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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	2026/06/01
		LAST REVIEW DATE
WEBROY STOCK CODE		STATUS
MANUFACTURING LOCATION	Webroy	SAFETY CRITICAL
MQC TYPE
Draft

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 and diameter.	Visual inspection and verification as per order	Check for correct quantity delivered, type and diameter.	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	Inspection of raw material by QA personnel.	Inspection	Raw material		Mild black wire. WIRE/MBH2/0500. Correct diameter 5mm +/- 0.08. Correct tensile - 500mpa to 750mpa.No score marks, no rust on wire.	Visual inspection, Micrometer	Mild black wire. SAE 1010/1008. Correct diameter Correct tensile - 500mpa to 700mpa.WIRE/MBH2/0500. Correct diameter 5mm +/- 0.08. Correct tensile - 500mpa to 750mpa.No score marks, no rust on wire.	Every batch	6179	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
	3	Move material to dedicated area for storage.	Transport	Raw material		Safe stacking of wire coils as per allocated areas and FIFO system.	Visual inspection.	Safe stacking of wire coils as per allocated areas and FIFO system	On receiving				Identification tags		Any difficulty experienced during this activity report to Stores Coordinator
	4	Issue wire to production.	Issuing	Raw material		Issue wire to production.	Verification as per buff tag Setter to measure wire diameter with vernier	Issue wire to production.	Every job as per request				Route card		Should the incorrect wire be issued to production stop process, correct and inform Stores Coordinator
	5	Form U Wire on Zukron 3	Forming	U Wire		Wire shall conform to checking fixture , wire to sit flat in fixture. No rust, Score Marks and Burrs allowed.	Visual Inspection and verification in checking fixture. First-off verification by Q.A	As per work instruction	First-off at start of production. In-process 9 parts every hour and last-off				Record on Electronic system		Should the first-off sample fail - stop process - reset machine and redo first-off. Any further non-conformance report to Supervisor
	6	Form Outer Wire on Zukron 3.	Forming	Outter Wire		Wire shall conform to checking fixture , wire to sit flat in fixture. No rust, Score Marks and Burrs.	Visual Inspection and verification in checking fixture. First-off verification by Q.A	As per work instruction	First-off at start of production. In-process 9 parts every hour and last-off				Record on Electronic system		Should the first-off sample fail - stop process - reset machine and redo first-off. Any further non-conformance report to Supervisor
	7	Transport Indivual U Wires & Outter Wires to Spot Welder.	Transport	U & Outter Wire		Correct handling of parts during this activity.	Visual verification.	N/A	Every order				N/A		Any difficulty experienced during this activity stop the process and report to Supervisor
	8	Dressing and cleaning of copper tips	Copper tips	Clean tips set to correct height		Clean and set to correct height. Heights XXXmm top and XXXmm bottom tip which will have a gap of XXmm between the copper tips.	Measure heights with a Tape measure or Steel rule.	Heights set prior to welding Cleaning of copper tips every 2 hours	Every 2 hours				Record on inspection system		Any problem experienced during this activity report to supervisor.
	9	Break Strength Test	Weld strength	Breaking strength		Conduct a chisel and hammer test (To determine weld strength) as part of first off approval.	Use a 10-15mm chisel, 1kg hammer for the test.	1 part per batch	Every batch				Record on inspection system		If the test fails, stop and call the supervisor.
	10	Load U Wire & Outter Wire in welding jig	Loading	Correctly loaded welding jig.		Correct loading of wires into the loading jig to ensure a good weld.	Visual inspection to ensure wires are touching, no gaps. Ensure all hold-down clamps are in place.	Visual inspection	Every order				Visual inspection. First-off in sample inspections		Any difficulty in loading jig, stop the process and call the supervisor.
	11	Welding & inspection of final product	Welding	Welded product		Welding of product.	Product to meet drawing and customer requirements No smash welds, no miss welds, no broken welds and no bent wires.	Visual verification in checking fixture for correct fitment.	First-off at start of production. In-process 9 parts every hour and last-off				Record on inspection system		Should the inspection requirements not be correct, stop the process and inform the supervisor.
	12	Transport welded products to stores for E - Coating	Transport	Welded products		Correct quantities.	Visual inspection.	As per job order	Every order				N/A		Should difficulty occur during transport inform Supervisor
	13	Send parts for E Coating.	Transport	Uncoated parts		Correct E Coating as per boundary sample.	Visual inspection.	Every batch	Every order				N/A		Any difficulty report to manager.
	14	Receive coated parts.	Receiving	Coated products		Correct coating on parts. Correct quantity received.	Visual inspection.	Every batch	Every order				N/A		Any issues report to Quality and Production manager
	15	Inspection of E - Coated products.	Inspection	Coated products		Correct coating as per (BSQ7E447) boundary sample. No cracks. colour - black.	Visual inspection/ verification.	Every order	Every batch				Record on inspection system		Any non-conforming parts shall be placed on hold and isolated. Raise SRAN and inform Stores Coordinator
	16	Receipt products into stock.	Receipting	Completed products		Correct quantity to be entered on to the stock system.	Visual verification.	Every batch	Every order				F.A Card.		Any discrepancies shall be reported to the Stores Coordinator
	17	Dispatching of products.	Transport	Completed products		TBSA XXX orange dunage bins XXXX, Pack XXparts in each box.	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	Completed product		Full dimensional as per SDS and PIS.	As per customer requirements.	1 complete product	As per schedule				Online audit system		Should the audit fail, the Production manager shall be informed immediately.