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 2024/06/10
    LAST REVIEW DATE 
WEBROY STOCK CODE STATUS
MANUFACTURING LOCATION Webroy SAFETY CRITICAL
MQC TYPE
Draft
Process Flow Key

Process TypeImage
PARTS STOCK
COMPONENT PART
PROCESS OPERATION
SAMPLING INSPECTION
100% INSPECTION
TRANSPORT
Responsible
Confirmation Level Key
NameImage
OPER
T/L
SUPERVISOR
MNGR
OPER
T/L
SUPERVISOR
MNGR


PROCESS FLOWNONAMEWORK ELEMENTCHECK ITEMRANKPROCESS CRITERIONINSPECTION METHODINSPECTION PLANFREQUENCYInspection No.(s)Work InstructionsRESPCHECK SHEETCONFIRM'N LEVELREACTION PLAN 
1Receiving 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.
2Move material to receiving storage area.Transport.Raw material. Store material correctly.Visual inspection.As per FIFO system.Every batch Visual inspection and FIFO. If difficulty occurs in storing raw material properly inform Stores Coordinator
3Inspection of raw material by QA personnel.Inspection.Raw material. SPEC. SAE1008. Material. WIRE/MBH2/0800 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 QD207.Every batch 6179
 1120
 Record on inspection system. Any non-conforming raw material shall be placed on hold and isolated. Raise SRAN and inform Stores Coordinator.
4Move 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 and rack identification. Any difficulty experienced during this activity report to Stores Coordinator.
5Issue 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.
6Form product on Huron 4.Forming.Product. SC Form wire as per checking fixture, part shall drop fit into the checking fixture. Correct tooling required. Angle required on moulded section - 32 degrees - 35 degrees. Product sits flat and has not lift when placed on a flat surface.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



Record on system. Should the first-off sample fail stop process and reset machine and re-do first-off.
7Notching.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. XXXAs per work instruction.First-off at start of production. In-process 1 part every hour and last-off Record on system. Any difficulty notching stop process and inform supervisor.
8Washing.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.Every order







Record on QD329 Expoxy Process Parameters. Any difficulty during washing stop process and inform supervisor .
9Epoxy coating.Coating.Products. 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 rod1 Rod hood per batch. Record process parameters on QD329 Record thickness on BIS Card. Any difficulty during this process report to supervisor.
10Moulding process and final inspection.Moulding.Products. 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. Refer to work instruction for all quality checks required to perform.100% Visual inspection of parts in the checking fixture.100% check in checking fixture.Every part.







Record every hour on system. Any difficulty experienced during this activity report to Supervisor.
11Pull test.Pull testPull of load SC Check load > 1000N minimum.Pull test1 Part.Weekly. Record results on Load test record sheet QD:XXX Any difficulty experienced during this activity report to supervisor.
12Taping of sponge.Applying tape and sponge.Product. Correct fitment of sponge as per drawing Sponge should have no gap after fitment.Visual and using checking fixture POKE YOKE device (XXX) for sponge fitment (CAR15/18). XXX verified every 12 monthsAs per work instruction.Every product. Record every 2 hours on Electronic system. Any difficulty experienced during this activity report to Supervisor.
13Packing of final product.PackingProducts. Correct quantity 22 products per bin Blue Bin No 4122 10 bins per pallet.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.
14Transport product to stores.TransportProducts. Correct bins and correct quantities.Visual inspection.As per works order.Every batch. F/A Card. Should difficulty occur during transport inform Supervisor.
15Receipting product to stores.Receipting.Products. 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.
16Dispatching of products.Transport.Products. 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.
17Layout functional inspection.Inspection.Product. Full dimensinal as per SDS.As per customer requirements.1 Complete product.As per schedule. Audit sheet. Should the functional layout fail the Production manager shall be informed immediately.