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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 wire is straightend correctly.
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.
- When placed in checking fixture, part shall fit flat in the slots between the pins.
- All angles, bends and rotation must be correct to fit in correctly in checking fixture.
Examples
Good part - fit CF - Drop fit required.
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- Part must fit correctly and align into checking fixture. (Drop fit)
- Wire must locate flush against checking fixture.
- Do not force fit part into checking fixture.
- Legs must fit center between pins.
- leg lengths not to protrude from slots.
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Place right formed part into profile slot, ensure that profile is correct and length is correct.
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Place left formed part into profile slot, ensure that profile is correct and length is correct.
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Ensure that the profile box section is aligned with the checking fixture.
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Verify that both the left and right leg length are correct. |
Not Good part - not fitting CF
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Part not aligning with checking fixture,
Legs sticking out of checking fixture
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Wire too long, does not fit into CF
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Wire bent/bowing: not straightened correctly
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Rotate off/ skew: not aligning with CF
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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 6230
- First-off sample to be tagged and remain with the checking fixture.
- Conduct in-process inspections every hour and record on system Inspection no. 6231
- 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: Inspection no. 7271
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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.
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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