| STEP | Cost Centre | PROCESS | OPERATION DESCRIPTION | CLASS | PRODUCT AND PROCESS CHARACTERISTICS | CONTROL METHODS | |
| 1 | 500 |
| Receive and verify quantity and type of raw material - by stores personnel |
| 4.5mm lightly oiled Copper coated wire as per purchase order | Verification of delivery note and order placed. Any discrepancy - contact supplier and resolve |
|
| 2 | 500 |
| Move raw material to incoming receiving area |
| Safe handling during transport and handling activity | Visual inspection |
|
| 3 | 505 |
| Inspection of raw material by QA Personnel |
SC
| Mild steel 4.5mm lightly oiled Copper coated
Wire Tolerance +/- 0.08mm. Copper 1.5g/m2 - Verify as per COA
No score marks, no rusty wire - compare tensile strength with COA and spec - correct grade
| Check wire diam with micrometer. Visual inspection of condition of wire. COA from supplier. Record on on-line inspection |
|
| 4 | 500 |
| Move raw material to storage area |
| Safe handling and loading during this activity | Visual inspection during this activity. Competent Hyster driver. FIFO System to control material |
|
| 5 | 500 |
| Issue wire to production |
| Correct identification of wire | Material buff tag, visual inspection |
|
| 6 | 15 |
| Load wire coil onto swift at Micro Mac and Zukron Machine |
| Safe loading and handling during this activity | Visual inspection during this activity. Competent Hyster driver |
|
| 7 | 15 |
| Form individual wires as per route card on Micro Mac / Zukron Machine |
SC
| As per correct fitment in checking fixture. No burrs allowed. | Visual inspection on in-process checking fixture.
Visual inspection for burrs and coating variance.
Record on BIS Card and on-line inspection. |
|
| 8 | 15 |
| Pack formed wires in KANBAN |
| Correct loading of wires on KANBAN system | KANBAN System |
|
| 9 | 16 |
| Dressing and cleaning of copper tips |
SC
| To ensure consistent welds | Copper tip height measurement.
File tips every 2 hours. |
|
| 10 | 16 |
| Weld Pull Test |
CC
| 4.5mm x 4.5mm Min 2400N, Max 9600N | Use Tensile tester to pull the sample wires and determine the point at which the wire or weld breaks. The reading should be between the min and max spec. |
|
| 11 | 16 |
| Load wires on welding jigs and start welding frames |
| No loose wires, no burrs and hold downs correctly fitted | Visual inspection
|
|
| 12 | 16 |
| Welding of frame |
CC
| Weld frame as per customer requirement. First-off sample must conform to drawing requirements | Visual inspection of frame after welding. Verification in checking fixture - record on BIS Card and on-line inspection . Should the frame not fit the checking fixture , stop process and report to supervisor |
|
| 13 | 16 |
| Place identification label |
SC
| Place Identification Tag on wire 3 after welding process on wire | Visual inspection and ensure label sealed correctly to avaoid it from coming loose. |
|
| 14 | 16 |
| Nibble all protruding wires and polish sharp edges when required |
| No burrs/ sharp edges allowed on frame | Visual and physical inspection by hand |
|
| 15 | 16 |
| Re-welding |
CC
| Any re-weld frame shall be marked at the re-welding point using a maker before welding process and then check on checking fixture for fitment. Weld Criteria to meet the same as those defined in the "Weld Frame" process above
| Inspection after reweld is the same as defined in the process "Welding of Frame". Goods are to be validated in the final checking fixture |
|
| 16 | 16 |
| Final inspection of frames |
SC
| Frame must conform to final checking fixture, must fit flat in fixture slots , not twisted, no bent wires , no loose welds, no miss coating, identification label secure, no protruding or unnibbled wires, no rust on frame and missing wires. No burrs. | Visual verification of fitment of frame and welds |
|
| 17 | 16 |
| Handling of non conforming frames |
SC
| Frames need to be isolated from production placed on reject stand. | Reject frames to be captured on system and disposed before end of shift. |
|
| 18 | 505 |
| Critical dimensions |
SC
| 5 critical dimensions to measure on frame per jig monthly and complete cpk. | Measure frame using tape measure, square and vernier |
|
| 19 | 16 |
| Packing of frames |
| 100 frames per chep bin.
Place label on bin No damage to frames. | Competent packer |
|
| 20 | 16 |
| Transport full CHEP bins to stores area for shipment |
| Safe loading and transportation of frames | Competent forklift driver |
|
| 21 | 500 |
| Receive full CHEP bins into stores area for shipment |
| Correct containers and correct quantities | Visual inspection
Confirmed orders |
|
| 22 | 500 |
| Dispatching of frames to customer |
| Correct quantities.
Correct labelling | Order request. Approved transporter Create invoice/delivery note |
|
| 23 | 16 |
| Verification and checking of welding jigs |
| No visual damage to welding jigs, no worn out slots | Visual inspection done by operator |
|
| 24 | 505 |
| Verification and checking of individual checking fixtures |
| No visual damage | Visual inspection by QA Personnel |
|
| 25 | 505 |
| Verification and checking of Final checking fixture |
| Checking fixture dimensionally correct | CMM report |
|
| 26 | 505 |
| Internal product audit |
| As per drawing requirements | Audit check sheet including dimensional report for 1 complete frame |
|