Work Instruction ID:   30475  
Work Instruction Number: 1064 Revision No. 6
Old Work Instruction Number:
Description
Date Created: 10/03/2021 16:01:54 Revision Date: 01/08/2024 13:48:41
Created By: Approved By:
StockCode: WorkCentre:
Customer Stock Code:    
       
Job Observation Frequency (Months)      
       
Creator Approval Date: 01/08/2024 15:26:42 Approved Date: 01/08/2024 15:47:24
Document Status: Current    
 
Work Instruction Rows
Line No.Header RowInstruction 
1

 

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.

 

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2

SETUP & PREPARATION

  • Ensure the machine configuration and setup is complete as per the Setter Training Manual.
    • Daily Maintenance
    • Physical Tooling is correct 8mm tooling required i.e correct bend head, sweep arm, pin and rollers. 
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      • Tooling not worn as this cause variation in the forming process. Should tooling found to be worn or damaged, generate a requistion and hand to supervisor
      • Correct tool is selected in the machine config.
      • Wire thickness is set in the machine config.
      • Adjust the overbends by performing a 90/20 setup.
      • Ensure wire is straight as this can cause a variation in the process.

Ensure the correct wire has been issued by validating GRN buff tag against the route card.

On the production system log the time as "Setting."

Load the Part Recipe found in the location "part recipe location" and prepare a complete First-Off sample.

Once the first-off is correct, on the production system end the "Setting"downtime and enter the job number and operation to start the job.

Enter the first-off inspection results in the production system.
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3

QUALITY CHECKS

The following checks should be performed:

 

  • Do not force the part into the checking fixture, the part shall drop fit in.
  • Check first-off matches the last-off.
  • The part shall be notched first and then checked in the fixture for fitment. (refer to work instruction number "1065" on notching criteria).
  • When setting the part or making an adjustment to the programe, mould the part to confim angle check in the final fixture.
  • Check gap in required section, 4mm - 6mm gap allowed. Check the gap using 4mm - 6mm wire in the final fixture.
  • Check front section after notching in the in-process fixture.
  • Use both clamps to secure part into the final fixture when checking.
  • Ensure the front profile angle is formed correct as this can cause the part to fail on the angle check in fixture and cause fitment issue at Toyota.
  • Ensure moulded end angle measures between 32 degrees - 35 degrees.
  • Place the product on a flat surface, must sit flat and not have a lift.

Examples

The below indicates how the part must fit the in-process checking fixture.

 

             Part of the machine                                          Part after notching / cropping

                                    

 

    

 

  

 

  

 

          

 

 

The below indicates how the part must fit the in the final checking fixture.

      

 

    

 

     

   

 

  

 

 

 

   

  • 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. See below examples of "OK & NG" parts.

                                 OK                                                                            NG 

  •    
  • Use NO GO gauge to check gap in moulded area, the NO GO gauge must not fit through the gap. See below examples of "OK & NG" parts.
  •                              OK                                                                         NG
  •       

 

Confirm the angle with a angle finder, place the product on a flat surface to confirm the angle. The angle must be between 32 degrees - 35 degrees.

   

 

 

Confirm the flatness by placing the product on a flat surface as per picure below. The product shall not have a lift.

   

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4

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 Number "14423" "Form on Huron". 
  • First-off sample to be tagged and remain with the checking fixture.

 

  • Conduct in-process inspections every hour and record on system Inspection  Number "15423" "Form on Huron" 

 

  • 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 and record on system Inspection  Number "15424" "Form on Huron"
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5

REJECTS

  • All reject parts are to be placed immediatley in the red reject bins provided.
  • All rejects should be logged on the system hourly. 

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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6

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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