Safety Checks and start-up

Gloves, protective glasses and ear plugs are to be worn throughout this operation.

Keep hands and clothing away from moving parts at all times.

• The press has a double activation buttons. The press will only stroke when both buttons are pressed.
• Ensure the safety cage is in place during operation

•  Check that the safety switch is up and not pushed down

• At the back of the press machine, locate the black knob.
• Push the knob in for 40 to 50 seconds to release air pressure

• Next to the press machine, on the right, locate orange switch board.
• Reset the press by turning the reset key from OFF to ON to OFF again.

• On the same switch board, press the green ON button to start the press machine.

Preparation

• Going back to the front on the press machine, place the first wire component in the fixture on the left in the position pictured below:

Stamping

• After placing the wire component in place, with both hands, press the two black buttons on the control panel to stamp the component.

Prepraration

• Remove the wire component from the stamping position and place it in the fixture on the right as pictured below:

• Place another component in the forming fixture on the left.

Forming

• Again, after placing the wire component in place and with both hands, press the two black buttons on the control panel to form the component.

Quality Checks

• Remove the component from the press machine and place it on then checking fixure to check for conformance.

• With the two go/no-go gauges, evalute the measurements of the width and thickness of the component.
• The go/no-go gauges have gaps used to evaulate an acceptable/unacceptable component.
• If the component fits in the no-go area (space beyond the indentation on go/no-go gauge) it is not an acceptable component.
• Otherwise should it only fit in the go area (space before the indentation on go/no-go gauge), it is acceptable.

• Using go/no-go gauge 1, evaluate the measurement of the neck area. Refer to the pictures below and measure using vernier where necessary.

• Using go/no-go gauge 2, evaluate the measurements of the entire hook area. Refer to the pictures below and measure using a vernier where necessary.

. GO and NO GO gauges must be used to confirm the entire hook area as per picture below.

   - Critical control area must maintain constant area.

           QUALITY ALERT

N.B  5S and good housekeeping to ensure separation of good and bad parts. Unformed parts should not be left lying around as there a risk of bad parts being mixed with good parts and can outflow to TSAM.

Quality Inspection Frequency

• The Last-off from the previous batch is to be compared to the current batch First-off. Last-off is to be placed in the production run.
• Complete a First-off before comencing with production, record on system Inspection Number 1054 "Flatten & Form Radius". 
• First-off sample to be tagged and remain with the checking fixture.

• Conduct in-process inspections every hour and record on system Inspection Number 1058 "Flatten & Form Radius"

• At the end of the batch, last part is to be tagged and kept with the checking fixture. First-off is to be placed in the production batch.

Rejects

All reject parts are to be placed immediatley in the red reject bins provided. All rejects should be logged on the system hourly. Reject Analysis No. 1018   Scrap / Reject bins are to be emptied at the end of end job or at the end of shift if the job is running at the end of shift

Performance Targets

Once the job has been logged on the system, you will be able to see the production figures and targets including the Total Qty made against the job, the quantity prodcued on the shift (day), the Std Time and the number of Parts required to be made per hour. The picture to the left provides and example.

Production figures are to be logged on the system every hour.