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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	2023/11/03
		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 raw material - Stores Personnel	Receiving	Raw material		Check for correct quantity delivered, type, Diameter. Check for COA	Visual verification and verification as per order	Visual inspection and verification as per order	Every batch		1090		Goods receive note book / delivery note		Should there be any discrepancies inform production planner / supplier immediately and make a note on P.O.D
	2	Move raw material to incoming inspection area	Transport	Raw material		Store material properly in bays	Visual verification	As per FIFO system	Every batch				Visual inspection		If difficulty occurs in storing raw material properly inform Stores Coordinator
	3	Raw material incoming inspection by QA Personnel	Inspection	Raw material	SC	Correct Ø - 6.00 mm ± 0.08 mm. 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 batch	6180	1120		Goods receive notebook / Buff tag and record findings on electronic sytem		Any non-conforming raw material shall be placed on hold and isolated. Raise SRAN and inform Stores Coordinator
	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 verification	As per FIFO system	On receiving				Identification tags		Any difficulty experienced during this activity report to Stores Coordinator
	5	Issue raw material to Production Personnel	Issuing	Raw material		Correct wire to be issued as per route card	Verification against buff tag	Every coil issued to production	Every job as per request		1080		Route card		Should the incorrect wire be issued to production stop process, correct and inform Stores Coordinator
	6	Straighten wire and cut to length	Cut to lengths	Box wire	SC	Correct cut length - 373.00 mm ±1.00 mm	Visual inspection and tape measure - As per work instruction no. 1224	As per work instruction	First-off at start of production. In-process 9 parts every hour and last-off	21488 21489 21490 21488 21489 21490	1224 1224		Record on inspection system		Should the first-off sample fail - stop process - reset machine and redo first-off. Any further non-conformance report to Supervisor
	7	Move straight cut wire to wire bender	Transport	Indivual Wires		Safe transportation of wires	Visual verification	N/A	Every order				N/A		Any difficulty experienced during this activity stop the process and report to Team leader
	8	Form loop wire on 12mm Huron Machine	Forming	Loop wire	SC	Wire shall conform to checking fixture , wire to sit flat in grooves on fixture to prevent fitment issues - refer CAR 45328	Visual inspection and checking fixture - As per work instruction no. 1225	As per work instruction	First-off at start of production. In-process 9 parts every hour and last-off	21491 21492 21493	1225		Record on inspection system		Should the first-off sample fail - stop process - reset machine and redo first-off. Any further non-conformance report to Team leader
	9	Move loop wire to spot welder	Transport	Indivual Wires		Safe transportation of wires	Visual verification	N/A	Every order				N/A		Any difficulty experienced during this activity stop the process and report to Team leader
	10	Form straight cut wire on wire bender	Forming	Box wire	SC	Wire shall conform to checking fixture , wire to sit flat in grooves on fixture to prevent fitment issues.	Visual inspection and checking fixture - As per work instruction no. 1226	As per work instruction	First-off at start of production. In-process 9 parts every hour and last-off	21494 21495 21496	1226		Record on inspection system		Should the first-off sample fail - stop process - reset machine and redo first-off. Any further non-conformance report to Team leader
	11	Move formed wires to spot welder	Transport	Indivual Wires		Safe transportation of wires	Visual verification	N/A	Every order				N/A		Any difficulty experienced during this activity stop the process and report to Team leader
	12	Assemble and spot weld wires	Welding	Welded part	SC	Part must conform to drawing requirements	Visual inspection and checking fixture - As per work instruction no. 1054	As per work instruction	Every part	21497 21498 21499	1227		Record on inspection system		Should the first-off sample fail - stop process - reset machine and redo first-off. Any further non-conformance report to Team leader
	13	Inspection of welded component	Inspection	Welded part in checking fixture	SC	Part must conform to drawing and checking fixture requirements. Sufficient weld penetration - material thickness on spot welded area should be 10.25 mm ±0.25 mm.	100% inspection on final checking fixture	As per work instruction	Every part	21497 21498 21499	1227		Record on inspection system		Should the inspection requirements not be correct, stop the process and inform the Team leader
	14	Pack welded components in bins	Packing	Welded parts		Correct quantities, correct packaging method	Visual verification	As per packaging specification	Every batch				F.A Card		Should the quantity be incorrect, stop process, verify quantity and add/remove products to meet quantity required
	15	Transport welded components to stores	Transport	Welded parts		Correct quantities as per F.A card	Visual verification	As per job order	Every order				N/A		Should difficulty occur during transport inform Team leader
	16	Receipt of components	Receipting	Completed parts		Correct quantity to be entered on to the stock system	Visual verification against F.A card	Every batch	Every order		1094		F.A Card		Any discrepancies shall be reported to the Stores Coordinator
	17	Dispatching of products	Transport	Completed parts		Bin type: 4622, QTY: 60 per bin	Visual verification	As per job order	Every order		1101		Delivery note/ invoice		Any difficulty experienced during this activity report to Stores Coordinator
	18	Layout functional inspection	Inspection	Parts		Full dimensional as per SDS and PIS.	As per customer requirements	1 complete product	As per schedule				Audit sheet		Should the audit fail, the Production manager shall be informed immediately