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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	2024/05/22
		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

Isringhausen

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	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 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 - 6.50 mm ± 0.06 mm. Correct type - Spring black wire. Tensile range 1380mpa - 1550mpa. No rusty wire. No score marks. No excessive drawing soap	Visual inspection and measure with a Micrometer	As per online incoming raw material inspection plan	Every consignment	6178	1120		Goods receive notebook/ Buff tag and record findings on system		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 Manager
	6	Straighten wire and cut to length	Straighten and cut to lengths	Product	SC	Correct cut length - 550.00 mm ±1.00 mm	Visual inspection and tape measure	As per work instruction	First-off at start of production. In-process 9 parts every hour and last-off				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	Product		Safe transportation of wires	Visual verification	N/A	Every order				N/A		Any difficulty experienced during this activity stop the process and report to Supervisor
	8	Form bend 1 on hand bender	Forming	Product	SC	Component shall conform to checking fixture, component to fit profile correctly on fixture to prevent fitment issues	Visual inspection and checking fixture	As per work instruction	First-off at start of production. In-process 9 parts every hour and last-off		1176		Record on inspection system		Should the first-off sample fail - stop process - reset machine and redo first-off. Any further non-conformance report to Supervison
	9	Form bend 2 on hand bender	Forming	Product	SC	Component shall conform to checking fixture, component to fit profile correctly on fixture to prevent fitment issues	Visual inspection and checking fixture	As per work instruction	First-off at start of production. In-process 9 parts every hour and last-off		1176		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
	10	Form radius	Forming	Product	SC	Component shall conform to checking fixture, component to fit profile correctly on fixture to prevent fitment issues	Visual inspection and checking fixture	As per work instruction	First-off at start of production. In-process 9 parts every hour and last-off		1176		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
	11	LTHT of torsion bar	LTHT	Product		240 °C for 30 mins	Visual verification. Record on heat treatment log sheet (QD:52)	Visual inspection temperature.	Every batch				Record oven temperature on QD:52		Any difficulty experienced during this activity stop the process and report to supervisor.
	12	Final inspection of torsion bar	Inspection	Completed products		Component shall conform to customer/ drawing requirements. Bend 1 length: 30.00 mm ±2.00 mm, bend 3 length: 63.00 mm ±2.00 mm, Correct overall length: 375.00 mm ±2.00 mm - Refer CAR 52420. No burrs/ sharp edges & correct fitment on checking fixture	Checking fixture, vernier and visual verification	As per work instruction	Every batch	10362 10363 10364	1176		Record on inspection system		Should the inspection requirements not be correct, stop the process and inform the Supervisor
	13	Transport completed components to stores.	Transport	Completed products		Safe loading and transporting of components.	Visual inspection.	As per job order	Every order				N/A		Should difficulty occur during transport inform Supervisor
	14	Receipt of components	Receipting	Completed parts		Correct quantity to be entered on to the stock system	Visual verification against F.A card	Cross off the F/A card to indicate it has been received on the system.	Every batch		1094		F.A Card		Any discrepancies shall be reported to the Stores Manager
	15	Despatching of components.	Transport	Completed products		Safe handling during this activity.	Verification of quantities as per sales order and delivery note.	As per job order	Every order		1101		Delivery note / invoice		Any difficulty experienced during this activity report to Stores Coordinator
	16	Internal product audit.	Inspection	Completed products		As per drawing and audit requirements.	Competent Q.A personnel conducting inspections.	1 complete product	As per schedule		1180		Audit sheet		Should the audit fail, the Production manager shall be informed immediately.