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MANUFACTURING QUALITY CHART

COMPILED BY		TEAM MEMBER 2
TEAM MEMBER 3		TEAM MEMBER 4
SUPPLIER	Webroy (Pty) Ltd	MQC No
CUSTOMER		REV No.
PART NAME		DATE INITIATED
PART No.		REVISION DATE	2024/05/21
		LAST REVIEW DATE
WEBROY STOCK CODE		STATUS
MANUFACTURING LOCATION	Webroy	SAFETY CRITICAL
MQC TYPE
Current

Process Flow Key

Process Type	Image
PARTS STOCK
COMPONENT PART
PROCESS OPERATION
SAMPLING INSPECTION
100% INSPECTION
TRANSPORT

Responsible
Confirmation Level Key

Name	Image
OPER
T/L
SUPERVISOR
MNGR
OPER
T/L
SUPERVISOR
MNGR

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 verification of raw materials by stores personel	Receiving	Raw material		Check for correct quantity delivered, type and diameter	Visual inspection and verification as per order	Delivery Note and order	Every Batch		1090		Goods Receive Note Book / Delivery Note		Should there be any discrepancies - inform Production planner / supplier immediately and make note on POD
	2	Move material to receiving storage area	Transport	Raw material		Store material correctly	Visual Inspection	As per FIFO System	Every Batch				Visual inspection and FIFO board		If difficulty occurs in storing raw material properly, inform Stores coordinator
	3	Inspection of raw material by QA personel	Inspection	Inspection	SC	Spring black wire. TSG 3531G - SWB.WIRE/SBS3/0380 & WIRE/SBS3/0500. correct diameter 3.8mm +/- 0.035 and 5mm +/- 0.045. No score marks, no rust on wire. Correct tensile 3.8mm = 1373mpa to 1569mpa and 5mm = 1460mpa to 1650mpa.	Visual Inspection / Micrometer	As per incoming raw material inspection plan QD207	Every consignment	6080 6081	1120		Goods Receive Note Book / Buff tag and record findings on electronic system		Any non-conforming raw material shall be isolated. Raise a SRAN and inform stores coordinator
	4	Move raw material to dedicated area for storage	Storage	Raw material		Safe stacking of wire coils as per allocated areas and FIFO system	Visual Inspection	As per FIFO System	On receiving				FIFO information board and rack identification		Any difficulty experienced during this activity report to Stores Coordinator
	5	Issue wire to production	Issuing	Raw material		Correct wire to be issued as per route card.	Verification as per buff tag. Setter to verify wire diameter with Vernier.	Every coil issued to production.	Every job as per request				Route Card		Should the incorrect wire be issued to production, stop the process, correct and inform Stores coordinator.
	6	Straighten and cut wire to length	Straighten and cut	Cut lengths		Correct length = 262.5mm - 263mm No burrs on ends Wire must be straight, no twist	Measure with tape measure. Visual inspection for burrs and straightness	First-off sample In-process inspection	First-off at start of production. In-process 1 part every hour and last off	6125 6126			Record on line inspection system		Should the first-off sample fail stop process and reset machine and re-do first-off
	7	Form wire on Wire Former	Forming	Wire forms	SC	Form wires	Visual inspection	As per work instruction	First-off at start of production, in-process 1 part every hour and last off	6082 6086 12392	1117		Record on electronic system		Should the first-off sample fail, stop process and reset machine and re do first-off sample and inform supervisor
	8	Induction heat treatment of wire after forming	Heat treatment	Temperature	SC	Induction heat wire after forming at 300°C +20°C	Digital infrared thermometer	Temperature of induction heating	Weekly	22542			Record of online inspection		Any difficulty experienced during this activity stop the process and report to supervisor
	9	Load wire forms on kanban	Loading	Wire forms		Load wires correctly on kanban	Visual inspection	Full Kanban	Every batch				NA		Any difficulty experienced during this activity stop the process and report to team leader
	10	Load wire forms into mould	Loading	Wire forms		As per work instruction	Visual inspection	Every batch	Every part				N/A		Any difficulty experienced during this activity stop the process and report to team leader
	11	Moulding of wire forms	Moulding	Wire forms		Correct injection as per requirement. Correct mould parameters . Ensure gate nozzles are turned off when not in use to avoid degradation of the plastic and carbonisation of nozzles.	Visual Inspection	As per job requirement	Every part	23619	1260		N/A		Any difficulty experienced during this activity stop the process and report to team leader
	12	Strip part from mould and inspect	Stripping and inspecting	Moulded wire forms		Correct injection. No missing pieces of plastic. No sprue & sharp edges. Overmoulded wires completely covered, look for under shooting. Operator initial on R/H side plastic moulded piece.The center part of the mould plastic not burnt & sticky. No short shots.	Visual Inspection and verification on final checking fixture. First-off verification by Q.A	First-off inspection In process inspection and last off	Every batch	6085 6088 12391	1261		Record on electronic system		Any difficulty experienced during this activity stop the process and report to team leader
	13	Load parts into bin	Packing	Completed parts		Correct quantity 15 parts per bin / 25 bins per pallet. Bin No. 4633	Visual inspection	As per works order	Every job as per request				FA Card		Any difficulty experienced during this activity stop the process and report to team leader
	14	Transport part to stores	Transport	Completed parts		Correct bins and correct quantity	Visual in spection	As per works order	Every job as per request				FA Card		Should any difficulty occur during transportation inform supervisor
	15	Receipt parts into stores	Receipting	Completed parts		Correct quantity to be entered into stock system	Visual	Every job	Every order		1094		FA Card		Any discrepancy shall be reported to stores coordinator
	16	Dispatching of parts	Transport	Transport		Correct loading of boxes and safe handling during transport activity	Visual	Every job	Every order		1101		Delivery note / Invoice		Any difficulty experienced during this activity stop the process and report to Stores coordinator
	17	Layout function inspection	Inspection	Inspection		Full dimensional	As per drawing and customer requirements	1 Complete part	As per schedule				Audit sheet		Should the functional layout fail, the production manager shall be reported immediately.