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SAFETY
Gloves and ear plugs are to be worn throughout this operation.
Safety glasses to be used when trimming.
 
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SCOPE
This work instruction will cover the manufacturing process including
- Forming Bend 1, 2 & 3
- Trimming bend
- Inspecting the products
- LTHT
- Packing products
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START JOB
On receipt of route card from supervisor to start manufacturing of the products the following procedures shall be adhered too:
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- Ensure the work area is clean and free of unneccesary items.
- Request the required bin/box from stores to pack the completed products.
- Log the job onto the production system to indicate the start time. Assign yourself as the operator on the job.
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- Set-up hand bender and form bend "1".
- Ensure stops are set correctly.
- Measure length on bend "1". (N.B. measured length end to end shall be 30mm +/- 2mm).
- Verify bend "1" in checking fixture profile. The scribbed lines indicate the MIN end length and the MAX end length is to the end of the C/F..
 
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- Set-up hand bender and form bend "2".
- Ensure stops are set correctly.
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- Set-up hand bender and form raidius (bend "3").
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- Trim Raidius (bend 3) with a hand grinder and not with a bolt cutter.
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- Measure bend 3 length after triming.
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Checking part in checking fixture
- Measure overall length with a tape measure from end to end. Required dimension is 375mm +/- 2mm.
- Place the raidius end (bend 3), ensure the part is against the end slot as per picture below.
- This part must drop fit into the checking fixture.
- The part must sit flush at the bottom slot in the middle block as per picture below.
- The short end on the RH side (bend 1) must sit against the end stop as per picture below.
- Using the GO / NO GO Gauge, validate the bend 3 length. The GO side (marked green) must fit in freely in slot and the NO GO side (maked red) must not be able to fit into slot.
- Validate bend 1 in the fixture cut out profile as per picture below.
- MIN end length is 28 and the MAX end length is 32mm.
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LTHT
- Required temperature for parts for LTHT is 300 degrees x 20 mins.
- Take note that parts will reduce 1 - 2mm in overall length after LTHT.
- Use blue box oven to LTHT parts.
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PACKING INSTRUCTIONS
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Pack parts neatly in bin / box ( not specified)
Total frames per bin / box to be packed = as per order quantity
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QUALITY INSPECTION
- The Last-off from the previous batch is to be compared to the current batch First-off. Last-off is to be placed in the production run.
- Complete a First-off before comencing with production, record on system Inspection no 10362.
- First-off sample to be tagged and remain with the checking fixture.
- Conduct in-process inspections every hour and record on system Inspection no. 10363
- At the end of the batch, last part is to be tagged and kept with the checking fixture. First-off is to be placed in the production batch: Inspection no. 10364
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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
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PERFORMANCE TARGETS
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Once the job has been logged on the system, you will be able to see the production figures and targets including
- The Total Qty made against the job
- The quantity prodcued on the shift (day),
- The Std Time and the number of Parts required to be made per hour.
The picture to the left provides and example.
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Production figures are to be logged on the system every hour.
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