SAFETY

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

Be careful of pinch points. Keep fingers clear at all times when the machine is operating.

SETUP & PREPARATION

• Ensure the machine start up procedure is followed. Refer to work instruction no. 1205
• Ensure the work area is clean and free of unneccesary items.
• Request the required bins from stores to pack the completed parts.
• Request request requred matrial  from stores (PLAS/MAST/BLACK, PLAST/PA60/000, TOYO/ADHE/0000, and sponges) as detailed on job card and ensure that bags are sealed on receipt. 
• Log the job onto the production system to indicate the start time. Assign yourself as the operator on the job.

Enter the first-off inspection results in the production system.

Inspection and checking of part after moulding

• Inspect every part in the checking fixture.

• Inspect moulded area visually for any flashes, undershooting and poor moulding causing .

• Inspect front portion  for any burrs , sharp edges,  and ensure the nothing is round.

• Using the grommit check front portion, grommit must fit through freely.
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• Place part in checking fixture  by starting with the front portion first .
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• Close down clamps on part in fixture.
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• Check the front section first, ensure the front section profile is correct. Use a 4mm - 6mm wire to check the gaps as per below picture. The front section is critical as this affects the angle and causing fitment issues at Toyota.

• Check gaps using a min 4mm wire and a max of 6mm wire . 
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• Check back angle by using the sliding tool, the tool must slide through freely .  Do not force the sliding tool to pass through or it will cause fitment issue at Toyota.
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• Use NO GO gauge to check gap in moulded area, the NO GO gauge must not fit through the gap . 
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Assembling of sponge

• Place part after inspection onto assembling of sponge in fixture and ensure the part is sitting into the slots.
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• Apply tape between POKE YOKE.
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• Take a sponge and apply solution with a ear bud on the inside of the sponge.
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• Place sponge onto tape between POKE YOKE and ensure the sponge is well secured onto part to prevent it from falling off .
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• Remove part and pack into bin after sponge assembly is complete.

Packing of parts

• Pack 22 parts in each bin.
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• Pack 10 bins of completed parts on pallet .

• Required bin size is  4122.

Examples of NG parts that is not exceptable

QUALITY INSPECTION

• 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. no. "22535 Overmould and fit sponge"
• First-off sample to be tagged and kept at work station.

• Conduct in-process inspections every 2 hour and record on system Inspection no. "6091 Overmould and fit sponge"

• 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.
• Conduct a last-off and record on inspection no."12388 Overmould and fit sponge"

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. 7 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