| 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 | 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 | Visual Inspection.
Coating thickness check done using thickness gauge |
|
| 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 |
|