| PROCESS FLOW | NO | NAME | WORK ELEMENT | CHECK ITEM | RANK | PROCESS CRITERION | INSPECTION METHOD | INSPECTION PLAN | FREQUENCY | Inspection No.(s) | Work Instructions | RESP | CHECK SHEET | CONFIRM'N LEVEL | REACTION PLAN | |
| 1 | Receiving verification of raw materials by stores personel | Receiving | Receiving |
| Check for correct quantity delivered, type, diameter, wire cod ,specification and tensile range | Visual inspection and verification as per order | Delivery note and order | Every batch |
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| Goods Receive book / Delivery note |
| Should there be any discrepancies inform production planner / supplier immediately and make note on POD |
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| 2 | Move material to receiving storage area | Transport | Transport |
| Store material correctly | Visual Inspection | As per FIFO System | Every Batch |
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| Visual inspection and FIFO Board |
| If difficulty occurs in storing raw material properly inform Stores coordinator. |
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| 3 | Inspection of raw material by QA personel | Inspection | Inspection |
SC
| Correct Diam 4.5mm / 6.0mm
Correct type SWB
No rusty wire / no score marks, tensile -700/900, specification =ASTM /A580/A580M-08, wire tolerance =0.025 | Visual Inspection / Micrometer | As per incoming raw material inspection plan | Every Consignment |
6163
6180
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1120
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| Goods Receive Note book / Buff tag and record findings on incoming receiving inspection sheet |
| Any non-conforming raw materials shall be place on hold and isolated. Raise a SRAN and inform stores coordinator |
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| 4 | Move raw material to dedicated area for storage | Storage | Storage |
| Safe stacking of wire coils onto racks as per allocated areas and FIFO system | Visual Inspection | As per FIFO System | On receiving |
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| FIFO Information board and rack identification |
| Any difficulty experienced during this activity report to Stores Coordinator |
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| 5 | Issue wire to production | Issuing | Issuing |
| Correct wire to be issued as per job card | Verification as per buff tag
Check diameter of wire using vernier | Every coil issued to production | Every job as per request |
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| Route Card |
| Should the incorrect wire be issued to production stop process, correct and inform Stores Coordinator |
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| 6 | Form outer wire on Huron | Forming | Forming |
SC
| Form wire as per checking fixture / drawing | Visual inspection.
Checking fixture
First-off sample
In process inspection and last off | First off- In process inspection and last off. | First off at start of production. In process 9 parts every hour to be verified in checking fixture and bundled |
6253
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1158
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| Record on line system |
| Should the first off sample fail - stop process reset machine and redo first off sample - Inform Supervisor |
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| 7 | Inspect wire form | Inspection | Inspection |
| Parts shall conform to checking fixture / drawing requirements | Check wire using checking fixture | 2 parts as per work instruction | 2 every hour |
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| Record on-line system |
| Any non-conformance shall be isolated. Raise NCR put a hold card and be place in quarantine store. Inform Quality Manager |
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| 8 | Transport wire to LTHT | Transport | Transport |
| Correct handling of wire forms during this activity | Visual Inspection | NA | Every job as per request |
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| NA |
| Any difficulty experienced during this activity report to supervisor |
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| 9 | LTHT outer wire | Heat Treatment | Heat Treatment |
| Correct temperature 300 degrees Celsius for 20 minutes | Visual | As per requirements | Every batch |
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| Record temperature on log sheet QD52 for every batch |
| Any non-conformance shall be isolated. Raise NCR put a hold card and be placed in quarantine store. Inform Quality Manager |
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| 10 | Form left and right hand box wire on Huron | Forming | Forming |
SC
| Form wire as per checking fixture / drawing | Visual inspection
Checking fixture | 2 parts as per work instruction | 2 every hour |
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| Record on-line system |
| Any non-conformance shall be isolated - raise NCR out a hold card and be placed in quarantine store. Inform Quality Manager |
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| 11 | LTHT left and right hand box wire | Heat Treatment | Heat Treatment |
SC
| Correct temperature 300 degrees Celsius for 20 mintues | Visual | As per requirements | Every batch |
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| Record temperature on log sheet QD52 for every batch |
| Any non conformance shall be isolated. Raise NCR put a hold card and be placed in quarantine store. Inform Quality Manager |
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| 12 | Rill sanding left and right hand box wire | Rill Sanding | Rill Sanding |
| Rill sanding as per method. | Visual Inspection | Every batch | Every order |
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| NA |
| Should any difficulty or problem occur report to supervisor immediately. |
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| 13 | Assemble part | Assembly | Assembly |
SC
| Assemble as per work instruction | 100% inspection on assembly jig | Every batch | Every order |
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| NA |
| Any problems shall be reported to the supervisor |
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| 14 | Inspection of frames | Inspection | Inspection |
SC
| Fits checking fixture
Long legs are parallel
Box wires should be flat and in line | Checking in final fixture | Entire batch | 1 frame every hour |
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| Record on-line system |
| Any difficulty experienced during this activity report to supervisor |
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| 15 | Pack finished frames in bins | Packing | Packing |
| Correct quantity 10 seat back per bin
20 bins per pallet | Visual | As per WIS | Every job |
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| FA Card |
| Should the quantity be incorrect stop process, verify quantity and add or remove frames to meet quantity required |
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| 16 | Transport parts to stores | Transport | Transport |
| Correct bins and correct quantity | Visual Inspection | As per works order | Every batch |
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| FA Card |
| Should any difficulty occur during transportation inform supervisor |
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| 17 | Receipt frames to stores | Receipting | Receipting |
| Correct quantity be into the stock system | Visual | Every batch | Every order |
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| FA Card |
| Any discrepancies shall be report to stores coordinator |
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| 18 | Dispatching of frmaes | Transport | Transport |
| Correct loading of bins and safe handling during transport activity | Visual | Entire batch | Every new order |
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| Delivery Note Invoice |
| Any difficulty experienced during this activity report to Stores Coordinator |
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| 19 | Layout function inspection | Inspection | Inspection |
| Full Dimension | As per fixture and customer requirements | 1 complete frame | As per schedule |
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| Audit sheet |
| Should the functional layout fail the production manager shall be informed immediately |
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