| PROCESS FLOW | NO | NAME | WORK ELEMENT | CHECK ITEM | RANK | PROCESS CRITERION | INSPECTION METHOD | INSPECTION PLAN | FREQUENCY | Inspection No.(s) | Work Instructions | RESP | CHECK SHEET | CONFIRM'N LEVEL | REACTION PLAN | |
| 1 | Receiving raw material - Stores Personnel | Receiving | Receipt of delivery of goods |
| Check for correct quantity delivered, type, Diameter.
Check for COA | Visual inspection and verification as per order | Delivery note and order | Every batch |
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| Goods receive note book / delivery note |
| If non-compliant - contact supplier and inform Quality Manager and Production planner |
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| 2 | Move raw material to incoming inspection area | Transport | Raw material |
| Store material properly in bays | Visual inspection | As per FIFO system | Every batch |
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| Visual inspection and FIFO board |
| If difficulty occurs in storing raw material properly, inform Stores Coordinator |
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| 3 | Raw material incoming inspection by QA Personnel | Inspection | Raw material |
SC
| Correct Diam - 6.5mm (WIRE/MBH2/0650). & 4.5mm (WIRE/MBH2/0450). Tolerance - +/- 0.08mm.
Correct type - SWM - B.
Tensile range = 550mpa - 750mpa.
No rusty wire.
No score marks.
No excessive drawing soap
| Visual inspection and measure with a Micrometer | As per incoming raw material inspection plan | Every consignment |
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| Goods receive note book / record findings on incoming inspection record sheet |
| Any non-conforming material shall be isolated - properly tagged and placed in quarantine store - inform Quality Manager , Stores co-ordinator , Production planner and supplier |
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| 4 | Move wire to storage area for safe stacking | Transport | Raw material |
| Safe stacking of wire coils onto racks as per allocated areas and FIFO system | Visual inspection | As per FIFO System | On receiving |
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| FIFO information board and Rack identification |
| Any difficulty experienced during this activity report to Stores Coordinator |
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| 5 | Issue raw material to Production Personnel | Issuing | Raw material |
| Correct wire to be issued as per job card | Verification as per buff tag Setter to measure wire diameter with vernier | Every coil issued to Production | Every job as per request |
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| Job card / route card |
| Should the incorrect wire be issued to Production, stop process, correct and inform Stores Coordinator |
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| 6 | Issue brackets to production | Issuing | Brackets |
| Correct brackets to be issued as per job card | Visual inspection | Every batch issued to production | Every job as per request |
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| Job card / route card |
| Should the incorrect brackets be issued to production , stop process and inform store co ordinator |
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| 7 | Form wire no 1 - outer frame wire on Huron Machine | Forming | Wire no. 1 Outer wire |
SC
| Wire shall conform to checking fixture , wire to sit flat in grooves on fixture to prevent fitment issues. | Visual Inspection.
Verify fitment on in-process checking fixture | First-off sampling ,
In process inspection and last off
| First-off start of shift and In process every hour last-off at end of shift |
61026103
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| Record on Electronic system |
| Should the first-off sample fail - stop process - reset machine and redo first-off. Any further non-conformance report to Supervisor |
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| 8 | Form wire no 2 - Inner wire on Zukron | Forming | Wire no. 2 Inner wire |
SC
| Wire shall conform to checking fixture requirements | Visual Inspection.
Verify fitment on in-process checking fixture | First-off sampling ,
In process inspection and
Last-off samples | First-off at start of shift -and in process inspection every hour - Last -off end of shift |
61046105
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| Record on Electronic system |
| Should the first-off sample fail, stop process - reset machine and redo First-off . Any further non-conformance report to Supervisor |
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| 9 | Form wire no 3 Inner wire on Huron | Forming | Wire no.3 Inner wire |
SC
| Part shall conform to checking fixture requirements | Visual Inspection.
Verify fitment on in-process checking fixture | First-off sampling 3 samples
In process inspection 9 samples
Last-off 3 samples | First-off at start of shift -and in process inspection every hour - Last -off end of shift |
61066107
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| Record on Electronic system |
| Should the first-off sample fail, stop process and reset machine,redo first-off. Any further non-conformance report to Supervisor |
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| 10 | Form wire no 4 - lower wire on Huron | Forming | Wire no. 4 Lower wire |
SC
| Part shall conform to checking fixture requirements | Visual Inspection.
Verify fitment on in-process checking fixture | First-off sampling ,
In process inspection and
Last-off | First-off at start of shift - in process inspection every hour - Last -off end of shift |
61086109
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| Record on Electronic system
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| Should the first-off sample fail, stop process and reset machine, redo first-off. Any further non-conformance report to Supervisor |
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| 11 | Welding Outter frame wire to bracket | Welding | Outer frame wire to bracket |
SC
| Pull test to be conducted upon First-off - spec -1100Nm minium. Weld settings correct. No miss weld, broken weld, weak weld and smash weld. No rust on brackets. | Verify weld paramater settings and record on system.
Visuall inspect bracket for any rust.
Visually inspect weld condtion. | Every batch | Pull test upon First-off for every batch . Pull test shall be 1100N minimum |
61102254822549
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| Record on Electronic system |
| Any difficulty experienced during this activity follow stop, call, wait procedure and report to supervisor |
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| 12 | Welding nut and pin onto bracket | Welding | Nut and pin onto bracket |
| Shall conform to drawing requirements.
Good weld penetration between nut/ bracket and pin.
Nut welded centrally onto bracket.
| 100% inspection of nut application. 100% visual inspection on welded nut for centrality.
Validation of ceramic sleeves prior to welding.
| As per work instruction | First-off destructive test performed on pin and bracket, drop test from height of 1.2m to determine weld strength of pin. |
61126113225316092
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1113
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| Record on Electronic system
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| Should any difficulty occur, stop and report to supervisor. |
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| 13 | Load welding jig for welding armrest | Loading | Wires |
| Wires shall fit welding jig properly - no skew / non conforming wires to be loaded in jig | Visual inspection | As per work instruction 238 | Every batch |
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| N/A |
| Should any difficulty occur , stop and inform Supervisor |
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| 14 | Weld armrest in jig | Welding | Wires |
| No loose welds / no smash welds - all welds shall conform to drawing specifications | Visual inspection | 100% | Every order |
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| Record on Electronic system |
| Should any difficulty occur , stop and inform Supervisor |
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| 15 | Inspect armrest in final checking fixture | Inspection | Armrest |
SC
| Armrest shall conform to final fixture , all wires on frame to fit in slots and not above to prevent fitment issues at customer | 100% inspection to ensure parts is drop fitting in fixture and wires on frame are fitting correctly on slots as required | As per work instruction 238 | Entire batch |
61146115
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| Record on Electronic sytem |
| Should any difficulty occur such as frames not drop fitting in fixture or wires fitting too high on slots on fixture , stop and inform Supervisor / Q.A |
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| 16 | Pack armrests in bins | Packing | Armrest |
| Correct quantities, correct packaging method | Visual inspection | As per work instruction 238 | Entire batch |
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| Record on F.A Card |
| Any difficulty experienced during this activity - stop process and report to Supervisor |
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| 17 | Transport Armrest to stores | Transport | Armrest |
| Correct bins and quantity | Visual inspection | As per job order | Entire batch |
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| F/A Card |
| Any damage during transport activity shall be reported to Supervisor and Stores Coordinator |
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| 18 | Receipt Armrest to stores | Receipting | Stock |
| Correct quantities into stock system | Visual / verification to order | Every batch | Entire order |
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| Order confirmation |
| Any shortage of products shall be reported to stores co ordinator |
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| 19 | Prepare order as per customer order requirements | Order preparation | Order quantities |
| Correct quantities - correct packaging - clear labelling | Visual / verification to order | Entire order | Every order |
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| Invoicing and delivery note - confirmation of accuracy |
| Any incorrect information found shall be reported immediately |
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| 20 | Ship products to customer | Transport | Batch of parts |
| Correct loading and proper stacking of containers in truck | Visual / verification to order | Entire order | Every order |
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| Delivery note / invoicing |
| Any problems experienced during transport activity shall be reported to Stores Coordinator immediately |
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| 21 | Layout functional inspection | Inspection | Completed part |
| Full dimensional | As per customer requirements | 1 Complete product | As per schedule |
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| Audit sheet |
| Should the functional layout fail the Production manager shall be informed immediately. |
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