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Work Instruction ID:		1051
Work Instruction Number:	1051	Revision No.	0
Old Work Instruction Number:
Description
Date Created:	11/02/2021 09:46:05	Revision Date:	11/02/2021 09:46:05
Created By:		Approved By:
StockCode:		WorkCentre:
Customer Stock Code:

Job Observation Frequency (Months)

Creator Approval Date:	14/05/2021 08:18:14	Approved Date:	14/05/2021 08:30:55
Document Status:	Current

Work Instruction Rows

Line No.

Header Row

Instruction

Safety checks

Gloves, protective glasses and ear plugs are to be worn throughout this operation.

Keep hands and clothing away from moving parts at all times.

Beware of hot parts after chamfering, use gloves.

Beware of small objects flying from the chamfer unit, safety glasses are required to protect eyes.

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Preparation

- Clean and dust off work surface
- Check the sharpness of the cutting blade
- Check if the start/stop buttons are functioning
After successful checks, load straight wire component into machine.

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Pull lever with black knob towards you till the stopper is in line with inserted wire component.

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Adjust wire component so that it sits flush with the stopper, end-to-end.

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Pull the lever on the left towards the right to lock the wire component in place.

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Chamfer

Press the start button to start the machine.

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Pull the lever with the black knob upwards and away from you to bring the chamfering blade toward the wire component.

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Complete the chamfer all round the circumference of the component by bringing the component into contact with the blade.

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Stopping

Once the chamfering process is complete, pull the leaver with black knob towards you and press the red STOP button.

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Once the machine has come to a complete stop, release the component by pushing the lever on the left towards the left.

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Repeat

Remove the component and turn it around to the opposite side.
Insert the component into the machine again, with the chamfered side in first.

PRODUCTION QUANTITIES ARE TO BE LOGGED ON THE PRODUCTION SYSTEM HOURLY

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Repeat chamfering process (steps 3 to 5)

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Quality Checks

With a vernier, measure the length of the chamfer on both sides.
An acceptable chamfer is between 0.5mm and 1.5mm.
Use the gauge to check the chamfer is in spec

Insert the chamfered rod into the gauge. Check the chamfer using the cut out slots on the sides

The chamfer should sit in the green area, between the small and large slots.

If the chamfer is less than the small slot or greater than the large slot it is out of spec.

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Quality Inspection Frequency

The Last-off from the previous batch is to be compared to the current batch First-off. Last-off is to be placed in the production run.
Complete a First-off before comencing with production, record on system Inspection Number 1052 "Chamfer Ends".
First-off sample to be tagged and remain with the checking fixture.

Conduct in-process inspections every hour and record on system Inspection Number 1056 "Chamfer Ends"

At the end of the batch, last part is to be tagged and kept with the checking fixture. First-off is to be placed in the production batch.

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Rejects

All reject parts are to be placed immediatley in the red reject bins provided.
All rejects should be logged on the system hourly. Reject Analysis No. 1018

Scrap / Reject bins are to be emptied at the end of end job or at the end of shift if the job is running at the end of shift

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Performance Targets

Once the job has been logged on the system, you will be able to see the production figures and targets including the Total Qty made against the job, the quantity prodcued on the shift (day), the Std Time and the number of Parts required to be made per hour. The picture to the left provides and example.

Production figures are to be logged on the system every hour.

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