| 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 mild black wire as per purchase order | Verification of delivery note and order placed . Any discrepancy |
|
| 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 |
CC
| Mild black 4mm wire , wire tolerance +/- 0.05mm , No score marks , no rusty wire , compare tensile strength with COA and spec - correct grade | Check wire diameter with micrometer. Visual inspection of condition of wire. COA from supplier. Record on incoming inspection document. Rod spec from supplier |
|
| 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 |
| Outsource bracket strip to Supplier to punch brackets |
| CC02 Bracket Strip Metal. SUPRAFORM HR190 | Visual inspection |
|
| 6 | 505 |
| Pressing and Inspection of brackets at supplier |
| Products need to conform to drawing specifications. | Visual verification. Measure required dimensions with a vernier. |
|
| 7 | 500 |
| Receive brackets from supplier , receipt into stock |
| Products must conform to drawing specifications | Visual inspection |
|
| 8 | 500 |
| Issue wire to production |
| Correct identification of wire | Material buff tag
Visual inspection |
|
| 9 | 15 |
| Form individual wires on Zukron / Huron. |
| Correct setting of machine
Products to conform to checking fixture | Record on BIS Card and Attribute sampling sheet QD:203
Checking fixture verification |
|
| 10 | 15 |
| Send loop wire and brackets to supplier for overmoulding. |
| As per drawing requirements | Visual inspection and measurement at supplier |
|
| 11 | 500 |
| Receive over moulded products from supplier , receipt into stock |
CC
| Products must conform to drawing specifications | Visual inspection |
|
| 12 | 500 |
| Issue loops and brackets to production |
| Safe handling and packing of products | Visual inspection |
|
| 13 | 6 |
| Load welding jig |
| Ensure all wires and brackets are seated correctly and hold down clamps are in place.
Ensure no gaps in between wires or wires and brackets | Visual verification |
|
| 14 | 6 |
| Weld Frame |
SC
| First-off sample must conform to drawing requirements | Verification on checking fixture - record on BIS Card . Should the parts not fit the checking fixture , stop process and report to supervisor |
|
| 15 | 6 |
| Inspect welded frame |
SC
| Ensure the welded frame fits the final checking fixture.
Ensure no loose or broken welds | Visual inspection and checking fixture. |
|
| 16 | 505 |
| Final inspection |
SC
| Frame shall conform to final checking fixture, must be flat in C/F grooves, no loose or broken welds. | Visual verification of fitment of frame and welds |
|
| 17 | 6 |
| Rework / Reweld Process |
SC
| Weld Criteria to meet the same as those defined in the "Weld Frame" process above | Inspection after rework/reweld is the same as defined in the process "Inspect Weld Frame". Goods are to be validated in the final checking fixture |
|
| 18 | 6 |
| Pack products into carboard boxes |
| As per packaging requirements | Description of product as per packaging requirments |
|
| 19 | 6 |
| Move completed boxes to stores using pallet jack |
| Safe loading and transporting of frames | Visual verification |
|
| 20 | 500 |
| Receive boxes into stores area for shipment |
| Correct quantities of frames | Visual inspection
Approved transporter |
|
| 21 | 500 |
| Dispatching of frames |
| Safe handling of boxes during this activity | Verification of quantities as per sales order and delivery note |
|
| 22 | 505 |
| Lay-out inspection |
| All requirement stipulated on drawing and customer requirements | Competent Q.A personnel conducting inspections |
|