MANUFACTURING QUALITY CHART



COMPILED BY TEAM MEMBER 2
TEAM MEMBER 3 TEAM MEMBER 4
SUPPLIER Webroy (Pty) Ltd MQC No
CUSTOMER REV No.
PART NAME DATE INITIATED
PART No. REVISION DATE 2021/01/15
    LAST REVIEW DATE 
WEBROY STOCK CODE STATUS
MANUFACTURING LOCATION Webroy SAFETY CRITICAL
MQC TYPE
Current
Process Flow Key

Process TypeImage
PARTS STOCK
COMPONENT PART
PROCESS OPERATION
SAMPLING INSPECTION
100% INSPECTION
TRANSPORT
Responsible
Confirmation Level Key
NameImage
OPER
T/L
SUPERVISOR
MNGR
OPER
T/L
SUPERVISOR
MNGR


PROCESS FLOWNONAMEWORK ELEMENTCHECK ITEMRANKPROCESS CRITERIONINSPECTION METHODINSPECTION PLANFREQUENCYInspection No.(s)Work InstructionsRESPCHECK SHEETCONFIRM'N LEVELREACTION PLAN 
1Receiving and verification of raw materialReceivingRaw material Check for correct quantity delivered, type and diameterVisual inspection and verification as per orderDelivery note and orderEvery batch Goods receive notebook / delivery note Should there be any discrepancies inform production planner / supplier immediately and make a note on P.O.D
2Move material to receiving storage areaTransportRaw material Store material correctlyVisual inspectionAs per FIFO systemEvery batch Visual inspection and FIFO board If difficulty occurs in storing raw material properly inform Stores Coordinator
3Inspection of raw material by QA personnelInspectionRaw material Correct material SWB 2.0mm +- 0.045mm No pitted rust, now score marks, no excessive drawing soap Phosphate coating as per CAR3/18Visual inspection MicrometerAs per incoming raw material inspection QD207Every consignment Goods receive notebook / Buff tag and record findings on incoming receiving inspection sheet QD40 Any non-conforming raw material shall be placed on hold and isolated. Raise SRAN and inform Stores Coordinator
4Move raw material to dedicated area forstorageStorageRaw material Safe stacking of wire coils on to racks as per allocated areas and FIFO systemVisual inspectionAs per FIFO systemOn receiving FIFO information board and rack identification Any difficulty experienced during this activity report to Stores Coordinator
5Issue wire to productionIssuingRaw material SC Correct wire to be issued as per job cardVerification as per buff tag Setter to measure wire diameter with vernierEvery coil issued to productionEvery coil Route card Should the incorrect wire be issued to production stop process, correct and inform Stores Coordinator
6Cut wire on Wire StraigntenerCut wire Cut lengths of wire SC Cut wire to 555mm +/- 1mmVisual inspection of burrs and measure length of wire with a tap measure Frst-off sample & In-process inspection First-off at start of production. In-process 1 part every hour Record first-off and in-process inspection on BIS card Should the first-off sample fail stop process and reset machine and re-do first-off
7Form wire form om Twin head machine FormingForming of wire form SC Parts to be formed correctly as per checking fixture requirements . Part must sit flat in checking fixtureVisual check and check on Checking fixture First-off sample In-process inspectionFirst-off at start of production. In-process every 9 hour. and bundle parts Record first-off on BIS Card and record in process inspection on Attribute sampling sheet QD:203 Any difficulty forming stop process and inform supervisor
8Form hooks on Bower machineFormingHooks SC Hooks to be formed correctly as per checking fixture requirements. Hooks must fit flat in checking fixtureVisual check on checking fixture for fitmentFirst-off sample and in-process inspectionFirst-off at start of production. In-process 1 part every hour Record first-off and in-process inspection on BIS Card Should the first-off sample fail or in-process inspection, stop immediately and inform supervisor
9Bundling and packing of partsBundling and PackingProduct Correct quantityBundle parts with rubber bands on either side in quantities of 25 and pack in allocated binsAs per customer requirementsEvery job F/A Card Should the quantities be incorrect, stop process verify quantity add or remove to meet required quantity
10Transport product to storesTransportProduct Correct bins and correct quantities of 2000Visual inspectionAs per works orderEvery batch F/A Card Should any difficulties occur during transport inform supervisor
11Receipting product to storesReceiptingProduct Correct quantity to be entered onto the stock systemVisualEvery batchEvery order F/A Card Any discrepancies shall be reported to stores coordinator
12Dispatching of productsDispatchingCompleted wire forms Correct loading of bins and safe handling during transport activityVisualEntire orderEvery order Delivery note / invoice Any difficulty experienced during this activity report to stores coordinator
13Layout functional inspectionInspectionProduct SC Full dimensionalAs per customer requirements1 complete productAs per schedule Audit sheet Should the functional layout fail, the production manager shall be informed immediately