Standard Operating Procedure (SOP) for Raw Materials

1. Purpose

To ensure that all raw materials received for the production of plastic pipes and fittings meet the required specifications, quality standards, and are suitable for use in the manufacturing process.

2. Scope

This procedure applies to all raw materials including PVC/PE resin, additives, stabilizers, color masterbatches, and recycled materials used in the manufacturing facility.

3. Responsibilities

• Storekeeper: Ensures materials are unloaded and stored as per guidelines.
• QC Inspector: Conducts quality checks and documents results.
• QC Supervisor: Reviews results, approves/rejects materials, and ensures proper sampling procedures are followed.
• Purchase Department: Ensures suppliers comply with quality requirements and provides necessary documentation.

4. Definitions

• PVC/PE: Polyvinyl Chloride / Polyethylene.
• Masterbatch: Concentrated mixture of pigments or additives.
• COA: Certificate of Analysis.
• MSDS: Material Safety Data Sheet.

5. Procedure

5.1 Material Receiving

• Upon arrival, storekeeper checks delivery documents (invoice).
• Materials are tagged with a “Quarantine” label and not used until QC clearance.

5.2 Sampling Method

• Follow sampling standard or company-defined procedure.
• Take samples from at least 3 different bags or batches for each material lot.

5.3 Inspection & Testing Parameters

5.4 Acceptance Criteria

• Based on product specification sheets or supplier COA.
• Any deviation must be escalated to QC Supervisor and documented.

5.5 Material Approval or Rejection

• If passed, tag as “Approved for Use” with QC stamp and move to approved storage area.
• If failed, tag as “Rejected” and isolate in the Rejection Area.
• Raise a Non-Conformance Report (NCR) and inform Purchase Department for corrective action.

6. Documentation

• Raw Material Inspection Report
• Material Batch Log Sheet
• COA and MSDS File
• NCR Log (if any rejections occur)

7. Storage Guidelines

• Store approved materials in clean, dry areas labeled by material type.
• Use FIFO (First In, First Out) or FEFO (First Expiry First Out) for date-sensitive materials.
• Maintain color masterbatch in sealed containers to prevent contamination.

8. Calibration & Equipment

• Ensure MFI Tester, weighing balances, moisture analyzers are calibrated monthly.
• Maintain calibration records and certificates.

9. Safety and Compliance

• Use PPE (gloves, goggles) during sampling and testing.
• Handle flammable or chemical additives as per MSDS guidelines.
• Follow company’s Environmental and Safety Policy for material disposal.

Approvals:

Approved By: [Factory Manager]] | Date: [DD/MM/YYYY]
Approved By: [Production Manager] | Date: [DD/MM/YYYY]
Prepared By: [Name/Title] | Date: [DD/MM/YYYY]