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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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PUNCHING TOOL SET UP
Tool height when opened is 66.20 mm (LH Front), 66.60 mm (RH Front), 65.70 mm (LH Back) & 66.20 mm (RH Back) - use gauge blocks/ slip gauges to verify. Refer pictures below:
The Gibb Height is 323.00 mm. Measured from the base of machine - use a tape measure to verify. 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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QUALITY CHECKS
The following checks should be performed:
- Do not force the part into the checking fixture.
- Component must drop fit on checking fixture (Profile of component to sit in between checking fixture pins).
- The legs should be parallel and flat.
- Overall width must measure 222.00 mm after stamping.
- After stamping the part legs shall be flat or have a 0.4mm MAX gap. Use a 0.5mm feeler gauge to check the gap. The 0.5mm gauge should not fit through.
- Both legs to sit flat when either leg is held down.
- When checking part for flatness ensure the flat side is on the bottom.
- Stamping thickness of the legs should be 4.70 mm - 5.00 mm.
- Ensure the part is corrrectly placed in the tool before stamping.
- Ensure the part fits in the profile of the press tool.
Examples
 
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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 Number "7274" "Inspection of stampped parts".
- First-off sample to be tagged and remain with the checking fixture.
- Conduct in-process inspections every hour and record on system Inspection Number "10369" "Inspection of stampped parts"
- 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 "10370" Inspection of stampped parts.
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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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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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