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EDITION
2026–2027 · Rev 03
Quality Control Plan · BS EN 124-2:2015
Control characteristics, inspection methods, sampling frequencies and acceptance criteria for every stage of manufacture, from charge make-up to container seal.
Verify supplier capability, process control, and production readiness before manufacturing begins.
Technical support for drawings, tooling, samples, and new product development.
On-ground inspections and progress monitoring to reduce defects and delivery risks.
Final quality, packing, quantity, and container loading checks before shipment.
With 15+ years of experience in NPD, foundry development, and production quality oversight, QX Engineering Private Limited supports international buyers with reliable technical representation across India.
We work as an extension of your engineering and procurement team, helping you identify capable suppliers, control production quality, monitor development progress, and reduce sourcing risks from initial drawings to final dispatch.
STANDARDS ARE PART OF THE SOURCING REQUIREMENT.
QX works with product requirements built around applicable international and customer-specific standards. Key standards and specifications include:
The applicable standard is determined by the product, destination market, project specification and contractual requirement.
Manhole covers and frames, access covers and frames, utility access covers, and inspection chamber covers.
Gully tops and gratings, drainage channel gratings, linear drainage castings, kerb drainage components, and road drainage castings.
Surface boxes, valve boxes, municipal infrastructure castings, sanitary and water infrastructure castings, and customer-specific foundry components.
Ductile iron castings and grey cast iron castings.
Work stops until QX releases it in writing.
A QX engineer is present for the activity.
QX reviews the records within 24 hours.
QX re-checks a sample of what the foundry released.
QX-recommended value, not set by the standard.
COLOUR CODE OF DECISIONS
Result inside the limit. Work continues.
Result unknown or at risk. Stop and wait for QX release.
Result outside the limit. Quarantine and raise an NCR.
THE THREE RULES OF EVIDENCE
Every check has a time-stamped photograph with the lot or heat number in the frame.
Records are attributable, legible, contemporaneous, original and accurate. Never written from memory.
Heat, lot, pallet and container seal numbers link every piece back to its melt.
Six linked stages keep the requirement, foundry, development, production, verification and shipment under technical control.
Drawing, specification, material, standard, load class, dimensions, testing and quantity; then foundry mapping, capability review, factory audit, process assessment and capacity assessment.
Pattern, core, gating, riser, simulation, trial casting and validation.
Melt control, sand parameters, moulding, core-making, fettling, machining and process monitoring; then dimensions, material, metallurgy, load and functional testing, visual inspection and documentation.
Quantity, identification, packing, container loading, traceability and shipment readiness.
We do not simply search for a supplier that says, “Yes, we can manufacture it.” We evaluate whether the foundry has the technical capability to manufacture it repeatedly.
We assess the complete requirement: drawing, material grade and properties, process capability, tooling and core systems, metallurgical control, testing and documentation, production capacity, and shipment readiness.
From outside India, it can be difficult to verify how a supplier melts metal, controls chemistry and sand parameters, maintains patterns, produces cores, controls gating and risering, handles delays and rejected castings, implements corrective actions, manages real capacity, or reports production status. QX operates on the ground and verifies the manufacturing reality behind the supplier presentation.
A list of 100 foundries is not supplier intelligence. QX develops a product-specific view of capability, process, capacity, quality, risk and suitability. The objective is to identify suppliers that make technical sense for your requirement.
We do not simply search for a supplier that says:
“Yes, we can manufacture it.”
We evaluate whether the foundry has the actual technical capability to manufacture it repeatedly.
What exactly is required?
What grade, chemistry and mechanical properties are required?
Can the foundry manufacture the geometry consistently?
Can the pattern and core system produce the required casting?
Can the foundry control the melt, treatment and final structure?
Can the required testing be performed and documented?
Can the supplier deliver the required volume consistently?
Can the finished castings be packed, identified and dispatched correctly?
02 / QX DOCUMENT REGISTER
Five document families and one numbering rule connect the master plan to the work instruction, inspection record and client report.
The rulebooks: parameters, frequencies, standards
QCP-01
Quality Control Plan for Ductile Iron Manhole Covers & Gully Tops (BS EN 124-2:2015)
QCP-02
Quality Control Plan for Cast Access Covers & Grates (AS 3996:2019)
QCP-03
Quality Control Plan for Channel Drainage Systems & Gratings (EN 1433)
QCP-04
Generic Quality Control Plan for Ferrous OEM & Machinery Castings
System level: who does what, when and how
SOP-01
Foundry Identification, Capability Assessment & Onboarding Procedure
SOP-02
New Product Development (NPD), Pattern Tooling & DFM Protocol
SOP-03
In-Process Production Monitoring & Shop-Floor WIP Tracking
SOP-04
Finished Goods Pre-Shipment Inspection (PSI) Procedure & AQL Sampling
SOP-05
Proof-Load & Permanent Set Testing Witnessing Procedure (EN 124 / AS 3996)
SOP-06
Non-Conformance Handling, Defect Investigation & CAPA (8D Process)
SOP-07
Anti-Rust Coating, Seaworthy Packaging & Container Loading Supervision
SOP-08
Field Inspector Code of Conduct, Ethics & Anti-Bribery Policy
Step by step, in the inspector’s hand at the foundry
WI-01
Spectrometer Calibration, Spark Test & Melt Chemistry Verification
WI-02
Green Sand Testing & Moulding Parameter Verification
WI-03
Pattern, Core-Box Tooling & Draft Angle Verification
WI-04
Visual Surface Defect Identification & Acceptance Criteria
WI-05
Dimensional & Gauge Mapping (Clear Opening, Flanges & Seating Planarity / Anti-Rock)
WI-06
Microstructure, Nodularity & Brinell Hardness Verification
WI-07
Bitumen / Paint Dry Film Thickness (DFT) Gauge Measurement
WI-08
Container Structural Inspection, Dunnage & Maritime Packing Check
The fillable forms that become the client report
IRF-01
Foundry Technical Capability & Infrastructure Audit Scorecard (100-Point Audit)
IRF-02
New Tooling & First Article Inspection Report (FAIR / PPAP Sheet)
IRF-03
Daily / Weekly Production Monitoring Flash Report
IRF-04
Pre-Shipment Quality Inspection Report (PSI)
IRF-05
BS EN 124 / AS 3996 Proof-Load Test Witness Certificate
IRF-06
Chemical & Mechanical Test Verification Log (Tensile, Hardness, Microstructure)
IRF-07
Non-Conformance Report (NCR) & Corrective Action Form
IRF-08
Container Loading Supervision & Seaworthy Packing Report
Onboarding foreign buyers and protecting QX
DOC-01
Master Services Agreement (MSA) for Quality Governance & Sourcing
DOC-02
Service Level Agreement (SLA) & Rate Card Schedule (A-la-carte, Retainer, Turnkey)
DOC-03
Technical Scope of Work (SOW) Template
DOC-04
Mutual Non-Disclosure Agreement (NDA, International Client)
DOC-05
Bilateral Non-Circumvention & Non-Disclosure Agreement (NCNDA, Local Foundries)
DOC-06
Client Project Onboarding & Technical Requirement Intake Form
So every record can be traced
QCP-nn
master plan
ITP-nn-CCC
order plan from QCP-nn for customer CCC
IRF-nn
form, filed under the visit report
IR-yy-nnn
visit report: year, serial
NCR-yy-nnn
non-conformance: year, serial
SUP-nnn
foundry qualification record
QX Engineering helps overseas buyers maintain consistent manufacturing standards through structured quality governance, on-ground inspections, and supplier accountability. Our team monitors critical checkpoints from development through final dispatch to reduce defects, improve traceability, and support reliable project execution.
We verify supplier capability, quality systems, and process controls.
We monitor key production stages to identify defects early.
We maintain inspection records, test reports, and material traceability.
We track supplier corrections until issues are properly resolved.
QCP-01 / CONTROLLED QUALITY PLAN
For ductile iron manhole covers and gully tops, QX’s reference plan turns specifications into a staged inspection path. Decisions are backed by photographs, same-day records and traceable heat, lot and dispatch details.
Controlled stages
Control steps
Hold points
Process gates
FIVE LINKED PROCESS GATES
01
Raw material, treatment and chemistry.
02
Sand, tooling and cores.
03
Pouring, cooling and finishing.
04
Fit, properties and performance.
05
Coating, packing and final release.
From foundry mapping and technical qualification through casting development, production monitoring, verification and dispatch, QX provides the India-side technical control to help keep your requirement on track.
