IMS Manual (1)

This Manual is UNCONTROLLED unless viewed on TCS Intranet

Integrated Management System Manual

BS EN ISO 9001:2008 BS EN ISO 14001:2004

OHSAS 18001:2007

Revision 13.0

Last Updated 11 March 2013 Last Reviewed 11 March 2013

Scope:

Design, manufacture Installation and Maintenance of Safety, Shutdown and Sequencing Controls, Electronic Process Monitoring and ControlEquipment, Control Panels and Switchboards for Industrial, Marine and HazardousArea

Applications. Design, Assembly and Commissioning of Steam and Hot Water Boilers.

Approved: P. Mountain

Checked: G. Evans

2013 Technical Control Systems Ltd. All Rights Reserved

Definitions, Abbreviations and Symbols

This document is UNCONTROLLED unless viewed on TCS Intranet

[List of all abbreviations used in the manual and definitions of relevant terms]

Definitions

l Environmental aspect (EA): An element of Technical Control Systems activities, products, or services that can or does interact with the environment (create an environmental impact)

l E-Project folder: An electronic folder located on the main server, used to hold all electronic documentation for a project and accessible via the TCS intranet.

l Significant environmental aspect (SEA): An environmental aspect deemed by the company as having, or potentially having, a significant impact on the environment.

l Non-conformity: Discrepancy between Technical Control Systems actual IMS activities and the procedures laid out in this manual (i.e., where the actual activities do not follow the procedures)

l Indicator: A measurable parameter or predictor of performance (Quality, Health & Safety or Environmental)

l Root cause analysis: Systematic process to uncover underlying causes of a particular issue or problem.

Abbreviations

l IMS Integrated Management System

l EA Environmental Aspect

l SEA Significant Environmental Aspect

Symbols used in Table of Contents:

NAVIGATION

Generic Amendment

Operational Procedure Objective or Target

Work Instruction Overview

Inspection Procedure Scope

Technical Table Checklist / test

Responsibilities Personnel related or

Structure Organisational Structure or

Policy or Graph or

Register Report

Audits Service Related

Rules Authorised Personnel only (e.g. managers) or

Database Index

Standards Document located on Internet or

Informative

DEFINITION/TYPE FOLDER DOCUMENT DEFINITION/TYPE DOCUMENT

Integrated Management System Amendment Record


1 August 2005 000 1 All First Issue of IMS Manual

10 January 2006

000 2 IMS Policy Policy reviewed and reaffirmed

18 July 2006 000 3 IMS Policy "To prevent pollution,"added to third paragraph.

18 July 2007 000 4 IMS Policy Policy reviewed and reaffirmed

04 December 2008

000 5 IMS Manual Title Page: BS EN ISO 9001:2000 changed to BS EN ISO 9001:2008

23 December 2008

000 6 Operating Procedures

OP120 Evaluation of Compliance added.

25 June 2009 000 7 OP 108 1. Nonconformance Control - Quality Release procedure changed.

2. "OHSAS 18001:1999" changed to "OHSAS 18001:2007" on IMS Manual Title Page. (Now Rev 3)

6 August 2009 000 8 IMS Structure Overview of Integrated Management System Model added (Plan-Do-Check-Act)

OP118 Record Section added to end of procedure and Contractors added to Responding to External Interested Parties (Now Rev 2)

29 July 2010 000 9 IMS Policy "To prevent pollution," changed to "To Prevent pollution, imjury and ill health" to comply with commitment requirements of OHSAS 18001:2007

OP105 OP105 Stores procedure modified. (Now Rev 3)

OP118 OP118 Communications procedure modified (Now Rev 3)

OP108 OP108 Non-conformance Control modified (Now Rev 3)

OP109 OP109 Corrective and Preventative Actions modified (Now Rev 2)

IP102 & IP103 "Reject Report" changed to "Non-conformance Report" in both Inspection procedures.

20 March 2012

000 10 OP104 OP104 Purchasing procedure modified (Now Rev 3)

OP105 OP105 Stores procedure modified (Now Rev 4)

11 July 2012 000 11 OP103 OP103 Engineering Procedure modified. (Now Rev 6)

OP114 OP114 Training Procedure modified (Now Rev 2)

15 February 2013

000 12 IMS Manual Site Service Co-ordinator added to the Organisational Diagram and the Health & Safety Organisational Diagram. Responsibilities of Site Services Co-ordinator added.

OP117 Sources of Information modified (Now Rev 4)

11 March 2013

000 13 OP105 OP105 Stores procedure modified (Now Rev 5)

DATE IMS REV. CLAUSE DESCRIPTION

Introduction


This Manual describes the Integrated Management System (IMS) of Technical Control Systems Ltd, and is the controlling document for all aspects of the management of Quality, Health and Safety, and the Environment.

The Management System is composed of integrated quality, environmental and occupational health and safety Management systems. It carries out activities in an effective way, combining three standards. The first of these is ISO 9001 for obtaining customers satisfaction. The second is ISO 14001 for corporate social responsibility and obtaining the satisfaction of interested parties. The third one is OHSAS18001 for obtaining the satisfaction of employees with a safe work environment provided, and other standards.

This manual serves as a high-level "road map" to Technical Control Systems IMS and to house the procedures which Technical Control Systems follow in implementing and maintaining its IMS.

This manual and subsequent revisions, is distributed by the IMS management representative to company directors, management and all TCS employees, especially those involved in performing work related to the IMS.

This manual also serves as the basis for Technical Control Systems internal assessment of its IMS.

This manual is a controlled document and the master copy is authorised by the Managing Director to indicate his approval.

Printed copies of this manual are only valid at the time of printing, and should be destroyed when the intended use is finished.

Integrated Management System Policy


Technical Control Systems Ltd are committed to the operation and ongoing development of our Integrated Management System ensuring that we support the highest level of manufacturing and service provision, product innovation and quality. The IMS comprises:

ISO9001 Quality Management

ISO14001 Environmental Management

Technical Control Systems Internal H&S System (to OHSAS18001)

The aim of the company is to produce efficient, economical and environmentally friendly LV switchgear and LV controlgear, provide a professional level of quality service and be committed to responding and providing innovative solutions to our clients needs.

IMS Policy

To strive for continuous improvement by establishing appropriate business goals and objectives and implementing the plans to achieve them.

To meet customer needs by providing quality products and services through an environment friendly production system.

To prevent pollution, injury and ill health, comply with laws and regulations to prevent prosecution, fines, adverse publicity and ensure the well-being of all personnel.

The scope of the policy is:

Design, Manufacture, Installation and Maintenance of Safety, Shutdown and Sequencing controls, Electronic Process Monitoring and Control Equipment, Control Panels and Switchboards for Industrial, Marine and Hazardous Area Applications.

Design, Assembly and Commissioning of Steam and Hot Water Boilers.

Integrated Management System:

The implementation and operation of the IMS has been undertaken to establish a formal mechanism for the adherence of the principles of ISO9001, ISO14001 and OHSAS18001 and corresponding need to create and review objectives and targets for the continual improvement of manufacturing and service provision as well as the Integrated Management System and its requirements to identify and comply with all legislative requirements and those others as defined and selected by the business.

The Policy is communicated to all direct and indirect employees of the business to ensure that Technical Control Systems Ltd delivers a unified service to all existing and prospective clients. As such we will publish our policy on our website allowing anyone external to the organisation to view our commitment to quality, health and safety and environmental management and the prevention of pollution, accidents and ill health, provision of a safe working environment and a continual improvement of these controls.

Technical Control Systems Ltd has established processes that measure and review the performance of the business and ensure the evolution of the nature and scope of the IMS and this Policy.

INTEGRATED MANAGEMENT SYSTEM POLICY

PAS99 ISO9001 ISO14001 OHSAS18001

4.2 5.1, 5.3, 4.2.2 4.2 4.2

Jonathan Somers, Managing Director

Signed:

Dated: 27 August 2012

Integrated Management System objectives


Create corporate value

n Improve profitability

n Promote environmental management

Enhance brand value and customer satisfaction

n Ensure on-time delivery

n Respond swiftly to complaints

n Improve service quality

n Improve Environmental communication

n Design environmental conformity products

Promote creation of safety and a clean efficient factory

n Prevent global warming

n Promote green procurement

n Reduce waste

n Enhance management of harmful substances

n Raise production/administrative efficiency

n Strive for zero-accidents

n Minimize risk through risk assessment

Integrated Management System Organisation Diagram


Click on a box for additional clarification on roles and responsibilities.

Note: Personnel with additional job title in brackets have a dual role within the company.

J. SOMERS

MANAGING DIRECTOR (PRODUCTION MANAGER)

D. FLETCHER FINANCIAL DIRECTOR

N. FOSTER

CONTRACTS DIRECTOR

D. JESSUP COMMERCIAL

DIRECTOR

N. STEWART

SALES DIRECTOR

ACCOUNTS DEPARTMENT

ENGINEERING DEPARTMENT

SALES DEPARTMENT

EXTERNAL

SALES

IMS COORDINATOR

PRODUCTION MANAGER

MATERIALS

CONTROLLER

P. MOUNTAIN

TECH. DIRECTOR (IMS COORDINATOR)

QUALITY

PRODUCTION DEPARTMENT

PURCHASING TEST & INSPECTION

HEALTH & SAFETY

SITE SERVICES CO-ORDINATOR

(SITE SUPERVISOR)

STORES

ENVIRONMENT

SITE

SUPERVISOR

SITE

OPERATIVES

SUB

CONTRACTORS

Integrated Management System Health and Safety Organisation Diagram


KEY [*]

[A] The Managing Director is responsible for determining the policies and objectives of the company and ensuring that the overall company quality, Health & Safety, and Environmental objectives are achieved and has direct responsibility for the management review and conclusion of any resultant corrective or preventative action.

[B] The elected Health & safety representative represents the workforce on health and safety generally, or makes representations on potential hazards and dangers; attends Health & Safety Committee meetings; makes regular workplace inspections and reports to the IMS Coordinator.

[C] Advises the company of safety legislation & updates.

[D] Responsible for ensuring the requirements of BS EN ISO 9001, BS EN ISO 14001 & OHSAS 18001, are implemented and maintained. Carries out audits, IMS updates, provides training where required and provide investigations and reports for any accidents/incidents.

[E] The Health and Safety Committee review and analyse accidents and incidents, issue corrective actions to prevent recurrence of accidents or incidents, review procedures and policies, risk assessments, new or impending legislation and suggest opportunities for improvements.

[F] Heads of Departments are responsible for the health and safety of staff and visitors in areas under their control.

[G] All staff must maintain satisfactory standards of health, safety and welfare within their authorised areas of responsiblility and cooperate with the company in meeting its statutory obligations on health and safety.

[H] Management and Supervisory staff are formally responsible for implementing the company's IMS Policy within their authorised areas of responsibility.

[I] Sub-Contractors to be aware of IMS Policy & to have read site guidelines. Same as [G].

[A] J. SOMERS

MANAGING DIRECTOR (PRODUCTION MANAGER)

[B] ELECTED HEALTH

& SAFETY REPRESENTATIVE

[C] BRITISH SAFETY COUNCIL (HSE ADVISORS)

[D] P.MOUNTAIN TECH. DIRECTOR

(IMS COORDINATOR)

[E] HEALTH & SAFETY

COMMITTEE

[F] D. FLETCHER FINANCIAL DIRECTOR

[F] N. FOSTER CONTRACTS DIRECTOR

[F] D. JESSUP COMMERCIAL

DIRECTOR

[F] N. STEWART

SALES DIRECTOR

[G] ACCOUNT CLERKS

[G] CONTRACT ENGINEERS

[G] ESTIMATORS

[G] SALES STAFF

[F] CHIEF TEST ENGINEER

[F] MATERIALS CONTROLLER

[F] PRODUCTION MANAGER

[G] TEST ENGINEERS

[G] STORES PERSONNEL

[G] PRODUCTION PERSONNEL

[H] SITE SERVICES CO-ORDINATOR

Note: Personnel with additional job title in brackets have a dual role within the company.

[I] SUB CONTRACTORS

[H] SITE SUPERVISOR

[G] COMMISSIONING ENGINEERS

[G] SITE OPERATIVES

Managing Director


The Managing Director is responsible for determining the policies and objectives of the company and ensuring that the overall company quality, Health & Safety, and Environmental objectives are achieved and has direct responsibility for the management review and conclusion of any resultant corrective or preventative action.

The Managing Director is also the Production Manager.

Financial Director


The Financial Director is responsible for:

l ensuring that the business complies in every respect with our statutory and TCS policy requirements.

l operating to consistently high standards and implementing processes to maximize benefit to the company.

l finance security and making recommendations for process improvements.

l preparing budgets, communicating and reporting on performance and recommending actions as appropriate.

l ensuring the commercial success of the contracts and the update of all financial budgets as a contract progresses.

Contracts Director


The Contracts Director is responsible for:

l the management and control of all design engineering and engineering office activities within TCS.

l the preparation and issue of engineering data.

l the translation of customer needs from the specifications and tender into technical design specifications for materials, products and processes.

l design reviews and verification of designs.

l resourcing all engineering projects.

l promoting the IMS throughout the engineering organisation.

l review, approval and assistance with executing testing procedures and method statements.

l contributing to the development of new concepts and techniques.

l ensuring the design is safe and the impact on the environment is minimised wherever possible.

l ensuring environmental requirements are incorporated into the design process.

Commercial Director


The Commercial Director is responsible for:

l the management and control of all tendering activities within TCS

l approval of all commercial matters in TCS relating to the preparation and submission of tenders to customers.

l implementing professional practices relating to tendering & negotiation with suppliers and clients.

l ensuring that customer requirements are translated from the product brief/enquiry into a quotation for products or services, and the subsequent review of customer orders.

l contributing to the development of new concepts and techniques.

l promoting the IMS throughout the tendering phase.

l ensuring environmental requirements are incorporated into the quotation process.

Sales Director


The Sales Director is:

l Responsible for identifying business needs and opportunities.

l Responsible for the sales and business development according to business plan.

l Responsible for a team of sales staff to be hired and trained based on sales growth.

l Responsible for developing the necessary commercial partnerships, resulting in high quality customer relationship management.

l Responsible for all Product Sales, Marketing and Sales Development Processes and Sales Operations and Support.

IMS Coordinator


The IMS Coordinator is the management representative with the responsibility and authority to ensure the requirements of BS EN ISO 9001, BS EN ISO 14001 & OHSAS 18001, are implemented and maintained, and is responsible for:

l monitoring and managing customer satisfaction and customer comment.

l ensuring that the requirements of the IMS are implemented and maintained, to achieve and retain industry recognised certification, and the enhancement of customer satisfaction.

l managing the interface with the BSI, our nominated third party auditors.

l determination of audit schedules, auditor competence and independence, the implementation of audits and management review meetings.

l providing IMS operational support to the business to ensure compliance with applicable standards, legislation and regulations.

l obtaining and updating all environmental licenses, approvals and permits.

l development for IMS programmes and systems for business-wide implementation.

l the review and monitoring of corrective/preventive actions.

l promoting the awareness of customer requirements throughout the company

l staff induction training to procedures.

l reporting to the Managing Director on the performance of the Integrated Management System and any needs for improvement.

Production Manager


The Production Manager is responsible for:

l The management and control of all production activities.

l Ensuring that products and services are manufactured or supplied to a level of quality which meets the needs and expectations of customers and complies with the requirements of the IMS.

l Issue and assignment of work to production and test personnel competent to carry out the work.

l Ensuring production target dates in the overall delivery schedule are maintained.

l Plan construction works in a manner that avoids or minimises impact on the environment.

l Ensure documented IMS management procedures are implemented across all sites.

l Promoting the IMS throughout the production department.

Specific tasks may be delegated to other personnel.

Materials Controller


The Materials Controller is responsible for:

l the management and control of the stores

l ensuring that bought-in materials are obtained in time to meet production target dates.

l implementing professional practices relating to sourcing, tendering, negotiation, contracting, measuring and monitoring of all activities (large, small, direct or indirect) which require supplier involvement.

l reducing material & running costs; either through cost take out or efficiencies through improved production.

l developing commodity strategies & driving sourcing methodology into the business.

Technical Director


The Technical Director is responsible for:

l inspection and testing, and for control of all inspection, test and measuring instrumentation.

l development, checking, approval, issue and control of all technical tables.

l maintenance and control of British Standards and other specifications.

l maintaining the company website and webtools.

l identification, verification, documentation and implementation of Statistical Techniques used by the Company.

l implementation of IT, to support the management, growth and development of TCS.

l ensuring that policies, procedures and other necessary information are maintained and available on the company intranet.

The Technical Director is also the IMS Coordinator.

Site Services Co-ordinator


The Site Services Co-ordinator is responsible for the management and control of all site activities, including execution of work, testing and commissioning

These responsibilities then including:

l The preparation and issue of Risk Assessments and Method Statemens (RAMS) for both standard deliveries and ongoing sitework.

l Organising delivery of LV assemblies within budget.

l Issue and assignment of work to site operatives competent to carry out the work.

l Liasing with the Test Department to ensure products are tested in time to meet target dates for delivery.

l Organise quotations for third party installation and ensuring they are within budget.

l Ensuring the effective application of servicing activities.

l The weekly inspection of all site vans, including organising annual servicing / MOT etc.

l Ensuring the commercial success of all site activities and the timely preparation of variations and invoices where required.

l Liasing with Site operatives and the Engineering department to ensure a swift resolution to any queries.

l Ensuring that training needs of site personnel are identified, organised and implemented.


Site Supervisor


The Site Supervisor is responsible for:

l Control of work on site and implementing/maintaining effective quality/health & Safety and Environmental controls.

l Supervising the day-to-day construction activities on site under the instruction of the Site Services Co-ordinator or Production Manager.

l Issue of Permits to Work where there is increased safety or environmental risks.

l Ensuring site activities comply with IMS procedures and method statements and that records are kept in accordance with the planned requirements.

l Notifying the IMS coordinator and Production Manager immediately in the event of a Health & Safety or Environmental accident or near miss.

l Cleaning up immediately any environmental accident under the direction of the IMS Coordinator.


Site Operatives


The Site Operatives are responsible for:

l Carrying out works as instructed by the Site Supervisor and/or Production Manager.

l Attending health & safety / environmental inductions.

l Conducting works in accordance with IMS procedures and method statements.

l Undertaking remedial action as required and ensuring health & safety and environmental controls are maintained.

l Cleaning up immediately any environmental accident under the direction of the Site Supervisor.

Sub Contractors


Sub Contractors are responsible for:

l Implementing works as directed by the Site Supervisor and/or Production Manager.

l Attending health & safety / environmental inductions prior to commencement of works.

l Complying with all relevant conditions of project approval and licensing requirements.

l Nominate a senior representative for liason with the Production Manager.

l Notify the Production Manager immediately in the event of a health & Safety or environmental accident/near miss.

l Provide adequate equipment/facilities on site to protect the health & safety of all personnel and the environment during their works.

l Undertaking remedial action as required and ensuring health & safety and environmental controls are maintained.

l Cleaning up any environmental spillage immediately after the incident, or at the request of the Production Manager.

IMS Overview


TCS have developed, documented and maintain an integrated management system(IMS) designed to ensure we continue to supply high quality products and services to our customers while providing a safe, healthy workplace for our employees and acting as a responsible member of our community.

The TCS company's IMS is designed to help us understand our environmental impacts and, through proactive management, reduce the risks that our productive operations pose to our employees and to the environment. The IMS is also the means through which the commitments expressed in our policy document are implemented.

The IMS covers all operations occurring on-site at our Leeds factory, from the point of entry of raw materials and energy, to the point of exit of finished manufactured products. In addition to manufacturing processes and activities, all off-site operations fall within the scope of the IMS, including delivery, erection and installation, and maintenance.

The IMS takes waste disposal into account in evaluating the environmental impacts of both on-site and off-site activities, even though TCS may not ultimately be the final disposer of the waste.

The IMS is organised and structured such that technical/administrative and human factors affecting the quality of products and services are controlled. The IMS demonstrates objective evidence of the attainment and maintenance of quality, ensuring customer confidence in the company's ability to deliver the desired quality. Additional evidence is provided by independent third party assessment of conformance of the quality system to the requirements of BSEN ISO9001:2008.

IMS Operational Procedures (OP's)

The IMS is defined in operational procedures (OP's) which are structured by either department operations or company wide operations. Each procedure details actions and requirements to be achieved in IMS objectives.

A OP number uniquely identifies each operational procedure.

In addition work instructions ('WI' series) and inspection procedures ('IP' series), which are detailed instructions of process or inspection activities, are used where necessary in supporting operational procedures and product quality.

All documented records, which are used to verify product quality and the achievement of the IMS are allocated a unique, number (IMSD No.'s) for control of identification and referencing.

Verification Resources and Personnel

Verification requirements, I.e. Inspections, product and IMS audits, are identified by TCS Limited. Adequate financial and physical resources in terms of plant and equipment are provided, together with the necessary training of specified personnel for verification purposes.

Management Representative

Technical Control Systems Ltd. has appointed the Technical Director as the company representative with the responsibility and authority to ensure the requirements of BS EN ISO 9001, BS EN ISO 14001 & OHSAS 18001, are implemented and maintained. In addition he has direct responsibility for inspection and testing, and control of all inspection, test and measuring instrumentation.

IMS Issue

All sections of the Integrated Management System are approved and authorized by qualified personnel and checked by the management representative prior to issue.

Operational procedures, Work instructions and Inspection procedures are installed on the company's intranet and are available to personnel with responsibility for ensuring adherence to them and to personnel for information/reference purposes. All updates to the IMS are controlled using the document control procedure - OP113. Issues to third parties external to the company or issues downloaded from the company's website are identified as 'Uncontrolled'.

Integrated Management System Structure


Click on a procedure title for a detailed summary.

IMS000 - Integrated Management System Manual

WI Series Work Instructions

IP Series Inspection Procedures

IMSD's IMS Records / Certifications

Operational Procedures (Departmental)

OP102 Sales Department

OP103 Engineering Department

OP104 Purchasing

OP105 Stores

OP106 Production Department

OP107 Test Department

Operational Procedures ( Company Wide)

OP101 Integrated Management

System

OP108 Non-Conformance Control

OP109 Corrective & Preventative

Action

OP110 Management Review

OP111 Audits

OP112 Records

OP113 Document Control

OP114 Training

OP115 Risk Assessment

OP116 Environmental Aspects

OP117 Legal Requirements

OP118 Communication

OP119 Emergency Preparedness &

Response

OP120 Evaluation of Compliance

IMS Organisational & Technical Interfaces


Note: An interface exists wherever two departments/segments touch.

Examples:

l A technical interface exists between the customer and the IMS, Suppliers, Sales, Engineering and Test.

l A technical interface exists between the Stores and Purchasing, Engineering, Production, Suppliers and IMS.

l In the case of Free-Issue equipment/materials, the customer may also be the supplier.

OP101 - Integrated Management System


The company has developed, implemented and maintains a documented Integrated Management System which meets the requirements of:

l BS EN ISO 9001: 2008 Quality management systems Requirements.

l BS EN ISO14001:2004 - Environmental management systems - Requirements with guidance for use.

l OHSAS 18001:2007 - Occupational health and safety management systems - Specification

The Integrated management system has been documented in a three tier system, namely:-

l The IMS Manual (IMS000).

l Operational Procedures (OP100 series).

l Work Instructions (WI100 series) and Inspection Procedures (IP100 series).

The documented Integrated management system specifies the company policies, responsibilities and procedures for meeting company objectives and the requirements of the international standards quoted above.

The scope of the Integrated Management System encompasses sales, design, procurement, manufacturing, inspection, testing, installation and servicing.

OP102 -Sales Department


All customer enquiries / requirements are translated from a product brief / specification into a documented quotation for materials, products and services at a price and delivery satisfactorily agreed between both parties. Integration of environmental aspects at this stage in the product design offers the flexibility to make changes and improvements to products.

During the quotation process, consideration is given to the following:-

l Improvement of energy efficiency: consideration of total energy use throughout the products life cycle, including the use phase.

l avoidance of potentially hazardous substances and materials in the product.

l design for reuse, recovery and recycling.

On receipt of each order a review is undertaken to ensure the following:-

l The requirements are defined and correctly specified and documented.

l Any requirements differing from those in the quotation are resolved.

l The requirements of the order can be met.

OP103 - Engineering Department


In order to ensure that the clients, safety and environmental requirements can be met, procedures are adopted to control and verify product design.

The design and verification activities are planned, and are assigned to personnel with adequate resources and sufficient experience and qualifications.

The organizational and technical interfaces between different departments are identified, and the necessary information is documented, transmitted and regularly reviewed to ensure the following:

l So far as is reasonably practicable, all products are safe for the purpose for which they are designed.

l Products are designed so that any necessary testing to ensure safety can be carried out.

l Adequate information about the safe use of all products is provided.

l The product is energy efficient, within the constraints posed by the client.

l Potentially hazardous substances and materials in the product are avoided.

l The product is designed for reuse, recovery and recycling.

The input specification requirements for the product design are identified and documented. They are subject to a review to ensure their adequacy. Discrepancies in the requirements are resolved with the party responsible for initiating the requirements. All design outputs are documented and reviewed to ensure they match with design inputs.

All design output specifications are controlled in authorization, identification, issue and modification, and are in a form that can be verified and validated.

OP104 - PURCHASING


The procurement of product and environmentally-related materials and/or services is controlled to ensure that the purchased product conforms to the specified requirements.

Assessment of Subcontractors

Sub-contractors are selected on their ability to meet the specified requirements. A list of approved sub-contractors is maintained through supplier assessment monitoring and control.

Purchasing Data

Purchase orders state sufficient data to clearly describe the product ordered, including as applicable:-

l Type, class, style, grade or other precise identification.

l Title or other positive identification, applicable specifications, drawings, inspection instructions and other relevant technical data.

l Title, number and issue of any international standard to be applied to the product.

Verification of Purchased Product

Where specified in the customers order, the customer or his Representative is afforded the right to verify, either at source or upon receipt, that the purchased product conforms to the specified requirement.

OP105 - STORES


Written instructions are adhered to for the identification and inspection/verification of goods received against purchase orders. Any goods found to be non-conforming are segregated and dealt with under non-conformance control and information fed back to the supplier assessment controls.

All material is identified, handled and stored in safe locations to prevent damage and deterioration, and is only issued to manufacturing against authorized documentation and signature.

The company has established a procedure for the inspection or purchaser supplied product (free issue).

The procedure contains the following:

l Goods receiving inspection activities to account for quantity, identification and detection of damage/corrosion during transit.

l Purchaser supplied product is periodically inspected during long term storage to detect signs of deterioration. Limitations on storage periods are assessed and material maintenance conducted to retain condition.

l Adequate identification of purchaser supplied product to prevent unauthorized misuse or disposal.

Conditions, which result in the unsuitability of product, are reported to the customer.

Information is maintained on usage and inventory of all hazardous materials, and the storage and shipping of waste hazardous materials is managed.

OP106 - PRODUCTION DEPARTMENT


The company has established a procedure for identifying the product during all stages of production, delivery and installation by means of marking and/or documentation.

Where specified in the order, the individual product or batches have a unique identification, which is recorded to ensure traceability.

Production and installation processes directly affecting quality, safety or the environment are identified and planned to ensure that they are carried out under controlled conditions.

Controlled conditions include:

l Documented work instructions, use of suitable equipment, compliance with reference standards.

l Control and monitoring of processes and product characteristics.

l Approval of processes and equipment.

l The stipulation of workmanship criteria through written standards or representative samples.

Servicing

Where specified in the contract, procedures for performing servicing and verifying that it meets the specified requirements are maintained.

Special Processes

Special processes, of which the results cannot be verified by subsequent inspection or testing, are continuously monitored or undertaken to documented procedures to ensure the specified requirements are met.

In-process use of Hazardous Substances

The use of hazardous substances is controlled by the use of suitable personnel protective equipment and COSHH Assessment sheets.

OP107 - TEST DEPARTMENT


RECEIVING INSPECTION

l Incoming substances are not used until they have been inspected or otherwise verified as suitable for use.

l Incoming products are not used or processed until they have been inspected or otherwise verified as conforming to the specified requirements.

In-Process Inspection and Testing

l Product is inspected and tested as required according to documented procedures. Process monitoring/control methods are used to establish conformance to the specified requirements.

l Product is held until the required inspection and test have been carried out.

l Any non-conforming product is identified.

Final Inspection and Testing

l Final inspection and testing is carried out in accordance with documented procedures to complete with evidence of conformance of the finished product to specified requirements.

l Dispatch of the product is not permitted until all the activities specified in the documented procedures have been satisfactorily completed.

Inspection and Test Records

l Records are maintained which demonstrate that the product has satisfactorily passed inspection and test.

Inspection and Test Status

l The inspection and test status of product is identified using marking/documentation to indicate conformance or non-conformance as a result of the inspections and test performed. The identification of inspection status is maintained throughout production and installation to ensure that only product which has been accepted is dispatched, used or installed.

l Inspection records identify the inspection authority responsible for the release of the conforming product.

Inspection, Measuring and Test Equipment

l Inspection, measuring and test equipment is controlled, calibrated and maintained to ensure that measurement uncertainty is both known and consistent with the required measurement capability.

l The measurements to be made and the required accuracy is identified on the drawings and the appropriate inspection, measuring and test equipment is made available.

l All inspection, measuring and test equipment is uniquely identified and calibrated at prescribed intervals to equipment traceable to National Standards.

l Calibration procedures are established for inspection, measuring and test equipment including equipment type, identification, calibration frequency, and acceptance criteria.

l Through the use of calibration records the calibration status of all inspection, measuring and test equipment is identified together with the results of previous calibration checks.

l Should inspection, measuring and test equipment be found to be out of calibration, the validity of previous inspection results using that equipment are assessed and documented.

l Adequate facilities are provided for the handling, preservation and storage of inspection, measuring and test equipment. Suitable environmental conditions are provided for the calibration of the equipment.

l Inspection, measuring and test facilities are safeguarded from adjustments which would invalidate calibration.

LIVE TESTING

The company has established procedures to control the electrical hazards present within test areas.

These controls include:

l Documented work instructions, use of suitable equipment and compliance with procedures.

l Exclusion of non-competent production personnel during testing.

l Products designed to minimise the risk of injury through electric shock.

OP108 - NONCONFORMANCE CONTROL


The company has established procedures to ensure that product which is non-conforming is prevented from use or installation.

Non-conformity Review and Disposition

The responsibility for the review and disposition of non-conforming product is assigned to specific personnel.

Non-conforming product is reviewed in accordance with the documented procedures and may be:

l Re-worked to meet the specified requirements.

l Accepted as is.

l Re-graded for alternative applications.

l Rejected or scrapped.

Where specified in the order, the customer's authority is obtained for the use or repair of non-conforming product.

Product, which has been repaired and re-worked, is re-inspected.

OP109 - CORRECTIVE AND PREVENTATIVE ACTION


The company has established procedures for corrective and preventative action which include the following:

Investigating the cause of repetitive non-conforming product and the necessary corrective action to prevent recurrence.

Analysis of processes and work operations, records, concessions, service reports and customer complaints, to detect and eliminate potential causes of non-conforming product.

Investigating the cause of injuries, diseases or dangerous occurrences and the necessary corrective action to prevent occurrence.

Analysis of processes and work operations and records to detect and eliminate potential causes of injury.

l Initiating preventative actions.

l Implementing changes to procedures resulting from corrective action.

l Systematic problems identified via system audits.

l Verification those corrective and preventive actions are effective.

OP110 - MANAGEMENT REVIEW


Management conduct reviews of the total Integrated Management System, on an on-going basis.

Elements that are included in the review are:

l Management objectives, assignment, delegations and methods to ensure they are achieving the required results.

l System failures identified by audits.

l System improvements recommendations.

l Verification that the corrective and preventive action system is effective.

l Quality, Health & Safety, and Environmental audits and evaluation of compliance with legal and other requirements.

l Communication(s) with external interested parties, including complaints.

l Training requirements.

l Integrated Management system development.

OP111 - AUDITS


Internal audits are conducted to verify whether company activities comply with planned arrangements and to determine the effectiveness of the Integrated Management System.

Audits are scheduled on the basis of the status and importance of the activity. Audits and follow-up actions are carried out in accordance with the documented procedures.

The results of the audits and any corrective actions are recorded and the appropriate personnel notified in order that timely corrective action is implemented.

OP112 - IMS RECORDS


The company has established procedures for the identification, collection, indexing, filing, storage, maintenance and disposition of IMS records.

IMS records, including pertinent sub-contractor records, are maintained to demonstrate the achievement of the required standards and the effective operation of the IMS.

All records are stored to enable their ready retrieval. The retention periods for records are documented in the application procedures.

Where specified in the order, these records are made available to the purchaser.

OP113 - DOCUMENT CONTROL


Document Approval and Issue

All documents and data relating to the requirements of the Integrated Management System are controlled. Prior to their issue they are reviewed and approved by authorised personnel. These controls ensure that:

The correct revisions of necessary documents are available where required.

Obsolete documents are not available for use.

Document Changes/Modifications

Changes or modifications to documents are reviewed and approved by authorized personnel. The revision status is recorded on each document.

After a practical number of revisions have been made the document is re-issued.

OP114 - TRAINING


The company has established procedures for the identification, provision and effectiveness of training for all personnel performing activities affecting the Quality, Health & safety, and environmental aspects of the company.

Personnel are trained in the Integrated Management System requirements. Records of training are maintained.

OP115 - RISK ASSESSMENT AND CONTROL


The company has established procedures for risk assessment, which include the following:

l Assessment of hazards.

l Identification of personnel at risk.

l Evaluation of risks arising from the hazards.

l Controls designed to eliminate or reduce the hazard.

l Records of risk assessment are maintained.

l Assessments are regularly reviewed.

OP116 - ENVIRONMENTAL ASPECTS


The company has established procedures for the identification of the environmental aspects of its activities, products and services which it controls and over which it may be expected to have an influence.

Environmental aspects are reviewed at least every two years or when there is a new or changed process or activity.

OP117 - LEGAL AND OTHER REQUIREMENTS


The company has established procedures for the purpose of identifying, accessing and communicating legal and other requirements that are applicable to its activities.

The legal and other requirements that apply to the company are a combination of European Directives, government statutes, regulations, as well as internal TCS policies.

The most current european, national and local legal and other requirements are reviewed at least annually.

OP118 - COMMUNICATION


The company has established and maintain a procedure for internal and external communications regarding environmental aspects and the Integrated Management System.

OP119 - EMERGENCY PREPAREDNESS AND RESPONSE


The company has a procedure to identify potential for, and respond to, accidents and emergency situations, and for preventing and mitigating the environmental impacts that may be associated with them. Emergency methods are reviewed on an annual basis and after the occurrence of accidents or emergency situations.

OP120 Evaluation of Compliance


The company has a procedure for evaluating compliance with relevant environmental legislation and regulations (legal requirements) associated with its operations as defined by section 4.5.2.1 of the EN ISO 14001 International Standard.

The results of the evaluation and any corrective actions are recorded and the appropriate personnel notified in order that timely corrective action is implemented.

Documents

IMS Manual (1)