| PROCESS FLOW | NO | NAME | WORK ELEMENT | CHECK ITEM | RANK | PROCESS CRITERION | INSPECTION METHOD | INSPECTION PLAN | FREQUENCY | Inspection No.(s) | Work Instructions | RESP | CHECK SHEET | CONFIRM'N LEVEL | REACTION PLAN | |
| 1 | Receiving raw material - Stores Personnel | Receiving | Receiving |
| Check for correct quantity, delivered, type and diameter on tag | Visual inspection and verification as per order | Delivery note and order | Every batch |
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|
| Goods receive Note Book / Delivery note |
| If non-compliant - contact supplier and inform Quality Manager |
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| 2 | Move Raw Material to incoming inspection areas | Transport | Transport |
| Store material properly | Visual inspection | As per procedures | Every batch |
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|
| N/A - Visual Inspection |
| If difficulty occurs in storing raw material properly, inform Stores Coordinator |
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| 3 | Raw Material incoming inspection by QA Personnel | Inspection | Inspection |
| Correct Diam - 4.5mm -
4.0mm / 3.5mm +/- 0.08mm
Correct type - SWM - B - No rusty wire / no score marks / no excessive drawing soap. COA from supplier | Visual insp / Micrometer | As per incoming raw material inspection plan | Every consignment |
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|
| Goods receive note book / record findings on incoming inspection record sheet |
| Any non-conforming raw material shall be isolated - properly tagged and placed in quarantine store - inform Quality Manager |
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|
| 4 | Move Wire to storage area for safe stacking | Transport | Transport |
| Correct size / correct grades as per FIFO System | Visual inspection | As per FIFO System | On receiving |
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|
| FIFO Information board and Rack identification |
| Any difficulty experienced during this activit reports to Stores Coordinator |
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|
| 5 | Issue Raw Material to Production Personnel | Issuing | Issuing |
| Correct wire to be issued as per job card | Verification as per buff tag | Every coil issued to Production | Every job as per request |
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|
| Job card sheet |
| Should the incorrect wire been issued to Production, stop proces, correct and inform STores Coordinator |
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|
| 6 | Form wire no 1 - outer wire on Micro - Mac bundle wire | Forming | Forming |
| Part to conform to drawing requirements | Check part on in-process checking fixture | First-off sampling
3 samples - in process inspection
9 samples - last-off 3 samples | First-off at start of shift - in process every hour - Last -off end of shift |
225562255722558
|
1244
|
| Record on BIS Card - record on attribute inspection sheet |
| Should the first-off sampled failed - stop process and re-set machine and redo first-off sample - inform Supervisor |
|
|
| 7 | Form wire no 2 Loop wire on Zukron | Forming | Loop wire |
| Part to conform to individual checking fixture requirements | Check part on in process checking fixture .
Loop wire must drop fit in checking fixture .
Loop legs on both ends must be parallel .
Length on loop to be formed correct and locating pin must fit through loop freely .
| First-off sampling 3 samples - in process inspection - 9 samples to be bundled as verification - last off sample to be kept in the checking fixture | First-off at start of shift - in process every hour - Last -off end of shift |
225432254422545
|
1241
|
| Record on BIS Card - record on attribute inspection sheet QD:203 |
| Should the first-off sample failed - stop process re-set machine and redo first off sample - inform Supervisor |
|
|
| 8 | Form wire no 3
Centre wire on Huron / Zukron machine - bundle wires | Forming | Forming |
| Part shall conform to drawing requirements | Check part on in process checking fixture | First-Off sampling - 3 samples - in process inspection
9 samples - last -off 3 samples | First-off at start of shift - in process every hour - Last -off end of shift |
6154615522547
|
1242
|
| Record on BIS Card - record on attribute inspection sheet |
| Should the first-off sanmple fail, stop process, reset machine and redo first-off sample - inform Supervisor |
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|
| 9 | Form wire no 4 - (L) wire left hand on Huron / Zukron machine - bundle wires | Forming | Forming |
| Part shall conform to drawing requirements | Check part on in process checking fixture | First-off sampling - 3 samples
In process inspection - 9 samples
Last -off sampling - 3 samples | First-off at start of shift - in process every hour - Last -off end of shift |
225652256622567
|
1246
|
| Record on BIS Card - record on attribute inspection sheet |
| Should the first-off sample fail, stop process, reset machine and redo first - off sample, inform Supervisor |
|
|
| 10 | Form wire no 5 outer wire left hand on Zukron - bundle wires | Forming | Forming |
| Part shall conform to drawing requirements | Check part on in process checking fixture | First-off sampling - 3 samples
In process inspection - 9 samples
Last-off sampling - 3 samples | First-off at start of shift - in process every hour - Last -off end of shift |
225592256022561
|
1245
|
| Record on BIS Card - record on attribute inspection sheet |
| Should the first-off sample fail, stop process, reset machine and redo first-off sample, inform Supervisor |
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|
| 11 | Forms wire no 6 - Outer wire right hand on Zukron - bundle wires | Forming | Forming |
| Part shall conform to drawing requirements | Check part on in process checking fixture | First-off sampling - 3 samples
In process inspection - 9 samples
LAst-off sampling - 3 samples | First-off at start of shift - in process every hour - Last -off end of shift |
225622256322564
|
1245
|
| Record on BIS CArd, record on attribute inspection sheet |
| Should the first-off sample fail, stop process, reset machine and redo first-off sample, inform Supervisor |
|
|
| 12 | Form wire no 7 - Inner wire on Micro-Mad Machine - bundle wires | Forming | Forming |
| Part shall conform to drawing requirements | Check part on in process checking fixture | First-off sampling - 3 samples
In process inspection = 9 samples
Last-off sampling - 3 samples | First-off at start of shift - in process every hour - Last -off end of shift |
225722257322574
|
1249
|
| Record on BIS CArd, record on atttribute inspection sheet |
| Should the first-off sample fail, stop process, reset machine and redo first-off sample, inform Supervisor |
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|
| 13 | Form wire no 8 (U) wire on Huron / Zukron machine - bundle wires | Forming | Forming |
| Part shall conform to drawing requirements | Check part on in process checking fixture | First-off sampling - 3 samples
In process inspection - 9 samples
Last-off sampling - 3 samples | First-off at start of shift - in process every hour - Last -off end of shift |
225532255422555
|
1243
|
| Record on BIS Card, record on attribute inspection sheet |
| Should the first-off sample fail, stop process, reset machine and redo first-off sample , inform Supervisor |
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|
| 14 | Place all formed wires on KANBANS | Stacking | Stacking |
| Parts must be properly packed as per part number on Kanban. Kanban qty 400 / as per order requirement. | Physically count parts on kanban | Select wires per batch run | Every new batch |
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|
| Record on BIS Card |
| any discrepancies or difficulty found during this activity shall be reported to Supervisor |
|
|
| 15 | Move loaded KANBANS to welding area | Transport | Transport |
| KANBANS must be correctly loaded with correct quantities | Visually inspect KANBAN to ensure parts are loaded correctly | Every new KANBAN | Every new batch |
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|
| Record on BIS CArd |
| Any discrepancies or difficulty found during thie activity shall be reported to Supervisor |
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|
| 16 | Load welding jig | Loading | Loading |
| Wires shall fit jig properly, no bent wires, no damaged wires, no rusty wires | Visual | 100% | Every new loaded jig |
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|
| Record on inspection sheet |
| Any incorrectly formed wires shall be isolated from production, place in dedicated area - inspect on end of shift - raise NCR |
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|
| 17 | Welding of frames | Welding | Welded frame |
SC
| All sections must be welded. Weld pull test required. | Visually inspect all welds mark each weld with a paint marking pen .
Refer to work instruction - WR/PWI/194 | 100% inspection on all welds . Weld pull to be conducted as stipulated on work instruction no 1053 | Every batch |
|
1053
|
| Record on BIS Card every hour and weld pull test sheet QD:284 |
| Any frame with loose welds, smash welds , frames not fitting final checking fixture , inform supervisor and place on hold . |
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|
| 18 | Inspect frame on final checking fixture - and inspect as per work instruction no. 1053 | Inspection | Inspection |
SC
| Frame shall be flat in jig, no skew wires, no loose/smash welds. pins to fit freely through loops, long loop to fit CF correctly, protruding wire (X3) to be more or less even in legth. Refer CAR no's. 19933, 45315 & 53444. | Visual inspection | 100% | Every order |
61552257522576
|
1053
|
| Record on BIS Card |
| Any non-conforming frame found during inspection shall be isolated from production, place in dedicated area, inspect at end of shift - raise NCR |
|
|
| 19 | Pack frames as per customer requirements | Packing | Packing |
| Correct quantities as per packaging instruction - 40 frames on specially made trolleys | Visual inspection - physical counting of frames | Every container | Every order |
|
1053
|
| As per work instruction |
| Any difficulty experienced during this activity shall be reported to Supervisor |
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|
| 20 | Move packed frames to stores area | Transport | Transport |
| Correct loading of trolleys and safe handling during transport activity | Visual | Every load | Every order |
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|
| N/A |
| Any damage to boxes during transport activity shall be reported to Stores Coordinator |
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|
| 21 | Receipt complete quantities into stock | Capturing | Capturing |
| Correct quantities to be captured into stock system | Visual verification | As per order | Every new order |
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|
| F/A Card |
| Any discrepancies shall be reported to Production Supervisor / Production PLanner |
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|
| 22 | Prepare order as per customer requirements | Order preparation | Order preparation |
| Correct quantities as per customer order placement | Visual inspection | Entire batch | Every new order |
|
|
| Delivery note - invoice |
| Any difficulty experienced during this activity shall be reported to Stores Coordinator |
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|
| 23 | Transport frames to customer as per order receipt | Transport | Transport |
| Correct loading and safe handling of trolleys during transport activity | Visual inspection | Entire batch | Every new order |
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|
| Delivery note - invoice |
| Any difficulty experienced during this activity shall be reported to Stores Coordinator |
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|
| 24 | Internal Auditing | Auditing | Auditing |
| All processes, product and systems shall comply to requirements | Verification of process, product and systems | Entire process | As per Audit schedule |
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|
| Audit check sheet |
| All audit findings shall be closed out as per requirements any delays will be reported to Production Manager |
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|
| 25 | Lay-out inspection and Product Audit | Inspection | Inspection |
| Full dimensional report, and other drawing requirements if applicable | Product audit will cover Layout Inspecting as it is a full dimensional of frame | 1 Part | As per Audit schedule |
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|
| Audit check sheet |
| Any non conformance shall be reported to Production Manager for correction |
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|
| 26 | Weld pull test set-up | Set-up | Set-up |
SC
| Select correct setup
4.5x4.5 / 4.5 x 3.5 or 3.5 x 3.5mm wire | Inspection | 1 Sample | 1 test weekly |
|
|
| Record on BIS Card and results on inspection sheet |
| Any difficulty experienced during the set-up shall be reported to the Supervisor for corrective action |
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|
| 27 | Weld pull test | Testing | Testing |
SC
| All weld pull test shall meet the requirements as per the check sheet | Visual inspection
Read load on tester and record on check sheet | 1 Sample | 1 test weekly |
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|
| Record on BIS Card and results on inspection sheet |
| Any weld failures during this test - stop process and inform Supervisor for corrective action |
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