| STEP | Cost Centre | PROCESS | OPERATION DESCRIPTION | CLASS | PRODUCT AND PROCESS CHARACTERISTICS | CONTROL METHODS | |
| 1 | 500 |
| Receive and verify quantity and type of raw material by stores personnel |
| 4.5mm / 5mm / 6mm mild black wire as per purchase order | Verification of delivery note and order placed. Any discrepancy contact supplier and resolve. |
|
| 2 | 500 |
| Move raw material to incoming receiving area |
| Safe handling during transport and handling activity | Visual inspection |
|
| 3 | 505 |
| Inspection of raw material by QA Personnel |
SC
| Mild steel 4.5mm / 5mm/ 6mm mild black wire (SAE 1010). Tolerance +/- 0.08mm. Coil steel sheet (CR 210) - 136.00 X 2.00 mm ±0.10. Verify as per COA. No score marks, no rusty wire, compare tensile strength with COA and spec. Correct grade | Check wire diameter and coil thickness with micrometer, check coil width with vernier. Visual inspection of condition of wire. COA from supplier. Record on on-line inspection |
|
| 4 | 500 |
| Move raw material to storage area |
| Safe handling and loading during this activity | Visual inspection during this activity. Competent forklift driver. FIFO system to control material |
|
| 5 | 500 |
| Issue wire to production |
| Correct identification of wire | Material buff tag
Visual inspection |
|
| 6 | 100 |
| Cut Swing wire (6.00 mm ±0.08) lengths on Wire straightener no. 8 |
| Correct setting of machine Products to conform to quality requirements | Record on BIS Card and on-line inspection |
|
| 7 | 15 |
| Form bends on swing Wire on Twinhead machine |
| Correct setting of machine Products to conform to checking fixture | fixture verification
Record on BIS Card and on-line inspection |
|
| 8 | 16 |
| Form loops on swing wire |
| Correct setting of hand bender, Products to conform to checking fixture | Checking fixture verification
Record on BIS Card and on-line inspection
|
|
| 9 | 15 |
| Form individual wires (Wire H - 4.50 mm ±0.08, Wire G - 4.50 mm ±0.08, Ref wire - 4.50 mm ±0.08, Wire D - 4.50 mm ±0.08, Wire F - 5.00 mm ±0.08 & Wire E - 5.00 mm ±0.08, Wire 9 & 10 - 5.00 mm ±0.08 as per route card on Micro Mac 1/ & 2 Zukron machine |
SC
| As per correct fitment in checking fixture
Burrs < 0.3mm acceptable | Visual inspection on in-process checking fixture
Visual inspection for burrs
Record on BIS Card and on-line inspection |
|
| 10 | 15 |
| Load wires on kanban and trolley |
| Correct loading of wires on KANBAN system and trolley | Visual verification |
|
| 11 | 104 |
| Press Brackets (Center) |
| Products need to conform to drawing specifications. | Visual verification |
|
| 12 | 104 |
| Transport brackets to bracket welding process |
| Correct handling of parts during this activity | Visual verification |
|
| 13 | 104 |
| Press Brackets (Left & Right) |
| Products need to conform to drawing specifications. | Visual verification |
|
| 14 | 104 |
| Transport brackets to bracket welding process |
| Correct handling of parts during this activity | Visual verification |
|
| 15 | 16 |
| Weld Pull Test |
CC
| 5mm x bracket 4500N to 8000N | Use Tensile tester to pull the sample wires and determine the point at which the wire or weld breaks. The reading should be between the min and max spec. |
|
| 16 | 16 |
| Weld brackets on to cross wires |
CC
| 2mm gap between wire and bracket after welding
L/R/C cross wires must be welded correctly | Bracket welding jig
Weld pull test. CPK of minimum 1.33 required
Visual inspection after welding
|
|
| 17 | 16 |
| Load welded cross wires onto swing wire |
| Cross wires must be correctly loaded in sequence. Left and right correctly positioned | Visual inspection by operator |
|
| 18 | 16 |
| Weld Pull Test |
SC
| 5mm x 5mm Min 2800N, Max 7500N
4.5mm x 5mm Min 2550N x 7590N | Use Tensile tester to pull the sample wires and determine the point at which the wire or weld breaks. The reading should be between the min and max spec. |
|
| 19 | 16 |
| Dressing and cleaning of copper tips |
SC
| To ensure consistent welds | Copper tip height measurement.
File tips every 2 hours. |
|
| 20 | 16 |
| Loading wires on welding jigs and start welding frames |
| No loose wires and hold downs correctly fitted | Visual inspection |
|
| 21 | 16 |
| Welding of frame |
SC
| Weld frame as per customer requirement.
First-off sample must conform to drawing requirements | Visual inspection of frame after welding.
Verification in checking fixture - record on BIS Card and on-line inspection .
Should the frame not fit the checking fixture , stop process and report to supervisor |
|
| 22 | 16 |
| Nibble all protruding wires and file sharp edges when required |
SC
| No sharp edges allowed on frame | Visual and physical inspection by hand |
|
| 23 | 16 |
| Re-welding |
CC
| Any re-weld frame shall be marked at the re-welding point using a maker before welding process and then check on checking fixture for fitment.
Weld Criteria to meet the same as those defined in the "Weld Frame" process above | Inspection after reweld is the same as defined in the process "Welding of Frame". Goods are to be validated in the final checking fixture |
|
| 24 | 16 |
| Inspect completed frames on final checking fixture |
SC
| Frame must conform to final checking fixture, must be flat, not twisted, no bent wires, no loose welds, no sharp edges, no weld splatter,no protrusion of wires. Swing wire brackets must be tweaked so that there is no movement of the swing wire - Refer CAR 53600. | Visual verification of fitment of frame and welds |
|
| 25 | 16 |
| Load frames onto kanban trolley, move to washing |
| Safe handling of frames on kanban trolley | Visual inspection |
|
| 26 | 106 |
| Clean frames in epoxy cleaning tanks |
| Frames should be free from oil residue
| Visual inspection |
|
| 27 | 106 |
| Loading on to epoxy conveyor |
| Frames must be properly hooked on to conveyor. Sufficient space to be allowed between frames | Visual inspection |
|
| 28 | 106 |
| Epoxy coat frames |
| Oven temperature 190-200 Deg.
Line speed 43-45 sec/m
Coating thickness 60-150 microns
Smooth finish no ripple effect.
No excess coating applied to swing wire ends. | Visual Inspection.
Coating thickness check done using thickness gauge.
Check coating thickness on swing wire ends using gauge in place. |
|
| 29 | 106 |
| Inspect coated frames at packing area |
SC
| Meet customer requirements
Check for any loose weld,miss weld,weld splatter,inconsistant coating, burrs and sharp edges. | Competent operators.
Visual inspection.
Measure coating thickness |
|
| 30 | 106 |
| Packing of coated seat frames into CHEP bins. |
| Place bubble wrap in between frames.
50 frames per bin. Place label on bin
No damage to frames. | Competent packer
|
|
| 31 | 106 |
| Transport full CHEP bins to stores area for shipment |
| Safe loading and transportation of frames | Competent forklift driver |
|
| 32 | 500 |
| Receive full CHEP bins into stores area for shipment |
| Correct containers and correct quantities | Visual inspection
Confirmed orders |
|
| 33 | 500 |
| Dispatching of seat frames |
| Correct quantities.
Correct labelling | Order request.
Approved transporter
Create invoice/delivery note |
|
| 34 | 505 |
| Verification and checking of welding jigs |
| No visual damage to welding jigs, no worn out slots | Visual inspection by QA Personnel |
|
| 35 | 505 |
| Verification and checking of individual checking fixture |
| No visual damage | Visual inspection done by operator |
|
| 36 | 505 |
| Verification and checking of final checking fixture |
| Checking fixture dimensionally correct | CMM report |
|
| 37 | 505 |
| Internal product audit |
| As per drawing requirements | Audit check sheet including dimensional report for 1 complete frame |
|