Gilbarco Printer Assembly Process Flow Overview

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Gilbarco Printer AssemblyProcess Flow Overview
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Flow Chart
MRB
No
Pass Inspection
Receiving
Receiving inspection
yes
Inventory / staging
Kitting / assembly
Inspection / Test
Pack / Ship
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Receive Raw Material into ERP

• Material procured from Approved Suppliers only
• Suppliers to ship ESD sensitive components in
  ESD protective shipping containers
• All containers to be clearly marked with ESD
  warning labels
• Verification of Supplier, Part Number, Purchase
  Order Number, and Quantity
• Receipts entered into ERP system by PO number.
• Move to Receiving Inspection

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Receiving Inspection

• Sample Inspections performed on incoming
  material based on AQL
• ICT and continuity tests on all electronic
  components, performed by supplier
• Certificate of Conformance (CofC) to accompany
  all lots of incoming components
• requiring test
• UL approved components to be clearly marked
  with UL label
• UL documents to filed in Receiving Inspection
• Electronic Vendor History cards track vendor
• incoming quality performance

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Receiving Inspection continued

• On-line password protected Receiving Inspection
  Instructions
• Electronic link to Gilbarco provided component
  specifications
• Controlled hardcopy component specs located in
  Receiving Inspection files
• Highlighted critical characteristics for sample
  inspection

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MRB
Any material not conforming to RPNs inspection
requirements will be properly identified as
defective material and moved to MRB. Material
will remain in MRB until the appropriate
disposition can be determined. If material is
rejected due to non-conforming characteristics
which are not listed on the component RII, the
non-conformity will be added to the RII for
future inspections. Per RPNs quality system, a
Supplier Corrective Action Request (SCAR) will be
initiated for any component rejected at Receiving
Inspection.
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Inventory / Staging

• Material passing inspection is moved to
  inventory staging area
• All material is moved using the appropriate ESD
  precautions
• ESD caution labels remain on sensitive
  components until assembly
• High percentage of material stored at
  point-of-use locations (B and C items)
• Remaining components staged in designated
  kitting area adjacent to manufacturing
• Material transported in ESD totes and metro
  carts

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Kitting / Assembly
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Manufacturing Process
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Manufacturing Process continued
Operators will assemble the printer assemblies
using tightly controlled on-line work
instructions. Instructions will include
workmanship standards, inspection and test
criteria, packaging instructions, and bill of
materials. CAD drawings and digital photos will
be used as visual aids to ensure built-in
quality.
The initial step of the work instructions will be
to apply a bar coded serial number label to each
unit for component warranty and product
traceablility.
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Final Inspection and Test
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Packaging / Post-Pack Audit

• Completed assemblies to be packed using JIT
  carts provided by Gilbarco
• RP Network to maintain safety stock for demand
  fluctuations
• KanBan / FIFO material management methods
• Outgoing quality to be monitored using random
  post-pack audits

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