Table below represents Manufacturing Process of Side, Roof, Floor, Front and Rear Frame
S/N
Description of Operation
Oper’n
1.
Receive stock materials and
procure utilities
o
2.
Measure, Mark and Trim
Profiles to size
o
3.
Clamp sections on the fixture
o
4.
Weld all set-up section joints
o
5.
Inspection of the web frame
o
6.
Kit the web frame according
to production lots
o
7.
Delivery of kitted web frames
to Kiira Vehicle Plant
o
Insp.
Move
Delay







Storage







Time Req’d
2 hr
Equipment\Tooling Used
Scribes, Mechanical Toolbox
0.5 hr
Hold Down Cam Clamps
3 hr
MIG Welding Machine
0.5 hr
Dial Gauges
1hr
8 hr
Table below represents Manufacturing Process Chart for Seat Base Die Guide Pins, Fasteners
S/N
Description of Operation
Oper’n
1.
Requisition from Stores
o
2.
Work Set up on Lathe
Machine
o
3.
Time to Engage, Tooling Set
Up
o
Insp.



Move
Delay
Storage



Dist. Moved
200m
Time Req’d
Equipment\Used
0.5 h
1.2 h
0.3 h
DMG eco Turn 310 (CNC
Lathe)
4.
Cylindrical Turning
o
5.
Facing Turning
o
6.
Parting or Cutting Off
o
7.
Surface finishing
o
8.
Move to the Galvanizing line
o
9.
Galvanizing and Curing
o












0.2
DMG eco Turn 310,
Indexable Cutter
0.1
DMG eco Turn 310,
Indexable Cutter
0.2
DMG eco Turn 310,
Indexable Cutter
3h
Universal Tool Grinder
24h
Zinc Plating Equipment
100m
Table below represents Seat Base Mold Set Assembly
S/N
1.
Description of Operation
Receive machined cavity ,
core plates, fasteners ,
bushings and guide pins
4.
5.
6.
7.
8.
o
Work Set up
o
Inspection of geometrical
tolerances and dimensions
o
Press Fitting of Guide Pins
Bushings
o
Press Fitting of Fastener
Bushing
o
Press Fitting of Sprue
Bushing
o
Press Fitting of Ejector Pin
Bushings
o
Assembly of all subassemblies
o
2.
3.
Oper’n
Insp.








Move
Delay
Storage








Dist. Moved
150m
Time Req’d
0.5 h
Equipment\Used
Forklift
1h
5h
Inspector 686 Bridge
Coordinate
Measuring Machine
0.5h
Manual Hydraulic Press
3h
Manual Hydraulic Press
0.5h
Manual Hydraulic Press
2h
Manual Hydraulic Press
4h
Table below represents Injection Molding
S/N
1.
2.
3.
Description of
Operation
Move assembled mold
to the Injection
Molding Shop
Mount the mold on
the Injection molding
machine
Work Set up and
Trouble shooting
Oper’n
o
o
o
4.
Curing & Drying
Plastic Material
o
5.
Preparation of
Cooling System
o
6.
Injection Molding
Trials
o
7.
Injection Molding of
Thermoplastics of
Seat Base
o
Apply adhesive
bonding of the Seat
Rest Thermoplastics
Allow for adhesive
curing
o
10.
Assemble Seat Rest
and Seat Base
o
11.
Inspect the finished
thermo plastic
assembly
o
Package the seat
thermo plastics
o
8.
9.
12.
o
Insp.












Move
Delay
Storage












Dist. Moved
Time Req’d
200m
0.5h
Fork Lift
5h
Work Holding Crane
Equipment\Used
Inspector 686 Bridge Coordinate
0.3 h
Measuring Machine
2h
Injection Molding Machine 260F2VII
0.5h
Injection Molding Machine 260F2VII
0.25h
Injection Molding Machine 260F2VII
0.1 h per
thermo
plastic
Injection Molding Machine 260F2VII
0.5 h
1.5 h
0.5 h
Assembly Jig and Fixture
Inspector 686 Bridge Coordinate
0.35h
Measuring Machine
0.3h per
thermoplastic
Table below represents Urethane and Foaming Process
S/N
Description of Operation
Oper’n
1.
Receive foam at LIL
o
2.
Trim the foam to required
shape
o
3.
Apply stitching to the
urethane
o
4.
Assemble Urethane and
Foam
o
5.
Package the dressed cushion
for transportation
o
Insp.





Move
Storage
Delay





Dist. Moved
Time Req’d
0.5 h
Equipment\Used
Foam Cutter
Heavy Duty Portable
1.2 h
Sewing Machine
0.25 h
0.2h
Table below represents Support Frame Fabrication
S/N
1.
2.
3.
4.
5.
6.
7.
Oper’n
Insp.
Receive angle bars at LIL
o
Measure, Mark and Trim
profiles
o
Assemble the trimmed
profiles
o







Description of Operation
MIG weld the joints
according to assembly
drawings
o
Package the frame
according to modularized
break down
o
Pre-Delivery Inspection of
the Seat Items
Deliver seat thermoplastic,
frame and dressed cushion
to KMC premises in Jinja
o
o
Move
Storage
Delay







Dist. Moved
Time Req’d
136 km
1-2 weeks
after ordering
Truck
0.2 h
Scriber and Band Saw
Equipment\Used
0.5h
0.5h
MIG Welding Machine
0.5h
0.5h per seat
set
Inspector 686 Bridge Coordinate
8h
Pallets
Measuring Machine
Table below represents Final Assembly
S/N
Description of Operation
Oper’n
Inspect the delivered
1. items and Procurement
Control
o
Assemble the thermo
2. plastic onto the support
frame
o
3. Assemble the entire seat
o
Inspect the quality of the
assembled seat
o
4.
5. Deliver to the customer
o
Insp.





Move
Storage
Delay
Dist. Moved
Time Req’d

136 km
2h
Hand Held Dial Gauges
0,8h
Assembly Jig and Fixture
0.5 h
Foam Cutter




Equipment\Used
Heavy Duty Portable
0.25
Sewing Machine
0.5h