Production Work Instruction

Transcription

1 Production Work Instruction Document: Trapped Air Ball Work Instructions Document No.: TABWI-1 Revision: 1 Revision Date: March 13, 2013 Approved By: Ossie Fowler, HR Manager; Marilyn Moore, Quality Supervisor; Mike Ingram, President 1. Remove frame from take-out devise 2. Place frame on cutting table / trim table 3. De-flash / trim excess plastic from frame 4. Inspect balls for deformities and cut an X in all rejects 5. Place excess flash on conveyor belt granulator 6. Hang frame on cooling rack 7. Remove frame from cooling rack after cooling for 12 minutes or 12 flats NOTE: Do not drill-out balls from a frame prior to the 12 min. cooling period 8. Place frame on drilling table 9. Center drill over ball then drill-out ball from frame 10. Place frame flat on conveyor belt to granulator 11. When counter reads 2,000 and red light flashes, stop the process 12. Tie top of bag before removing the bag from the bag rack 13. Remove full bag of products from the bag rack 14. Install an empty bag on the bag rack 15. Write your employee number on the upper right-hand corner on each side 16. Transport full bag to the finished product staging area / storage 17. Repeat this cycle until the production plan is fulfilled

2 1. Remove frame from take-out devise A) Pull down on frame B) The plastic material will separate from the take-out device C) Safety: Employees must wear safety glasses and gloves when completing this action Take-Out Device Flat

3 2. Place frame on cutting table / trim table A) The frame is to be laying flat on the table, not hanging off the table or un-level B) The plastic material will separate from the take-out device C) Safety: Employees must wear safety glasses and gloves when completing this action Cutting Table Frame

4 3. De-flash / trim excess plastic from frame A) Use a sharp trimming tool / knife B) Cut-off the excess plastic as shown below C) Safety: Employees must wear safety glasses and gloves when completing this action Trim alongedge of frame Excess Plastic Cutting Tool

5 4. Inspect balls for deformities and cut an X in all rejects A) Use a sharp trimming tool / knife B) the 'X' will notify the driller of the defect and the ball will not be cutout of the frame C) Safety: Employees must wear safety glasses and gloves when completing this action Cut an 'X' in all bad balls Bad Shot / Bad Ball

6 5. Place excess plastic on conveyor belt granulator A) Safety: Employees must wear safety glasses when completing this action Conveyor Belt Excess Plastic

7 6. Hang frame on cooling rack A) Place frames in order on the cooling rack to allow the frame to cool for 12 minutes or 12 frames before drilling B) Safety: Employees must wear safety glasses when completing this action Insert frame between arms Cooling rack rotates Place frame in order on the cooling rack

8 7. Remove frame from cooling rack after cooling for 12 minutes or 12 flats A) Do not remove a frame from the cooling rack prior to the 12 min. cooling period or 12-frame cycle B) Safety: Employees must wear safety glasses when completing this action Cooling rack rotates Remove frame in rotational order for cooling purposes

9 8. Place frame on drilling table A) Frame must be laying flat on table and in-between the frame locators B) Safety: Employees must wear safety glasses when completing this action Frame Locators Balls will line-up with holes on drilling table

10 9. Center drill over ball then drill-out ball from frame A) Do not cut into ball B) If a ball is damaged, stop the process and capture the ball C) Safety: Employees must wear safety glasses when completing this action Drill

11 10. Place frame flat on conveyor belt to granulator A) Safety: Employees must wear safety glasses when completing this action Frame Conveyor

12 11. When counter reads 2,000 and red light flashes, stop the process A) The red light will flash when the counter reaches 2,000 B) Safety: Employees must wear safety glasses when completing this action Red Light Counter

13 12. Tie top of bag before removing the bag from the bag rack A) Safety: Employees must wear safety glasses when completing this action Tietop of bag

14 13. Remove full bag of products from the bag rack A) Position the forklift forks under the bag B) Lift-up on the bag to remove the tension the bag loops C) Drive in reverse to remove the bag from the bag rack 4 Bag Loops Forklift Forks positioned under bag

15 14. Install an empty bag on the bag rack A) Place each bag loop over the rack as shown B) Drive in reverse to remove the bag from the bag rack 4 Bag Loops

16 15. Write your employee number on the upper right-hand corner on each side of the bag

17 16. Transport full bag to the finished product staging area / storage A) Drive forklift in reverse to storage location Driving in Reverse Forks under bag

18 Quality Contorl Specifications Specifications: Trapped Air Ball is to be 4" diameter and black in color No punctures or holes that would prevent the ball from floa ng Weight must be between: grams each Inspection Instructions 1. Quality Control is responsible complete a visual inspection of one frame on an hourly basis 2. Quality Control is responsible to weigh each ball in one frame on an hourly basis 3. The inspection is to be documented on the Trapped Air Ball Inspection Form TABWI Revision 1 Nonconforming Material: 1. All product that do not meet the above specification are to be identified and controlled in conformance with the Nonconforming Material Procedure. 2. If an employee identifies bad material, the employee is responsible to place the bad material in a rejected material bin. 3. If bad material continues to be produced, stop production and notify Quality Control without delay.