Qri Guidelines

8/6/2019 Qri Guidelines

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[07] QUALITY ASSURANCE MANUAL [QAS]Master File No:[MF][MFG][15]

Page no. 48 of 96

Subject : COMMON INSPECTION, SAMPLING AND ACCPETANCE PROTOCOL

Released by :

S Patnaik

General Manager Manufacturing

Asian Paints Limited6 A, Shanti Nagar,

Vakola Pipeline Road,Santacruz EastMumbai - 400 055

Approved by :

S Patnaik

General Manager -Manufacturing

Section 14.00 - QUALITY RATING INDEX

QUALITY RATE INDEX

1. Quality Rate Index (QRI) is computed at the plant as per the guidelines issued by SCRC

2. Officer - Production / QA collects the data for each batch of finished product, resin and non-resin

intermediates and records it as per format given in Annexure

3. Scores are given against each batch processed in the plant as per QSG guidelines

4. SS /Executive - QA do a random check of the data to ensure that the scores are computed in line with

QSG guidelines

5. Monthly average scores under each product category are sent to QSG by the 7th

of each month for the

previous month, as per formats given in Annexure

6. Chief Manager - SCRC collates QRI scores received from each plant and publishes monthly QRI report

as per Annexure

METHODOLOGY FOR QRI DATA RECORDING

1. Strokes in the case of finished products is a measure of number of adjustments made during the

process of thinning/tinting to get all the properties within specifications.

2. The first checking of RS / Shade is referred to as Zero Stroke. Further adjustments to the batch, panel

application and checking of RS / Shade each time constitutes a different stroke starting from 1.

3. In case of DTS bases, the officer records no. of thinning strokes while for others, thinning and tinting

strokes are calculated separately and higher of the two is considered for QRI computation. This data

gets collected from Tintermans log sheet / register

4. % Completion is taken as the percentage of output to the input during processing stage. For material

where final approval is taken in calibrated mixers, output is derived based on dip level of mixer. For

others it becomes the value obtained as per SAP purchase order

5. RM Quantity deviation is recorded if one or more raw materials mentioned in the formulation are

added less or in excess than the specified ISO limits for the particular RM category than standard

quantity in formulation.


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6. Un-recommended RM refers to those RMs which are not part of the formulation but have been added

to get the quality of the batch within accepted limits as per consent from T/F. RMs mentioned under

special instructions in the formulation, if added, are not accounted for as un-recommended RM

7. If a batch meets more than one QRI criteria, the one having the lowest score is considered. For

example if a batch has completion of 100%, 1 thinning stroke, RM quantity deviation beyond ISO limits

and one un-recommended addition, the QRI score of the batch is accorded as 6 even though it meets

criteria of 7, and 10.

8. The above methodology is followed unless and until there are special instructions from Chief Manager -

SCRC to compute the scores differently for any category of products

9. QRI score of a particular section/block or product category is the simple average of QRI scores of all

batches produced therein during the month

10. Plant level QRI score for the month is the weighted average of QRI scores of individual sections/blocks

depending on the number of batches produced in each section/block


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Page no. 50 of 96


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S Patnaik


Quality Rating for Paint Batches including Intermediate ( Non Resin )

Description Rating

Scrap as waste 1

Reprocessed in low cost product 2

Reprocessed in same quality pdt > 3 lots 3

Reprocessed in same quality pdt < 3lots but material

unapproved for > 2days

4

Additional processing for quality attainment 5

RMs beyond permissible limit & if addition is unrecommended 6

RM Deviation beyond permissible limit 7

Deviations in in-process checks 7.5% Completion 95-105, batch in >2 strokes 8

% Completion 97-103, except,Aus,Utsav and syn tinter (90-

110% completion), batch in 2 strokes

9

% Completion 97-103, except,Aus,Utsav and syn tinter (90-

110% completion), batch in 1 stroke

10


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Page no. 51 of 96


Released by :

S Patnaik




Approved by :

S Patnaik


Quality Rating for Resins and Emulsion Batches

Description Rating

Scrap as waste 1

Reprocessed / Blended in low cost resin 2

Reprocessed in same quality resin > 3 lots 3

Reprocessed in same quality resin < 3lots but material

unapproved for > 3 days

4

Reactor thinned batch when not specified in SPI 5

Deviations against documented formulation / SPI 6

% NVM (Final In-process value) within 3 sigma 6.5

% NVM (Final In-process value) within 2 sigma, color within

specfn. & filtration more than one stroke

7

% NVM (Final In-process value) within 2 sigma, color within

specfn. & filtration in one stroke

8

% NVM (Final In-process value) with 1 sigma, color within

specfn. & filtration in 1 stroke

9

% NVM (Final In-process value) with 1 sigma, color value of

max specification - 1 & filtration in 1 stroke

10

CLARIFICATIONS ON QRI GUIDELINES FOR PAINT AND NON RESIN INTERMEDIATES

1. Formulations that allow some percentage of raw materials to be added if required [raw materials

forming part of the formulation but instruction in the formulation allows them to be added if

required]:

a. Formulations indicated above are accepted only if the standard quantity of each of these raw

materials does not exceed 0.5%.

b. All existing formulations that do not meet the above requirement are reviewed and plants need to

raise DCRs to correct these formulations. DCRs are raised in order to correct such formulations that


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Page no. 52 of 96


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S Patnaik


may have been released in past and these need not be linked to deviations of RM against standard

quantities. New designs that do not meet the above criteria are not accepted in the GM-1 / Design

Review stage.

c. For all such raw materials with if required conditions, the present guidelines of allowable deviations

are applicable and if the total actual quantity added to the batch deviates from the standard quantity

and the extent of deviation is beyond the allowed limits, then the QRI score of 7 is assigned to such

batches.

2. Actual percentage completion is used for computation of QRI. The exceptions to this rule are

a. When half-pack drums or after pack samples of a product-shade are added to the same product-

shade batch, then the extent of increase in % completion of the batch arising due to half-pack

addition is ignored while assigning the QRI score to the batch.

b. Addition of batches produced in PEL to bulk batches of same product shade is ignored while

assigning the QRI score to the batch. In case of deviated PEL batches if the additions to the bulk

batches are as per blending plans released by Manager - QA, then such additions are ignored while

assigning the QRI score to the batch.

3. Raw materials that do not form part of the formulation but are allowed to be added for adjustments

[through special instructions mentioned at the end of the formulation] can be added only upto 0.5%.

If the actual quantity added to the batch exceeds 0.5%, then QRI scores treat this as a deviation. Trend of

these deviations is observed and DCRs are raised to correct the formulations.

4. In case of 173H batches, the guideline for processing received from TF is considered as the formulation

and the QRI score is arrived at accordingly. If there are any deviations from the instructions (both in

actual raw material added or any processing instruction), then QRI score reflects such a deviation

5. Reuse of waste in paint / intermediate batches:

a. If addition of wastes to the paint / intermediate batches is meeting all the requirements of the Waste

Minimization Schemes approved by TF and incorporated in [MF][MFG][06], then deviations in tinter

consumptions or percentage completions or deviation in any other raw materials or higher number of

adjustments resulting due to such additions are not considered while deriving the QRI score. QA

department can assign a lower QRI to a batch in case they can establish that deviations in raw

materials or higher number of adjustments in the batch are not related to reuse of waste.


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Approved by :

S Patnaik


b. If there are any additions made to the batch that are not part of the approved waste minimization

schemes, then such additions are regarded as un-recommended and the plant proposes the scheme

to QSG for taking it up with TF for approval. In case there are additions of waste beyond

recommended limits, then such batches require clearance from TF and a QRI score of 7 is assigned

to such batches.

6. If the standard tinter quantity is 1.0 % or below, deviations from standard quantities are tracked for trends

and in cases where excess quantities are being added consistently, DCRs are raised in order to correct

such formulations.

7. In case of paints, if there are any deviations in in-process checks which is required are recorded in

[QR][PRD][20], then such batches are assigned a QRI of 7.5. Example: Batches where pH or premixing

viscosities etc are not within allowed limits etc are assigned a QRI of 7.5. If there is a requirement in the

F-sheet, against any of the parameters mentioned below, then, the QRI scoring in the category of

deviations in in-process checks is carried out as under:

a. Non-reporting of the observed value in the batch card: QRI = 7.5

b. Observed value is reported in the batch card, but is found to deviate: QRI = 7.5

c. Observed value is reported in the batch card, and is as per requirement: QRI = 10.0

The following parameters, if required to be maintained as per the F-sheet, are considered as in-process

parameters and the QRI rating is given based on the reporting and / or deviation in the observed value

during processing of the batch as against the requirement in the F sheet:

a. Solvent Based Paints and Intermediates

i. Premix Viscosity

ii. Sand milling Viscosity

iii. Dispersion wherever applicable

iv. Premix Temperature

v. Sand milling Temperature

vi. Flow rate for AMCs and Enamel bases

vii. Finish

b. Stiff Paints and Intermediates

i. Pugging Viscosity


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S Patnaik


ii. Clarity on glass plate

iii. Casein (process temp)

iv. Jelly clarity

v. Dispersion (for tinters, where applicable)

c. Water Based Paints and Intermediates

i. Grinding Time

ii. Jelly Clarity

iii. pH (Jelly)

iv. pH (Before Emulsion Addition)

v. Grinding Temp.

vi. Dispersion (for tinters, where applicable)

vii. Finish

8. If there is a deviation in in-process checks of any of the premix batches that have been clubbed in the

mixer, then the QRI value assigned to the mixer batch is 7.5.

9. However, in batches where extra grinding time or sand mill passes (more than that permitted by the

formulation) then such batches are assigned a QRI score of 5 (Additional processing for quality

attainment). The assessment of whether an additional grinding or a sand mill pass has been given while

processing is made against the instructions provided by the designer in the formulation. Since mixing and

grinding times are monitored and controlled manually by operators, minor deviations in adherence to

instructions of mixing and grinding times can be ignored while assigning QRI scores.

10. In case NCP material are added into a batch after taking approval from TF / Manager - QA, and meet

their guidelines (quantity added, product shade into which NCP needs to be added and other process

conditions that are required to be met if stated), then the addition of NCP is not be treated as un-

recommended addition and its impact on % completion, tinter deviation and number of adjustments are

ignored while assigning QRI score.

11. For batches that require clearance from TF and are assigned a QRI of 7, plant QA continues to assign

QRI of 7 to such batches till TF releases an alternate stroke and the plant switches to the new stroke

successfully.

12. The QRI scores of batches meeting the criteria indicated below is not included in the month end reports:


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[08] Production Manual [PRD]

Section No. 7.02 ISO 9001 : 7.5

Subject : Modifications to Approved Processes

Page : 70 of 124

7.02.1 GENERAL

a) Modifications to approved processes are, generally, of two types :

i) those which can be decided upon independently by the plant

ii) those which need the approval of the Technology Function.

b) This section describes the procedure for controlling the modifications statedabove.

c) The General Works Manager / Senior Works Manager (Taloja) is responsiblefor implementing this procedure.

7.02.2 DESCRIPTION

a) Modifications to approved processes for paints and intermediates other thanthose processed for the customer, that can be decided upon independentlyby the plant are :

i. Variations in the quantities of any raw materials or intermediates for thepurpose of adjusting batch quality parameters.

The concerned Senior Officer / Section Officer / Officer is authorised to carryout minor changes in the quantities of ingredients while processing paints.These changes should not exceed the limits given below :

1. Plant personnel making finished products and intermediates (nonresins) designs of which are released by TEDE / NPL / CGWS groupsare authorised to carry out minor changes in the quantities ofingredients while processing paints and intermediates (non resins) asdescribed below:

No Ingredient Products PermittedDeviations

Examples

1a Binder Solvent Based GlossEnamels (*)

-5 to +5 PBW Std Qty 80%,allowable limits


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are 75 85%1b All Solvent Based

Products excludingGloss Enamels

0 to +4 PBW Std Qty 80%,allowable limitsare 80 84%

2a Emulsion Stiff Paints -8 % to +12% Std Qty 20%,allowable limitsare 18.4 to

22.4%2b All Other Water BasedProducts (*)

-2 % to +14% Std Qty 20%,allowable limitsare 19.6 to22.8%

3 Solvent All Solvent BasedProducts (*)

-5 to +5 PBW Std Qty 80%,allowable limitsare 75 85%

4 Water All Water BasedProducts (*)

-5 to +5 PBW Std Qty 80%,allowable limitsare 75 85%

5 Rutile

Slurry

All Water Based

Products

0 to +2 PBW Std Qty 2%,

allowable limitsare 2 to 4%

6 OpaquePolymer

All Water BasedProducts

-2 to +2 PBW Std Qty 2%,allowable limitsare 0 to 4%

7a Tinters Any product whereTinter % is between 1.0% to 2.0 % PBW

-50 % to +50% Std Qty 1.6%,allowable limitsare 0.8 to 2.4%

7b Any product whereTinter % is less than orequal to 1.0 % PBW

All deviations arepermitted

7c Any product whereTinter % is greater thanor equal to 2.0 % PBW

-20 % to +20% Std Qty 3%,allowable limitsare 2.4 to 3.6%

8 Additives All Water Based andSolvent Based Products(*)

-20 % to +20% Std Qty 3%,allowable limitsare 2.4 to 3.6%

9a PercentageCompletion

WB Tinters and Stainers(AUS & Utsav Stainers)

90% to 110% -

9b All Solvent BasedIntermediates (Nonresin) and Products. All

95% to 105% -


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Water Intermediates(Non Resin) Products(other than WB Tinters,AUS and Utsav Stainers)

The above permissible limits apply to only those ingredients that arepresent in the formulation. If an ingredient is not present in the

formulation, then the above limits of deviation do not apply to thatingredient in that formulation. Example: Row number 2b is notapplicable to Stainers since emulsion is not an ingredient of Stainerformulations.

If there are any deviations in the quantity of binder added in the batch,all the driers are added proportionately in order to ensure that theBinder to Drier ratio in the standard design is maintained in the batch.Similarly the proportion of Emulsion to Coalescent solvents ismaintained to that of standard design in the batch.

Rows in which (*) is given in Product Column indicates that the

permissible limits indicated in that row are also applicable toIntermediates (Non Resins) for that product category

Any special instructions in the formulation supersede the abovepermissible limits.

2. Plant personnel making intermediates (resins) designs of which arereleased by TEDE / NPL / CGWS / NPLI / CGIC groups are authorisedto carry out minor changes in the quantities of ingredients whileprocessing intermediates (resins) as described below:

a. Quantities of recommended solvent/(s) should not vary by morethan +/- 3 percent of total quantities of resin and solvent/(s) (resinsolution) recommended for thinning. Whenever applicable, ratio ofsolvent blends should be adhered to

3. Plant personnel making finished products and intermediates (nonresins) designs of which are released by NPLI / CGIC groups areauthorised to carry out minor changes in the quantities of ingredientswhile processing paints and intermediates (non resins) as describedbelow:


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No Ingredient Products PermittedDeviations

Examples

1a Binder Solvent Based GlossEnamels (*)

-5% to +5%PBW

Std Qty 50%,allowable limits are45 55%

1b All Solvent Based (SB)Products excluding

Gloss Enamels

-3% to +3%PBW

Std Qty 50%,allowable limits are

47 53%2 Solvent All Solvent BasedProducts (*)

-5% to +5%PBW

Std Qty 15%,allowable limits are10 20%

3a Tinters All Solvent BasedProducts where shadeis made from Tinter &Tint Base combinationand Tinter % is between0 to 5% PBW

-1% to +1%PBW

Std Qty 4%,allowable limits are 3to 5%

3b All SB and EmulsionBased Products where

shade is made fromTinter & Tint Basecombination and Tinter% is greater than equalto 5% PBW

-20% to +20%of Std Qty

Std Qty 6%,allowable limits are

4.8 to 7.2%

3c All SB and EmulsionBased Products whereshade is made from co-grinding and Tinter % isbetween 0 to 2 PBW

-0.75% to+0.75% PBW

Std Qty 1.5%,allowable limits are0.75 2.25 %

3d All SB and EmulsionBased Products whereshade is made from co-grinding and Tinter % isgreater than equal to 2PBW

-25% to +25%of Std Qty

Std Qty 2.5%,allowable limits are1.875 3.125%

4 Additives All Solvent BasedProducts (*)

-0.5% to +0.5%PBW

Std Qty 0.3%,allowable limits are0 0.8%

5 Emulsion All Emulsion BasedProducts (*)

-2% to +14% ofStd Qty

Std Qty 50%,allowable limits are49 to 57%


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6 Water All Emulsion BasedProducts (*)

-3% to +3%PBW

Std Qty 10%,allowable limits are7 to 13%

7 CoalescingSolvent

All Emulsion BasedProducts (*)

0% to 0.5%PBW

Std Qty 0.5%,allowable limits are0.5 to 1.0%

8a Percentage

Completion

Tinters and Stainers 90 % to 110 % -

8b All other Solvent Basedand Emulsion Products(*)

95 % to 105 % -

The above permissible limits apply to only those ingredients that arepresent in the formulation. If an ingredient is not present in theformulation, then the above limits of deviation do not apply to thatingredient in that formulation.

If there are any deviations in the quantity of binder added in the batch,all the driers are added proportionately in order to ensure that the

Binder to Drier ratio in the standard design is maintained in the batch.Similarly the proportion of Emulsion to Coalescent solvents ismaintained as close as possible (because there are limits topermissible deviations in case of coalescent solvents) to that ofstandard design in the batch.

Rows in which (*) is given in Product Column indicates that thepermissible limits indicated in that row are also applicable toIntermediates (Non Resins) for that product category

Any special instructions in the formulation supersede the abovepermissible limits.

4. If a batch requires changes that exceed the limits given above, thensuch changes are approved by the concerned Chief Manager / SeniorManager / Manager / Executive Technology. The concerned ChiefManager / Manager / Executive Technology can authorize the SeniorManager Quality Assurance / Manager Quality Assurance (Taloja) toapprove changes exceeding the limits given above on their behalf. Thenature of changes and the limits upto which approvals can be given bySenior Manager Quality Assurance / Manager Quality Assurance(Taloja) are indicated in the authorization letters issued to Senior


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Managers Quality Assurance / Manager Quality Assurance (Taloja)from the respective General Managers in Technology Function.

If a batch requires changes that exceed the limits given above, then theExecutive / Manager / Senior Manager - Production / Manager Production (Taloja) seek approval from the Senior Manager QualityAssurance / Manager Quality Assurance (Taloja) prior to exceeding

these limits. If the Senior Manager Quality Assurance / Manager Quality Assurance (Taloja) is authorized to approve the change, thenthe changes are approved by Senior Manager Quality Assurance /Manager Quality Assurance (Taloja). Details of all variations inquantity of raw materials and intermediates for such batches is recordedand maintained as [QR][PRD][034].

In case the changes required to be made exceed the limits for whichauthorization can be given by Senior Manager Quality Assurance /Manager Quality Assurance (Taloja), then such changes are approvedby the concerned Chief Manager / Senior Manager / Manager /Executive Technology. The Senior Manager / Manager / Executive /

Officer Production in such cases seek approval from the concernedperson in Technology Function either verbally or on e-mail prior toexceeding the limits given above in the production batch. The ChiefManager / Senior Manager / Manager / Executive Technologyapproves / does not clears the deviations based on whether in hisopinion the deviations will / will not affect the quality of the product.

For every production batch where deviations in quantity of raw material /intermediate added to the batch has been approved by TechnologyFunction, an e-mail giving details of all the deviations in the batch issent to the concerned person in Technology Function who hasapproved them. Details of all such batches where deviations in

quantities of raw materials and intermediates have been approved byTechnology Function are recorded and maintained as [QR][PRD][034].

At the end of every month the details of all the batches where deviationsin quantities of raw materials and intermediates required approval fromSenior Manager Quality Assurance / Technology / Manager QualityAssurance (Taloja) are sent to the concerned Chief Manager / SeniorManager / Manager / Executive Technology for review and finalapproval. Records of these approvals are maintained in[QR][PRD][034].


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Data on the number of such batches is maintained and the causes forsuch deviations are analysed. The General Works Manager / SeniorWorks Manager (Taloja) reviews the same on a six monthly basis. Datais provided to the Management Representative every six months fordiscussion in the Management Review.

ii. Use of nonconforming product / reprocessing of finished products andintermediates:

Proposal for use of non conforming product / reprocessing of finishedproducts is forwarded to Production Department by the Senior Manager -Quality Assurance / Manager Quality Assurance (Taloja) who evaluatesand accords his approval as described in [07][08.01].

b) Deviations in in-process parameters observed are intimated to the Manager- Production / Production Executive / Senior Officer / Section Officer by the

Officer. The Manager - Production / Production Executive / Senior Officer /Section Officer investigates the causes of such deviations and records thesame in [QR][PRD][020]. This is periodically reviewed by Executive /Manager - Production on monthly basis and by Senior Manager - Production/ Manager Production (Taloja) on quarterly basis. This is also recorded in[QR][PRD][020] .

c) Consumption or reuse of any waste is done in accordance with guidelines ofwaste utilisation. These guidelines are approved by Technology Function andare available as [MF][MFG][06]. Specific instructions on reuse of waste areavailable in [WI][PRD][040].

e) Changes in the processing methods require the approval of a Chief Manager / Senior Manager Technology. Manager - Safety in case of a substantialchange in the method of processing. In case of Taloja Plant, Senior WorksManager is consulted for safety aspects.

f) For recurring production and quality problems or change in the approvedprocess, the Production Department forwards design change request toSCRC and other plants for data for the same product after collating the datafrom all the plants where the products are made. SCRC forwards the same toconcerned Chief Manager / Senior Manager Technology. The reason for


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Section No. 7.02 ISO 9001 : 7.5


change being sought is also indicated. This request is available as[QR][PRD][009]. The decision on whether to continue production on theformulation of which a change has been requested is taken by the SeniorManager Production / Manager Production (Taloja) , pending a reply fromthe concerned Chief Manager / Senior Manager Technology on the DesignChange Request.

g) The Technology Function evaluates the proposed change and eitherapproves or rejects it. The concerned Chief Manager / Senior Manager Technology informs the decision to the General Works Manager / SeniorWorks Manager (Taloja) through a new Design Output as described in[04][05.04]. Upon review of the above, the General Works Manager / SeniorWorks Manager (Taloja) arranges for updation in SAP and IPS as describedin [08][07.01].

h) In case of paints processed for the customer, the Senior Officer / SectionOfficer / Officer refers to [MF][APG][57] and [MF][APG][59] for alternate rawmaterials and intermediates respectively. The advice of the Executive -Safety / Senior Works Manager (Taloja) is sought regarding the safety

aspects of the process implementation on the shop floor whenever there is asignificant change from practices followed.

In the case of paints processed for the customer, modifications torecommended material additions and process parameters can be carried outas per [MF][APG][63].

i) Paint left over during the manufacturing process in mixers or pipelines or inthe form of half packed containers and finished goods returned from BSR isreused by the Officer as per [WI][PRD][041]

j) Certain experimental / trial batches are taken based on ideas generated

within production with changes in raw materials and machinery to study theefficacy of the processing / filtration machine etc. The number of suchexperimental / trial batches are restricted to a maximum of three batches. Adetail report is sent to Technology Function. This record is available as[QR][PRD][023]. Subsequent batches based on above changes areprocessed only after the clearance from Technology Function and in case ofEngineering Services wherever required.

Documents

Qri Guidelines