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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 and not worn.
- 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.
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.
- The legs should be equal in length leg length = 42mm +/- 0.5 before stamping.
- The overall formed width must measure 221.00 mm before stamping.
- The part must sit against the "left" pins on the checking fixture as indicated below.
- Profile must fit correctly between checking fixture pins.
- The legs should be parallel.
- Parts shall sit flat when placed on a flat surface or have a max gap under the legs of 0.9mm. Use a feeler gauge to verify the gap under the legs.
- Both legs shall sit flat when either leg is held down.
Examples
Formed part off the machine.
.jpg)
NG leg length. OK leg length.
 
NG - leg not flat.
 
OK - leg is formed flat.
Ok condition - both legs sit flat when held eith leg is held down. NG condition - leg is not sitting flat when held down. This is not exceptable.
 
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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 Number "7272" "Inspection of formed wire".
- First-off sample to be tagged and remain with the checking fixture.
- Conduct in-process inspections every hour and record on system Inspection Number "7273" "Inspection of formed wires"
- 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 "10368" "Inspection of formed wires".
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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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