SAFETY  

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

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

1. Ensure to wear ear protection when working in noise zone area.
2. Open shoes are prohibited on factory premises.
3. All necessary PPE to be worn when working in spray booth.
4. Gloves to be worn when removing frames from the line required.                                                                                

PREPARATION

• • Clean and dust off work surface
  • Check the sharpness of the cutting blade
  • Check if the start/ stop buttons are functioning        

   

• After successful checks, load straight wire component into machine.

SET UP INSTRUCTIONS

1. Use the Big Roller

2. Distance from the cutter to sensor 360mm

3.The number of curves for the spring is 11.

INSTRUCTIONS FOR FORMING ENDS.

1. Locate the edge of the spring between the pin and locating tool.

2. Press the pedal to form the edge of the spring.

3. Repeat steps 1 & 2 for the other edge of the spring, ensuring both ends are formed.

INSTRUCTION FOR LTHT

1. Set oven temperature to 300°C.

2. Load spring into baskets and place into oven.

3. Allow for springs to be cooked for 20 minutes @ 300°C - Record temperature on Oven log sheet (QD 52/04/16).

4. Take out the basket from the oven and let it cool down for ±20 minutes.

INSTRUCTION FOR STRETCHING

1.Place spring onto the stretching machine .

2. Press the right pedal to stretch/open the spring then press the left pedal to close the spring.

QUALITY INSPECTION

1. Ensure that the spring passes on checking fixture.

2. Make sure that the part is sitting flat.

3. Do not force the spring into checking fixture.

4.  Make sure that the edges are not protruding.

5.  No rust, burrs or sharp edges to be present on springs.

6. Ensure that the correct dunnage is used to pack springs after checking (Bin type - 4311)

Record results for First off inspection (No. 6243 - Form convolute, No. 20453 - Form ends & No. 20456 - Stretch), In process inspection (No. 6244 - Form convolute, No. 20454 - Form ends & No. 20457 - Stretch) & Last off inspections (No. 6245 - Form convolute, No. 20455 - Form ends & No. 20458 - Stretch).

Any non-conforming part shall be isolated from production process and placed in reject/ suspect bin and reported to the supervisor/ team leader.

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. 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 shows an example of Performance Targets.

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