEDURE

TITLE : Procedure for Calibration of Gauges &
Instruments. required. Accordingly he shall amend relevant documents.

PR.NO : QP-11-01 PAGE NO : 4 OF 6 ISSUE NO : 01 REV NO : 00 DATE : 16.03.1997

18. The gauges, instruments found acceptable during calibration (or recalibration after necessary rework / repairs) shall be attached with indicators indicating next calibration / inspection due date. These indicators may be stickers, markings,colour coding, etc.

19. Some of the devices to be used in production process or needing frequent handling may not be suitable for attaching indicators as mentioned in 18. In such cases, their calibration status and next calibration due date shall be obtained from their respective History cards maintained by Engr. Calib.. 20. Based on the non-confromance report, Engr. Calib. shall take appropriate steps to :- carry out repairs / adjustment of the gauge, instruments & equipments. For Inspection Fixtures, repairs shall be the responsibility of Tool Room Incharge. - recalibration inspection of the same after repairs and adjustments. - attach calibration status indicator based on the re-calibration results. - the device if found not repairable / not adjuatable and no more fit for use, stickers indicating status REJECTED shall be attached to it & taken out of line & subsequently shall be scrapped. 21. Any device needing repairs, if can not be corrected immediately and which needs to be used in production / inspection continuously / frequently, Engr. Calib. shall arrange for inspection of product manufactured out of the use of equipment / instrument under consideration for the area corresponding to defective area on equipment / instrument. If the accuracy observed on product is within acceptable limits the use of equipment / instrument shall be permitted. However, control plan of the product shall be modified or attached with appendix to include inspection of area / dimension affected by defective part of the equipment / instrument and shall be allowed till the results of inspection are within acceptable limits. Thereafter use of equipment / instryment shall be banned and sent for repairs. 22. It is responsibility of Engr. Calib. to get the repairs carried out on equipment / instrument at the earliest after detection of defect. 23. After repairing of equipment / instrument when satisfactory results are obtained in production the control plan amendment shall be withdrawn or included permanently as felt appropriate by Q. A. Incharge. 24. Necessary remarks to this effect shall be maintained on all related decouments by Engr. Calib..

JAI

QUALITY ASSURANCE PROCEDURE

TITLE : Procedure for Calibration of Gauges &
Instruments.

PR.NO : QP-11-01 PAGE NO : 5 OF 6 ISSUE NO : 01 REV NO : 00 DATE : 16.03.1997

25. Calibration of measuring and test equipment devices can be requested by the user at any time regardless of calibration due date for that device following occurances of any event that places accuracies of the device in doubt. In such cases shall check the need for calibration and arrange for same. 26. In case gauge / measuring instrument falling due for calibration is the only gauge / instrument available for use and to be sent out side for calibration, Q. A. Incharge shall lay-down alternative inspection procedure for the parameters being checked by the gauge / instrument under consideration till the gauge / instrument is received

back duly calibrated by calibration agency. Any limitation in obtaining results to required accuracy the matter shall be discussed with AGM. Q. A. and if felt necessary communicated to customer through marketing to keep them informed and obtain their approval. 27. Engr. Calib., however shall try to overcome such situation by arranging for spare set of all gauges which can be used at the time when one set of all gauges which can be used at the time when one set is sent for calibration or by differing the production plan of the items needing gauges falls due for calibration through marketing department. Control 28. In case of any gauge or device is found out of calibration at any time, the matter shall be immediately referred to Engr. Calib. by the users of the device. 29. This situation can occur when : - The instrument is doubtful for accuracy as described in 25 above and when it is subjected for verification test, is found non conforming. - During the calibration on due date, as per schedule, the device is found out of calibration. - The Devices in use, after due date of calibration, as per schedule ie. calibration is overdue. 30. Under all above conditions, Engr. Calib. shall withdraw, the gauge or the device under consideration from the production or inspection line and arrange for the calibration. Engr. Calib. shall fill up the details & submit it to Q. A. Incharge. 31. Q. A. Incharge shall identify the batches inspected with the use of device under consideration (under recalibration) between last calibration to till date and attach Hold tag to the available quantities in hand out of the same. He will then verify records of last calibration carried out for the device and ensure the validity of the same. This will ensure that inaccuracy, if any, is occured only after last calibration. 32. If possible ie. if other valid device is available for inspection of the same parameter on the products under Hold. He shall arrange for inspection of the same.

JAI

QUALITY ASSURANCE PROCEDURE

TITLE : Procedure for Calibration of Gauges &
Instruments.

PR.NO QP-11-01 PAGE NO : 6 OF 6 ISSUE NO : 01 REV NO : 00 DATE : 16.03.1997

33. If such devices not available, the batch under Hold shall be kept pending till the device under consideration is repaired and validated by calibration or replaced and validated by calibration or replaced by new one and then used for inspection of Hold batch. 34. Products found non conforming shall be handled as per regular procedure for handling of non conformance. 35. If the device is found out of calibration, needing any repairs adjustments and again calibration, during calibration explained in 30 then necessary corrective action shall be initiated .

36. Q. A. Incharge shall then assess the possible effect on final quality of products inspected with the device under consideration and passed on to customer during this period. Only if the effect is crucial and affecting final quality of the customers products also, he shall immediately discuss the matter with the VP and inform through marketing to customer about the identification numbers of the products which are suspected to be defective and may hamper the final quality of the product. 37. AGM (QA) shall investigate possible reasons for the device to go out of calibration and if necessary take appropriate corrective actions like change in calibration procedure, change in calibration schedule, frequency of calibration, training of the calibration in-charges, training of the user and monitoring system for other gauges for no occurance of the event. 38. Engr. Calib. shall maintain the record of actions taken in this regard which shall be referred in future for deciding calibration frequency and procedures for other gaues by way of filling up format number. 39. Measurement System Variation shall be as per MSA manual Refer WI-11-22 & WI-11-23.