INTRODUCTION
1.1 The
Directorate of Quality Assurance (Naval), has been set
up as part of the Directorate General of Quality Assurance under the Ministry
of Defence (Department of Supplies).
1.2 The Directorate of Quality Assurance (Naval)
is responsible for myriad QA related functions in respect of equipment and stores
that are procured by the different procurement divisions of the Government for
the Indian Navy and Indian Coast Guard
History of DQA (N)
2.1 At the
time of
2.2 The
Ordnance Factories (OFs), established during British Rule in India that worked
to full capacity in the period of the World Wars, were left with spare
manufacturing base in the post independence period. With the aim of utilizing
this surplus capacity it was decided to indigenously manufacture Naval items/stores to support the IN Ships. Accordingly a small Technical Cell was
constituted in 1953 in
2.3 The various stages of transformation that
the organization went through are pictorially represented below.
DQA(N) DQA(WP) ARMY NAVY
COMMON
ORGANISATION
CHAPTER - IV
ROLE & FUNCTIONS OF DQA(N)
4.1 The
Directorate of Quality Assurance (Naval), is directly responsible
to the Directorate General of Quality Assurance (DGQA) for its role and
functions. The primary functions of the DQA(N) are:-
(a) Render Quality Assurance cover for equipment/spares for the Naval electrical/electronic equipment and Naval Stores procured
by various organizations of the Indian Navy (IN) and Indian Coast Guard (ICG).
(b) Custodian of all data and information of all Naval Stores and
Naval Electrical / Electronic equipment being designated Authority Holding
Sealed Particulars (AHSP).
(c) Vendor Assessment and consequent Vendor Registration for Naval
equipment and stores. The DQA(N) also carries out
vendor capability assessment on case to case basis for procurement of special
equipment for the IN.
QA ACTIVITIES OF DQA(N)
5.1 QA
activities encompass all planned and systematic actions necessary to provide
adequate confidence that a product or service will satisfy the customer of the
given requirements for Quality. It
includes all QC (Quality Control) action, which are operational techniques and
activities that are used to fulfill requirements for the quality.
5.2 As
mentioned earlier DQA(N) {Dte of Quality Assurance
(Naval)} is responsible for Quality
Assurance of all Naval Electronic/Electrical/Weapon equipment and their spares,
and also for general Naval Stores of
patternised nature , which are used on board IN ships, submarines and Coast
Guard ships.
5.3 The
aim of Quality Assurance is to provide evidence and establish confidence about
the quality of product.
5.4 QA
function starts from design stage, selection of suitable vendor, Quality of raw
material, manufacturing processes, QA checks/tests etc. If the specifications
are correctly laid down and QA activities performed as per specification, no
store is likely to fail in its performance.
5.5 Quality
Assurance activities are undertaken by DQAN on stores materialising from Pvt.
Trade and Public Sector Undertakings through various Quality Assurance
Establishments (QAE) set up throughout the country. Each QAE has a zonal jurisdiction as well as
a specialised field. The DQA(N) is the QA Authority
and the regional/specialist QAEs are the QA Agency for each of the Purchase
Orders.
5.6 As Naval
stores and equipment include a variety of multi-technology and multi-disciplinary
items, their QA procedures are specific to the product. However this website only highlights the
general procedure, which is applicable to most of the products.
5.7 The
basic tenet pertains to the fact that quality of the product is the
responsibility of manufacturer. The QA organisation only guides and monitors
and assures Quality of the product.
5.8 In fact
the role of QA organisation starts from identification of suitable
manufacturers having proper infrastructure, Quality Control facilities and
resources etc. This is achieved through capacity assessment/Vendor
Registration.
5.9 Once a
Supply Order is placed on a manufacturer, the same is to be scrutinised by the
QA agency. The governing specifications/paper particulars mentioned in the
contract become the base line for QA activities.
5.10 The
Manufacturer submits his Quality Assurance Plan (QAP)/Drawing and Acceptance
Test Procedure (ATP) in consultation with QA agency to DQAN HQ for approval.
5.11 Incoming
raw material is checked for conformity as Inwards Goods Inspection (IGI) by
manufacturer and records maintained. The QA agency has full access to any or
critical material/record for verification. A few important checkpoints are
marked as CHP (Customer Hold Points). Manufacturer can proceed further only
after clearance on these points by the QA agency.
5.12 The QA
agency is involved during production processes particularly at critical stages
known as stage inspection.
5.13 After
final assembly/production, the manufacturer carries out pre-inspection of
stores and submits the same to QA agency along with a call letter.
5.14 Manufacturer
is expected to provide all test facilities. In case some of the facility is not
available in their premises, the tests are performed in DGQA labs or any other
Govt. approved lab and testing charges are borne by the manufacturer.
5.15 In case
of some purchase orders, provision of supplying pilot samples and according
clearance of bulk production by QA agency is stipulated. In such cases QA activity can be divided into
two parts.
(a) QA on Pilot Samples (PS)
(b) QA on Bulk Supply
5.16 PS is
subjected to all tests as mentioned in approved ATP. Tests vary from product to
product. However, in general, visual examination, dimensional checks, weight
measurement, physical checks etc are some of the common checks while
functional/performance checks, safety checks, environmental checks and
durability checks vary.
5.17 PS if
found satisfactory during testing is subjected to user’s trials suggestions of
users are incorporated and a Bulk Production Clearance (BPC) is accorded.
5.18 Manufacturer
starts bulk production and QA agency reserves the right of stage inspection.
5.19 QA
activity on bulk supply is carried out on pre-determined sampling basis
(depending upon type & nature of stores). A few routine tests are carried
out on 100% and other acceptance tests are carried out on random sampling
basis.
5.20 Destructive
tests/environmental tests are carried out on one sample or a pre-decided Qty,
which is generally at 1% of lot offered.
5.21 Test
results are critically scrutinised. Cross-confirmatory and surprise/vigilance
checks are carried out before sentencing the lot for acceptance/rejection
5.22 Accepted
stores are then marked with Acceptance mark and I/Notes are issued Quality of
packing material/packing is checked.
5.23 In case
of any occurrence of a defect, the QA Estt. undertake
defect investigation and find remedial measures.
5.24 Quality
audit/Quality surveillance checks are carried on the manufacturer’s records/processes,
where self certification status has been granted.
5.25 On
imported stores, no QA checks are performed except identification of products based on
documents and visual checks for transit damage (if any).
5.26 Item
developed for first time and cleared after successful QA checks are codified by
Dte of Standardisation by allotting DS Cat No. to Item/component. DS Cat Nos. are also reflected in hand books of items. The item can be
demanded by the users based on DS Cat Nos allotted from Material Organisation
.
30 Steps in Quality
Assurance followed by DQA(N) for indigenous items
5.27 Quality
Assurance is a highly responsible job to ensure that only quality products are
produced through control on raw material and processes and non-conformed product
does not reach to the users. The 30
steps followed by DQA(N) are as follows :-
1. Ensure that contract is placed on a DGQA registered firm.
2. Scrutinise and review the contract to ascertain that
specifications and other documents are properly defined.
3. Understand the QR/specification/drawing and other paper
particulars governing contract.
4. Keeps a watch on the critical raw material/components/sub-assy
/assy being procured by contractor from suppliers.
5. Draw samples for material testing and send to approved lab (duly
sealed) for testing.
6. If required, visit supplier to verify the
process/infrastructure.
7. Provide guidance/assistance to contractor during production/hold
ups.
8. Verify production processes of contractor and assure stage
checks.
9. Assist contractor to formulate QAP/ATP/drawings of product and
approval at Dte level.
10. Study and understand QAP/ATP.
11. Study the call letter (Challan) submitted by contractor.
12. Critically study the pre-inspection report of contractor.
13. Check validity of delivery period.
14. Ensure availability of test and measuring equipment with regard
to accuracy and precision required.
15. Where test facility is not available, arrange testing in
Defence/Govt. approved lab at contractors cost.
16. Check calibration status of test and measuring equipment, before
undertaking QA activity.
17. Perform/witness all tests as per governing specification/QAP
& ATP on pilot samples (PS) and bulk supply and prepare test reports.
18. Compare test results with pre-inspection report.
19. PS if found acceptable to be subjected to F/F tests and detailed
environmental tests (i.e. climate and durability)
20. Accord Bulk Production Clearance on successful trials of PS.
21. Study and apply sampling plan during bulk QA checks.
22. Safeguard against willful mixing of rejected/un-inspected stores.
23. HOE to study test report and perform vigilance check before
giving a ruling on acceptance/rejection.
24. Mark the accepted stores with acceptance mark.
25. Deface/destroy rejected stores.
26. Obtain guarantee certificate as per contract and issue I-Notes.
27. Check quality of packing material/Quality of packing.
28. Analyse the defect (if any), observed by consignee/users.
29. Find out remedial measure in consultation with contractor.
30. Intimate procurement agency of major issues (rejections &
defects observed).
5.28 Quality Audit and Surveillance DQA(N) carries out “Quality
Audit/surveillance checks” only in respect of
following cases :-
(a)
Self Certification granted for the product.
(b)
Shipyard Inspection items, where QA cover is provided by Shipyard
/Third Party. This is based on revised procedure mentioned in para 1.11 above.
(c)
Ordnance Factory supplied items. This is based on revised MoD policy
mentioned at para 1.9 above.
5.29 Acceptance
procedure for imported items. No
QA checks performed on imported stores except for identification of stores
based on their documents and visual checks for transit damage (if any). The
lists of documents to be checked are as follows:
(a)
Bill of lading
(b) Country of origin
(c) Shipping bills
(d) Bill of entry for
warehouse.
(e) Original manufacturer’s
test certificate/QA/Guarantee Certificate.
(f) PAC/firm’s confirmation
certificate.
(g) Firm’s guarantee certificate
as per S.O.
5.30 Standards and Specification used. The various specifications referred for
preparation of QAP/ATP are as follows :-
(a) Ministry of Defence publications like Joint Services Specifications, Joint Service Guidelines etc.
(b)
Bureau of Indian Specifications
(c)
British Specifications.
(d)
GOST
(e)
MIL Standards
(f)
DEF Standards
(g)
Naval Engg. Specifications NES
(h)
Naval Constructor’s Documents NCD
(i)
ASTM
(j)
JSS 55555
(k)
DQA(N) document of 2006 on ESS
5.31 A brief write up on
some of the above standards is placed at
Appendix A.
5.32 Types of tests conducted on Electronic equipment
.
The tests essentially comprise of following :-
(a) Qualification of components
(b) PCB – Bare board testing/components mounting
(c) Rack arrangements/ cabling and routing
(d) Testing of panels
(e) Environmental testing of panels & communication equipments
(f) Environmental stress screening
(g) EMI/EMC tests
(h) Software Quality Assurance—Unit level testing
(i) System Performance checks
(j) Factory Acceptance Tests
5.33 Types of tests conducted on General Stores. The highlights of testing
are as follows :-
(a) As per QAP drawn up for the item and in conformance of the
purchase order
(b) Pilot samples inspection at vendor premises and testing at
QA/Govt approved labs.
(c) Paints and chemicals as per the relevant test procedures
(d) Package inspection
(e) Stipulation of Shelf life
5.34 Types of tests conducted on Electrical Items
The
electrical items include batteries, cables, light fittings, Generators, motors,
panels, switch board etc. The tests
applicable for cables and batteries are highlighted as an example in subsequent
paragraphs. Similarly other
products are covered by their dedicated tests.
5.35 Cables
(a) Visual Inspection for
quality of finish
(b) Physical tests for
dimensional and constructional details . In respect of
cables tests on tensile strength, elongation at break ,ozone
test , polymer identification ete are conducted.
(c) Electrical tests like high
voltage, conductor resistance, insulation resistance, spark test on cores , gas
flame test , flammability test etc