Work Instruction ID:   16300  
Work Instruction Number: 1190 Revision No. 3
Old Work Instruction Number:
Description
Date Created: 23/08/2022 08:35:32 Revision Date: 28/03/2023 08:41:19
Created By: Approved By:
StockCode: WorkCentre:
Customer Stock Code:    
       
Job Observation Frequency (Months)      
       
Creator Approval Date: 11/04/2023 08:50:27 Approved Date: 12/04/2023 14:17:33
Document Status: Current    
 
Work Instruction Rows
Line No.Header RowInstruction 
1

 

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.

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

 

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2

.PUNCHING TOOL SET UP

.Tool height when opened is 74.00 mm on both sides(use gauge blocks/ slip gauges to verify. Refer pictures below:

                   

 .The left and right side must be level and measure 74.00 mm.

.The Gibb Height is 330mm. Measured from the base of machine. Refer pictures below.

                   

SETUP & PREPARATION

  • Ensure the correct parts are accompanied with a BIS card.
    • Daily Maintenance is completed.
    • Stamping Tool is correct and not worn.
    • Tool is secure on press.
    • Ensure to test the press to prvent it from jamming by not putting a part in the tool and stamped it. 
    • Check pressure levels - Pressure should be set between 7 - 8 Bars.

 

On the production system log the time as "Setting."

 Prepare a First-Off sample and ensure that it is verified by Quality.

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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3

QUALITY CHECKS

The following checks should be performed:

  • Do not force the part into the checking fixture.
  • The legs should be parallel and flat.
  • When placed on a flat surface the legs should not rock.
  • After stamping the part legs shall be flat or have a 0.40 mm MAX gap.  Use a 0.5mm feeler gauge to check the gap. The 0.5mm gauge should not fit through. 
  • When checking part for flatness ensure the flat side is on the bottom.
  • Stamping thickness of the legs is from 4.50 mm - 4.70 mm.
  • Ensure the part is corrrectly placed in the tool before stamping.

Examples

 

NG gap too big after stamping. 0.50 mm feeler gauge is fitting through.

 

 

OK - part is flat, the 0.50 mm feeler gauge does not fit through.

                   

 

 

 

  

 

 

 

 
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4

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 Number "8279" "Assembled Frame First-off". 
  • First-off sample to be tagged and remain with the checking fixture.

 

  • Conduct in-process inspections every hour and record on system Inspection  Number "8280" "Assembled Frame Inprocess" 

 

  • 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 system Inspection  Number "10371"
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5

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
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6

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.
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