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CQA/19/2016/001
DIVISION All Divisions of Tata Steel REV. NO. 00
DEPARTMENT All EFFECTIVE 01.07.16
SECTION DATE
Annexures:
5.0 ANNEXURES
(i) Form A1, A2, A3 (ii) Checklist Form B
(i) Vice Presidents (ii) Chiefs (iii) EICs (iv) GMs of Mining, Manufacturing and
Service providing Departments /Divisions of Tata Steel where changes occur
6.0 DISTRIBUTION to maintain consistency of product and service quality those are required to
be captured, recorded, archived and referred for standardization of processes
and systems.
::ampclopn02.doc
PREPARED BY APPROVED BY AUTHORISED BY
NAME Alok Kumar Manash Banerjee Alok Krishna
DESIGNATION Sr. Mgr. CQA Head CQA Chief (TQM, BPE & CQA)
SIGNATURE
DATE 25th June 2016 30th June 2016 30th June 2016
DOCUMENT Managing Q-Changes DOC NO. CQA/19/2016/001
DIVISION All Divisions of Tata Steel REV. NO. 00
DEPARTMENT All EFFECTIVE 01.07.16
SECTION DATE
Introduction
Different triggers lead to requirements of change (e.g. Int. /Ext. Customer demands, Product
specification, Process layout, Technology, Supplies from vendors, People), which involves a
meticulous planning of the change process. These changes may affect product & service
quality either directly or indirectly.
The various types of changes (temporary/permanent, emergency, trial) must be captured,
analyzed, recorded, communicated and archived for future references. This helps alignment
of our manufacturing/service processes with the changing needs and demands of the
customer/next process.
Therefore, the following procedure is prepared for carrying-out Quality changes for
implementation across all functions of Tata Steel.
This procedure provides details on how to manage a Q-change and can be used as per the
requirements of respective department or division. Implemented of this procedure may be
done through a manual or IT based system as per the convenience of the department.
However, each of the steps given needs to be adhered to.
::ampclopn02.doc
PREPARED BY APPROVED BY AUTHORISED BY
NAME Alok Kumar Manash Banerjee Alok Krishna
DESIGNATION Sr. Mgr. CQA Head CQA Chief (TQM, BPE & CQA)
SIGNATURE
DATE 25th June 2016 30th June 2016 30th June 2016
DOCUMENT Managing Q-Changes DOC NO. CQA/19/2016/001
DIVISION All Divisions of Tata Steel REV. NO. 00
DEPARTMENT All EFFECTIVE 01.07.16
SECTION DATE
::ampclopn02.doc
PREPARED BY APPROVED BY AUTHORISED BY
NAME Alok Kumar Manash Banerjee Alok Krishna
DESIGNATION Sr. Mgr. CQA Head CQA Chief (TQM, BPE & CQA)
SIGNATURE
DATE 25th June 2016 30th June 2016 30th June 2016
DOCUMENT Managing Q-Changes DOC NO. CQA/19/2016/001
DIVISION All Divisions of Tata Steel REV. NO. 00
DEPARTMENT All EFFECTIVE 01.07.16
SECTION DATE
::ampclopn02.doc
PREPARED BY APPROVED BY AUTHORISED BY
NAME Alok Kumar Manash Banerjee Alok Krishna
DESIGNATION Sr. Mgr. CQA Head CQA Chief (TQM, BPE & CQA)
SIGNATURE
DATE 25th June 2016 30th June 2016 30th June 2016
DOCUMENT Managing Q-Changes DOC NO. CQA/19/2016/001
DIVISION All Divisions of Tata Steel REV. NO. 00
DEPARTMENT All EFFECTIVE 01.07.16
SECTION DATE
The committee, as understood, may approve, reject or cancel the proposed change.
Rejection of proposed change implies that further work is required to be done to bring-
out more insight in to various aspects of the change proposal.
5. Communication:
Approved change should be communicated to all concerned for various preparation and
approval activities with external/internal agencies. Any awareness/training session, if
required should be imparted to the change execution committee within the time
proposed to carry-out the change.
6. Implementation/Installation:
The change proposed, once approved, should be executed as per the plan by MQC
execution team.
The processes to manage the change and final desired outcome should be documented
and communicated.
7. Confirm Effectiveness:
To confirm the effectiveness of change carried out, it is required to verify the outcome
with intended results. Holding the gain report should be generated and audited to
capture the long term effectiveness. This effect and outcome should be reviewed.
8. Closure:
Once the verification of satisfactory implementation is done, the change is required to be
closed formally. (sign off, physical or on net)
When the change has been confirmed to be effective, and all of the MQC action items
have been confirmed to have been completed, then and only then, may the MQC be
confirmed closed and records updated accordingly.
Approver should finally approve of the processes as completed and allow of closure
through online or system as established.
::ampclopn02.doc
PREPARED BY APPROVED BY AUTHORISED BY
NAME Alok Kumar Manash Banerjee Alok Krishna
DESIGNATION Sr. Mgr. CQA Head CQA Chief (TQM, BPE & CQA)
SIGNATURE
DATE 25th June 2016 30th June 2016 30th June 2016
DOCUMENT Managing Q-Changes DOC NO. CQA/19/2016/001
DIVISION All Divisions of Tata Steel REV. NO. 00
DEPARTMENT All EFFECTIVE 01.07.16
SECTION DATE
MQC Metrics
Carrying-out management of Q-change has various metrics which defines the success of MQC
process as a system; its liveliness & effectiveness. Various metrics can be listed as:
Number of MQCs initiated
MQC Execution Compliance (Percentage of MQCs executed vs. Initiated)
Percentage of audited changes that used MQC as change procedure
Average time taken between MQC for same area and job
Percentage of work orders/requests that were wrongly classified as Replacement-in-
Kind (RIK) but should have been MQCs
Percentage of changes that went through MQC process but was reviewed incorrectly
Errors identified through audit in MQCs
Percentage of temporary MQCs where the temporary conditions were not
corrected/restored to original state by the deadline
To review the effectiveness of the system, further metrics may be added as required by
department or division.
::ampclopn02.doc
PREPARED BY APPROVED BY AUTHORISED BY
NAME Alok Kumar Manash Banerjee Alok Krishna
DESIGNATION Sr. Mgr. CQA Head CQA Chief (TQM, BPE & CQA)
SIGNATURE
DATE 25th June 2016 30th June 2016 30th June 2016
DOCUMENT Managing Q-Changes DOC NO. CQA/19/2016/001
DIVISION All Divisions of Tata Steel REV. NO. 00
DEPARTMENT All EFFECTIVE 01.07.16
SECTION DATE
Document for
Individual or team
Review & Approval
requirement for
MQC
4
Analysis of 8
Closure
Resources & Impact
1
Is MQC
Required? Analysis of Trial
5
Execution of MQC, Report
Approval Yes
No 2 Post change review
Yes of MQC
Prepare MQC 6
No
document 7
MQC Rejected
MQC falls under
Replacement in 3 Trials &
Kind RIK category Commissioning
Make Corrections &
Amendments
::ampclopn02.doc
PREPARED BY APPROVED BY AUTHORISED BY
NAME Alok Kumar Manash Banerjee Alok Krishna
DESIGNATION Sr. Mgr. CQA Head CQA Chief (TQM, BPE & CQA)
SIGNATURE
DATE 25th June 2016 30th June 2016 30th June 2016
DOCUMENT Managing Q-Changes DOC NO. CQA/19/2016/001
DIVISION All Divisions of Tata Steel REV. NO. 00
DEPARTMENT All EFFECTIVE 01.07.16
SECTION DATE
2. Routing this form for approval takes so long we can never get anything done
Explanation: Following a laid out process helps sail smooth & reduces the chance of error. It also
helps in archiving of the document for future reference.
3. We are a warehouse / light manufacturing / data center / repair facility We dont have anything
that could impact adversely.
Explanation: Analyze risk proactively. It is strongly recommended that impact of failure for not
making/ while carrying the change be studied comprehensively.
6. This is just a platform / procedure change. Its not like we were changing a pipe or something. We
dont need to approve or document
Explanation: Platform or Procedural change also requires training and user involvement. This is
for wide publicity and subsequent training to user community.
::ampclopn02.doc
PREPARED BY APPROVED BY AUTHORISED BY
NAME Alok Kumar Manash Banerjee Alok Krishna
DESIGNATION Sr. Mgr. CQA Head CQA Chief (TQM, BPE & CQA)
SIGNATURE
DATE 25th June 2016 30th June 2016 30th June 2016
DOCUMENT Managing Q-Changes DOC NO. CQA/19/2016/001
DIVISION All Divisions of Tata Steel REV. NO. 00
DEPARTMENT All EFFECTIVE 01.07.16
SECTION DATE
Definitions:
Roles & Responsibilities
Roles Responsibilities Hierarchical Position
Initiator Frontline engineer/manager who has felt IL6 to IL4
need for the change; Should propose the
change and prepare the necessary
documentation
Manager Senior to Change Initiator from the same IL3 (Sectional Head)
vertical. Potential effect analysis through
Checklist and risk mitigation to be
completed under Managers ownership.
Technical Review A cross-functional team of experts from Seniors in different
Committee operation, maintenance, QA & TG to do domain; IL4 to IL3
the impact analysis and approve the go
ahead for changes
Change Exec. Group A team of frontline engineer/ managers IL6 to IL4
to execute the change after the due
diligence is complete. Change initiator
must be a part of this team.
Approver To check the effectiveness & approve the IL3 to IL2
closure of change after reviewing the
documents; guide for any post change
activity (training etc.)
Coordinator Custodian of MQC documents; arranges IL5/IL4; Improvement
for Audit, training, renewal and record Manager
keeping of MQC
::ampclopn02.doc
PREPARED BY APPROVED BY AUTHORISED BY
NAME Alok Kumar Manash Banerjee Alok Krishna
DESIGNATION Sr. Mgr. CQA Head CQA Chief (TQM, BPE & CQA)
SIGNATURE
DATE 25th June 2016 30th June 2016 30th June 2016
DOCUMENT Managing Q-Changes DOC NO. CQA/19/2016/001
DIVISION All Divisions of Tata Steel REV. NO. 00
DEPARTMENT All EFFECTIVE 01.07.16
SECTION DATE
Domains of MQCs: There are multiple areas which may require changes to bring in
desired results. The various areas for changes are:
Equipment Change Procedural Change
Chemical Change Process Change
IT Change Control Limit Change
Personal Change Infrastructure Change
This is required to be understood that a change may be required simultaneously in one or
more domain. The nature of changes may also differ like temporary, permanent, trial or
emergency. The nature of change requirement must be understood clearly after proper
deliberation within the Approver or TR committee.
Types of MQC:
RIK (Replacement In Kind)
An item (equipment, material used in the process, procedures, organizational structures,
people, etc.) that meets the design specification, for the item it is replacing. This can be
an identical replacement or any other alternative specifically provided for in the design
specification, as long as the alternative does not in any way adversely affect the function
or safety of the item or associated items. For nonphysical changes (relating to
procedures, personnel, organizational structures, etc.), no specification, per se, may exist.
In these cases, the reviewer should consider the design and functional requirements of
the existing item (even if nothing is written down) when deciding whether the proposed
modification is an RIK or a change.
Permanent Change
Any change with an intention of not returning the system to its original design falls under
this category. E.g. A product specification change making the previous grade obsolete.
::ampclopn02.doc
PREPARED BY APPROVED BY AUTHORISED BY
NAME Alok Kumar Manash Banerjee Alok Krishna
DESIGNATION Sr. Mgr. CQA Head CQA Chief (TQM, BPE & CQA)
SIGNATURE
DATE 25th June 2016 30th June 2016 30th June 2016
DOCUMENT Managing Q-Changes DOC NO. CQA/19/2016/001
DIVISION All Divisions of Tata Steel REV. NO. 00
DEPARTMENT All EFFECTIVE 01.07.16
SECTION DATE
Control of Document:
Control of document is essential/must do process after MQC. The document must be
completed in all respect and archived on an IT based system or document register so that
the same is easily retrievable.
The document should be so retained that it is available as long as the changed entity
(system/process/equipment etc.) is in use.
Renewal of Process:
The procedure shall be reviewed and revised as necessary and, at a minimum, not later
than one year from the date of the last revision. Any necessary change, if felt so, should
be incorporated in the procedure as per the requirement of the departments & divisions.
::ampclopn02.doc
PREPARED BY APPROVED BY AUTHORISED BY
NAME Alok Kumar Manash Banerjee Alok Krishna
DESIGNATION Sr. Mgr. CQA Head CQA Chief (TQM, BPE & CQA)
SIGNATURE
DATE 25th June 2016 30th June 2016 30th June 2016
DOCUMENT Managing Q-Changes DOC NO. CQA/19/2016/001
DIVISION All Divisions of Tata Steel REV. NO. 00
DEPARTMENT All EFFECTIVE 01.07.16
SECTION DATE
::ampclopn02.doc
PREPARED BY APPROVED BY AUTHORISED BY
NAME Alok Kumar Manash Banerjee Alok Krishna
DESIGNATION Sr. Mgr. CQA Head CQA Chief (TQM, BPE & CQA)
SIGNATURE
DATE 25th June 2016 30th June 2016 30th June 2016
Form No: CQA/MQC/2016/01 (A) Rev: 0.0 Eff. Date: 01.07.2016
Change Title:
1
Form No: CQA/MQC/2016/01 (A) Rev: 0.0 Eff. Date: 01.07.2016
Estimated Cost of
Implementation
Initiator *
Operations
IEM
Mechanical Maintenance
Tech./TS/QA
Safety/ Others
*Please note signature of Operations, IEM, Mechanical Maintenance, TS/QA and Safety is mandatory
and all checklists are required to be attached for carrying changes.
# In case of Emergency Change Senior most employees will fill the form and take written / oral approval
from the Head / Chief.
2
Form No: CQA/MQC/2016/01 (A) Rev: 0.0 Eff. Date: 01.07.2016
Head Operations/
Head of Department
Head IEM
Others (Technology
Group/ QA, Safety
etc.as applicable)
Head
(Tech. Review
Committee)
Note:
For all types of changes Form A and Form B should be filled in and forwarded to technical review
committee
All Impact Analysis and Post Change Review on Quality & Safety are mandatory for Medium and
Complex Changes; however exemptions can be obtained with permission of technical review
committee.
3
Form No: CQA/MQC/2016/01(B) Rev: 0.0 Eff. Date: 01.07.2016
Form B Checklist
PREPARED BY APPROVED BY
NAME : NAME :
DESIGN. : DESIGN. :
SIGNATURE : SIGNATURE :
DATE : DATE :
Form No: CQA/MQC/2016/01(B) Rev: 0.0 Eff. Date: 01.07.2016
PREPARED BY APPROVED BY
NAME : NAME :
DESIGN. : DESIGN. :
SIGNATURE : SIGNATURE :
DATE : DATE :