| 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 protector clips - Stores Personel | Receiving | Protector clips |
| Check for correct quantity delivered and type. | Visual inspection and verification as per order | Check for correct quantity delivered and type. | 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 | Inspection of protector clip by Q.A | Inspection | Protector clips |
| No burrs and sharp edges. Material marking (>PP/PE<) shall be indicated on the back surface. No cracks, no deformation, no short shot. Colour - natural. | Visual inspection and measure with a vernier. | Measure 5 components per batch. | Every batch |
11380
|
|
| Record on inspection sytem. |
| Any non-conforming Protector clips shall be placed on hold and isolated. Raise SRAN and inform Stores Coordinator |
|
|
| 3 | Receiving Bracket - Stores Personel | Receiving | Brackets |
| Check for correct quantity delivered and type. | Visual inspection and verification as per order | Visual inspection and verification as per order | |
|
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 |
|
|
| 4 | Inspection of Bracket by Q.A | Inspection | Brackets |
| As per drawing and inspection criteria | Visual inspection and measure with a vernier. | Measure 5 components per batch. | Every batch |
|
|
| Record on inspection sytem. |
| Any non-conforming Protector clips shall be placed on hold and isolated. Raise SRAN and inform 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 | Inspection of raw material by QA personnel | Inspection | Raw material |
SC
| Mild black wire. SAE 1010/1008. WIRE/MBH2/0800. Correct diameter 8mm +/- 0.08. Correct tensile - 500mpa to 700mpa.WIRE/MBH2/0500. Correct diameter 5mm +/- 0.08. Correct tensile - 500mpa to 750mpa.No score marks, no rust on wire. | Visual inspection, Micrometer | As per incoming raw material inspection QD207 | Every batch |
10596179
|
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 |
|
| 7 | Move 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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|
| 8 | 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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|
| 9 | Form Straight Wire on Zukron 3 | Forming | Straight wire |
SC
| Wire shall conform drawing , Wire must be straight. No rust, Score Marks and Burrs. Overall length - 305mm +/- 1.5 | Visual Inspection and measure length with a tape measure. First-off verification by Q.A | As per work instruction | First-off at start of production. In-process 9 parts every hour and last-off |
236742367623677
|
1286
|
| 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 |
|
|
| 10 | Form U Wire on Zukron 3 | Forming | U wire |
SC
| Wire shall conform to checking fixture , wire to sit flat in fixture. Overall length - 310mm +/- 1. Leg lengths - 26.6mm +/- 0.5. No rust, Score Marks and Burrs. | Visual Inspection and verification in checking fixture. First-off verification by Q.A | As per work instruction | First-off at start of production. In-process 9 parts every hour and last-off |
236782367923680
|
1285
|
| 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 |
|
|
| 11 | Form Outer Wire on 12mm Huron | Forming | Outter wire |
SC
| Wire shall conform to checking fixture , wire to sit flat in fixture DATUM points.Both legs must be flat. No rust, Score Marks and Burrs. | Visual Inspection and verification in checking fixture. First-off verification by Q.A | As per work instruction | First-off at start of production. In-process 9 parts every hour and last-off |
236712367223673
|
1284
|
| 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 |
|
|
| 12 | Transport Indivual Wires to Spot Welder. | Transport | Indivual wires |
| Correct handling of parts during this activity. | Visual verification. | N/A | Every order |
|
|
| N/A |
| Any difficulty experienced during this activity stop the process and report to Supervisor |
|
|
| 13 | Dressing and cleaning of copper tips | Copper tips | Clean tips set to correct height |
SC
| Clean and set to correct height. Heights 190mm top and 167mm bottom tip which will have a gap of 55mm between the copper tips. | Measure heights with a Tape measure or Steel rule. | Heights set prior to welding Cleaning of copper tips every 2 hours | Every 2 hours |
23689
|
|
| Record on inspection system |
| Any problem experienced during this activity report to supervisor. |
|
|
| 14 | Break Strength Test | Tensile Tester | Breaking strength |
SC
| Break strength of weld portion shall be material failure. | Use the tensile tester to pull the sample wires until the wire breaks or the weld fails. Wires from the current batch of wire are to be used for the test. | 1 part per batch | Every batch |
23693
|
|
| Record on inspection system |
| If the test fails, stop and call the supervisor. |
|
|
| 15 | Load Indivual Wires in welding jig | Loading | Correctly loaded welding jig. |
| Correct loading of wires into the loading jig to ensure a good weld. | Visual inspection to ensure wires are touching, no gaps. Ensure all hold-down clamps are in place. | Visual inspection | Every order |
|
1287
|
| Visual inspection. First-off in sample inspections |
| Any difficulty in loading jig, stop the process and call the supervisor. |
|
|
| 16 | Welding Seat Cushion. | Welding | Product |
| Welding of part. | Part to meet drawing and customer requirements No smash welds, no miss welds, no broken welds and no bent wires. | Visual verification | Every part |
|
1287
|
| Record on inspection system |
| Should the first-off sample fail, stop process, redo first-off and retest. If 2nd first-off fails inform Supervisor immediately. Should the weld test fail, stop process and inform Supervisor immediately |
|
|
| 17 | Inspect Seat Cushion in final checking fixture. | Inspection | Welded wires |
SC
| Frames shall fit in checking fixture. Part to sit flat on DATUM points.No lift on legs allowed. No weak, broken, smashed welds allowed. No rust and burrs on frames. | Visual inspection refer to work instruction for fitment requirements. | Visual verification in checking fixture for correct fitment. | First-off at start of production. In-process 9 parts every hour and last-off |
|
1287
|
| Record on inspection system |
| Should the inspection requirements not be correct, stop the process and inform the supervisor. |
|
|
| 18 | Transport welded parts to stores for coating | Transport | Welded wires |
| Correct quantities. | Visual inspection. | As per job order | Every order |
|
|
| N/A |
| Should difficulty occur during transport inform Supervisor |
|
|
| 19 | Send parts for PA coating | Transport | Uncoated parts |
| Correct PA coating as per boundary sample. | Visual inspection. | Every batch | Every order |
|
|
| N/A |
| Any difficulty report to manager. |
|
|
| 20 | Receive coated parts | Receiving | Coated parts |
| Correct coating on parts. Correct quantity received. | Visual inspection. | Every batch | Every order |
|
|
| N/A |
| Any issues report to Quality and Production manager |
|
|
| 21 | Inspection of coated parts. | Inspection | Coated parts |
SC
| Correct coating as per boundary sample. No cracks. Colour - black. PA coating hacthing area - 50mm + 5 - 0 PA coating thickness - 0.8mm ± 0.3. | Visual inspection/ verification. | Every order | Every batch |
11379
|
|
| Record on inspection system |
| Any non-conforming parts shall be placed on hold and isolated. Raise SRAN and inform Stores Coordinator |
|
|
| 22 | Assemble protector clip onto part | Assembly | Protector clips |
| Ensure protector clip is secure on front end hooks. | Visual verification. | Every batch | Every order |
236842368623687
|
1289
|
| Record on inspection system |
| Any problems experienced with assembly of protector clips shall be reported to supervisor |
|
|
| 23 | Weld bracket. | Welding | Welded bracket |
SC
| Welding of bracket | Part to meet drawing and customer requirements No smash welds, no miss welds, no broken welds and no bent wires.
Weld length = 15mm +/- 3. | Every batch | First-off at start of production. In-process 9 parts every hour and last-off |
|
1290
|
| 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 |
|
|
| 24 | Inspection of welded parts with brackets. | Inspection | Welded bracket |
| Bracket correctly welded. | Visual. | As per work instruction | First-off at start of production. In-process 9 parts every hour and last-off |
236902369123692
|
1288
|
| 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 |
|
|
| 25 | Pack welded parts into bins. | Packing | Completed products |
| Correct quantity = 14parts per bin. TBSA black dunage bins used for the seat backs. | Visual verification. | As per supplier packaging specification | Every order |
|
|
| F.A card |
| Should the quantity be incorrect, stop process, verify quantity and add/remove products to meet quantity required |
|
|
| 26 | Receipt parts into stock. | Receipting | Completed products |
| Correct quantity to be entered on to the stock system. | Visual verification. | Every batch | Every order |
|
|
| F.A Card. |
| Any discrepancies shall be reported to the Stores Coordinator |
|
|
| 27 | Dispatching of products. | Transport | Completed products |
| TBSA black dunage bins used for the seat back, Pack 14 parts in each box. | Visual verification. | As per job order | Every order |
|
1101
|
| Delivery note / invoice |
| Any difficulty experienced during this activity report to Stores Coordinator |
|
|
| 28 | Layout functional inspection. | Inspection | Completed product |
| Full dimensional as per SDS and PIS. | As per customer requirements. | 1 complete product | As per schedule |
|
|
| Audit sheet |
| Should the audit fail, the Production manager shall be informed immediately. |
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