| 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 material by stores personel. | Receiving | Raw material |
| Spring Black Wire 1.6mm wire as per purchase order. | Verification of delivery note and order placed . Any discrepancy. | Delivery note and order | Every batch |
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| Goods receive note book / delivery note |
| Should there be any discrepancies inform production planner / supplier immediately and make a note on P.O.D |
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| 2 | Move material to receiving storage area. | Transport | Raw material |
| Safe handling during transport and handling activity. | Visual inspection. | As per FIFO system | Every batch |
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| Visual inspection |
| If difficulty occurs in storing raw material properly inform Stores Coordinator |
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| 3 | Inspection of raw material by Q.A. | Inspection | Raw material |
| Spring black 1.6mm wire , wire tolerance +/- 0.025mm , No score marks , no rusty wire , compare tensile strength with COA and spec - correct grade. | Check wire diameter with micrometer. Visual inspection of condition of wire. COA from supplier. Record on incoming inspection document. Rod spec from supplier. | As per incoming raw material inspection QD207 | Every consignment |
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| 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 |
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| 4 | Move raw material to storage area for storage. | Transport | Raw material |
| Move raw material to storage area for storage. | Visual inspection during this activity . Competent forklift driver , FIFO system to control material. | As per FIFO system | On receiving |
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| Identification tags |
| Any difficulty experienced during this activity report to Stores Coordinator |
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| 5 | Issue wire to production. | Issuing | Raw material |
| Correct identification of wire. | Material buff tag Visual inspection. | Every coil issued to production. | Every job as per request |
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| Route card |
| Should the incorrect wire be issued to production stop process, correct and inform Stores Coordinator |
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| 6 | Coil and inspect Circlip. | Coiling | Product |
SC
| Correct setting of rings as per drawing requirements.
1. I.D off coiler = 14.4mm - 14.6mm.
2. Gap off coiler = 3.8mm - 4.5mm.
3. No Burrs allowed. | Record on electronic system. | First off sample, thereafter 9 parts every hour and a last-off. | Every batch |
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| Record on BIS card and
Record on online inspection |
| Should any of the parts not conform to requirements - stop production: inform supervisor.
Reset machine and do another first off sample. |
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| 7 | Transport Circlip to LTHT. | Transport | Product |
| Safe movement using a trolley to transport rings. | Visual verification. | Every batch | Every order |
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| N/A |
| Any damage to parts shall be reported to Stores Supervisor |
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| 8 | LTHT of Circlip. | LTHT | Product |
| Safe loading and off-loading of rings.. | Visual verification. | Visual inspection temperature. | Every batch |
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| Record oven temperature on QD:52 |
| Any difficulty experienced during this activity stop the process and report to supervisor. |
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| 9 | Final inspection of Circlip. | Inspection | Completed products |
| Circlip shall conform to customer/drawing requirements.
1. I.D = 13.8mm - 14.2mm.
2. Garp = 3.0mm.
3. No Burrs allowed. | Record on electronic system. | First-off, in-process and last off. | Every batch |
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| Record results on online inspection |
| Should the inspection requirements not be correct, stop the process and inform the supervisor. |
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| 10 | Transport completed Circlips to stores. | Transport | Completed products |
| Safe loading and transporting of Circlips. | Visual inspection. | As per job order | Every order |
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| N/A |
| Should difficulty occur during transport inform Supervisor |
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| 11 | Receive Circlips into stores area. | Receipting | Completed products |
| Correct quantities of Circlips. | Visual inspection Approved transporter. | Every batch. | Every order |
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| F.A Card. |
| Any discrepancies shall be reported to the Stores Coordinator |
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| 12 | Dispatching of Circlips. | Transport | Completed products |
| Safe handling during this activity. | Verification of quantities as per sales order and delivery note. | As per job order | Every order |
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| Delivery note / invoice |
| Any difficulty experienced during this activity report to Stores Coordinator |
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| 13 | Internal product audit. | Inspection | Completed products |
| As per drawing and audit requirements. | Competent Q.A personnel conducting inspections. | 1 complete product | As per schedule |
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| Audit sheet |
| Should the audit fail, the Production manager shall be informed immediately. |
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