Quality Manual

KAROONI Knit Composite Ltd.
QUALITY MANUAL
Revision No.: 02
Revision Date: 20-02-2009
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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
Clause or Sub-clause Exclusion Justification

7.3 Design Development KAROONI Knit Composite
Ltd. does not design or
develop garments it
manufactures.
7.5.2 Validation of Processes for KAROONI Knit Composite
Production and Service Ltd. manufactures
Provision readymade garments which
can be inspected and tested
without destroying the piece
being inspected and tested.
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:
Documents related to this Manual include:
 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.
Quality Management System
The Quality Management System of KAROONI Knit Composite Ltd. is documented and
maintained in 4 (four) tiers. They are:
Tier 1 – Quality Policy, Quality Objectives, Quality Manual

Tier 2 – Master Procedures
Tier 3 − Work Instructions, Specifications, etc.
Tier 4 – Forms/ Registers/ Checklist
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CLAUSE: 4 QUALITY MANAGEMENT SYSTEM
4.1 General requirements

KAROONI Knit Composite Ltd. has created, documented, implemented and maintained a
Quality Management System and its effectiveness will be continually improved to achieve
compliance with ISO 9001:2008.
Cross-functional Flowchart (see annexure – A) shows the order and interaction of
KAROONI Knit Composite Ltd. quality management system general processes. The order
of activities and interaction of specific (department, machine, product or service) quality
management system processes with other quality processes can be found on flow charts
associated with them. The criteria and methods for effective control of processes are found in
Master Procedures, Work Instructions, Quality Objectives, and Specifications etc. The
information necessary for effective operation and monitoring of these processes is found
within available controlled documents throughout KAROONI Knit Composite Ltd. Upon
the completion of measurement and monitoring of the processes and analysis of the data,
appropriate action is taken to assure intentions are achieved and opportunities for
improvement are acted on.
Management of these processes is accomplished in accordance with the requirements of ISO

9001:2008
KAROONI Knit Composite Ltd. controls the suppliers as per the system defined in clause
7.4 Purchasing.
Related Documents:
Process Interaction Flow Chart (Annexure- A)
4.2 Documentation requirements
4.2.1 General
KAROONI Knit Composite Ltd. has confirmed to include the following documents
in its quality management system:
 statements of quality policy
 statements of quality objectives
 this quality manual
 the documents referred to in this quality manual
 any documents required to avoid varied implementation of the processes
needed to deliver KAROONI Knit Composite Ltd. products and services
 the records described in Control of Records.
Related Documents:
Quality Policy, Quality Objectives, Master Procedures, Work Instructions

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CLAUSE: 4 QUALITY MANAGEMENT SYSTEM (cont.)
4.2.2 Quality manual
This quality manual contains:

 a scope statement with exclusions (See Exclusion table)
 reference to the quality management system procedures.
 reference to Cross-functional Flowchart, which provides a description of the
interaction within the quality management system.
 organogram
Related Documents:
Process Interaction Flow Chart (Annexure- A)

Organogram (Annexure- B)
4.2.3 Control of 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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CLAUSE: 4 QUALITY MANAGEMENT SYSTEM (cont.)
4.2.4 Control of records
Records are maintained to demonstrate conformance to requirements and of the effective

operation of the quality management system, legal and customer requirements
Quality Records List is available with each Department Head and Management
Representative for easy identification.
Retention time is selected based on company’s own requirements; consideration has also
been given to legal and customer requirements. Retention time and disposal method of
records are identified in quality records list.
Records are preserved in such a way that ensures legibility and easy retrieval.
KAROONI Knit Composite Ltd. allows its customers, and third party auditors to verify
records if it is a part of the contract.
 MP-04-02: Control of Records
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CLAUSE: 5 MANAGEMENT RESPONSIBILITY
5.1 Management commitment
The following are expressions of KAROONI Knit Composite Ltd. management

commitment to develop, implement and improve the effectiveness of the quality management
system:
 Communication about the importance of fulfilling customer, legal and
regulatory requirements occurs throughout the company. That communication
happens through the use of:
- General and product, service or process specific training

- Retraining when and where shortfalls appear
- Displays and postings in the prominent points/areas of the facilities
- Periodic communication meetings- recorded in training record
- Specific emphasis in provided documentation
 The quality policy
 The quality objectives
 The management reviews
 Assurance the availability of resources to achieve the quality objectives and
continuously improve the effectiveness of the system.
Related Documents
 Quality Policy
 Quality Objectives
 Management Review Meeting Minutes.
5.2 Customer focus
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.’s mission is to achieve business excellence through
customer satisfaction by understanding, accepting, meeting and exceeding customer
expectations.
 Karooni Knit Composite Ltd. follows ISO 9001:2008 International Standards on

Quality Management System to ensure consistent quality of products and services to
achieve customer satisfaction.
 The management of Karooni Knit Composite Ltd.’s commits itself to quality as the
prime consideration in all its business decision.
 The entire employee follows ISO 9001:2008 documented procedures to ensure

compliance with quality standard to achieve the quality & efficiency.
Approved By: Managing Director / DMD Revision: 02

Date: February 20, 2009
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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5.4 Planning
5.4.1 Quality objectives

The following, measurable quality objectives, have been formulated as the policy
highlights by the highest level of management:
 Customer Satisfaction
 Reduce Defect/Process Loss
 Continual Improvement
The above quality objectives are rolled down to department’s level.
5.4.2 Quality management system planning

The yearly quality plans are created considering the following and they are endorsed
by the top management:
 the quality objectives 5.4.1

 the requirements of quality management system in 4.1
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
5.5 Responsibility, authority and communication
5.5.1 Responsibility and authority
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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5.5.2 Management representative
Managing Director/Deputy Managing Director has appointed management

representative from its top management. The assigned duties include:
 overseeing the implementation and maintenance of the quality system

in accordance with ISO 9001:2008 requirements.
 identifying on the need for improvement of the quality management
system.
 reporting to Managing Director/Deputy Managing Director on the
status of the quality management system and need for improvements.
 encouraging and assisting in extending the understanding of customer
requirements to the degree necessary throughout the organization.
5.5.3 Internal communication
The highest level of management and functional departments share data or

information, indicating the performance and effectiveness of the quality management
system, throughout the organization in the following ways:
 generating periodic reports in printout form with graphical
presentation where possible, and communicating to the
concerned personnel
 placing data and reports on computer network or notice board.
 discussing reports and data in business sessions/ management
review meeting
 using internal memorandum
5.6 Management review

5.6.1 General
In order to ensure the continuing suitability, adequacy and effectiveness, the highest
level of management will conduct periodic reviews of the quality management
system. The reviews can address the quality management system entirely or in parts,
as long as the entire quality management system is reviewed at least once in every 6
(six) months. An expected outcome of that review is the determination of the need for
any change or to reveal opportunities for improvement to the quality management
system, including adjustments to the quality policy and quality objectives.
Management review records are maintained.
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5.6.2 Review input

Periodic performance and opportunities for improvement are determined by reviewing
following.
 results of audits
 customer feedback
 process performance and product conformity
 preventive and corrective action status

 follow-up actions from previous management reviews
 changes that could affect the quality management system

 recommendations for improvement
 the overall suitability, adequacy and effectiveness of quality
management system
 additional agenda, if any.
5.6.3 Review output

Actions associated with the following are included in the output from management
review:
 improvement of effectiveness of the processes of the quality management
system
 overall improvement of the quality management system effectiveness
 improvements of products related to customer requirements
 resource needs.
Management review records are maintained.
 MP-05-01: Management Review

 Management Review Meeting Minutes
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CLAUSE: 6 RESOURCE MANAGEMENT
6.1 Provision of Resources

Resources for the following purpose are provided on time:
 to implement and maintain the quality management system
 to continually improve upon the quality management system effectiveness
 to ensure customer satisfaction through consistent achievement of customer
requirements.
6.2 Human Resources

6.2.1 General
Any one in KAROONI Knit Composite Ltd., having an assignment that can affect
product quality, must be competent through education, skills, training and experience
as necessary. Requirements for education, skills, training and experience can be found
in Position wise Job Specifications maintained by the concerned department.
Competency is determined by pre-testing where possible and by the temporary
assignments. Apprenticeships are also used to develop competency. Annual training
need assessments of the existing employees are also done.
6.2.2 Competence, training and awareness
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.
 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.
Changes to the infrastructure are planned and incorporated in Specifications, relevant

documents (Work Instructions) etc. When all the needs have been identified, it is the
responsibility of the highest level of management to approve those necessary for the
achievement of product and/or service requirements.
6.4 Work environment
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.
 WI/MAIN-01: Maintenance Activities (Electrical)

 WI/MAIN-02: Maintenance Activities (Mechanical)
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CLAUSE: 7 PRODUCT REALIZATION

7.1 Planning of Product Realization:
The products are realized by the following processes:
 receiving specifications and purchase order from customers
 purchasing of raw materials as per need.
 inspecting and testing of incoming materials (raw materials) against specifications
and using official methods
 production using by the approved methods
 inspection of the products and releasing those meet specification
 delivery of released products for buyer destination.
7.2 Customer Related Processes

7.2.1 Determination of Requirements Related to the Product
Marketing & Merchandising, Quality and Production identify all buyer requirements as they
interface with the buyer and as the product or service development takes place:
 product specifications provided by the customer

 product performance requirements provided by the customer
 customer stated availability requirements
 customer stated delivery requirements
 customer stated support needs
 determination of application related requirements, if not provided by
the customer (if any)
 determination of relevant legal requirements if any
- Customs Authority, etc.
 determination of relevant environmental requirements if any
- customer imposed (for example, a customer requirement to be ISO
14000 certified)
 determination of any other relevant requirements
- safe usage instruction, etc.
7.2.2 Review of Requirements Related to the Product

All inquiries and orders are reviewed to ensure that:
 The buyer requirements are properly and adequately defined,

 Differences between requirements in the order under review and those in the previous
documents are resolved
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 The company has the capability to meet the order requirements.
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.
 Customer Order
 Order Amendment Records
 All others specification provided by customer
7.2.3 Customer Communication
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
7.4.1 Purchasing process
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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7.4.2 Purchasing information
The company specifically identifies or makes reference to specifications of purchased items

in the Purchase/Work Order or Letter of Credit (L/C) thus supplier can supply materials as
per company’s requirements.
7.4.3 Verification of Purchased product
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.
 MP-07-01: Supplier Selection & Evaluation

 MP-07-02: Purchasing
7.5 Production and service provision
7.5.1 Control of Production and Service Provision
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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Products are released after necessary inspections by Quality Control Department prior to the
final inspection from buyers.
Production is scheduled and accomplished by qualified individuals using capable equipment

designed to ensure that a quality product is delivered in a timely fashion.
 WI/CUT-01: Cutting Activities
 WI/DYE-01: Dyeing Activities
 WI/KNIT-01: Knitting Activities
 WI/SEW-01: Sewing Activities
7.5.3 Product Identification and Traceability
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.
7.5.4 Customer Property

Customer property of KAROONI Knit Composite Ltd. is stored and preserved with proper
identification. Customer Property which is incorporated to product at different stages is
inspected upon receipt for conformity to specified quality standards and is identified as per
test status.
In case of any loss, damage or any other abnormal occurrence experienced to the customer
property, it is immediately notified to the customer.
7.5.5 Preservation of Product
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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Identification of products and packing is done as per requirements of the customer mentioned
in the Purchase Requirement. Where such requirements not stated in Purchase Requirement
KAROONI Knit Composite Ltd. apply its own method.
To deliver to customer destination KAROONI Knit Composite Ltd. takes all the
precautions to ensure that product quality is maintained during transportation.
 WI/STR-01 Work Instruction: Store Activities
7.6 Control of Monitoring and Measuring Equipment
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.
Calibration is to make against nationally or internationally recognized standards. KAROONI

Knit Composite Ltd. uses services of Bangladesh Standards and Testing Institution (BSTI)
and other renowned sources in the world where required.
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.
 WI/CAL-01: Calibration
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CLAUSE: 8 MEASUREMENT, ANALYSIS AND IMPROVEMENT
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.
8.2 Monitoring and measuring
8.2.1 Customer satisfaction
GM/Managers, Merchandising & Marketing Manager are responsible to measure customer

satisfaction. Customer Satisfaction shall be measured through Customer survey and no. of
complain received analyzed monthly. Customer surveys are conducted through sending
Customer Feedback Form to all customers to measure customer satisfaction once a year. The
collected data are analyzed and findings are used as a customer focus for improvement.
8.2.2 Internal audit
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.
 MP-08-01: Internal Audit
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CLAUSE: 8 MEASUREMENT, ANALYSIS AND IMPROVEMENT (cont.)
8.2.3 Monitoring and measurement of process

Quality management system process are monitored and measured when required in
accordance with specific product plans. When departures from planned results occur, process
specific reaction plans and Nonconforming Material Control, correction and corrective action
where appropriate. Criteria of monitoring and measurement of other processes will be found
in quality objectives and achievement of these objectives will be measured as defined in
corporate and departmental objectives.
8.2.4 Monitoring and measurement of product

KAROONI Knit Composite Ltd. monitor and measures the characteristics of products at
different stages of production process to determine conformance to specified requirements by
the customer. Quality Control Manager shall be responsible for over all performance of
inspection and testing of in-coming, in-process and finished products/ materials.
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.
 WI/QC-01: Accessories Inspection

 WI/QC-02: Grey Fabric Inspection
 WI/QC-03: Dyed Fabric Inspection
 WI/QC-04: Cutting Inspection
 WI/QC-05: Sewing Inspection
 WI/QC-06:Finishing Inspection
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8.3 Control of nonconforming product
Identifying non-conformities and subsequent elimination of the non-conformities are

performed through careful analysis.
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.
The disposition of non-conformity may be:

 Reprocess/rework
 Sell to customer by informing the non-conformity
 Destroy
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.
 MP-08-02: Control of Non-conforming Products
8.4 Analysis of data
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:
 to assess customer satisfaction levels

 to determine success rates in fulfilling customer requirements
 to gather knowledge on trends associated with products and processes
in order to initiate appropriate preventive action.
 to maintain awareness of the performance of suppliers and request
them to take action to correct or improve the performance where
required.
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8.5 Improvement
8.5.1 Continual improvement
At KAROONI Knit Composite Ltd., continual improvement is:
 a part of the quality policy

 reflected in the quality objectives
 a part of the actions taken upon audit results
 driven by opportunities surfacing from data analysis
 a result of corrective action when the action taken corrects a new
problem
 always a result of preventive action
 a required output from management review
8.5.2 Corrective action
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:
 reviewing nonconformities including customer complaints

 the determination of causes of nonconformities
 assessing the need for actions to avoid recurrence
 the determination of corrective actions needed
 the implementation of determined corrective actions
 making records of the outcomes from actions taken
 verifying the effectiveness of corrective actions taken
 MP- 08-03: Corrective Action
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8.5.3 Preventive action
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:
 the determination of potential nonconformities

 the determination of causes of potential nonconformities
 the determination of preventive actions needed
 the implementation of determined preventive actions
 making records of the outcomes from actions taken
 reviewing preventive actions taken.
 MP-08-04: Preventive Action
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Brief Description of the Interaction of the Departmental Processes:
Interaction between Merchandising and Production:
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.
Interaction between Merchandising and Quality Control:
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.
Interaction between Production and Quality Control:
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.
Interaction between Production & Store:
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.
Interaction between Marketing & Merchandising and Sample Section:
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.
Interaction between Marketing & Merchandising and Commercial/Procurement:
After the finalization of the order contract, Commercial/Procurement Department is

acknowledged about this from the Marketing & Merchandising Department. The Commercial
Department opens the Back-to-Back L/C against the master L/C of each order. All the
financial amendment is done by the Commercial Department and it is informed to the
Marketing & Merchandising Department and Top Management.
Interaction between Admin and all other Department:
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:
Top Management Decision
(Policy)
Customer Requirement Admin & Compliance

Requirements
(Input)
(Input) (Input)
Sample Marketing & Procurement

Merchandising
Production Planning
Monitoring &
Control
Production
Maintenance Quality Control
Commercial
Store
Shipment to Customer
(Output & Goal)
Customer Satisfaction
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Annexure-B
Organogram:
Pls. see the attachment
Page 27 of 26

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KAROONI Knit Composite Ltd.

Revision Date: 20-02-2009

Clause or Sub-clause Exclusion Justification

Documents related to this Manual include:

Revision Date: 20-02-2009

Quality Management System

Tier 1 – Quality Policy, Quality Objectives, Quality Manual

Revision Date: 20-02-2009

CLAUSE: 4 QUALITY MANAGEMENT SYSTEM

4.1 General requirements

Management of these processes is accomplished in accordance with the requirements of ISO

Quality Policy, Quality Objectives, Master Procedures, Work Instructions

Revision Date: 20-02-2009

CLAUSE: 4 QUALITY MANAGEMENT SYSTEM (cont.)

4.2.2 Quality manual

This quality manual contains:

Process Interaction Flow Chart (Annexure- A)

4.2.3 Control of documents

Revision Date: 20-02-2009

CLAUSE: 4 QUALITY MANAGEMENT SYSTEM (cont.)

4.2.4 Control of records

Records are maintained to demonstrate conformance to requirements and of the effective

 MP-04-02: Control of Records

Revision Date: 20-02-2009

CLAUSE: 5 MANAGEMENT RESPONSIBILITY

5.1 Management commitment

The following are expressions of KAROONI Knit Composite Ltd. management

- General and product, service or process specific training

5.2 Customer focus

Revision Date: 20-02-2009

 Karooni Knit Composite Ltd. follows ISO 9001:2008 International Standards on

 The entire employee follows ISO 9001:2008 documented procedures to ensure

Approved By: Managing Director / DMD Revision: 02

Revision Date: 20-02-2009

CLAUSE: 5 MANAGEMENT RESPONSIBILITY (cont.)

5.4.1 Quality objectives

 Reduce Defect/Process Loss

The above quality objectives are rolled down to department’s level.

5.4.2 Quality management system planning

 the quality objectives 5.4.1

5.5 Responsibility, authority and communication

5.5.1 Responsibility and authority

Revision Date: 20-02-2009

CLAUSE: 5 MANAGEMENT RESPONSIBILITY (cont.)

5.5.2 Management representative

Managing Director/Deputy Managing Director has appointed management

 overseeing the implementation and maintenance of the quality system

5.5.3 Internal communication

The highest level of management and functional departments share data or

5.6 Management review

Revision Date: 20-02-2009

CLAUSE: 5 MANAGEMENT RESPONSIBILITY (cont.)

5.6.2 Review input

 process performance and product conformity

 preventive and corrective action status

 changes that could affect the quality management system

5.6.3 Review output

 MP-05-01: Management Review

Revision Date: 20-02-2009

CLAUSE: 6 RESOURCE MANAGEMENT

6.1 Provision of Resources

6.2 Human Resources

6.2.2 Competence, training and awareness