| 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 and off loading incoming raw material | Receiving Stores Personnel | Receiving Stores Personnel |
| Correct quantity delivered as per order, no damage to wire coils. | Visual inspection. | Entire batch | Every delivery |
|
|
| Purchase order - Delivery note, Receiving Inspection Instruction sheet |
| Should there be any discrepancy with delivery inform supplier immediately - Stores Coordinator |
|
| 2 | Incoming raw material inspection by Quality Personnel | Inspection | Inspection |
| Rod spec: SWRH 82 A
(imported) SWRH 82 B
(local wire)
Diam 6.5 +/- 0,036mm Tensile strength: 1422 - 1618 Mpa | Using micrometer
Visual inspection
Material Certificate | Select randomly 40% of the consignment | Every batch |
|
|
| Incoming raw material inspection document - COA Certificate - Spec. TSG3531G |
| should there be any non compliance as per the required standard - inform Q A |
|
| 3 | Move material to storage area | Transporting | Transporting |
| No damage to material during transport | Visual inspection | Inspect storage racks after placement | Every batch |
|
|
| N/A |
| Should any difficulty occur during this activity report matter to Stores Coordinator |
|
|
| 4 | Issue raw material to production as per works order - confirm wire is correct type and diameter | Inspection Issuing | Inspection Issuing |
| Verify correct type
Measure diam
Verify job card | Visual inspection
Measuring
6.5mm diam | Inspect wire coil issued by stores | As per job request |
|
|
| Conformation as per job card / order |
| Any difficulty must be reported to the Stores Coordinator |
|
|
| 5 | Move material to production - wire straightener area | Transporting | Transporting |
| No damage to material | Visual inspection | Entire batch | As per job request |
|
|
| N/A |
| Any damage to wire during transport process Report to Stores Coordinator |
|
|
| 6 | Straighten and cut wire products | Straightening and cutting | Straightening and cutting |
| Correct length
1468mm +/- 2mm
No score marks
No bent wires
No burrs | Measuring Visual inspection | First-off sampling inspection | 2 samples every 1/2 hour |
|
|
| BIS Card |
| Problems with machine / incorrect cutting of wire must be reported to the Supervisor - raise NCR |
|
|
| 7 | Forms bends on dedicated bender | Bending | Bending |
| Correct length,
Correct radius,
Correct angle: 48-50 Deg ,
Correct profile angle | Checking fixture | Check 3 samples at start - First off
place samples in oven for 15-20 min, then verify on C/F as per work instruction WR/PWI/84 | First off 2 samples every half hour |
|
|
| Record on BIS Card and
Record on QD: 345 Results of process |
| Should any difficulty be experienced during bending process - inform Supervisor |
|
|
| 8 | Place 30 Torsion Bars in Batch Oven | Transporting Motion | Transporting Motion |
| No damage to wire products | Visual | Monitor products when entering / leaving oven | Regular basis during process |
|
|
| N/A |
| Problems with LTHT Process must be reported to the Supervisor immediately, Raise NCR |
|
|
| 9 | Heat treatment process | Stress relieving | Stress relieving |
| Correct oven temperature
300 Deg Correct time - 15 - 20 min | Visual on temp gauge and timer | As per requirements | Every batch |
|
|
| Record on temperature log sheet QD52 at oven |
| Stop process notify supervisor Raise NCR |
|
|
| 10 | Remove products from conveyor oven for torque testing | Torque testing | Torque testing |
| Torque @ 73.6 deg +-10 deg should be 17.1N.m +/- 3N.m
Torque @ 167.9 deg +-10 deg should be 39.0N.m +/- 3N.m and spray paint accordingly. | Visual on electronic meter | First off sampling and in process inspection | First off 100% inspection |
|
|
| Electronically |
| Any difficulty experienced during this activity report to Supervisor - isolate rejected bars from production |
|
|
| 11 | Final inspection of Torsion Bars | Inspection | Completed parts |
| Torsion Bar must fit final checking fixture | Visual and verification of dimensions in checking fixture | First off, 100% inspection of each part on fixture for conformity and mark orange as break point I.D | 100% inspection |
|
|
| Record on BIS Card |
| Any difficulty experienced during this activity report to Supervisor - isolate rejected bars from production |
|
|
| 12 | Scrap and reworking process | Reworking | Reworking |
| All reworking products must conform to drawing and customer specifications
Scrap to be remove daily | Visually on final checking fixture | All reworking products | As they occur |
|
|
| Record scrap on requisition
Should rework occur record on Rework BIS Card |
| Any rejects found during manufacturing process must be placed in reject bin - Raise NCR and Inform Supervisor |
|
|
| 13 | Packaging of final products | Packaging | Packaging |
| Correct quantities
20 Torsion Bars per Toyota blue bin Correct identification | Visual inspection and count | Each box | 100% |
|
|
| F/A Sheet |
| Any difficulties experienced during this process must be reported to Supervisor immediately |
|
| 14 | Product / Shipment Audit | Auditing | Auditing |
| Process and products must conform to drawing and customer specifications and requirements | Visual verification
MEasuring of products | As per audit schedule | As per Audit schedule |
|
|
| Audit check sheet |
| Should any of the audits not meeting the specified criteria as on the audit sheet, stop process and inform Supervisor - immediately
plan of action in place |
|
|
| 15 | Functional Lay-Out Inspection | Inspection | Inspection |
| Meet all customer specfications and drawing specifications | Visual / MEasurement Fitment | Select 3 sets of Torsion Bars for inspection | Once per year |
|
|
| Audit check sheet |
| Any failure during this inspection shall be reported to Prod Manager for immediate action |
|
|
| 16 | Transportation of products to customer | Transport | Transport |
| Correct loading
Order quantities as per order | Visual | Confirm every order with actual load | Every shipment |
|
|
| Delivery note
Call off note |
| Any discrepancy / difficulty during this process must be reported to the Store MAnager |
|