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, cut a piece of wire to  check straightness. 

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. The First-off sample must be sent for heat treament. Required tempreture is 300 degrees x 20 mins.

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 the checking fixture, part shall sit flat.
• All angles, bends and rotation must be correct to fit  correctly in the checking fixture.
• Ensure that the Outter wire and box wire First-off is set correctly to fit in the checking fixture before LTHT and vaildate the parts after LTHT into the fixture.
• Appearance -No surface residue, rust , Score Marks, Burrs.
• Ensure that the Outter wire is set to fit the checking fixture profile and not rely on the next process to tweak and align parts to fit in the final fixture.

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. 10350 (Forming of Outer wire), 10354 (Forming of LH Box wire) & 10357 (Forming of RH Box wire)
• First-off sample to be tagged and remain with the checking fixture.

• Conduct in-process inspections every hour and record on system Inspection no. 10351 (Forming of Outer wire), 10355 (Forming of LH Box wire) & 10359 (Forming of RH Box wire)

• 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: Inspection no. 10352 (Forming of Outer wire), 10356 (Forming of LH Box wire) & 10360 (Forming of RH Box wire)

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. 155 (Outer wire), 156 (Left box wire) or 157 (Right box wire) 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.