Terms of reference

The project terms of reference were to advise and assist Reedley Fabrics to implement an ISO 9001 compliant quality management system. The project involved 15 consultancy days. A testimonial for this project from the Operations Manager is included in this web site.

Project aims and objectives

The objective of the project was to achieve ISO 9001 registration with an accredited certification body within 7 months of starting the project (the first project meeting was on 11^th August 1998, and so registration was planned for March 1999).

The organisation

Reedley Fabrics develops and manufactures warp knitted fabrics, predominantly for industrial use. As such, Reedley is the largest manufacturer of automotive seat cover linings in the United Kingdom. In addition, the company exports about 15% of its products to Europe. More recently, Reedley is developing new fabrics for industrial and non-industrial use, e.g. high visibility jacket fabrics, football kits, linings for clothes, cycle helmets, etc. Warping and knitting is carried out by Reedley at its own manufacturing facility, whilst finishing activities are carried out by specialist sub contractors in accordance with Reedley processing and performance specifications. The company employs around 15 staff at 2 sites; head office is at Cheadle in Cheshire and the warping/knitting plant is in Ilkeston in Derbyshire. Batch traceability of yarn is maintained through the warping, knitting and finishing processes and test results are provided for each finished fabric. For a very small proportion of the fabrics sold (<1%), the company acts as a merchant, i.e. without having control over the manufacturing process. However, the purchasing, storage and despatch of these fabrics is controlled as per manufactured fabrics.

Process of delivery of the ISO 9001 project

The project started in August 1998. Reedley Fabrics staff were helped by Hawkstone Consulting Ltd. with the following elements of their quality system:-

·         a review of current systems and the identification of changes to meet the requirements of ISO 9001

·         the development of the policy manual

·         the production of the procedures (11 off) and operating instructions (2 off)

·         creation of some new quality records, the indexing of all the records and production of a records index

·         internal audit training and implementation, including the provision of internal auditor certificates

·         selection of an accredited certification body (ISO QAR)

·         amendments to documentation and systems as a result of the ISO QAR document review (carried out in January 1999)

·         preparation for and attendance at the management review meeting

In addition, Hawkstone Consulting completed several audits prior to the formal assessment.

The project was 40% funded by Business Link Stockport.

The outcomes

Reedley Fabrics achieved ISO 9001 on 25^th March 1999, 7 months after starting the project, with only 5 minor non compliances. In doing so, they have developed a practical quality system with a minimum of paperwork and bureaucracy.  They will now be able to market themselves with ISO 9001 registration, a fact that should ultimately increase sales. Quality problems and complaints are now being formally recorded and objectives have been set at the management review for quality improvement.

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   Last modified: May 16th,  2007