ENG HING PLASTIC INDUSTRIES SDN BHD
ISO 9001
PROCESS CONTROL
Document No. : QP-PC
Revision No. : 03
Document Type : Quality Procedure
Effective Date : 01/05/2018
AMENDMENT LOG
Rev. Date Reason For Change Reviewed Approved
Ms. Elina Mr. HL Lee
00 01/07/06 New Issue.
(QMR) (MD)
01 15/09/08 To delete clause 2.2) vii) , to add clause 2.3 iv) and amended clause 3.2) QMR MD
02 08/08/09 Convert ISO 9001:2000 to ISO 9001:2008 version. QMR MD
03 01/05/18 Transition to ISO 9001:2015 standard
THE COPYRIGHT IN THIS DOCUMENT IS VESTED IN ENG HING PLASTIC INDUSTRIES SDN BHD. IT MUST NOT BE
REPRODUCED, IN WHOLE OR PART, OR DISCLOSED TO THIRD PARTIES EXCEPT WITH THE WRITTEN CONSENT OF ITS
MANAGEMENT.
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PURPOSE
The purpose of this procedure is to establish a system for effective planning and production
processes in order to meet production target and product’s quality requirements as well as
customer’s requirements.
SCOPE
This procedure is applicable to the planning process and control of production processes involved
in the production of plastic packaging materials at Eng Hing Plastic factory.
REFERENCE
This procedure is designed to conform to the requirements of ISO 9001:2015 clause 8.5.1.
Quality Procedure:
QP-NC Control of Nonconformance
QP-STR Storage
QP-CR Contract Review
QP-PUR Purchasing
QP-I&T Inspection and Testing
QP-MEC Machine & Equipment Control
QP-TRN Training
Work Instructions
Job Description
DEFINITIONS
SPM Senior Production Manager
PM Production Manager
PPE Production Planning Executive
STS Section Supervisor
QAM QA Manager
QAS QA Assistant
PROCEDURE
1.0 Quality Planning
1.1 The SPM/PM/PPE shall establish a Manufacturing Process Flowchart (refer to
attachment) to document all critical processes involved in the production of the
product.
1.2 The SPM/PM/PPE shall monitor the work execution to ensure achievement of the
various acceptance requirements. This is to be carried out in accordance to the
Manufacturing Process Flowchart.
1.3 Where a process or product is found to be not in compliance with the
Manufacturing Process Flowchart, the Non-Conformance Report shall be issued in
accordance to the procedure QP-NC: Control of Nonconformance by the
concerned personnel.
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2.0 Production Planning
2.1 Upon the confirmation and approval of Sales Order (SO) by the Managing
Director, the SPM/PM/PPE shall receive one copy of the SO from the Sales &
Accounts Department.
2.2 Based on the SO information, the SPM/PM/PPE shall then generate a Production
Job Sheet which provides details on:
i) Job Number
ii) Customer Name
iii) Type of Product
iv) Dimension
v) Quantity Ordered
vi) Formulation
2.3 The Production Job Sheet consists of 3 copies to be distributed as follows:
i) Production Office filing (Blue Copy)
ii) Extrusion Section (White copy)
iii) Cutting Section (Pink copy)
iv) Rewinding, Post gusseting, slitting, offline printing and laminating (Using
white copy [with condition the job without extrusion process] or
photostate copy by indicate the process concerned on PJS)
2.4 Based on the total order received, the urgency and delivery requirements of
customers, the SPM/PM/PPE shall prepare a Extrusion Planning Schedule to plan
for production date daily.
2.5 The Extrusion Planning Schedule shall then be distributed to all the respective
process sections for their execution of work accordingly to the schedule.
2.6 This schedule may be reviewed if new Sales Orders are received that require
urgent or immediate delivery due to customer’s request.
2.7 When preparing Extrusion Planning Schedule, the following shall be taken into
consideration:
i) Delivery date required
ii) Availability of manpower
iii) Machine optimization and productivity
iv) Availability of raw materials
3.0 Production Process
3.1 The SPM/PM/PPE shall records all SO received into the Operation Report for the
purpose of monitoring the progress of each job.
3.2 The flow of processes involved in the production of the finished product is
outlined in the Manufacturing Process Flow Chart (refer to WI-PC-01).
3.3 The production personnel shall request the raw material required based on the
Production Job Sheet by submitting the Internal Requisition Form to the Store
Supervisor.
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3.4 The production personnel shall carry out the processes in accordance to the
relevant Work Instructions on:
i) Blending Process
ii) Blown Extrusion Process
iii) Printing Process
iv) Cutting Process
v) Slitting Process
vi) Rewinding Process
vii) Punching Process
viii) Post Gusseting Process
3.5 In-Process Quality Control and Final Quality Control shall be conducted at the
various control points as per the documented procedure QP: I&T and Quality
Plan and the result recorded into the inspection records.
3.6 Upon the completion of all processes, the finished product shall be send for
packing according to the in-house requirement or customer’s needs (refer to QP-
STR: Storage procedure).
3.7 The finished product shall then be sent to the finished product store for storage
before arrangement made for delivery (refer to QP: Storage procedure).
3.8 The SPM/PM/PPE shall prepare a daily and monthly production summary reports
that show the production output yield to be submitted to the Managing Director
for review.
4.0 Acceptance Criteria
4.1 The /SPM/PM/PPE is responsible to ensure that all specifications related to the
product manufactured shall be complied with throughout the processes involved.
4.2 The Production Job Sheet shall be used in defining the acceptance criteria for the
respective product.
4.3 For products with printing, the “Master Sample” form shall also be used to define
the acceptance criteria for the customer.
5.0 Use of Equipment, Machine and Working Environment
5.1 The SPM/PM/PPE shall ensure that the equipment, machine and working
environment present at the factory is suitable for carrying out the production
processes properly.
5.2 The respective process section Supervisor/Assistant Supervisor shall ensure that
the equipment and machine used in the factory is performed with the necessary
preventive maintenance as per procedure QP-MEC: Machine & Equipment
Control.
5.3 The QAM shall ensure that equipment and tools used in production are well
maintained and calibrated at appropriate interval in accordance to the procedure
QP-MEC: Machine & Equipment Control.
5.4 The working environment at the factory must also be found to be conducive for
workers to work in where sufficient lighting, good ventilation and adequate
cleanliness should be present at all time.
5.5 Should it found to be unacceptable in any of the above, the SPM/PM/PPE shall
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issue a Corrective Action Report in accordance to the documented procedure QP-
CPI: Corrective, Preventive and Improvement.
6.0 Competency of Personnel
6.1 All the organisation’s personnel involved shall be selected based on their
qualification, experience or demonstrated capabilities as per the documented
Job Description.
6.2 Training needs requirement for organisation’s employees shall be identified as
per procedure QP-TRN: Training.
7.0 Workplace Safety
7.1 Workplace safety is the responsible of the SPM/PM/PPE where he/she shall
ensure adequate safety precaution measures are taken to prevent accidents from
happening to workers.
7.2 The SPM/PM/PPE shall assess the risks and hazards involved in the workplace and
then ensure that the appropriate precaution to prevent accidents is taken i.e. use
of personal protective equipment, provision of first aids, proper training for new
employees in handling of machines, tools and equipment.
7.3 The SPM/PM/PPE shall ensure that a designated personnel is assigned to respond to
any incidents of emergency or accidents such as having access to the relevant
facilities, including first aid box and contact number of the relevant parties i.e.
ambulance, hospital etc.
RECORDS
Operation Report
Extrusion Planning Schedule
Production Job Sheet
Daily Production Report
ATTACHMENT
PC-A1: Manufacturing Process Flow Chart
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