QualityBinder Work instruction Work Instruction · USD 49
WI-014: Final inspection, aluminium bracket 7740
Bench 4, final inspection cell. To be performed on every batch before packing. Read with PR-006 Nonconforming Product.
A work instruction is not a procedure. It tells one person at one bench exactly what to do with what is in front of them. This one was written at bench 4, watching the job run, with the inspector who does it.
Document control
- Document number
- WI-014
- Version
- 3.0
- Effective
- 12 October 2026
- Owner
- Quality Manager
- Approved by
- Operations Director
- Next review
- 12 October 2028
- Classification
- Controlled copy. Printed copies are uncontrolled
- Supersedes
- WI-014 v2.2
Scope
Purpose and scope
This instruction covers final dimensional and visual inspection of part 7740 before packing. It applies to all batches regardless of customer. It does not cover in process inspection at the mill, which is WI-009.
| Item | Detail |
|---|---|
| Part | 7740, aluminium bracket, 6082-T6 |
| Operation | Final inspection, after deburr and before packing |
| Station | Bench 4, final inspection cell |
| Typical batch | 250 to 400 pieces |
| Sampling | Per clause 4. Not 100 percent unless the batch is flagged |
| Related documents | PR-006 Nonconforming Product, WI-009 In process inspection, drawing 7740 rev F |
Duties
Responsibilities
| Role | Responsibility |
|---|---|
| Inspector | Performing the inspection, recording results, quarantining rejects |
| Cell leader | Releasing the batch, authorising rework, signing the inspection record |
| Quality Manager | Concessions, customer notification, and any change to this instruction |
| Operator | Presenting the batch clean, deburred and with the route card complete |
Setup
Equipment and preparation
| Equipment | ID | Calibration due |
|---|---|---|
| Digital calliper, 0 to 150 mm | GAU-018 | 14 March 2027 |
| Bore gauge, 10 to 18 mm | GAU-031 | 2 February 2027 |
| Go/no go pin gauge, 12H7 | GAU-044 | 9 June 2027 |
| Surface plate and height gauge | GAU-007 | 28 November 2026 |
| Illuminated magnifier, 3x | n/a | n/a |
Check the calibration label before use. A gauge past its due date must not be used, and any batch inspected with one must be reported to the Quality Manager the same day.
- Drawing 7740 at rev F on the bench. Confirm the revision, do not assume
- Route card present and the deburr operation signed
- Bench clear of the previous batch and of any loose parts
- Gauges wiped and zeroed on the setting ring
Sampling
How many pieces to check
| Batch size | Sample | Accept | Reject |
|---|---|---|---|
| Up to 150 | 13 | 0 | 1 |
| 151 to 280 | 20 | 0 | 1 |
| 281 to 500 | 32 | 0 | 1 |
| Flagged batch, any size | 100 percent | n/a | n/a |
A batch is flagged if the previous batch of 7740 was rejected, if the tool was changed mid run, or if the customer has raised a complaint on this part in the last 90 days.
Checks
Inspection characteristics
| Char | Feature | Nominal and tolerance | Gauge | Record |
|---|---|---|---|---|
| C1 | Overall length | 84.00 mm, plus or minus 0.10 | GAU-018 | Measured value |
| C2 | Mounting bore | 12.00 mm H7 | GAU-044 | Pass or fail |
| C3 | Bore to edge | 18.50 mm, plus or minus 0.15 | GAU-031 | Measured value |
| C4 | Flange thickness | 6.00 mm, plus 0.00 minus 0.12 | GAU-018 | Measured value |
| C5 | Flatness, mounting face | 0.08 mm maximum | GAU-007 | Measured value |
| C6 | Burrs and sharp edges | None detectable by hand | Visual, 3x | Pass or fail |
| C7 | Surface finish and marking | No scoring, part number legible | Visual, 3x | Pass or fail |
C1 and C3 are customer designated key characteristics. Their measured values are recorded for every piece in the sample, not just a pass or fail. This is a contractual requirement on the Rowan Engineering contract and applies to all 7740 batches regardless of customer.
Method
Steps
- 6.1
Draw the sample
Take pieces from across the batch, not from the top of the box. Spread the draw over the container.
- 6.2
Measure C1 on each sample piece
Calliper across the length, at the marked datum. Record every value on the inspection record.
- 6.3
Gauge C2
Go end must enter under its own weight. No go must not start. Do not force either end.
- 6.4
Measure C3 and C4
Record C3 for every piece. C4 to the nearest 0.01 mm.
- 6.5
Check C5 on the surface plate
Three points minimum. If the piece rocks, it fails before you measure.
- 6.6
Visual C6 and C7 under the magnifier
Run a gloved finger along the flange edge. Burrs that catch are a fail even if nothing is visible.
- 6.7
Decide accept or reject
Clause 4. One failure anywhere in C1 to C7 rejects the batch.
- 6.8
Complete the inspection record
Clause 8. Incomplete record means the batch is not released, however good the parts are.
- 6.9
Release or quarantine
Accepted batches go to packing with the signed record. Rejected batches go to the red quarantine bay under clause 7.
Exceptions
Nonconformance handling
| Finding | Action | Authority |
|---|---|---|
| Any characteristic out of tolerance | Quarantine the whole batch, red label, raise NCR under PR-006 | Inspector, immediately |
| Burrs only, no dimensional failure | Return to deburr as rework. Re-inspect the full sample afterwards | Cell leader |
| Marginal C1, within 0.02 of the limit | Not a failure. Record the value and note the trend for the cell leader | Inspector |
| Customer asks to accept out of tolerance parts | Concession request in writing only. Never a verbal agreement | Quality Manager |
| Gauge found out of calibration after use | Quarantine every batch inspected with it since the last good check | Quality Manager, same day |
| Drawing on the bench is not rev F | Stop. Do not inspect to a superseded drawing | Inspector, stop work |
Records
Required records
| Record | Form | Retained | Held by |
|---|---|---|---|
| Final inspection record | QF-014 | 7 years | Quality, scanned to the batch folder |
| Nonconformance report, where raised | QF-006 | 7 years | Quality |
| Concession, where granted | QF-011 | 7 years, with the customer approval attached | Quality |
| Rework re-inspection | QF-014, marked rework | 7 years | Quality |
Seven years is the Rowan Engineering contract requirement, which is longer than your standard three. The longer period has been applied to all 7740 records rather than only Rowan batches, because separating them at the point of filing has failed twice before.
8.1 Batch release signature
QF-014, foot of form
Batch no. ____________ Qty ________ Date ____/____/______
Sample size ______ Accepted [ ] Rejected [ ] NCR no. ________
Inspected by ______________________ Stamp ______ Time ________
Released by ______________________ Stamp ______ Time ________
(cell leader, or Quality Manager where a concession applies)Document control
Revision history
| Version | Date | Author | Change |
|---|---|---|---|
| 3.0 | 1 October 2026 | QualityBinder | Rewritten at the bench with the inspector. C1 and C3 identified as key characteristics requiring recorded values; sampling plan corrected; retention extended to 7 years across all batches. Supersedes v2.2, which is withdrawn. |
| 2.2 | 4 March 2025 | Kestrel Quality | Gauge IDs updated after the calliper replacement. |
| 2.1 | 17 September 2024 | Kestrel Quality | Flatness limit tightened from 0.12 to 0.08 following the Rowan complaint. |
| 2.0 | 2 May 2023 | Kestrel Quality | Reissued at drawing rev E. |