Pictorial Work Instruction Sheets (PWIS)

Pictorial Work Instruction Sheets (PWIS) : 

Pictorial Work Instruction Sheets (PWIS) Prof. K.Umachandran Participants - 05.12.09 Executive Director Head Production Head Maintenance Head Quality Head Tooling Production Systems Participants – 30.12.09 All Shop floor In-charges FOUNDRY APPLICATION

Above all – to the CUSTOMER we mean BUSINESS & SATISFACTION. : 

Above all – to the CUSTOMER we mean BUSINESS & SATISFACTION. At each work station, the operator should be just “DOING” what he is instructed upon to do. The Operator should follow the instructions meticulously. Productivity can be ensured as the LEARNING CURVE picks up. QUALITY is ensured in the Work detailing stage itself. DO RIGHT from FIRST Paves way for Multi tasking Comprehension of a PHOTO is easier than any Drawing (2D / 3D) or Specific written description. Load on supervision is reduced. Work audits can be done to assure Quality. Work Place improvement – Visual Display

Concentrate : 

Concentrate Care should be ensured while preparation of PWIS All Technical Heads can be involved “Picture perfect” detailing should be vetted as cleared for display. The Department heads should be involved in finding the display LOCATION standardize the fixtures, ergonomic facilitation to the operator, access to Change over of PWIS w.r.t product etc., The Department heads to divide the task as Small Group activities (SGA) based on the product families and involve the LINE SUPERVISORY in value additions and preparation.

Slide 4: 

DO’s DO NOT’s Customer / Product Operation # - Operation Name Operator # Time / Operation Guages

Slide 5: 

Example – XYZA Center Housing Core Setting Moulding # Operations – 5 # Operators – 3 Total Time – 15 sec # Operations – 8 # Operators – 9 Pictorial Work Instructions which follow in subsequent slides are ONLY illustrative and doesnot follow the regular Work flow.

Slide 6: 

DO’s Blow the air in core seating area’s of the CSF Ensure level seating of the Axle Bore core DO NOT’s Avoid hook core damage while flower core setting in the axle core Core Setting # 2- Flower core and Axle bore core placement Operator # 2 3 sec/ core 12345 -XYZA - CENTRE HSG

Slide 7: 

STATION # 1- VENT DRILLING (COPE) DO’S Open all the required shown vents by drilling Open the vent by drilling fully Drilling should be done straight Open the vent in the corresponding working station Ensure the vent rod length and replace, if necessary DO NOT’S Avoid failure to open any required vent Avoid half way drilling Avoid inclined drilling operation Avoid drilling while box moving Avoid mould damage by drilling operation Operator #1 23 sec/mould L=520mm D=6mm 12345 -XYZA - CENTRE HSG

Slide 8: 

Packing cores DO’s Ensure level seating of packing cores DO NOT’s Avoid packing core high seating Avoid loose sand particles falling on the mould while packing core setting STATION # 3- Packing Core setting Operator # 3 20 sec/mould 12345 -XYZA - CENTRE HSG