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SAFETY
Gloves and ear plugs are to be worn throughout this operation.
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SETUP & PREPARATION
- Ensure the start up preperation , purging and shut down is followed and complete as per work instruction no. "1203" (Start-up, purging and shutting down).
- Daily Maintenance
- Ensure Process parameter settings are correct, record on system at the beginning of shift.
Prepare a First-Off sample.
Once the first-off is correct, on the production system log the job on the system 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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LOADING AND UNLOADING
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LOADING
1. Pick up 2 wires and load onto the mould, line the wires up between the pins
2. Use the hammer to tap the wires into the locating pins
3. Make sure the wires are sitting flat on the mould before pressing the green button.
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4. The 2 operators will need to press the green run buttons simultaneously to run the machine.
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UNLOADING
1. Waiting for the rotating table to stop completely.
2. Use both hands to remove the part from the mould
3. Press both buttons to rotate jig.
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QUALITY CHECKS
The following checks should be performed:
- Check for any broken plastic
- Check for any miss-injection, not all the plastic has been moulded in the required areas.
- Check for bleeding or flash.
- Check center plastic that locates onto the sensor has been moulded and mark it with a blue marker.
- 100% Visuall check every part and then put inspector initials as confirmation and traceability.
- No visible rust.
- Correct injection.
- No sprue.
- No sharp edges Overmoulded wires to be completely covered, look for under shooting.
The below image shows a part that is correctly moulded. The yellow arrows indicate the areas were the parts has be moulded.
QUALITY ALERTS
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OK
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NG
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OK
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NG
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OK
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NG
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OK
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NG
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OK
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NG
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TRACEABILITY
BREAK POINT I.D
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PACKAGING
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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. "16456"
- First-off sample to be tagged and remain with the checking fixture.
- Conduct in-process inspections every hour and record on system Inspection no. "16458"
- At the end of the batch, last part is to be tagged and kept at the work station. First-off is to be placed in the production batch
- Conduct a last-off inspection at the end of every batch and record on system Inspection no. "16460"
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REJECTS
- All set-up rejects are to be placed immediatley in the red reject bins provided.
- All process rejects are to be placed immediately 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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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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