Document No.

: OSP-16

Operating System Procedure

Production
and
Production Planning

(Clause 7.5 of ISO 9001:2008)

Production & Service Provision

Signatory Name Designation Signature Date

Prepared By: Jacob John Section Manager 24 Aug 10

Krisanta Mae Management

Reviewed By: 24 Aug 10
Armintia Representative

Regional General
Approved By: Osama Odeh 24 Aug 10
Manager

Document No.: OSP-16 Revision No.: 02

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Document Title: Production and Production Planning Revision Date: 24 Aug 2010
This document is property of Alu Nasa. It cannot be reproduced or transmitted to a third party without prior authorization.
 Amendment Records

Revision
S/N Amendment Details Revision Date
No.
1. Reference International Standard was updated to ISO
1 9001:2008. 01 04 Aug 10
2. Amended according to ISO 9001:2008 requirements.
1. Incorporate the Production Planning procedure
including the critical points.
2. Establish new forms for Production Planning use.
3. Update the Duties and Responsibilities for Production.
4. Revision of some Production Forms.
2 02 24 Aug 10
5. Other forms were considered obsolete and were
removed from the procedure.
6. Identification and Control over Measuring Equipment
was established.
7. Modification on the procedure format

Document No.: OSP-16 Revision No.: 02

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Document Title: Production and Production Planning Revision Date: 24 Aug 2010
This document is property of Alu Nasa. It cannot be reproduced or transmitted to a third party without prior authorization.
 Index

Section Contents Page

i Covering Page 01

ii Amendment Records 02

iii Index 03

1 Purpose 04

2 Scope 04

3 Abbreviations and Definitions 04

4 Duties and Responsibilities 04

5 Procedure 07

5.1 Production Control 07

5.2 Work Instruction 08

5.3 Validation of Processes 08

5.4 Identification and Traceability 09

5.5 Client Property 09

5.6 Preservation of Product 09

5.7 Production Planning 10

6 Work Instruction 10

7 Appendices 10

8 Related Records 10

9 Related Documents 11

10 Reference Documents 11

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Document Title: Production and Production Planning Revision Date: 24 Aug 2010
This document is property of Alu Nasa. It cannot be reproduced or transmitted to a third party without prior authorization.
1. Purpose
The purpose of this procedure is to describe the method of handling different activities such as
the following:
Handling production activity under controlled condition such as machining, assembly,
structural bonding, packaging & dispatching
Products are suitably identified and traceable throughout product realisation.
Preservation of materials/products is maintained to ensure conformity with the
requirements, shall include identification, handling, packaging, storage, & protection.
Generation of Production Plan based on priorities and availability of resources.

To demonstrate the performance and to evaluate the effectiveness of this procedure thru their
related activities, this shall include data generated as a result of monitoring and measurement
through the following:
To monitor the results of production productivity by comparing the production plan
against the production output within three (3) consecutive months.
To monitor the results of product quality by comparing the product inspected against
the product accepted within three (3) consecutive months.

2. Scope
The scope of this document applies to all production and production planning activities that are
carried out by the Alu-Nasa and all personnel dealing with these activities.

3. Abbreviations and Definitions

3.1. Abbreviations
 WI - Work Instruction
 OSP - Operating System Procedure
 QMR - Quality Management Representative
 NCR - Non Conformance Report
 FRM - Form
 Appx - Appendices

3.2. Definitions
 Quality related activity
Machining (Cutting, Shearing, Drilling, Milling, Crimping, Slitting, Lathe, Notching,
Punching, Routing, Grooving, Folding, Bending, Rolling, Grinding, Polishing,
Buffing) assembly, structural bonding, packaging & dispatching

 Documents needed for fabrication

“Fabrication Order (OSP-14-FRM-09)” including fabrication drawing, assembly
drawing, material take off/listing, shop drawing, setting up drawing, etc.

4. Duties and Responsibilities

Position: Section Manager
o Responsible for ensuring that the standard procedures are adhered by the
Production Section.
o Responsible for establishing Work Instruction to all quality related activities to be
carried out in the production.

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Document Title: Production and Production Planning Revision Date: 24 Aug 2010
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 o Responsible for checking and approval of all “Fabrication Order (OSP-14-FRM-09)”
received for fabrication.
o Responsible to check and ensure that all “Fabrication Order (OSP-14-FRM-09)”
received are approved and signed by the signatory prior to fabrication work.
o Responsible for planning & scheduling of production activities in accordance with
project programme to ensure the timely execution and production productivity.
o Responsible for monitoring of production to ensure that the correct product is
manufactured as per product requirements.
o Responsible for the accuracy and suitability of all the machines, tools & equipments
& measuring devices to ensure that the correct products are being provided.
o Ensure that wastage materials should be properly utilized in the production from
other project to minimize wastage.
o Responsible for issuing of all related documents prior to production execution.
o Responsible for monitoring of production activities and ensure that the production
output meet against production plan in every quality related activities.
o Responsible for coordination in every station/section/activity prior to execution of
work throughout the production.
o Ensure that all raw materials, Client property, in-process materials, finish products,
non conformance products in the production should have proper identification to
prevent mixing of items during production execution and servicing activities.
o Responsible for coordination with the Quality Engineer prior to product quality and
calibration of measuring devices used in the production.
o Responsible for monitoring of all materials/products for preservation and/or outgoing
prior to dispatch in the production, shall include proper identification & traceability (if
necessary), handling, packaging, storage and protection.
o Responsible for monitoring of production activities in accordance with approved
project programme.
o Responsible to register the production output to demonstrate the performance of
production activities and to evaluate the effectiveness of their production plan.

Position: Production Planner

o Responsible for devising plan in the distribution of manpower, machines and
materials so that the monthly productivity target and requirements of each product
can be achieved as per schedule.
o Preparing of the production planning of the different fabrication orders.
o Controlling and monitoring of the production processes of the production processes
of the fabrication orders.
o Review fabrication orders for information and fabrication compliance.
o Scheduling the new issued fabrication order to the factory in accordance with the
materials, machines and manpower’s availability.

Position: CNC Programmer

o Responsible for programming and job setting for CNC machining.
o Responsible for executing the fabrication activities as per the work instruction.
o Ensure that the machine/equipment is suitable prior to use to meet the product
requirements.

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Document Title: Production and Production Planning Revision Date: 24 Aug 2010
This document is property of Alu Nasa. It cannot be reproduced or transmitted to a third party without prior authorization.
Position: General Foreman
o Responsible for collecting all materials required for fabrication from the store in
accordance with “Fabrication Order (OSP-14-FRM-09)” and material take off.
o Responsible for allocation of work to all Foremen before executing their works.
o Monitor and check the work in progress to ensure that the work is progressing in
controlled condition.
o Responsible in allocating work in order to meet the production schedule.

Position: Foreman
o Responsible in allocating work per instruction of General Foreman in order to meet
the production schedule.
o Responsible for monitoring and checking every piece of materials to be fabricated in
every designated area in accordance with the “Fabrication Order (OSP-14-FRM-
09)” released.

Position: Machine Operator

o Responsible for executing the fabrication activities as per the work instruction.
o Ensure that the machine/equipment used is suitable prior to meet the product
requirements.
o Ensure that the measuring devices used are calibrated and accurate.
o Ensure that fabricated materials are correct in accordance with “Fabrication Order
(OSP-14-FRM-09)” to meet the product requirements.
o In case of breakdown the operator reports to his immediate superior or Section
Head who, in turn, informs the Maintenance Section.

Position: Fabricator
o Responsible for executing the fabrication day to day activities in the production.
o Ensure that the measuring devices used are calibrated and accurate.
o Ensure that fabricated materials are correct in accordance with material cutting list
to meet the product requirements.
o Responsible for the assembly of all fabricated materials as per instruction of in
charge Foreman in accordance with cutting list material to meet the product
requirements.

Position: Helper
o Assisting in the day to day fabrication activities in the production.
o Assisting the fabrication for proper handling, packing, storage and protection of
materials to ensure that the product is in safe, secure and in a proper area.

Position: Quality Management Representative (QMR)

o To ensures the implementation of the procedure.

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Document Title: Production and Production Planning Revision Date: 24 Aug 2010
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5. Procedure
5.1. Production Control
5.1.1. The Section Manager is responsible for planning, execution and monitoring
production to meet the product requirements.
5.1.2. The Section Manager receives documents needed for fabrication from Technical
Department that describes the characteristics of the products to be fabricated.
5.1.3. The Section Manager is responsible for establishing Work Instruction to all quality
related activities to be carried out in the production.
5.1.4. The Section Manager is responsible for the accuracy and suitability of all the
machines, tools & equipments & measuring devices to ensure that the correct
products are being provided.
5.1.5. The Section Manager is responsible for planning & scheduling of production
activities and manpower in accordance with project programme to ensure the timely
execution and production productivity.
5.1.6. The Production Planner should forward all relevant documents to Section Manager
who will arrange to give a full set of copy to the General Forman for material
fabrication.
5.1.7. The Section Manager should collect all materials required for fabrication as per
“Material Issue Voucher (OSP-19-FRM-04)” from the store in accordance with
“Fabrication Order (OSP-14-FRM-09)”, “Material List (OSP-14-FRM-10)”, “Material
Take-off (OSP-14-FRM-07)” and allocating of works and personnel’s to all Foremen
for execution. Refer to “Manpower Allocation (OSP-16-FRM-05
5.1.8. The Section Manager should monitor and check the work in progress of every
quality related activities as per the following form to ensure that the work is
progressing in controlled condition.
 “Daily Production Report (OSP-16-FRM-04)”
 “Daily Production Report Summary (OSP-16-FRM-09)”
5.1.9. In case of Non-Conformance during work in-process due to machine/equipment,
measuring devices, documents, materials, workmanship, safety environment,
quality, etc., a report should be submitted to his immediate superior or Section Head
to inform the Quality Section who will raise a “Non Conformance Report” (QSP-05-
FRM-01).
5.1.10. The Section Manager is responsible to register the production input and output in
“Production Monitoring Register (OSP-16-FRM-01)” to demonstrate the
performance of production activities and to evaluate the effectiveness of the
production plan in accordance with the project programme.
5.1.11. All finished products must be segregated from work-in-process products. Finished
products shall be handed over to the Quality Engineer along with the “Material
Handover Note (OSP-16-FRM-03)” for checking product quality before dispatching.
5.1.12. Materials which are considered scrap after machining process should be registered
to “Scrap Records (OSP-16-FRM-07)”, indicating the reason for scrap.
5.1.13. All products accepted by the Quality Engineer should be marked with “Accepted”
and all products which are not accepted should be marked with “Rejected”.
5.1.14. After identifying any non-conforming product, the concerned department in-charge
should segregate them from the conforming products and must be properly
identified with appropriate signage for easy traceability. The Quality Engineer
(Originator) who took the inspection should generate a “Non Conformance Report”
(QSP-05-FRM-01).

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 5.1.15. Quality Engineer shall arrange a copy and distribute to the following:
 1 copy to recipient for acknowledgement receipt along with the original.
 1 copy to originator for reference and records/file.
 1 copy to QMR for monitoring and controlling all company NCR’s.
 1 copy to other concerned department if necessary.

5.2. Work Instruction

5.2.1. Written WI’s instructs personnel involved in production in performing their particular
tasks or operations. These explain how individual activity, equipment and /or
machine operate, define the steps required to perform certain operations and /or
inspections and warn against safety hazards etc. WI’s are established for operations
where it is considered that the absence of such instructions would adversely effect
production. Refer to the following Work Instruction:
OSP-16-WI-01 Work Instruction – Machining
OSP-16-WI-02 Work Instruction – Assembly
OSP-16-WI-03 Work Instruction - Structural Glazing Application &
Testing Control
OSP-16-WI-04 Work Instruction - Remedial Work

5.2.2. When deciding whether WI’s are required for individual operations, the following
points should be assessed.
 The importance of the individual operation and its potential impact on quality.
 The complexity of the operation.
 Any history of quality problems linked with operations.
 The general level of competency of operators.
 Work instructions are prepared by the Section Manager, reviewed by the Quality
Management Representative, and approved by the Regional General Manager.
They are then made available for all operators at required locations throughout
the department.
 The Section Manager decides what training, if any, is required for the concerned
operators. Refer to “Competence, Awareness & Training (OSP-10)” quality
system procedure.

5.3. Validation of processes

5.3.1. All the processes used by Au Nasa production in which defects cannot be detected
through subsequent inspection and testing procedures and where deficiencies can
only be found when the product is in use are validated.
5.3.2. For particular projects, 3rd party inspection is carried out, to ensure compliance with
Client specifications.
5.3.3. The material and operating procedures for the above are specified and
documented. All parameters and operating conditions are defined and maintained.
5.3.4. The Production Section maintains the qualification records of the operators and a
copy is kept by the Administration Department.

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Document Title: Production and Production Planning Revision Date: 24 Aug 2010
This document is property of Alu Nasa. It cannot be reproduced or transmitted to a third party without prior authorization.
 5.4. Identification and Traceability
5.4.1. Identification is the unique numbering of products to prevent the mixing of items
during the production and servicing activities.
5.4.2. During processes the products are identified as follows:
 The “Fabrication Order (OSP-14-FRM-09)” number identifies all the products
during work in process.
 At the end of the process all the products are identified by which has the
following details.
 Company name & logo
 Project number & name
 Item/tag/code/part/mark/unit number
 Structural Bonding Line (if necessary)

5.4.3. Traceability is the system used to trace the history of products through production
and inspection and testing, in case of product complaints.
5.4.4. The traceability of products produced by the Production Section should be recorded
as follows:
 To maintain the “Fabrication Order (OSP-14-FRM-09)” records, detailing date of
manufacture and processes required for manufacture.
 To maintain the inspection records.

5.5. Client Property

5.5.1. Alu-Nasa ensures adequate control of client supplied products, which the company
use or has responsibility for whilst in their position. While under company control, all
Client property is properly identified, verified, protected and safeguarded prior to
and during use.
5.5.2. The Client supplied product is verified for conformity and/or suitability. If any such
product is found to be unsuitable for use, it will be recorded and the client will be
informed accordingly. Likewise, should any such product be lost or damaged, the
events and product details will be recorded and the Client notified.
5.5.3. For further information, refer to “Client Property (OSP-18)” operating system
procedure.

5.6. Preservation of Products

5.6.1. Following equipment is used for the safe handling and transportation of products
within the production and storage areas.
 Forklifts
 Trolleys
 Pulleys/chain blocks

5.6.2. All outgoing material/product should be marked with project specific markings to
ensure that every material/product should have proper identification and traceability
to prevent mixing of items during production and servicing activities in accordance
with “Fabrication Order (OSP-14-FRM-09)”.
5.6.3. Upon dispatch of materials/products to site, each specific unit/items should be
itemized and the project number in “Delivery Order (OSP-19-FRM-05)” should be
specified for the purpose of identification and traceability.
5.6.4. Upon delivery to site, each materials/product should check the identification/marking
against the “Setting-out Drawings” to ensure correct installation.
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Document Title: Production and Production Planning Revision Date: 24 Aug 2010
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5.7 Production Planning
5.7.1 Production Planner will receive Work Order and Material Take-Off documents from
Technical Department which will then be logged on the “Work Order Register”
(OSP-16-FRM-10) and “Material Take Off Register” (OSP-16-FRM-11)
5.7.2 All received technical documents will be checked by the Production Planner whether
it is complete, correct or adequate to the project. “Technical Documents Checklist”
(OSP-16-FRM-12) will be used to log all status of the received documents. In case
of incomplete, wrong or inadequate documents, Production Planner shall give
immediate feedback to Technical Department and wait until all documents are
complete to start the planning.
5.7.3 Production Planner will check the Material availability thru “Material Tracking
Register” (OSP-16-FRM-13) in coordination with the Store. If material is not
available, purchases requisition must be made by the Store In- Charge.
5.7.4 Production Planning shall consider other factors that are significant in generating
the “Production Plan” (OSP-16-FRM-14). This shall include but not limited to:
Priority, Deadline from Client, Availability of resources and Dispatch schedule.
These will be coordinated to different departments of the organization
5.7.5 Once “Production Plan” (OSP-16-FRM-14) is complete, a copy will be distributed to
the Section Manager along with other Technical Documents.
5.7.6 During actual production, Production Planner shall constantly coordinate with the
Section Manager regarding the status of the project. Progress of the project will be
monitored thru “Production Status Completion Register” (OSP-16-FRM-15).
5.7.7 Production Planner shall validate whether the plan has been executed based on
schedule. Any delays must be justified by the Section Manager and maybe re-
considered on the next plan.

6. Work Instruction
 OSP-16-WI-01 Work Instruction - Machining
 OSP-16-WI-02 Work Instruction - Assembly
 OSP-16-WI-03 Work Instruction - Structural Glazing Application & Testing
Control
 OSP-16-WI-04 Work Instruction - Remedial Work

7. Appendices
 OSP-16-Appx-01 Organization Chart

8. Related Records
 OSP-16-FRM-01 Production Monitoring Register
 OSP-16-FRM-03 Material Handover Note
 OSP-16-FRM-04 Daily Production Report
 OSP-16-FRM-05 Manpower Allocation
 OSP-16-FRM-07 Scrap Records
 OSP-16-FRM-09 Daily Production Report Summary
 OSP-16-FRM-10 Work Order Register
 OSP-16-FRM-11 Material Take Off Register

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  OSP-16-FRM-12 Technical Documents Checklist
 OSP-16-FRM-13 Material Tracking Register
 OSP-16-FRM-14 Production Plan
 OSP-16-FRM-15 Production Status Completion Register
Obsolete Forms:
 OSP-16-FRM-02 Daily Manpower Report
 OSP-16-FRM-06 Product Order Status
 OSP-16-FRM-08 Material Machining Status

9. Related Documents
 QSP-05 Control of Non-Conforming
 QSP-06 Corrective Action
 OSP-10 Competence, Awareness & Training
 OSP-18 Client Property
 QSP-05-FRM-01 Non Conforming Report
 OSP-19-FRM-04 Material Issue Voucher
 OSP-19-FRM-05 Delivery Order
 Project Programme

10. Reference Documents

 Supplier’s Catalogue

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Document Title: Production and Production Planning Revision Date: 24 Aug 2010
This document is property of Alu Nasa. It cannot be reproduced or transmitted to a third party without prior authorization.