SAFETY

Ear, hand and eye protection must be worn throughout this operation.

Be careful of pinch points and weld sparks. Keep fingers clear and eyes protected at all times when the spot welder is in operation.

SETUP & PREPARATION

• Ensure the spot welder set up is complete.
  
  • Correct program & weld settings are used - as per spot welder data parameter check sheet (QD:328/02/19).
  • Air & water flow is adequate.
  • Copper tips are dressed.
  • Copper tip heights are correct.
• Fill in the data parameter check sheet - QD:328/02/19 before running production.

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."

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.
  • The legs should be equal in length.
  • The legs should be parallel to each other.
  • When placed on a flat surface the legs should not rock.
  • Wire to sit flat in fixture.
  • Destructive test should be conducted upon First off.
  • Material thickness across welded portion = 10.00 - 10.50 mm.
  • Apprearance - no burrs, weld splatter, rust and score marks allowed.

Examples:

QUALITY INSPECTION

• The Last-off from the previous batch is to be compared to the current batch's First-off. Last-off is to be placed in the production run.
• Complete a First-off before commencing with production, and record on system Inspection.
• First-off sample to be tagged and remain with the checking fixture - Inspection Number 21497.
• Conduct in-process inspections every hour and record on system Inspection - Inspection Number 21498.
• At the end of the batch, last-off part is to be tagged and kept with the checking fixture. First-off is to be placed in the production batch - Inspection Number 21499.

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.