| 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 by stores personel | 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 personel | Inspection | Raw material |
SC
| Correct material 4.5mm +/- 0.045mm spring wire. WIRE/SBS3/0450. Specification - .EN 10204. Tensile range - 1400mpa to 1600mpa. 6mm +/- 0.006mm spring wire. WIRE/SBS3/0600. Specification - .TSG 3531G SWB. Tensile range - 1150mpa to 1350mpa. No pitted rust, no score marks, no excessive drawing soap | Visual Inspection / Micrometer | As per incoming raw material inspection QD207 | Every Consignment |
82896193
|
1120
|
| Goods receive notebook / Buff tag and record findings on on-line 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 for storage | Transport | 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 |
| Issue wire to production | 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 LH & RH box wire | Forming | Product |
SC
| Form LH & RH box wire as per checking fixture | Visual inspection for fitment in Checking fixture. Parts shall fit in checking fixture.Rotate,angles and Leg lengths correct. | First-off sample & In-process inspection and last-off | 9 Parts every hour |
103541035510356103571035910360
|
1160
|
| Record on BIS card and on-line inspection system |
| Should the first-off sample fail stop process and reset machine and re-do first-off. |
|
|
| 7 | Form outer wire on Huron | Forming | Product |
SC
| Form outter wire as per checking fixture, outter wire to sit in checking fixture profile correctly. Legs paralell and not formed too wide. Rotate,angles and Leg lengths correct. | Visual inspection for fitment in Checking fixture. Parts shall fit in checking fixture. | First-off sample & In-process inspection and last-off | 9 Parts every hour |
103501035110352
|
1160
|
| Record on BIS card and on-line inspection system |
| Should the first-off sample fail stop process and reset machine and re-do first-off. |
|
|
| 8 | Transport wire forms to LTHT | Transport | Products |
| Correct handling of products during this activity | Visual Inspection | Entire batch | Every job as per request |
|
|
| NA |
| Any difficulty experienced during this activity report to supervisor |
|
|
| 9 | LTHT | Heat Treatment | Products |
SC
| Correct temperature 300 degrees Celsius for 20 minutes | Visual verification | Every batch | Every job |
|
|
| Record temperature on log sheet QD:52 for every batch |
| Any discrepancy shall be reported to supervisor |
|
|
| 10 | Transport products to assembly area | Transport | Products |
| Correct products that fits the checking fixture. correct quantity as per job request | Visual verification | Every batch | As per job request |
|
|
| NA |
| Should any difficulty occur during transportation inform supervisor |
|
|
| 11 | Shoot clips and Assemble product on mould plate | Assembly | Products |
SC
| Ensure clips are secure on product and not loose or missing.
Assemble mould plate onto product correctly, mould plate clip must be secure on product, no cracks or looseness. | 100% inspection on assembly jig
| Every batch | Every order |
|
|
| NA |
| Any discrepancies shall be reported to supervisor |
|
|
| 12 | Inspection of completed products | Inspection | Completed product |
SC
| Product shall fit in final fixture correctly, product to fit in slots in fixture. Legs must align in the C/F slot and must not be high. Box wire legs on product must be flat. No rust, burrs or surface residue on product and no gap between the mould plate.
No missing or loose clips. | Visual | First-off sample & In-process inspection and last-off | In process, 9 parts every hour |
932393249325
|
1209
|
| Record on BIS card and on-line inspection system |
| Any difficulty experienced during this activity report to supervisor |
|
|
| 13 | Pack products into bin | Packing | Completed product |
| Correct quantity. 12 Seat backs per bin.
Bin No 4633, blue
25 bins per pallet | Physical counting of products | as per customer requirement | Every job |
|
|
| 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 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 | Lay-out inspection | n/a | Seat Back product |
| compliance to drawing requirements and customer specifics - full dimensional report | Measurement of all required dimensions | 1 Complete product | As per schedule |
|
|
| records of all findings |
| should there be any failures, inform customer and production manager |
|