AS - IS SYSTEM STUDY DOCUMENT

FOR

QUALITY MANAGEMENT

AT

KAY BOUVET ENGINEERING PVT.LTD.

As-Is System Study Document for Quality Management – Confidential By:- Sandesh L.Bonde Page 1

PROPRIETARY NOTICE

This report contains confidential information of Adroit Infotech Pvt.Ltd.,Pune which is provided for the sole purpose of permitting the recipient to use for internal purpose for SAP project execution activity. In consideration of receipt of this document, the recipient agrees to maintain such information in confidence and to not reproduce or otherwise disclose this information to any person outside the group directly involved in similar activities, except that there is no obligation to maintain the confidentiality of any information which was known to the recipient prior to receipt of such information from Adroit Infotech or becomes publicly known through no fault of recipient, from Adroit Infotech or is received without obligation of confidentiality from a third party owing no obligation of confidentiality to Adroit Infotech and above specified product vendors.

SECURITY WARNING

The information contained herein is proprietary to Adroit Infotech Pvt.Ltd.,Pune and may not be used, reproduced or disclosed to others except as specifically permitted in writing by Adroit Infotech. The recipient of this document, by its retention and use, agrees to protect the same and the information contained therein from loss or theft.

VERSION HISTORY:

VERSION NO.

DATE CHANGED BY APPROVED BY

REVIEWED CHANGES MADE

QM 1.0 Sandesh Bonde

As-Is System Study Document for Quality Management – Confidential By:- Sandesh L.Bonde Page 2

TABLE OF CONTENTS

1) INTRODUCTION………………………………………………………………………….……………………….04

2) OUR UNDERSTANDING OF KEBPL QUALITY MANAGEMENT……………………….05

3) AS-IS (EXISTING BUSINESS PROCESS)…………………………………………………………063.1 BUSINESS PROCESS OVERVIEW…………………………………………………………………...063.2 BUSINESS PROCESS DETAILS (PROCUREMENT PRODUCT )…………………………073.3 QUALITY PARAMETERS OF PROCURED RAW MATERIAL (IN-HOUSE)……………083.4 QUALITY PARAMETERS OF PROCURED RAW MATERIAL (THIRD PARY)………..08

4) AS-IS BUSINESS PROCESS DETAILS (FINISHED PRODUCT)……………………..09

4.1 QUALITY PARAMETERS OF FINISHED COMPONENTS (THIRD PARTY)……………104.2 QUALITY PARAMETERS OF FINISHED COMPONENTS (IN-HOUSE)……..…………10

As-Is System Study Document for Quality Management – Confidential By:- Sandesh L.Bonde Page 3

KAY BOUVET ENGINEEERING PVT. LTD.

1. INTRODUCTION

KAY BOUVET ENGINEERING PVT LTD. is one of the companies of KAY GROUP equipped with modern infrastructure for precision heavy engineering fabrication, machining & assembly facilities. Kay Bouvet Engineering Pvt. Ltd, India is a heavy engineering company certified as an ISO 9001:2008 company which has the strong & sound engineering capabilities, efficient quality manufacturing setup & best modern infrastructures. KBEPL is into business areas like erection and commission of sugar plants, distillery and alcohol - ethanol plants, power generation plants, specialized equipments and general heavy engineering equipments. Special products Division was started in 1999 to serve the Nation by manufacturing & supplying specialized equipments & machinery required by Defense Organization, Department of Atomic Energy and Nuclear Power Corporation of India & also Public Sector Companies as well as Private & Co-Operative sectors. KBEPL India is also having technical tie up with world renowned companies in various areas in order to deliver high quality service & equipment at highly competitive prices. KBEPL have three manufacturing units in which two units are located in Satara, Maharashtra and one unit in Yamuna Nagar, Haryana.

STRATEGY

To be no.1 in quality, cost and delivery for precision assemblies, systems and machined parts by adopting latest and innovative technologies/systems.

Total focus on customer requirements by proactive approach. To involve and contribute at design level by way of concurrent engineering with

customer.

STRENGTH

Over 3 decades experience in erection & commissioning of sugar plants, one decade of experience of in special products which serves the growth of the nation.

Customer focus. Just in time delivery to customers. Well organized logistics. Certified quality management system. Delighted, satisfied and strong corporate customer base.

As-Is System Study Document for Quality Management – Confidential By:- Sandesh L.Bonde Page 4

2. OUR UNDERSTANDING OF KBPL QUALITY MANAGEMENT.

The material is procured as per the specifications given in various drawings and accordingly the purchase orders are issued to suppliers. It is mandatory for the suppliers to provide manufacturer test certificate (MTC) for the material ordered on them. In rare case of MTC not being made available by the   supplier, the material is subjected to mechanical testing to ascertain the mechanical properties and chemical composition in a Govt. Lab or other source as per the requirement of PO.

The quality department is responsible for store inspection of the various raw materials by correlating the MTC, marking of material as per drawing, fit up of the unit as per the technical parameters of drawings and or Indian Standards for fabrications, welding procedure to be adopted, non destructive testing of welding, dimensional checkup before and after welding, inspection of pre - machined items & inspection of complete unit after fabrication. Forward the stage wise inspection report to production department for necessary repair or rectification and lastly final inspection reports to production department for acceptance of finished goods and to arrange the final inspection by Client/Third Party as the case may be.

As-Is System Study Document for Quality Management – Confidential By:- Sandesh L.Bonde Page 5

3. AS-IS (EXISTING BUSINESS PROCESS)

3.1 BUSINESS PROCESS OVERVIEW

The Quality department is responsible for quality activity in KBEPL.

THE STRUCTURE IN THE QUALITY DEPARTMENT IS AS FOLLOWS.

As-Is System Study Document for Quality Management – Confidential By:- Sandesh L.Bonde Page 6

M.D.

C.E.O.

V.P. (OPERATION)

SR.MANAGER (Q.A.)

Q.A. ENGINEER

JOB INSPECTOR

3.2 AS-IS BUSINESS PROCESS DETAILS (PROCUREMENT PRODUCT)

Not OK Not OK

OK OK

BRIEF BUSINESS PROCESS

1) Third party has done the quality inspection of raw material which is requiring for Specialized Equipments only.

2) If raw material is not being as per specification, it returns to vendor again.3) If it is according to specification keeps in store.4) Quality department (in house) has done the quality inspection of raw material

which is requiring for general heavy manufacturing.5) If raw material is not being as per specification, it returns to vendor again.6) If it is according to specification keeps in store.

As-Is System Study Document for Quality Management – Confidential By:- Sandesh L.Bonde Page 7

Raw Material Procurement

Third Party In House

Quality Inspection Activities

Quality Inspection Activities

Vendor Vendor

Store Store

3.3 QUALITY PARAMETERS OF PROCURED RAW MATERIAL (IN-HOUSE)

1) Quality department require Test Certificate (T.C.) with procure raw material i.e. hot rolled plate sheet.

2) According to T.C. check quality parameters i.e. length, width and height.

3.4 QUALITY PARAMETERS OF PROCURED RAW MATERIAL (THIRD PARTY)

1) Quality department send the coupon to third Party i.e. ELCA Quality Systems & Calibration Pvt. Ltd.

2) Third Party checks the raw material and has been given the report like following.A) Tensile Test 1

a) Flat (mm), width (mm), thickness (mm), area (mm2) and gauge length (mm)b) Yielding load (KN)c) Final length (mm)d) Yield stress (N/mm2)e) U.T.S. (N/mm2)f) Elongation (%)g) Elongation as per ISO2566 (%)h) Fracture (WGL)i) Ultimate load (KN)

B) Tensile Test 2a) Flat (mm), width (mm), thickness (mm), area (mm2) and gauge length (mm)b) Yielding load (KN)c) Final length (mm)d) Yield stress (N/mm2)e) U.T.S. (N/mm2)f) Elongation (%)g) Elongation as per ISO2566 (%)h) Fracture (WGL)i) Ultimate load (KN)

C) Bend Test (1 & 2)

a) Final result-Acceptable or not.

D) Impact Test

a) Required values as per standards.

E) Chemical Analysis

a) It includes C%, Si%, P%, Ni%, Cu%, CE%, Mn%, S%, Cr%, Mo%, V%,

4. AS-IS BUSINESS PROCESS DETAILS (FINISHED PRODUCT)

As-Is System Study Document for Quality Management – Confidential By:- Sandesh L.Bonde Page 8

BRIEF BUSINESS PROCESS

1) Quality department receive call from production department regarding the quality inspection of product.

2) In case of Specialized Equipments manufacturing, quality inspection activities will be hand over to Third party.

3) Third party gives inspection report.4) Approval of finished product to dispatch.5) In case of general heavy manufacturing, quality department start preparatory

with help of drawing available.6) Quality inspection activity will be done by quality department.7) Quality department gives inspection report and approval of finished product.

4.1 QUALITY PARAMETERS OF FINISHED COMPONENTS (IN-HOUSE)

As-Is System Study Document for Quality Management – Confidential By:- Sandesh L.Bonde Page 9

Inspection call from Production Dept

Finished Product

Specialized Equipments Manufacturing General Heavy Manufacturing

Start preparatory from drawing

Quality Inspection Activities

Inspection call to Third part from quality department

Finished Product

Quality Inspection Activities

The finished component is measured as per the dimensions and technical notes given in the drawing to ensure that finished product is perfectly manufactured to meet the drawings requirement.

4.2 QUALITY PARAMETERS OF FINISHED COMPONENTS (THIRD PARTY)

The finished component is measured as per the dimensions and technical notes given in the drawing to ensure that finished product is perfectly manufactured to meet the drawings requirement.

BUSINESS PROCESS OWNER’S SIGN OFF (AS-IS)

As-Is System Study Document for Quality Management – Confidential By:- Sandesh L.Bonde Page 10

The information given by KBEPL representative in the ‘As Is’ workshops conducted has been covered in this document by Adroit Infotech,Pvt.Ltd.,Pune QM consultant. This AS-IS document will be the baseline for mapping of ‘To Be’ processes in SAP.

INFORMATION PROVIDED BY

SR.NO.

NAME DESIGNATION DATE SIGNATURE

1 Mr. H.G.Joshi Quality In charge

2 Mr. S.Kaushal Quality In charge

INFORMATION UNDERSTOOD AND CONFIRMED BY

SR.NO.

NAME DESIGNATION DATE SIGNATURE

1 Mr. Ravindranath KC SAP Project Manager

2 Mr. Sandesh Bonde PP-Consultant

INFORMATION REVIEWED AND APPROVED BY

SR.NO.

NAME DESIGNATION DATE SIGNATURE

1 Mr.P.B.Khanwilkar V.P.

2 Mr.Manish Ojha KBEPL Project Manager

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