| 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 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. |
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| 2 | Move material to receiving storage area. | Transport | Raw material |
| Store material correctly. | Visual inspection. | As per FIFO system | Every batch |
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| Visual inspection. |
| If difficulty occurs in storing raw material properly inform Stores Coordinator. |
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| 3 | Inspection of raw material by QA personnel. | Inspection | Raw material |
| Mild black wire. SAE 1010. WIRE/MBH2/0450. Correct diameter 4.5mm +/- 0.05. No score marks, no rust on wire. Correct tensile - 550mpa to 750mpa. | Visual inspection, Micrometer. | As per incoming raw material inspection QD207 | Every consignment |
6116
|
1120
|
| Goods receive notebook / Buff tag and record findings on electronic system. |
| Any non-conforming raw material shall be placed on hold and isolated. Raise SRAN and inform Stores Coordinator. |
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| 4 | 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. |
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| 5 | 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. |
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| 6 | Form product on Zukron machine and inspect. | Forming | Product |
| Product 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 | Checking fixture verification, visual inspection of rust, score marks and burrs. | As per work instruction. | First-off, in-process and last-off inspection. |
236512365223653236542365523656
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| 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. |
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| 7 | Packing of products. | Packing | Product |
| Correct quantity = 60 parts per bin. | 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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| 8 | Transport completed parts to stores for dispatch. | Transport | Completed products |
| Correct quantities. | Visual inspection. | As per job order. | Every order |
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| N/A |
| Should difficulty occur during transport inform Supervisor |
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| 9 | Receipt product into stock. | Receipting | Product |
| 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. |
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| 10 | Dispatching of products. | Transport | Product |
| QTY: 60 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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| 11 | Layout functional inspection. | Inspection | Product |
| 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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