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SETUP & PREPARATION
- Ensure the machine configuration and setup is complete as per the Setter Training Manual.
- Daily Maintenance
- Physical Tooling is correct
- Correct tool is selected in the machine config
- Wire thickness is set in the machine config
- Adjust the overbends by performing a 90/20 setup.
Ensure the correct wire has been issued by validating GRN buff tag against the route card.
On the production system log the time as "Setting."
Load the Part Recipe found in the location "part recipe location" and prepare a First-Off sample.
Once the first-off is correct, on the production system end the "Setting"downtime and enter the job number and operation to start the job.
Enter the first-off inspection results in the production system.
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QUALITY CHECKS
- Ensure that each part is checked on checking fixture and "Good" parts are breakpointed.
- Ensure that non-conforming parts that are not fitting on checking fixture are kept aside/ isolated from good batch.
- A concession must be raised and rework documents must be generated for reworking of non-conforming parts.
- Reworked parts are to be 100% checked on checking fixture and breakpointed accordingly.
- Ensure that both legs front and back section on the products are sitting flat as this this crucial for the welding process.
- Gap between the legs shall be 21mm.
Example of a good part (RH) - 72613-0A040
Example of a good part (LH) - 72614-0A040
The following checks should be performed:
- Do not force the part into the checking fixture, place the top section in the checking fixture slot first.
- .Ensure part is against the block as indicated in picture below.
- The R/H use your left hand to ensure part is agsinst the block.
- The L/H use your right hand to ensure part is against the block.
R/H LH
 
- After part is placed in fixture, use the clamp to secure the part.
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Example of a bad parts:
 
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QUALITY INSPECTION
- 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 no.1072 (SPRG/RAMS/006) & 1076 (SPRG/RAMS/0007).
- First-off sample to be tagged and remain with the checking fixture.
- Conduct in-process inspections every hour and record on system Inspection no. 2071 (SPRG/RAMS/0006) & 2072 (SPRG/RAMS/0007).
- 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 and record on the system the last off inspection no. 13402 (SPRG/RAMS/006) & 13403 (SPRG/RAMS/0007).
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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. 1020 - (SPRG/RAMS/0006) & 1019 - (SPRG/RAMS/0007)
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
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PERFORMANCE TARGETS
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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.
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Production figures are to be logged on the system every hour.
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