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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	2023/09/21
		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	Receiving		Check for correct quantity delivered, Material 9mm Mild Steel wire in coil form	Visual inspection and verification as per order	Delivery note and order	Every batch				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	Transport		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	Inspection		Mid Black Wire WIRE/MBH1/0900 9mm +/- 0.08mm. Material- SAE 1008. Tensile range 550mpa to 750mpa - correct diameter No score marks - no rusty wire, Correct grade, correct tensile - verify material compositions as per spec	Visual inspection Micrometer for wire diameter COA from supplier - record findings on incoming inspection document	As per incoming raw material inspection QD207	Every consignment	1047	1120		Goods receive notebook / Buff tag and record findings on incoming receiving inspection no. 1047		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	Storage		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	Issuing	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	Straighten wire and cut to length	Cutting	Cut lengths	SC	Correct cut length = 420mm +/- 1mm	Visual inspection Measure with tape measure	First-off sample In-process inspection	Every batch	1051 2074 22524			Record first-off and in-process inspection 1 part every hour record on BIS card		Should the first-off sample fail stop process and reset machine and re-do first-off
	7	Move part to chamfer tool	Transport	Bent wire form		Safe transportation of wires	Visual Inspection	Every batch	Every batch				NA		Any difficulty report to the supervisor
	8	Chamfer ends	Chamfer	Chamfered Wire		Chamfer ends. Top Chamfer 1mm +- 0.5mm Bottom Chamfer 1mm +- 0.5mm	As per work instruction - 1051 Measure with a Vernier	First-off In process inspection	Every batch	1052 1056 22527	1051		Record First off and in process inspection 1 part every hour record on BIS card		Any difficulty report to the supervisor
	9	Form bends 1 and 2	Forming	formed bend 1 - loop and 2 kink		Correct length as per drawing , as per fitment on in-process checking fixture.	Visual Inspection. As per work instruction - 1054. Verify fitment on in-process checking fixture	First-off sample In-process inspection	Every Batch	1053 1057 22525	1054		Record every hour on BIS Card		Any difficulty report to supervisor
	10	Flatten and form radius	Press	Press Wire Form		Correct radius Correct diameter of flattened wire Must conform to checking fixture. No unformed parts left lying around that can get mixed in the bin with finished parts. 5S and good housekeeping to ensure separation of good and bad parts.	Visual inspection. As per work instruction - 1049.	First off In process inspection	Every Batch	1054 1058 22526	1049		Record First-off and In Process Inspection every hour on BIS card		Any difficulty report to supervisor
	11	Sub-Contract part for Galvanising	Sub-Contract Process	Pressed Wire		Safe handling of part during transport to sub contractor	Visual Inspection	Visual Inspection	Every batch				NA		Any issue report to production manager
	12	Receive plated part from sub contractor	Receiving	Plated Part		Correct Plating Plating Thickness 5 to 60 microns	Visual Inspection	Sampling Inspection during receiving	Every batch	1055			Receiving Inspection Sheet		Any issues report to production planner and quality team leader
	13	Receipting product to stores	Receipting	Receipting		Correct quantity to be entered on to the stock system	Visual	Every batch	Every order				F/A Card		Any discrepancies shall be reported to the Stores Coordinator
	14	Packing of final product	Packing	Packing		40 Parts per bin Plastic bin size 4616	Visual	As per work instruction	Every job				F/A Card		Should the quantity be incorrect, stop process, verify quantity and add/remove products to meet quantity required
	15	Dispatching of products	Transport	Transport		Correct loading of bins and safe handling during transport activity	Visual	Entire order	Every order				Delivery note / invoice		Any difficulty experienced during this activity report to Stores Coordinator
	16	Layout functional inspection	Inspection	Inspection	SC	Full dimensiomal	As per customer requiremetns	1 Complete product	As per schedule				Audit sheet		Should the functional layout fail the Production manager shall be informed immediately.