TASK SPECIFIC SAFETY

Welding glasses are worn when performing this operation. Danger of weld splatter. Gloves to be worn due to hot welded products Ensure the generic factory PPE is worn at all times. Overalls, Closed Shoes, Ear plugs

MACHINE SET UP PROCESS.

1. Switch on the machine and press the green button to start.

2. Check setting on the PC display.

SELECT THE FOLLOWING MODULES

  Weld Setting  =Programe  2

  Pulation         =01

  Up slope         = 00

  Hold                 =10

  Heat  2            =55%

  Weld 2             =15

  Cool                  =01

  Heat 1               =45%

  Weld 1               =29%

  Squeeze             =13

Pre Squeeze         =10

These setting are 95% guide for a quick set up on welder.

COPPER TIP HEIGHTS

1. Check copper tips heights as follows

TOP            =217mm

BOTTOM    = 167MM

GAP            =35mm

WELDING OF PART

1. Insert wire components into welding jig.

LOADING SEQUENCE OF WIRE

  1.Load outer wire into jig                           2.Load U wire 1 into jig    

          3.Load U wire 2 into jig                           4.Load Straight wire into jig

5. Secure clamps to hold wires in place for Welding

6. Verify wire components that the clamps are secure and check if the wires are all centralized.

7. Use Spot Welder to weld components together.

8. Verify on Checking Fixture if the dimension is correct using the Datum line and tolerances (1.5mm) as per the diagram below.

QUALITY

1/ Conduct First-off - 5 parts send through to each process to check WELDING and WIRE movement

when welding each indivual wires

2/ In-process inspections - check 1 part every hour and record on BIS Card and log on inspection system

3/ Check each weld for bad weld and smash weld

4/ Both legs must sit flat and not rock

QUALITY INSPECTION

• The Last-off from the previous batch is to be compared to the current batch's First-off. Last-off is to be placed in the production run.
• Complete a First-off before commencing with production, and record on system Inspection.
• First-off sample to be tagged and remain with the checking fixture. Inspection Number 11382

• Conduct in-process inspections every hour and record on system Inspection, Inspection Number  11383

• At the end of the batch, last - the off part is to be tagged and kept with the checking fixture. First-off is to be placed in the production batch, Inspection Number 11384.

REJECTS

All reject parts are to be placed immediatley in the red reject bins provided. All rejects should be logged on the system hourly.  Scrap / Reject bins are to be emptied at the end of end job or at the end of shift if the job is running at the end of shift