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CORPORATE QUALITY MANAGEMENT

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1. Quality System

1. Guidance and Support to all ITI Units for Implementation / Surveillance / Re-certification of • ISO 9001 Quality Management

System (QMS)• ISO 14001 Environmental

Management System (EMS) 2. Quality related MoU targets3. Quality related Issues4. Quality Policy and Quality Manual

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1. Qualification Approval and Standardization of Electronic Components,

2. Qualification Approval and Standardization of Electromechanical and Mechanical Components, PCBs & Raw Materials

3. Vendor Development and Vendor Rating4. Corporate Standards5. Reliability Engineering Laboratory6. Component Testing Laboratory

2. Components,VDC,VRC, Standards and Reliability

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UnitQ A Heads

Dept. 946CAG ,VDC,VRC,STD,REL,CT

(F 56 R&D, BG Plant)

Dept. 961Q uality System

(Corporate)

AG M (Q A)(Corporate)

G M (R&D and Q A)Head

Corporate Q uality M anagem ent

Corporate QA Organisation Chart

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1. Corporate QA played a key role in bringing up

the Plants to meet the ISO 9000 requirements

through training, document preparation,

auditing and other activities and enabled the

Units to get ISO 9000 Certification with out

engaging any external consultants. Trained and

experienced Manpower of Corporate QA was

well utilised for this purpose.

2. Providing training to Plant Personnel whenever the ISO 9001 standard is revised to enable Plants to align with the new requirements.

Quality System ….details -1

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3. Pre-assessment audits of the plants prior to certification / re-certification by the Certifying Body to assess their preparedness.

4. Coordination with the Certifying Body and providing necessary support and guidance to plants during Certification Audit.

5. Conducting special Quality Audits and Product Audits to ensure that the Quality System is implemented and continual improvement is made.

6. Organizing Quality related Training Programs such as SPC, SQC, Six Sigma, 5S, TQM , Quality Cost etc.

Quality System ….details -2

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Quality System ….details -3

7. Faculty for training programs on FMEA, Reliability Engineering, Component Standardisation, Vendor development etc.

8. Providing necessary help and guidance to Plants to get Approved Inspection Scheme (AIS) Status from the Major Customer namely BSNL.

9. Interaction with BSNL CGM-QA Bangalore, to resolve Quality related problems of ITI Equipment when required

10. Image building activities such as applying for prestigious awards such as Rajiv Gandhi award etc.

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Quality related MoU Targets

The MoU between ITI and Govt. of India carries a weightage of about 4 points for Quality System under the Dynamic Parameter Category. The following objectives are covered

1. AIS (Self Certification) for selected product

2. Product / System Quality Audits

3. ISO 9001 QMS Certification

4. ISO 14001 EMS Certification

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Status of Quality related MoU TargetsYear MoU Target Status

2009-10 ISO 14001 Certification for Naini Plant Under Progress

2008-09 ISO 14001 Certification for BG Plant Achieved

2007-08

AIS for SIM Card – Palakkad Plant Achieved

System/Product Audit GSM – MKP Plant Achieved

System/Product Audit GSM – RB Plant Achieved

Product Audit CLIP phone – Naini Plant Cancelled

2006-07

ISO 14001 upgradation 1996 to 2004 - PKD Achieved

AIS for DDF –Naini No-Low volume

ISO 14001:2004 for entire MKP Plant Only PCB/Hybr

2005-06AIS for SIM Card – Palakkad Plant Postponed

Renewal of AIS for OCB-TAX -Palakkad Achieved

2004-05 ISO 14001 certification for Palakkad Plant Achieved

Perform System/Product Audits – 8 Audits Achieved

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Quality Policy

The Quality Policy is released by the Corporate QA after Top Management’s Approval.

1. First Quality Policy - 31 Mar 1990

2. First Revision - 25 Sep 2002

3. Second Revision - 05 May 2007

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Quality Manual

Quality Manual is the top level document for Quality

Management System and is released by Corporate QA.

Issue 1 (Old) - Mar 1980 - Pre-ISO

Issue 2 (Old) - Jun 1982 – Feedback from WB Expert - Pre-ISO

Issue 1- Sep 1992 - ISO 9001:1987 requirements

Issue 2- Mar 1993 - Feedback - ITI Units and Certifying Bodies

Issue 3- Apr 1995 - ISO 9001:1994 requirements

Issue 4- Jan 1996 - Feedback - ITI Units and Certifying Bodies

Issue 5- Apr 2002 - ISO 9001:2000 requirements

Issue 5- Apr 2002 Amend 2 – May 2007 Quality Policy Revision

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Quality System Status

1. ISO 9001 Quality Management System

– All the Six Manufacturing Plants Of ITI are

Certified for ISO 9001 QMS Standard– Implementation of ISO 9001 for the following

Units of ITI are under progress

1. Network Systems Unit, Bangalore

2. Corporate Marketing, Bangalore

2. ISO 14001 Environmental Mgt System– Three Manufacturing Plants of ITI are certified

for ISO 14001 EMS Standard

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STATUS OF ISO 9001 QMS CERTIFICATION

Sl.No Plant Certificate Validity Certifying Body

1 Bangalore ISO 9001: 2008 1st Feb 2012NVTQC, Bangalore

2 Mankapur ISO 9001: 2008 1st Feb 2010KEMA Quality B.V. Netherlands

3 Naini ISO 9001: 2000 * 14th Nov 2010 IRQS, Mumbai

4 Palakkad ISO 9001: 2000 * 16th Sept 2011 IRQS, Mumbai

5 Raebareli ISO 9001: 2008 1st Aug 2011NVTQC, Bangalore

6 Srinagar ISO 9001: 2000 * 1st Sep 2011NVTQC, Bangalore

* ISO 9001: 2008 upgradation after surveillance audits during 2009

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STATUS OF ISO 14001 EMS CERTIFICATION

Sl.No Plant Certificate Validity Certifying Body

1 Bangalore ISO 14001: 2004 1st Oct 2011NVTQC, Bangalore

2 Mankapur ISO 14001: 2004 1st Dec 2011NVTQC, Bangalore

3 Palakkad ISO 14001: 2004 27th Jan 2011 IRQS, Mumbai

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1. Evolved 15 Digit Coding Scheme for Electronic Components, providing Unique Identification of Components during Design, Procurement, Manufacturing and Maintenance.

2. Issue of Codes for New Components used In R&D Projects

3. Qualification Approval of Electronic Components after Testing and Evaluation

4. Created Component Data Base (CDB) with Component and Approved Supplier information

Component Approval Group

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Component Approval Group …contd.

5. Maintenance and Updating of Component Data Base for approved Components and Vendors and distributing to user departments of ITI Plants for procurement purpose

6. Preparation of “Hand Book of Preferred Components” for R&D

7. Guidance to R&D Engineers on selection and use of Electronic Components

8. Participation in R&D Design Review meetings

9. Alternate Source development for single source and obsolete components

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Component Approval Group …contd…2

10. Identification of equivalent ITI Codes for Components used in ToT Projects to utilise surplus inventory and avoid production bottlenecks.

11. Interaction with CACT, BSNL QA, Bangalore for approval of components after testing the components at ITI labs. (Bangalore / Naini) .

12. Participation in LCSO (Electronic Components Standardization Organization) and BIS panel / committee meetings for Defence and non- Defence Component Standardization

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INTERACTION WITH VENDORS &

PROCUREMENT OF SAMPLES

EVALUATION OF SAMPLES AS PER

SPECIFICATION

ARE RESULTS OK?

COMPONENT APPROVAL GROUP

ACCORD APPROVAL

INPUT TO DATABASE

USAGE OF DATABASE

VENDOR REGISTRATION AND ASSESMENT

COMPONENT APPROVAL COMMITTEE

R & D CONCURRENCE

NON-CONFORMANCE

CORRECTIVE ACTION

NOYES

Flow Chart for Component Approval

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Component Approval Tests

Group 1Solder, Mech,

Climatic tests

Group 2Damp Heat

Steady State

Group 6 Corrosive

Atmosphere

Group 3Life

Elect & Mech

Group 4Mould Growth

Group 5Resistance to

solvent,Sold.heat

Group 0Parametric

& Functional

Based on JSS 50101

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Component Data Base (CDB)

Items covered in this Data Base1. Transistors, Diodes, LEDs and Display Devices

2. Integrated Circuits and Semiconductor Devices

3. All types of Resistors

4. All types of Capacitors

5. Inductors, Transformers and Magnetic Components

6. Crystal devices, Crystal Oscillators

7. Relays, Switches and Electromechanical Components

8. Microwave components

9. Opto electronic and Fiber Optic components

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Component Data Base (CDB) …contd

• Version 241 released on 16th June 2009 contains 9017 Codes (15 Digit) for Electronic Components

• 664 Foreign and 315 Indigenous sources• Data Base contains details of Code, Description,

Part No.,Vendor info and Approval status• CDB Versions emailed to ITI Units every month• Major Users: Bangalore and Naini• Master Data Base is dynamically updated as and

when required every day. • Introduced in July 1995. Migrated from “Oracle”

to “MS Access” Platform during 2008.

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VDC DIRECTORY (VDB)

Items covered in this Data Base1. Raw Materials and Alloys

2. Precious metals

3. Wires and Cables

4. Insulating Materials

5. Plastic and Rubber

6. Packing materials

7. General Chemicals and PCB Chemicals

8. Electrical items

9. Mechanical Components

10. Miscellaneous items

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VDC DIRECTORY (VDB) …contd

• VDC Directory released on 1st April 2009 contains 588 Items ( some having 15 Digit codes)

• 1830 Indian Sources and 260 Foreign sources• Data base contains Code, Description, Family,

Section, Vendor info and Approval status• VDB Versions emailed to ITI Units every month• Major Users: Bangalore and Naini• Master Data Base is dynamically updated as and

when required every day. • Introduced in 1992. Migrated from “dbase” to

“MS Access” Platform during 2009.

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Vendor Development and Rating -VDC,VRC

1. Vendor development for critical raw materials, components and sub-assemblies (other than electronic components) with specific thrust on obsolete / single source items to achieve cost effectiveness.

2. Issue of Technical Qualification (TQ) and type approvals after evaluation of components, and assemblies

3. Preparation of vendor rating data and providing information for purchase decisions.

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Vendor Development and Rating VDC,VRC …contd.

4. During 1999, 15 digit coding scheme was evolved for Raw materials, Wires & Cables and Fasteners to facilitate easy identification, procurement and storing purpose. This was incorporated in the Data Base and ITI Specifications during 2001.

5. Maintenance of Data Base for approved vendor list, periodic updating and providing latest information to all the plants of ITI for procurement purpose.

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Corporate Standards

1. Developing and maintaining company level standards for raw materials, finishing standards and testing standards either by in-house development or by adopting National / International standards. 503 Standards have been developed and maintained as per details below

1. B Series 155 Standards

2. D Series 310 Standards

3. WMS Series 15 Workmanship Standards

4. BU Series 23 Bangalore Unit Standards

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Corporate Standards …contd.

2. Participation with BIS ( Bureau of Indian Standards ) and contributing to formulate National standards.

3. Representation in BIS & LCSO committees4. Liaison with BIS, LCSO, Corporate

Standards of various organisations and other Standards bodies.

5. Inventory and Cost reduction through unification & variety rationalisation

6. Evolution, implementation and maintenance of uniform material codification system

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Reliability Engineering Laboratory

1. Environmental Testing for Electronic Components, sub systems, modules and Complete Systems

2. Environmental tests as per

1) JSS 55555 for Defence Equipment

2) QM-333 for BSNL equipment.

3) JSS 50101 for Components

3. 15 imported climatic chambers of various sizes including walk-in chambers (1 CFt to 252 CFt)

4. Temperature -55°C to 150°C, Humidity 20 to 95% RH. Altitude up to 50,000 feet

5. Preferred Laboratory for BSNL

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Reliability Engineering Laboratory …contd

6. Products from Other ITI Units also have been evaluated in this Laboratory

7. Guidance to R&D and Production regarding Environmental tests and optimal test schedules

8. As ITI rep in BSNL QA Sub-Committee for QM 333 Revision, taken care of ITI’s points.

9. Spare Capacity utilised for Revenue Generation through testing for other Organisations

10. Revenue Generation during 2008-09

ITI Products (Equivalent test Charges) Rs. 8,85,957

Non-ITI Products (Payment received) Rs. 4,21,351

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Reliability Prediction and Analysis

1. Reliability Prediction and Analysis is a contractual requirement of most of the BSNL and Defence Tenders. Railway customers are also insisting now.

2. Reliability Prediction Reports have been generated for most of the R&D products such as Microwave Systems, Line systems, Fiber Optic systems and Secrecy Equipment.

3. ASCON Phase 1 Network Availability calculations as per customer requirement.

4. More than 50 Reports have been generated from 1996 to Jan 2009

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1. This laboratory is equipped with a variety of test instruments, jigs and power supplies for testing and evaluation of electronic components such as resistors, capacitors, crystals, semiconductor devices, integrated circuits etc.

2. These instruments include digital LCR meter, Semiconductor Test System, Breakdown tester, Crystal test system, multi meters etc.

Component Testing Laboratory

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Indigenisation / Localisation activity

Approval of items for Mankapur GSM-BTS Project

Under localization activity for GSM-BTS Project, Evaluation Reports for 90 items comprising Connectors, Cable assembly and Cables, PCBs, Mechanical parts etc. were forwarded to ITI Mankapur Unit during the past three years. Out of this, only 70 items have been recommended by ITI for getting “Technical Qualification” (TQ) from M/s ALCATEL, France