🏭 DGMS Factory Inspection & Audit Checklist – Appendix XIX
Factory inspection is a mandatory step before DGMS grants approval for:
Flameproof equipment
Intrinsically safe equipment
Gas detectors
Electrical machinery
PPE & safety devices
Importer-based equipment
DGMS verifies whether the manufacturer’s production system matches the approved design, standards & safety requirements. Appendix XIX of the DGMS Approval Policy explains exact factory audit points, which we decode below in simple OME style.
🔹 1. Purpose of DGMS Factory Inspection DGMS conducts factory audits to ensure:
✔ Correct manufacturing practices ✔ Consistency with technical drawings ✔ Proper quality & safety checks ✔ Calibration of testing equipment ✔ Good traceability system ✔ No unauthorized modification ✔ Adequate test facilities ✔ Controlled production environment
🔹 2. When Is DGMS Factory Audit Mandatory?
A factory audit is needed in:
1) New DGMS Approval Before issuing approval for the first time.
2) Renewal (Every 3 Years) To verify consistent quality.
3) Suspension / Complaint Cases On receiving field complaints.
4) Imported Equipment (IAR Audit) DGMS inspects service facilities of the Indian Authorized Representative.
🔹 3. Components of DGMS Factory Audit (Appendix XIX)
A DGMS audit covers 8 major sections:
⭐ 1) Quality Management System (QMS) DGMS checks:
ISO 9001 compliance
QMS manual
Quality policy
Organizational structure
Document control
Corrective & preventive action (CAPA) system
All processes must be documented.
⭐ 2) Manufacturing Infrastructure DGMS verifies:
Machinery & tools
Flameproof machining facilities
CNC machines
Winding machines
PCB assembly line (for IS equipment)
Painting/finishing
Assembly line layout
Equipment must match the approved drawings.
⭐ 3) Flameproof (FLP) Production Facilities DGMS checks:
Flamepath machining capability
Surface finish (Ra ≤ 6.3 μm)
Dimensional gauges
Torque-controlled tightening tools
Thread gauges
Air pressure test setups
Over 60% rejections occur due to poor flamepath machining.
⭐ 4) Testing Infrastructure Factories must have: For FLP Equipment:
⭐ 6) Material Traceability & Stores Every part must be traceable to:
Batch number
Supplier certificate
Material grade
Inspection report
Raw material acceptance
DGMS checks whether materials used = material in technical drawings.
⭐ 7) Quality Control Records Factory must maintain:
Incoming inspection reports
In-process inspection
Routine test results
Final inspection checklist
Non-conformance records (NCR)
CAPA reports
DGMS ensures all products are batch-tested before dispatch.
⭐ 8) Compliance with Approved Drawings The most important part:
❌ ANY deviation from drawing = Rejection Examples:
Flamepath dimensions changed
Material changed
PCB design modified
Thickness variations
Fastener grade change
Only DGMS-approved drawings must be in production.
🔹 4. DGMS Factory Audit Procedure
DGMS Issues Audit Notice ↓ Manufacturer Prepares Documents ↓ DGMS Inspection Team Visits Factory ↓ Verification of QMS, Testing & Production ↓ Check Against Appendix XIX Checklist ↓ Non-Conformity Report (if any) ↓ Corrective Action by Manufacturer ↓ Audit Clearance Issued If non-conformity is not resolved → DGMS rejects/withdraws approval.
🔹 5. Documents Required During DGMS Factory Audit
ISO 9001 certificate
QAR/QAN
Calibration certificates
Raw material test certificates
Purchase records
Test equipment list
Batch test reports
TG (Technical File)
Flamepath measurement reports
Employee qualification/skill matrix
🔹 6. Common Reasons for Audit Failure
❌ Flamepath machining errors ❌ Lack of calibration ❌ No batch test reports ❌ Unauthorized design changes ❌ Poor traceability system ❌ QMS not updated ❌ Production vs. drawing mismatch ❌ Fabricated test reports ❌ Non-certified raw materials
🔹 7. How to Prepare for DGMS Factory Audit (Checklist)
✔ Ensure ALL drawings are DGMS approved
✔ Maintain proper calibration records
✔ Keep dedicated gauges for flamepaths
✔ Maintain raw material certification
✔ Ensure batch-wise QC records
✔ Provide traceability of every component
✔ Train QC inspectors & operators
✔ Keep production as per QMS manual
🔥 25 MCQs (DGMS Pattern) with Answers
1) Factory audit requirement comes from — a) Appendix VI b) Appendix XIX c) CMR 2017 d) Indian Standards e) None Ans: b
2) DGMS audit checks —
a) GST b) HR files c) Manufacturing & testing d) Parking area e) None Ans: c
3) Calibration records must be —
a) Optional b) Mandatory c) Rare d) Weekly only e) None Ans: b
4) ISO required for DGMS approval —
a) ISO 22000 b) ISO 27001 c) ISO 9001 d) ISO 45001 e) None Ans: c
5) Ex equipment drawings must be —
a) Verbal b) DGMS approved c) Hand-sketched d) Suggested only e) None Ans: b
6) Flamepath finish should be —
a) Rough b) Painted c) Smooth (Ra ≤ 6.3 μm) d) Cracked e) None Ans: c
7) Unauthorized design change leads to —
a) Discount b) Promotion c) Rejection/withdrawal d) Team party e) None Ans: c
8) Test equipment must be —
a) Random b) Calibrated c) Broken d) Cheap e) None Ans: b
9) QAR stands for —
a) Quality Alteration Reference b) Quality Assurance Report c) Quantity Audit Result d) Quota Adjustment Rule Ans: b
10) Factory audit ensures —
a) Festivals b) Employee leave c) Production matches approved drawings d) Salaries e) None Ans: c
11) PCB changes need —
a) No permission b) Fresh DGMS approval c) Manager approval d) Storekeeper permission e) None Ans: b
12) Flamepath measured using —
a) Tape b) Rope c) Feeler gauges/micrometers d) Colour card e) None Ans: c
13) Raw material certificate ensures —
a) Colour b) Smell c) Weight d) Correct grade used e) None Ans: d
14) Field trial data required for —
a) First approval b) Renewal c) GST audit d) Factory layout e) None Ans: b
15) DGMS checks QMS —
a) Monthly b) Sometimes c) During audit d) Every day Ans: c
16) Batch testing is —
a) Optional b) Mandatory c) Not needed d) Temporary Ans: b
17) Flameproof test facility required for —
a) Footwear b) Ex-d equipment c) Gas cylinders d) Uniforms Ans: b
18) Test reports must be —
a) Editable b) Original & signed c) Only photocopies d) Verbal Ans: b
19) Factory audit fails if —
a) Machines working b) Drawings correct c) Calibration outdated d) QMS updated Ans: c
20) Production deviation from drawing —
a) Allowed b) Forbidden c) Encouraged d) Free Ans: b
21) Material traceability used for —
a) Decoration b) Music c) Fun d) Tracking materials used Ans: d
22) Testing infrastructure includes —
a) Toy tools b) HV tester, gauges, pressure test c) Paint brushes d) Fans Ans: b
23) Factory layout part of —
a) Finance b) QMS documentation c) Housekeeping d) Labour law Ans: b
24) DGMS audit team looks for —
a) Company profit b) Employee holidays c) Compliance & safety d) Office chairs Ans: c
25) Purpose of DGMS factory audit —
a) Increase sales b) Reduce workers c) Ensure safe & compliant manufacturing d) Save electricity Ans: c
🔚 Conclusion
DGMS Factory Inspection (Appendix XIX) ensures that equipment is manufactured with proper quality, safety, calibration & control. A high-quality audit system ensures:
Zero design deviation
Authentic testing
Reliable performance
Safe use in gassy mines
Every manufacturer must follow Appendix XIX to avoid rejection, suspension or withdrawal of DGMS approval.
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