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MANUFACTURING QUALITY CHART

COMPILED BY		TEAM MEMBER 2
TEAM MEMBER 3		TEAM MEMBER 4
SUPPLIER	Webroy (Pty) Ltd	MQC No
CUSTOMER		REV No.
PART NAME		DATE INITIATED
PART No.		REVISION DATE	2024/08/27
		LAST REVIEW DATE
WEBROY STOCK CODE		STATUS
MANUFACTURING LOCATION	Webroy	SAFETY CRITICAL
MQC TYPE
Current

Process Flow Key

Process Type	Image
PARTS STOCK
COMPONENT PART
PROCESS OPERATION
SAMPLING INSPECTION
100% INSPECTION
TRANSPORT

Responsible
Confirmation Level Key

Name	Image
OPER
T/L
SUPERVISOR
MNGR
OPER
T/L
SUPERVISOR
MNGR

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 and verification of raw material	Receiving	Raw material		Check for correct quantity delivered, type and diameter	Visual inspection and verification as per order	Delivery note and order	Every batch		1090		Goods receive notebook / delivery note		Should there be any discrepancies inform production planner / supplier immediately and make a note on P.O.D
	2	Move material to receiving storage area	Transport	Raw material		Store material correctly	Visual inspection	As per FIFO system	Every batch				Visual inspection and FIFO board		If difficulty occurs in storing raw material properly inform Stores Coordinator
	3	Inspection of raw material by QA personnel	Inspection	Raw material		SPEC. TSG3533G. Material. WIRE/MBH2/0800 SAE 1008 - 8.0mm +/- 0.08mm. Tensile range 550mpa to 750mpa No pitted rust, now score marks, no excessive drawing soap Phosphate coating as per CAR3/18	Visual inspection Micrometer	As per incoming raw material inspection	Every consignment	6179	1120		Record on inspection system		Any non-conforming raw material shall be placed on hold and isolated. Raise SRAN and inform Stores Coordinator
	4	Move raw material to dedicated area forstorage	Storage	Raw material		Safe stacking of wire coils on to racks as per allocated areas and FIFO system	Visual inspection	As per FIFO system	On receiving				FIFO information board and rack identification		Any difficulty experienced during this activity report to Stores Coordinator
	5	Issue wire to production	Issuing	Raw material	SC	Correct wire to be issued as per job card	Verification as per buff tag Setter to measure wire diameter with vernier	Every coil issued to production	Every coil				Route card		Should the incorrect wire be issued to production stop process, correct and inform Stores Coordinator
	6	Form wire on 12mm Huron	Forming	Product	SC	Form wire as per in-process checking fixture no. CFIX00119, part shall drop fit into the checking fixture. Correct tooling required. Angle required on moulded section - 30 degrees - 35 degrees. Product sits flat and has not lift when placed on a flat surface - Refer CAR No. 53438.	Visual inspection, confirm products in the checking fixture. Use a angle finder to check angle.	First-off - 5 parts, which is sent through each process to check notching and wire movement. 5 parts to be stamped and coated for each batch	First-off at start of production. In-process 9 parts every hour and last-off	14423 15423 15424	1064		Record on Electronic system		Should the first-off sample fail stop process and reset machine and re-do first-off
	7	Notching process	Notching	Notched area		Correct dimensions on notch as per drawing. Depth of notch 6mm +- 0.02mm as per drawing. No burr after cropping, max burr 0.2mm. correct placement of the parts in the grooves and correct position in order to be notched correctly.	Visual check as per Work instructions. Check for burrs using measuring Gauge No. SPRG/TOYO/0064 Vernier	As per work instruction	First-off at start of production. In-process 1 part every hour and last-off	1041 6089 12399	1065		Record on Electronic system		Any difficulty notching stop process and inform supervisor
	8	Washing	Cleaning Tanks	Products		Remove oil and rust. Check chemical PH and temps are to specification. If grease remains increase wash time (CAR 3/18 & 2/18)	Visual inspection. Refer to work instruction	Every batch	Daily		1069		Record on QD329 Expoxy Process Parameters		Any difficulty during washing stop process and inform supervisor
	9	Epoxy coating of rods	Coating	Coated rods	SC	Line speed 43-35 sec/m Oven temperature 190-200 deg Smooth finish, check for pin holes, ripples, score marks Coating thickness 80-125 microns. Refer to work instruction	Visual inspection Coating thickness gauge	Coating thickness test 5 readings per rod	1 Rod hood per batch	1042 6090	1143		Record process parameters on QD329 Record thickness on system		Any difficulty during this process report to supervisor
	10	Moulding process and final inspection	Moulding	Product	SC	Check process parameters on QD329. Check for burrs after mould on part Remove flash Check for pinch point below moulded part Fits checking fixture. sliding bar must slide through freely on angle check, angle on mouldd section shall be 30 - 35 degrees. Refer CAR No. 53438.	100% Visual inspection of parts in the checking fixture.	100% check in checking fixture.	Every part	1043 6091 12388	1063 1205		Record every hour on Electronic system		Any difficulty experienced during this activity report to Supervisor
	11	Load pull test	Load pull	Load pull	SC	Check load > 1000N minimum	Pull test	1 Part	Weekly				Record results on Load test record sheet QD:304		Any difficulty experienced during this activity report to supervisor
	12	Taping of sponge	Taping	Product		Correct fitment of sponge as per drawing Sponge should have no gap after fitment	Visual and using checking fixture POKE YOKE device (PY001) for sponge fitment (CAR15/18). PY001 verified every 12 months	As per work instruction	Ever rod hood		1063		Record every hour on Electronic system		Any difficulty experienced during this activity report to Supervisor
	13	Packing of final product	Packing	Products		Correct quantity 22 products per bin Blue Bin No 4122 10 bins per pallet	Visual	As per work instruction	Every job		1063		F/A Card		Should the quantity be incorrect, stop process, verify quantity and add/remove products to meet quantity required
	14	Transport product to stores	Transport	Products		Correct bins and correct quantities	Visual inspection	As per works order	Every batch				F/A Card		Should difficulty occur during transport inform Supervisor
	15	Receipting product to stores	Receipting	Products		Correct quantity to be entered on to the stock system	Visual	Every batch	Every order		1094		F/A Card		Any discrepancies shall be reported to the Stores Coordinator
	16	Dispatching of products	Transport	Products		Correct loading of bins and safe handling during transport activity	Visual	Entire order	Every order		1101		Delivery note / invoice		Any difficulty experienced during this activity report to Stores Coordinator
	17	Layout functional inspection	Inspection	Product	SC	Full dimensiomal	As per customer requirements	1 Complete product	As per schedule				Audit sheet		Should the functional layout fail the Production manager shall be informed immediately.