standard operation procedure (cage forming)
DESCRIPTION
SOPTRANSCRIPT
STANDARD OPERATION PROCEDURE
Cage Forming
1. OperatorA. Ensure that the machine can run properly
i. Caging Machine (P400 and P600)(1) Check:
(a) Control panel(i) Ensure that all button can functional (ii) If there is problem immediately inform the Production Supervisor
Make sure all button can be functional
(b) Copper bar(i) Ensure that free from steel waste
Use grinder to grind away the steel waste(ii) Change the position (iii) Keep properly and do not lost it
If exhausted, use the other copper bar
Change the position
(c) Copper ring(i) Ensure that free from steel waste(ii) Change the position
Copper ring must free from steel waste
Rotate the copper ring
(d) Carbon brush(i) Check the condition, if there is abnormal immediately inform the Production
Supervisor
Carbon brush Check for abnormality
(e) Caging stand support(i) Ensure that all stand support can be functional(ii) Inform the Production Supervisor if there is problem immediately
(f) Plate guider
This hole always at 6 o’clock position
B. Set the machine to perform the specified cage size
C. Loaded the PC bars to the machine and secure in position
i. Check the lengthii. If PC bars uneven length segregate the PC bars
iii. Collect the shorter or longer PC bars until enough to produce a cage
How to check for uneven length
Can proceed
Segregate the bars
D. Use correct size of PC bars and spiral wire
i. Follow the table below:
Pile size (mm) No. PC bars x PC bars Dia. Spiral Dia. (mm)
250 6 x 7.1 mm 3.8
300 7 x 7.1 mm 3.8
350 9 x 7.1 mm 3.8
400 8 x 9.0 mm 3.8
450 8 x 9.0 mm 3.8
500 10 x 9.0 mm 4.0
600 14 x 9.0 mm 4.5
E. Initiate the machine by selecting the representative cage size
i. Select proper setting(1) Size (mm) – 250, 300, 350, 400, 450, 500, or 600(2) A, B or C for forming type based on size(3) Length (m) – 6, 9, 12, or 15 (4) Adjust the control for welding
(a) Heat control(b) Heat time
F. Inspect and verify the welding quality and pitch length as per specificationi. All loose welding shall be tied with G.I wires where applicable
(1) Tied at minimum 4 points
Loose cage shall be tied with G.I wire
4 points
Rearrange the spiral wire and tied at minimum 4 points
ii. Check pitch length
Tool for measure pitch length
How to use the tool
iii. Check the uneven length of PC bars cage
How to check:1. 2.
Can send the cage to the next section (assembly). Loose the uneven length of bars, rearrange the bars and tied back the bar with G.I wire. Do not easily
to destroy the cage. G. Record all the number and sizes of cage formed in auto cage forming records
i. Record based on actual hourly cage outputii. Reject cage must be recorded
2. SupervisorA. Ensure that the operators wear proper personal safety equipment.B. Monitor the cage forming process.C. Check the welding quality and pitch length as per specification.D. Ensure that the reject of cage must be clear at the end of the shift.E. Ensure that the PC bars from reject cage and recycle spiral wire need to be used.
PERFORMANCE REQUIRED
Size Length Qty. in 1 hour
250 6 289 1812 14
300 6 239 1512 12
350 6 209 1312 10
400 6 189 1112 9
450 6 169 1012 8
500 6 149 912 7
600 6 129 812 6