RAW MATERIAL & INCOMING PARTS CONTROL:
Raw Material is procured from standard & established sources. The incoming material is subjected to appropriate metallurgical, chemical & mechanical testing as per sample plans. Raw material is stored in designated areas. Color Coding schemes for identifying various grades of raw materials are established. All incoming semi - finished & finished items are subjected to receipt inspection for dimensional accuracy, metallurgical performance & functional testing. Inspection & acceptance norms are fixed & a system for disposing off the rejected material are established.

METALLURGICAL PROCESS:
From the approved drawings, various manufacturing parameters are classified into critical, major & minor characteristics. Parameters requiring closer tolerance & control are highlighted. Based on the above checklist complete manufacturing process & equipment is specified. Stage inspection, Final inspection & performance testing procedures are established. Depending upon criticality of the parameter & its likely variability in manufacturing process, the amount of inspection viz. 100 % sampling etc. are specified.

PROCESS CAPABILITY:
Process capability studies of critical machines & processes are carried out to ensure the manufacturing process & equipment have the capability to meet the desired quality parameters. In order to achieve this, first piece inspections are carried out to ensure that all quality parameters are acceptable. The first piece inspection will be repeated after machine resetting, tool change & specified intervals.

INSPECTION:
Detailed inspection instruction & check list are prepared & made available to the shop inspection staff for measuring, checking & testing various quality parameters to ensure that only accepted parts are passed on the next stage.
Periodicity of recalibration & checking of the entire inspection & Q. C. equipment
are specified. Records showing the actual frequency of checking are maintained.

SAMPLING:
Sampling Plan as per IS 2500 are used. Lot by lot sampling inspection procedures
are adopted at every stage of process / manufacturing. Pre - dispatch lot sampling inspection as per IS 2500 is carried out.

PROCEDURES:
A step by step assembly sequence & procedure are worked out & written instructions for the shop staff are made available. Necessary check points are established. An identification system to ensure that only the passed components are fed to the next stage.

INSPECTION STATUS:
During the manufacturing operations the inspection status of the valves at each stage are marked by color coding or tray cards. In addition aggregate status are identified by card stickers.

DISPOSAL OF REJECTED MATERIAL:
Whenever economical, segregation of good material from a rejected lot may be permitted. The rejected material shall be color identified for rework. This data is kept in records for future reference & corrective action. Record of action taken in respect of solving any production / quality problems are preserved.
Valves that cannot be salvaged or reworked are scrapped by breaking & / or deforming. In receipt inspection stage, the material is stored in rejection area, identified & the supplier informed.

IDENTIFICATION:
In order to keep track of the parts starting from the receipt to the finish, & for monitoring their field performance, each part shall bear permanent identification marks giving the part number / supplier code, work order number, year of manufacture. Method of location for marking are specified as per customer requirement.