Srwf Quality Manual

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S UDI ROCKWOOL F CTORY Co

J I

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QU LITY M NU L

Sau di RO Kw oo l

ISO 9001:2008 Clause: 4.2.2

I Document No.: QMM

SCOPE

Manufacturing Marketing Sales

After Sales services of Rockwool Thermal

Acoustical

insulation materials for residential industrial purpose .

The scope extends to all Company personnel in terms of their individual and corporate responsibilities for

Quality. This QMS Manual describes and dictates the quality system used by SAUDI ROCKWOOL and is

modeled after the ISO 9001 :2008 standard. Due to the nature of production, testing and service provided in

this quality system, exception to [section 7.3 pertains to 'Design and Development', 7.5.2 pertains to

'Validation of processes for production and service provision' and section 7.5.4 which pertains to 'Customer

Property'J is being taken.

PURPOSE ADMINISTRATION OF TH E QUALITY MANUAL.

The Purpose of this Quality Manual is to formally establish the foundation upon which the Quality

Management System operated by our Company is documented and implemented.

Based Upon the requirements of ISO 9001:2008, this Quality Manual defines the Organizational structure of

SAUDI ROCKWOOL, together with Policies and Objectives for Quality that under proper operational

management:

.:. Aim to enhance customer satisfaction .

:. Assure consistent conformance to product and service standards .


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SAUDI ROCKWOOL FACTORY Co.

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QUALITY MANUAL

S audi Rockwool

ISO 9001 :2008

Clause: 4.2.2

I Document No.: QMM

COMPANY PROFILE

SAUDI ROCKWOOL

was established in year 1412-Hijri corresponding to

(1992-G) as

specialized in

the production of the Rockwool (Thermal, Acoustical and Fire Resistant Insulation).

SAUDI ROCKWOOL' s manufacturing unit is situated in d Industrial Area, P.O.Box: 145, Riyadh:

11383, Kingdom of Saudi Arabia.

SAUDI ROCKWOOL has installed up to date machinery and test equipment from the leading

manufacturers in hermal coustical Industry.

The very quick success of SAUDI ROCKWOOL has experienced mainly due to its commitment to

excellence, quality and best customer service. SAUDI ROCKWOOL' s policy of offering the highest

possible standards guarantee, that all material chosen for their high quality, durability, and competent

in the world market.

SAUDI

ROCKWOOL offers high-grade products under Commercial Registration No. 10100972741001

and using wealth of knowledge from highly qualified engineers and well skilled workers and

professionals.

SAUDI

ROCKWOOL not only take pride in the Quality of their Products but in the ability

to respond quickly to customer requirements.

SAUDI

ROCKWOOL is small enough to be flexible and

large enough to meet the demands of the market.

We have illustrious and prompt position in Kingdom Ministries as reliable Manufacturer since 14 years

of active experience, such as in Saudi ARAMCO, SABIC, KNPC, Petrochemical Ind. Co.-Kuwait etc.

also in all over Saudi Arabia Kingdom and in Local Market. The availability of locally based

experienced application engineering and design are outfitted by very Experience Engineers which can

handle more comfortably as well as part of our job.

The Mission of our company in continued business expansion, is striving always to improve upon


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QUALITY MANUAL

Saudi ROCKwool

ISO 9001:2008 Clause: 4.2.2

I Document No.: QMM

MANAGEMENT COMMITMENT

Our Management Team is committed to:

Maintain a high Profile in leading the Quality Awareness Strategy to assure compliance with

requirements and continually improve the effectiveness of the Quality Management System operated.

An ongoing strategy of Continuous Improvement striving always to better previous performance in

terms of operational practice and Quality in it's broadest sense.

Establishing measurable Objectives at appropriate levels and functions of the organization, whereby

performance in the achievement of defined goals may be monitored and continually updated as

targets are met, in line with the Ongoing Improvement Strategy.

Encouraging participation and support for the implementation of this Policy through Training,

Empowerment and Delegation, operating a formal Quality Management System meeting the

requirements of ISO 9001:2008.

Building long term relation ship with our customers and suppliers based upon mutual trust and

respect, actively liaison with them to enable us to Plan in advance the technology and processes that

will assure that products are produced consistently correct to specification, within the agreed time

scale, at an optimum cost.

As a General Manager I accept my fundamental responsibility for the Quality of Products and

Services provided to our customers. I will discharge my responsibility through my management team

who will, by direction and example, ensure that this policy is understood, accepted, implemented and

maintained throughout our organization.


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QUALITY MANUAL

Saudi ROCKW D OI

ISO 9001:2008 Clause: 4.2.2

I Document No.: QMM

1. SCOPE

QUALITY MANAGEMENT SYSTEMS IS09001 :2000 - REQUIREMENTS

The scope of SAUDI ROCKWOOL' s Quality Management System under the framework of ISO

9001:2008 (E) standard is defined as:

Manufacturing, Marketing, Sales

After Sales services of Rockwool Thermal

Acoustical

insulation materials for residential

&

industrial purpose

fl

This Quality Manual clearly specifies the scope related to SAUDI ROCKWOOL's Manufacturing

Thermal

Acoustical insulation materials

in the Kingdom of Saudi Arabia. This is the first level

document, which outlines the Quality Management System of the company and shows how, the

requirements of ISO 9001:2008(E) standard are met through effective implementation of the system.

The ultimate goal is to enhance the customer satisfaction through the effective control and

implementation of the system through timely measures for continuous improvement. The system

assures the conformity to customer requirements and to the applicable regulatory and legal codes.

1.1. Application:

In this Quality Manual Design

&

Development - 7.3 and the Customer Property - 7.5.4 and Validation

of Processes for production and service provision - 7.5.2 have been excluded in consideration to the

nature of business.

2. NORMATIVE REFERENCE


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QUALITY MANUAL

Saudi RockwD OI

ISO 9001:2008 Clause: 4.2.2

I Document No.: QMM

4.1 General:

SAUDI ROCKWOOL is to establish, document, implement and maintain a quality management system

and Continually Improve its effectiveness.

This will be achieved by:

Identifying the processes needed and their application in the organization.

Determining the sequence and interaction of these processes.

Documenting responsibilities and control applied to ensure effective operation

and control.

Ensuring the availability of resources and information necessary to support the

operation and monitoring of these processes.

Monitoring, Measuring and Analyzing the outputs of all business processes,

re-qualifying the processes where necessary to achieve the planned results or

to continually improve and add value to the processes.

4.2. DOCUMENTATION REQUIREMENTS:

4.2.1 General:

The Quality Management System documentation will include:


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Saudi R O C I < W D D I

ISO 9001:2008

Clause: 4.2.2

I

Document No.: QMM

4.2.4 Control of Quality Records.

A formal procedure QAP 02 will direct the

Generation Reporting

Indexing Filing

Collection

Security

And maintenance of all records generated by the Quality Management System.

The Record in hard copy or electronically processed will demonstrate the effectiveness of the

Quality System operated and that all contracted product standards have been achieved. The

records will be maintained for defined periods established by our company, or as consistent

with contract requirements or prevailing legislation.

Records will be subject to systematic review and analysis as an integral part of the

company's Internal Audit Plan and Management Review Process to identify any apparent

trends. It also proves the effectiveness of their application and identifies opportunities for

improvement.

The disposal of records at the end of their retention period will be carried out under controlled

conditions designed to protect the status of any confidential or exclusive information.

By this means SAUDI ROCKWOOL will ensure that at all times, records remain legible,

identifiable and retrievable.

Reference Documents:


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QUALITY MANUAL

Saudi R O C K W D Il I

ISO 9001 :2008

Clause: 4.2.2

I Document No.: QMM

5.2 Quality Policy.

Quality Policy has been defined on page No.4 of this manual. Quality policy, approved by the

General Manager and have published it in strategic locations throughout the organization as an

integral element of the company's Quality Awareness Program and will be reviewed as an integral

part of Company's Management Review meetings to assure its integrity and suitability in the light of

customer response and current business strategy.

5.4 Planning.

5.4.1 Quality Objectives

SAUDI ROCKWOOl Quantifiable Quality Objectives, including those required to realize

product standards will be established at all relevant functions and levels of the organization.

The corporate Quality Objectives are to:

Department

Responsibility

bjectives

Production

> - Reduce oxygen consumption to

Cupola furnace

> - Cupola line production yield

> - Coke consumption/ton of finished

product

> - Cupola line product weight

variation

Production Manager, Shift

Supervisor, Furnace

Operators, Control Room

Operator, Rock Charger,

Superintendent.

Time Monitoring Present

Span. Tools Status

Maintenance

Percentage of breakdown time per

running Hr monthly:

> -

New line to be max. 2

Maintenance Manager

Mech. Maintenance Eng.

Elec. Maintenance Eng.


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QUALITY MANUAL

SaudiROCKW D O I

ISO 9001 :2008 Clause: 4.2.2

I Document No.:

QMM

5.5.2 ManagementRepresentative

Top management has appointed a member of management, who irrespective of other

responsibilities shall have responsibility and authority that includes:

Ensuring processes needed for the quality system are established, implemented and

maintained.

Reporting the performance of the quality system and improvement needs to top

management.

Ensuring the promotion of awareness of customer requirements throughout the

organ ization.

5.5.3 Internal Communication.

Management will ensure that appropriate channels of communications are established to

clearly define responsibilities and authorities, ensure the understanding of customer or

statutory

1

regulatory requirements and to report upon and demonstrate the effectiveness of

the Quality Management System in Operation.

5.6 ManagementReview.

5.6.1 General.

At determined intervals SAUDI ROCKWOOL Management will conduct formal Management

Review Meetings, chaired by the General Manager and organized by MR to establish the

ongoing effectiveness of the Quality System in terms of Customer Satisfaction, the

achievement of objectives and as a focus for Continuous Improvement.


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QUALITY MANUAL

Saudi ROCKW D O I

ISO 9001:2008 Clause: 4.2.2

I Document No.: QMM

M a n ag e m en t R e vie w m e e tin g r ep ort

M a n a g em e nt R e vie w

O r g a n iz a ti on S t ru c tu r e

Ob jec t i ves as a Con t in u o u s Imp ro v eme n t

Qu a l it y P o l ic y

F M M R .01 Q ua lity R eco rd

Q A P .06 Q ua lity A ssu ra nce P ro ced ure .

A p pe n dix A -01

FMQM 0 1

Pa g e :0 3

of

th is Q u a lity S y ste m M a n ua l.

6. RESOURCEMANAGEMENT

6.1 Provision of Resources.

The SAUDI ROCKWOOL as an Organization at all times will be adequately resourced in terms

of equipment, raw materials, work areas, and trained personnel to enable all functions to

operate effectively in terms of:

Managing, performing and verifying the effectiveness of all business activities.

Implementing and maintaining the Quality Management System and continually

Improving its effectiveness.

Enhancing Customer Satisfaction.

6.2 Human Resources.


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QUALITY MANUAL

Saudi ROCKW D O I

ISO 9001 :2008

Clause: 4.2.2

I

Document No.:

QMM

their personal performance every year. If any employee found incompatible, training

will be provided accordingly to fulfill our quality needs.


Tra in i ng, Compe t e n c y

&

Admin i s t ra t i on

N e w Em p lo ye e T ra in in g R e qu es t

Em p lo y e e T ra in in g R e q u es t .

Em p lo y e e T ra in in g R e c o rd

PersonnelFollowingup

&

EvaluationRegister

SOP

04

FM . TR .01

FM . TR .. 0 2

FM . TR . 0 3

FM .TR .04

S y s te m Op e ra tin g P r oc e du re

Qu a l it y Re c o r d




6.3 Infrastructure 6.4 Work Environment

As an integral part of planning for the Product Realization, the infrastructure and work

environment to achieve conformance to product requirements will be planned, implemented

and maintained. Machines and supporting equipment were maintained as per schedule and

closely watch the breakdown time as well as cost of the maintenance.

The machine maintenance have been controlled by proper planning and scheduling as per

the System Operating Procedure SOP 05.


E q u ipm e n t M a in te n a nc e

M a c hin e M a in t R e qu es t

P re ve n tive M a in t w o rk o rd er

E q u ipm e n t d e ta il r ep o rt

O u t s id e M a i nt en a n ce /F a b ric a tio n R e q u es t

New I n st a lle d ma c h i n e/ e qu ipme n t

E m e rg en c y S to p R e qu e st

S p are p art s R e -o rd e r le ve l

SOP 05

FM .M T 0 1

FM .M T 0 2

FM .M T 0 3

FM .M T 0 4

FM .M T 0 5

FM .M T 0 6

FM .M T 0 7

S y ste m O p er at in g P ro ce d ur e









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QUALITY MANUAL

Saudi RO CKwool

ISO 9001 :2008 Clause: 4.2.2

I

Document No.: QMM


R e c eive d M a te ria l In s pe c tio n R epor t

S to c k L e dg e r

D a il y P r o du c tio n P lan

P r oduc ti o n O rd er

I n te r n a l T r a n sf e r of S t or ed p ro d uc ts

R e p ro c e s si ng O r d er

D a il y L is t of P r o d uc t ion

Process C o n tro l F lo w C h a rt

Wo r k I n s tr uc t ions

7.2 Customer Related Processes.

FMST 0 1

FMST 03

FM PR .0 1

FM PR .0 3 -

04

Qu a li ty R e co rd

Q u a l it y R e co rd

Q u a li ty R e c ord

Q u a l it y R e co rd

FM PR .0 5

FM PR .0 6 - 08

P FG .0 1 - 0 3

W I.P R .0 1 - 1 3

Q u a l it y R e c o rd

Q u a l it y R e c o rd

Process Cha r ts

7.2.1 Determination of Requirements Related to the Product.

SAUDI ROCKWOOL will determine and document the customer's requirement as an

integral part of customer's contract for Sales. It shall be regularly monitored through

visits and meetings. Customer's complaints shall be forwarded to SAUDI

ROCKWOOL through Tel, emails, Fax or visits.

Customer's requirements including delivery and post delivery activities where

applicable.

Product specifications, Standards and user Instructions as applicable.

Reference to any regulatory requirements.

Statutory or legal requirements not stated by the customer but necessary for

specified or intended and safe use, where known.

Any additional requirement will be determined by the Organization.

7.2.2 Review of Requirements Related to the Product.


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QU LITY M NU L

S audi R OC Kw oot

ISO 9001 :2008

Clause: 4.2.2

I

Document No.:

QMM

By this means SAUDI ROCKWOOL will ensure that all Technical, Commercial, Legal

and Quality conditions of the contract are fully understood and acceptable to both the

customer and SAUDI ROCKWOOL prior to completing the contract, and that our

company has the ability of meeting all contract conditions, Right First Time.


Qu o ta tio n C o n tr ac t R e vie w

Quo ta t i on / C o n tr ac t R e v ie w F o rm (Am e n dm e n t)

S a le s O rd e r

S a le s P r od u ct io n R e q u es t

Q u a rt ely S a le s F o rc a st

C u s to m e r C o n tr ac t R e vie w P r oc e ss

F a st M o vin g S ta nd ar d P ro d uc t L is t

P r ic e L is t

7.2.3 Customer Communication.

FMSA 0 1

FMSA0 1 - a

FMSA 0 2

FMSA 0 3

FMSA 0 4

P FG .S AC U 1 .1

Append i x

SA01

Append i x

S A 02

SAUDI ROCKWOOL will be pro-active communicating with customers. Organization

has been equipped with best Intercom Telephone system to access all department

easily by the customers.

SAUDI ROCKWOOL used to communicate with the customers in particular in relation

to:

The provision of product information.

Handling Customer orders and inquiries .

Dealing proficiently in the event of customer complaints and customer's

feedback or any queries from customers ..

7.3 Design and Development.


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Saudi R O C Kw ool

ISO 9001:2008 Clause: 4.2.2

I Document No.:

QMM


Purchas i ng

Supp li e r E va lu a t io n

P u rc h as e O rd e r

N ew - S u p plie r A s s e ssm e n t

Re-Eva l ua t i on of Supp l ie r

A p pr ove d S u pp lie r L is t (A S L )

P u rc h as e R e q ue s t

Q u o t at io n R e q u e st

Q u o te A n a ly sis R e p or t

S am p le A p pr ova l F o rm

Purchase

P u r ch a s e P r o du c t I ns p ec tio n

N ew S up plie r E v alu a tio n Re-Eva l ua t i on of

Ex is ti n g Supp li e rs

P u r ch a s e P r o ce s s

7.4.2 Purchasing Information.

SOP 08

FMPU01

FMPU02

FMPU03

FMPU04

FMPU05

FMPU06

FMPU07

FMPU08

PFCPU02

PFC .P U0 3

P FCPU01

S y s tem Op e ra tin g P r o ce d u re

Qu a l it y R e c o rd








F lo w C h art

F lo w C h art

F lo w C h art

All purchase orders or contracts placed with the suppliers will contain a clear

description of the requirements and will cross-reference any specifications, certificate

or other standards to be applied. Any changes to the procurement document require

the same degree of control as the original issue.

7.4.3 Verification of Purchased Product.

Purchased products will be inspected upon receipt into the company to the degree

necessary to assure conformance to specified purchase requirements. Concerned

Inspectors shall sign on the Receipt Voucher of that material.


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QUALITY MANUAL

S audi ROCK woot

ISO 9001 :2008

Clause: 4.2.2

I Document No.:

QMM

The availability of Work Instructions and System Operating Procedures.

The use of suitable equipment.

The availability and use of monitoring and measuring devices.

The implementation of monitoring and measuring and

The implementation of release, delivery and post delivery activities.


P r oc es s C o nt ro l C har t

Da ily P rod uc tio n P lan

R e ce ive d M a te r ia l In spec t io n R e po rt

Quality C ontrol

Pro ce ss C on trol

PF C .PR .0 1 -0 3

F M .PR .0 1

F M .S T .0 1

S OP.0 2

S OP.0 1

7.5.2 Validation of Process for Production

ServiceProvision.

SAUDI ROCKWOOL undertakes no Validation of Process for Production & Service

Provision. It is not in the scope of SAUDI ROCKWOOL' s Quality Management

System.

7.5.3 Identification andTraceability.

Each Material like Raw Material 1 Spare Parts 1 Finished or Semi Finished Products

and allocated areas shall be identified, upon receipt and through out the process to

determine the material status. Monitoring and Measuring results shall be recorded.


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Sau d i RO K wo o l

ISO 9001 :2008 Clause: 4.2.2

I Document No.:

QMM

7.5.5 Preservation of Products.

Documented Storage, Handling, Delivery & Preservation procedure SOP.O? and a

strategy of Safety and Handling practice assures that

SAUDI

ROCKWOOL employ

due diligence to good engineering practice in terms of:

Safety material handling for both the Material and the Handler .

The operation of equipment and machinery.

Any hazards associated to the handling of substances Hazardous to Health.

Al l Raw Material and Finished goods storage area will be effectively managed to the

degree necessary in terms of security, identification and the preservation of material

and products in the storage area.

All stock movements into or out of storage area will be subject to the principles of

stock rotation in First In First Out (FIFO) basis.


Con t ro l

of

N o n - C o n fo rm i ng M a te ria l/ P r o du c t

Pu rchas i ng

Supp li e r E va lu a t io n

S t o res

S ale s O rd er

R e c eive d M a te ria l In s pe c tio n R e p or t

7.6 Control of Monitoring Measuring Devices.

QAP 0 3

SO P 08

SOP . 07

FMS A .02

FMS r 0 1

Q .

A s s u ra n c e P r o ce d u re .

S

Op e ra tin g P r o ce d u r e

S Op e ra tin g P r o ce d u r e


Qu a l it y R e c o rd .

All Monitoring and Measuring Devices invovled in the assurance of product quality will be


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QUALITY MANUAL

Sau d i RO K Woo l

ISO 9001:2008 Clause: 4.2.2

I

Document No.:

QMM

The SAUDI ROCKWOOL will plan and implement the monitoring, measurement, analysis and

improvement processes needed to:

Demonstrate conformity of Products.

Ensure conformity of the Quality Management System.

Continually improve the effectiveness of Quality Management System.

8.2 Monitoring Measurement.

8.2.1 Customer Satisfaction.

SAUDI ROCKWOOL will be pro-active in determining to degree to which the products

and services provided to customers continue to meet or exceed their expectations of

Quality.

This will be achieved through planned visit to key accounts and statistically designed

questionnaire survey will be provided to identify the strength and weaknesses of

SAUDI ROCKWOOL and direct the improvement process. Continuous Improvement

will be done by using latest technology and highly skilled man power.


N o n C o n fo rm i ng M a t er ia l R e p o rt/P o te n tia l P r ob le m FMNC .0 1

Cor rec t ive P re ve n tive A c tio n Q A P 05

C u s tom e r S a tis fa c tio n S u rve y FM C C .0 1

Cor rec t ive & P r e ve n tiv e A c t io n R e g is t er. FM C P o01

C u s t ome r C omp l a in t S a tis fa c t io n S u rve y SOP .

10

Qu a lit y R e c o r d

Q u a lit y A s s u ra n c e P r o c ed u r e

Q u a lit y R e c o r d.

Q u a lit y R e c o r d

S y s tem Ope ra t in g P r o c ed u r e


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QUALITY MANUAL

Saudi Rockwoo l

ISO 9001 :2008

Clause: 4.2.2

I Document No.:

QMM

The results of Internal Audits will be recorded, maintained and subject to further

review as an integral part of Management Review Meeting, thus assuring the

effectiveness of the Audit program in achieving desired goals.


I n te r n a l Au d i t

Aud i t S chedu l e

In te rna l A u d it C h e c klis t

N o nco n fo rm a n ce R e po rt/Correct ive

Act ion R eque s t (N C R IC AR )

In te rna l A ud it R epo rt

C AR Sta tu s L og

Q A P 0 4

FM /A01

FM IA 02 .

FM IA 03

FM IA 0 4

FM IA 05

8.2.3 Monitoring Measurementof Processes.

Qu a lit y A s s u ra n c e P r o ce d u re .

Q ua l it y Re co r d .

Q u a lit y R e c o rd

Q ua lit y R e c o rd

Q ua lit y R eco rd .

Q ua lity R eco rd .

The SAUDI ROCKWOOL use suitable methods for monitoring where applicable, the

measurement of quality management system processes.

These methods demonstrating the ability of processes to achieve planned results.

When planned results are not achieved, Correction and Corrective Actions shall be

taken as appropriate, to ensure the Conformity of the Product.


P ro c es s C o n tro l F low Cha r t

Q u a lit y C o n tr ol P r o ce d u re

P FC .P R . 01 -03

SOP .02


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QUALITY MANUAL

Saudi Rockwool

ISO 9001:2008

Clause: 4.2.2

I Document No.: QMM

Preventing inadvertent use or installation of product is accomplished through the use of

QAP.05 Quality assurance Procedure for Control of Non Conforming Products. All non

conforming material or products identified at any stage of processing will be subject to formal

procedures that will provide for their Prominent identification and Segregation where

applicable into Quarantine areas.

Recording, reporting and review of these Non Conformances.

Assignment of actions required for the disposition of the Non Conforming Products.

Assignment of actions required upon In-process or already Dispatched to the

customers.

As an integral part of the review of any reported non-conforming products, effort to

established the cause of the non conformance and actions required to prevent from

Recurrence of similar non conformance, will be paramount.

The proposed supply of any product not totally in conformance to contracted specifications,

will be formally reported to the customer to get the necessary approval.

In the event that assigned actions involve re-process / repairthe DGM Technical, Q.C

Manager along with M.R will decide and assure the effectiveness of such actions.

All records associated to the control of Non Conforming Products will be subjected to review

and analysis at Management Review Meetings in order to identify any significant trends or

failure modes warranting corrective and preventive action.



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QUALITY MANUAL

Saudi ROCKW D OI

ISO 9001 :2008

Clause: 4.2.2

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Document No.: QMM

Effects Analysis. The records generated forming an integral part of ongoing

Improvement Process.


C o rrec t ive

P re vent ive A ct ion

In te rn a l A ud it

Q AP 05

Q AP 04

Q ua lity A s su ra n ce P r oc e du re .

Q ua li ty A ssu ra n ce P r oc e du re .


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SAUDI ROCKWOOL FACTORY CO.

ORGANIZATION STRUCTURE

PUR UREMENT

M N GER

HUM N

RESOUR E

CEO GIG

GENERAL MANAGER

S LES

M N GER

M RKETI NG

M N GER

OPER TI ON

M N GER

ec

Support Manager t

Issue: 2/1

Issued by: _~ ~

APPENDIX:A-Ol

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