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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.
1. Ensure Collet Chuck is tightend and there is no visible thread showing. Refer to OK and NG picture below.
| OK Picture of Collet Chuck tightend, thread is not visable. |
NG Picture of Collet Chuck, thread is visable. |
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2. Ensure no wire is sticking out as per picture below.
| OK Picture where wire is not sticking out. |
NG Picture of wire stick out in machine. |
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STARTING UP AND BENDING
1. Check to see if the sensor bolts are not stripped or worn as this can cause the sensor to get loose and affect the bend angles of the part.
N.B: if the programme has been adjusted, if the sensor is replaced or the locking bolt has been replaced a new first-off shall be done to requalify the production run.
2. Press the Initialize button.
3. Loosen Collet Chuck with a spanner.
4. Put chamfered side of part in machine, ensure it is pushed to stop against Collect Chuck.
 
5. Tighten Collect Chuck.
6. Select LH or RH by pressing required button.
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7. Once required button for LH or RH is sellected it will start to form part.
8. Loosen Collect Chuck and remove part.
9. Repeat step 2 - 7 to continue production.
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CHECKING METHOD ON CHECKING FIXTURE
1. Place part in checking fixture, if you are working with the LH ensure a RH part is in the fixture before coming part and locking clamps or and is you are working with the RH ensure the LH is in the fixture.
Check every part in the checking fixture.
Refer to boundary samples at work station to make reference.
2. Lock both clamps on part in checking fixture as per picture below.
3. Use required GO / NO GO plate to check gap of part in the middle. Only the Go side of the plate which is 0.5mm must slide through under part as per picture below for both hands.
4. Check front profile of part by placing it in required cut out portion in fixture as indicated on picture below.
5. Check grooved part in GO / NO GO area in checking fixture as indicated below. Part must fit in GO area and not fit in NO GO area.
 
6. Measure the height of legs by placing on a flat surface with a vernier as per picture below. Required spec is 8mm - 9mm.
7. There must be no burrs, deformation and cracks allowed.
8. Parts must drop fit in checking fixture.
9. Inspect every part in the checking fixture.
9. Any difficulty experienced, stop and inform supervisor.
QUALITY ALERT
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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 1064 (SPRG/RAMS/0000) or 1073 (SPRG/RAMS/0001)
- First-off sample to be tagged and remain with the checking fixture.
- Conduct in-process inspections every hour and record on system Inspection Number 2063 (SPRG/RAMS/0000) or 2062 (SPRG/RAMS/0001)
- 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 15426 (SPRG/RAMS/0000) or 15427 (SPRG/RAMS/0001)
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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. 2019 (RAMS/0000) or 2020 (RAMS/0001)
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
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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 produced 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.
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Production figures are to be logged on the system every hour.
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