SAFETY

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

Be careful of pinch points. Keep fingers clear at all times when the machine is operating.

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 wire is straightend correctly.

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.

QUALITY CHECKS

The following checks should be performed:

• Do not force the part into the checking fixture.
• When placed in checking fixture, part shall fit flat in the slots between the pins.
• All angles, bends and rotation must be correct to fit in correctly in checking fixture.
• First -Off matches the last - off.
• Angle and bends correct and fits into the fixture slots.
• Part leg is flat when placed on a flat surface.
• Appearance - No burrs, score marks, rust.
• Ensure the wire is straightend correctly.
• in process checks and NG part separation -  E.g. you are required to run 1000 parts. You run 200 parts into a box. You complete the first-off at the
  start of the job, every 200 parts you do an in-process check and place a new empty bin under the
  machine to collect parts. On the third box of 200 you find the part does not conform. You can be
  confident the first 2 boxes are correct as you did an in-process checks after each and confirmed the
  parts to be good. You only need to isolate the third box and sort to identify how many non-conforming
  parts were produced. Without the in-process checks on each box you would need to check all 600
  parts made in the batch.

Examples

"OK" condition  

"NG" condition

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 7258
• First-off sample to be tagged and remain with the checking fixture.

• Conduct in-process inspections every hour and record on system Inspection no. 7259

• 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 last-off on system Inspection no. 19442

REJECTS

All reject parts are to be placed immediatley in the red reject bins provided. All rejects should be logged on the system hourly.  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.