| 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 3/16 Bundy tube lengths - Stores Personnel | Receiving | 3/16 Bundy tubes |
| Check for correct quantity delivered and size. | Visual inspection and verification as per order | Delivery note and order | Every batch |
|
1090
|
| Goods receive note book / delivery note |
| Should there be any discrepancies inform production planner / supplier immediately and make a note on P.O.D |
|
| 2 | Move 3/16 Bundy tube lengths to receiving storage area | Transport | 3/16 Bundy tubes |
| Store tubes correctly | Visual inspection. | As per FIFO system | Every batch |
|
|
| Visual inspection |
| If difficulty occurs in storing raw material properly inform stores coordinator |
|
| 3 | Inspection of 3/16 Bundy tube lengths by Q.C. | Inspection | 3/16 Bundy tubes |
SC
| Overall length - 6.00 M, No damage, distortion or burrs. Wire must fit in freely. | Tape measure, visual inspection. | Measure 5 components per batch. | Every batch |
23616
|
|
| Record on inspection sytem. |
| Any non-conforming ferrules shall be placed on hold and isolated. Raise SRAN and inform Stores Coordinator |
|
|
| 4 | Move 3/16 Bundy tube lengths to dedicated area for storage | Transport | 3/16 Bundy tubes |
| Safe stacking of tubes as per allocated areas and FIFO system. | Visual inspection. | As per FIFO system | On receiving |
|
|
| Identification tags |
| Any difficulty experienced during this activity report to Stores Coordinator |
|
|
| 5 | Receiving raw material - Stores Personnel | Receiving | Raw material |
| Check for correct quantity delivered, type and diameter. | Visual inspection and verification as per order | Delivery note and order | Every batch |
|
1090
|
| Goods receive note book / delivery note |
| Should there be any discrepancies inform production planner / supplier immediately and make a note on P.O.D |
|
|
| 6 | Move material to receiving storage area . | Transport | Raw material |
| Store material correctly. | Visual inspection. | As per FIFO system | Every batch |
|
|
| Visual inspection |
| If difficulty occurs in storing raw material properly inform Stores Coordinator |
|
|
| 7 | Inspection of raw material by QA personnel. | Inspection | Raw material |
SC
| Spring steel wire. SWB TSG 3531 G. WIRE/SBS3/0200. Correct diameter 2mm +/- 0.035. Correct tensile 1471 Mpa - 1716 Mpa. No score marks, no rust on wire. | Visual inspection, Micrometer. | As per incoming raw material inspection QD207 | Every consignment |
6158
|
1120
|
| Goods receive notebook / Buff tag and record findings on electronic sytem |
| Any non-conforming raw material shall be placed on hold and isolated. Raise SRAN and inform Stores Coordinator |
|
|
| 8 | Move raw material to dedicated area for storage. | Transport | Raw material |
| Safe stacking of wire coils as per allocated areas and FIFO system. | Visual inspection. | As per FIFO system | On receiving |
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|
| Identification tags |
| Any difficulty experienced during this activity report to Stores Coordinator |
|
|
| 9 | Issue 3/16 Bundy tube lengths to production | Issuing | 3/16 Bundy tubes |
| Issue tubes to production | Verification as per buff tag | Every batch issued to production | Every job as per request |
|
|
| Route card |
| Should the incorrect wire be issued to production stop process, correct and inform Stores Coordinator |
|
|
| 10 | Issue wire to production. | Issuing | Raw material |
| Issue wire to production. | Verification as per buff tag Setter to measure wire diameter with 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 |
|
|
| 11 | Cut 3/16 Bundy tubes to 'U-Clip' lengths | Cutting | Product |
| Correct length - 50.00mm +/- 2mm, No burrs/ sharp edges | Vernier, visual inspection. | As per work instruction | First-off, in-process and last-off inspection |
236122361323615
|
1258
|
| Record on electronic system |
| Should the first off sample fail - stop process - reset and re-do first off. Any further non-conformance report to Supervisor |
|
|
| 12 | Transport 'U-Clips' to crimping press | Transport | 'U-Clip' |
| Correct handling of parts during this activity | Visual verification. | Visual verification | Every order |
|
|
| N/A |
| Any difficulty experienced during this activity stop the process and report to Supervisor |
|
|
| 13 | Form wire on Zukron machine | Forming | Wire form |
| Wire shall conform to drawing and wire profile must comply to checking fixture, Wire must be flat. No rust, no score Marks. Burrs <0.20 mm | Visual Inspection and measure length with a tape measure. First-off verification by Q.A. | As per work instruction | First-off, in-process and last-off inspection |
236022360323604
|
1254
|
| Record on Electronic system |
| Should the first-off sample fail - stop process - reset machine and redo first-off. Any further non-conformance report to Supervisor |
|
|
| 14 | Transport formed wire to crimping press. | Transport | Wire form |
| Correct handling of parts during this activity. | Visual verification. | Visual verification | Every order |
|
|
| N/A |
| Any difficulty experienced during this activity stop the process and report to Supervisor |
|
|
| 15 | Assemble U-Clip and crimp. | Assemble and crimp | Wire form |
| Crimping of U-Clip. | Part to meet drawing and customer requirements. Wire ends must be meet U-Clip dimple to ensure correct crimping. U-Clip must be assembled/ crimped securely. Ferrule shall not be loose on product, pull by hand to test if Ferule is secure. | Visual verification | Every part |
|
1255
|
| Record on inspection system |
| Should the first-off sample fail - stop process - reset machine and redo first-off. Any further non-conformance report to Supervisor |
|
|
| 16 | Inspect part in final checking fixture. | Inspection | Completed products |
| Part shall sit flat and comply to checking fixture. Ferrule to be crimped securely. No rust, burrs, damage or distortion. | Visual inspection refer to work instruction for fitment requirements. | Visual verification in checking fixture for correct fitment & assembly. | First-off, in-process and last-off inspection |
236052360623607
|
1255
|
| Record on inspection system |
| Should the inspection requirements not be correct, stop the process and inform the supervisor. |
|
|
| 17 | Pack assembled parts into dunnages. | Packing | Completed products |
| Correct quantity = 50 parts per bin. Bin type: 4616. | Visual verification. | As per packaging specification | Every order |
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| F.A Card |
| Should the quantity be incorrect, stop process, verify quantity and add/remove products to meet quantity required |
|
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| 18 | Transport completed parts to stores for dispatch. | Transport | Completed products |
| Correct quantities. | Visual inspection. | As per job order | Every order |
|
|
| N/A |
| Should difficulty occur during transport inform Supervisor |
|
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| 19 | Receipt parts into stock. | Receipting | Completed parts |
| Correct quantity to be entered on to the stock system. | Visual verification. | Every batch. | Every order |
|
1094
|
| F.A Card. |
| Any discrepancies shall be reported to the Stores Coordinator |
|
|
| 20 | Dispatching of products. | Transport | Completed parts |
| Bin type: XXX, QTY: XXX per bin. | Visual verification. | As per job order | Every order |
|
1101
|
| Delivery note / invoice |
| Any difficulty experienced during this activity report to Stores Coordinator |
|
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| 21 | Layout functional inspection. | Inspection | Completed products |
| Full dimensional as per SDS and PIS. | As per customer requirements. | 1 complete product | As per schedule |
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| Audit sheet |
| Should the audit fail, the Production manager shall be informed immediately. |
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