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SAFETY
Ensure PPE is worn.
- Overalls
- Safety Glasses
- Ear plugs
- Gloves
Ssfey glasses are to be worn when performing this operation, danger of weld spaltter.
Gloves to be worn due to hot welded products.
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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.
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COPPER TIP HEIGHTS
Check copper tips heights as follows
Top =217mm
Bottom = 167mm
Gap =35mm
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BREAKING STRENGTH TEST
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.
Prepare test peice sample as per picture below, use a 5mm and 8mm wire welded.
Switch on the tensile machine in the side and then press the green button
Insert the bottom block and push the bolt through the block to secure it.
Insert welded wire into top block and push the bolt through the block to secure it.
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Press the zero botton and then press hold botton to clear the read out untill it blinks.
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Press the down botton until the welded test piece of wire breaks
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Should the pull test fail to meet requirements, weld new wires and re-do the weld pull test. If the second weld pull test fails, stop and report to supervisor and quality.
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LOADING INDIVUAL WIRES IN THE WELDING JIG
1. Place outter wire in the welding jig first.
Secure outter wire with the clamps.
2. Place 2 x U wires in the welding jig second.
Secure U wires with the clamps.
3. Place straight wire in the welding jig last.
Secure Striaght wire with the clamps.
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WELDING OF THE INDIVUAL WIRES
The below picture shows the welding sequence in number form to indicate where to start welding the wires from.
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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 23681.
- Conduct in-process inspections every hour and record on system Inspection, Inspection Number 23682.
- 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 23683.
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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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