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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.
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SETUP & PREPARATION
- Ensure the machine configuration and setup is complete as per the Setter Training Manual.
- Daily Maintenance
- Physical Tooling is correct
- 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 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 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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QUALITY CHECKS
The following checks should be performed:
- Do not force the part into the checking fixture.
- Ensure all wires sit in the slots and not above.
- Measure width of legs after LTHT outside to outside = 273.3mm + 10mm
Examples
| OK Wire sitting in the slot and below the top of the slot |
NG part. Sitting above the slots and pin. |
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| Examples of good and bad fitment |
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| Below is a example of a rejected part found at TBSA. The width is too wide. Required spec is - 273.3mm + 10mm |
Below is a example of a good part found at TBSA. The legs is nor formed wide. |
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HEAT TREATMENT (LTHT)
Ensure the process is logged on the production system.
Place the formed wires in the box oven for 20 minutes at 300 degrees Celcius.
Warning. Parts leaving the oven are hot. Ensure you are wearing gloves when handling parts
Leave the parts to cool before transporting.
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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. "3077".
- First-off sample to be tagged and remain with the checking fixture.
- Conduct in-process inspections every hour and record on system Inspection no. "3079".
- 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 no. "12389".
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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. 2023
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 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.
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Production figures are to be logged on the system every hour.
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