| STEP | Cost Centre | PROCESS | OPERATION DESCRIPTION | CLASS | PRODUCT AND PROCESS CHARACTERISTICS | CONTROL METHODS | |
| 1 | 500 |
| Receiving and verification of raw material by stores personel |
| Mild black wire 4.0mm as per purchase order | Verification of delivery note and order placed. Any discrepancy, place raw material on hold and inform production planner, supplier and raise SRAN. |
|
| 2 | 500 |
| Move material to receiving storage area |
| Safe handling during transport and handling activity | Visual inspection |
|
| 3 | 505 |
| Inspection of raw material by Q.A |
SC
| Mild black wire, 4mm +/- 0.05, MATERIAL = SAE 1010 ,tensile range = 530mpa - 630mpa.
No pitted rust, no score marks, no excessive drawing soap.
| Check wire diam. With micrometer - Visual inspection of condition of wire - Compare tensile strength, grade and spec against COA from supplier - record on incoming inspection document QD:40. |
|
| 4 | 500 |
| Move raw material to storage area for storage |
| Safe loading and handling during this activity | Visual inspection during this activity. Competent forklift driver. FIFO system to control material. |
|
| 5 | 500 |
| Issue wire to production |
| Correct identification of wire | Material buff tag, visual inspection |
|
| 6 | 15 |
| Select 4mm tooling / select 100% T6 wire program and set - MICRO MAC Machine |
| Correct setting of machine.
| Visual verification |
|
| 7 | 15 |
| In process inspection |
SC
| Correct fitment on checking fixture.
| Visual inspection on in-process checking fixture.
Visual inspection for burrs.
Record on attribute sampling sheet QD:203 |
|
| 8 | 15 |
| Pack formed wire products onto Kanban tolleys |
| pack wire as per kanban quantity | Physical counting of products |
|
| 9 | 15 |
| Send over mould long wires to supplier for over moulding of products |
SC
| As per drawing requirements | Visual inspection |
|
| 10 | 500 |
| Receive over mould long wires from supplier - receipt into stock |
SC
| Products must conform to drawing specifications | Visual inspection and of moulded wires |
|
| 11 | 500 |
| Issue over mould long wires to production |
| Safe handling and packing of products | Visual inspection |
|
| 12 | 6 |
| Transport to manufacturing area |
| As per job quantities | Visual verification |
|
| 13 | 6 |
| Call-up 100% welding program from control unit at Robotic welder |
| Ensure correct program is selected | Visual verification |
|
| 14 | 6 |
| Load welding jig and manufacture first-off sample |
CC
| First off sample must conform to checking fixture and drawing requirements | Verification on checking fixture |
|
| 15 | 6 |
| Re-weld frame |
SC
| (Isolate from production - place onto reweld stand. Until frame can be manually rewelded.
Scrap parts place on reject trolley to be scrapped at end of shift.
Frame should be rewelded at the marked point | Visual inspection of re-weld points and validate frame onto Final Checking Fixture for fitment. |
|
| 16 | 6 |
| In process inspection of finished frames |
CC
| Frames must conform to checking fixture, must be flat, not twisted, no bent wires , no loose welds | Visual verification checking fixture - 100% inspection during production |
|
| 17 | 6 |
| Pack frames into card board boxes |
| Correct FELT001 card board box.
Correct quantities and Correct labelling | Visual inspection |
|
| 18 | 6 |
| Move completed frames to stores using pallet jack |
| Safe loading and transporting of frames | Visual inspection |
|
| 19 | 500 |
| Receive boxes into storage area |
| Correct quantities of frames | Visual inspection Confirmed orders |
|
| 20 | 500 |
| Invoice and ship frames to customer |
| As per order placement | Verification of quantities as per sales order and delivery note |
|
| 21 | 505 |
| Internal product and shipment audits |
| Product and Shipment audits to meet criteria as per customer requirements and drawing requirements | Competent auditors conducting internal audits as per schedule |
|